Gilera 633499 Workshop Manual

WORKSHOP MANUAL

633499

Runner Purejet

WORKSHOP

MANUAL

Runner Purejet

The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions shown in this publication are available in all Countries. The availability of single versions

should be checked at the official Piaggio sales network.

"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

WORKSHOP MANUAL

Runner Purejet

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio­Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a
basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are
unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along
with the specific tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

PURE JET INJECTION INJ PJ

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well­ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid open flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the
work surfaces except the tapered couplings before refitting.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.

Vehicle identification

Frame prefix: ZAPC 3610000001001
Engine prefix: ZAPC361M

Characteristics Runner Purejet

CHAR - 2

Dimensions and mass

DIMENSIONS

Specification Desc./Quantity

Total vacuum weight

gear sequence

93 kg.

Max width 720 mm.
Max length 1800 mm.
Wheelbase 1290 mm.

Seat height 830 mm.

Engine

ENGINE

Specification Desc./Quantity

Type single-cylinder, two-stroke

Number of cylinders 1

Bore 40

Stroke 39.3 mm

Cubic capacity 49.40 cc

Compression ratio 11.5 : 1 (±0.9)

Throttle body 20 Bing 71/20/104

Engine idle 2000 g/min.

Air filter sponge impregnated in fuel mixture (fuel + 50% oil)

Starting system electric starter

Lubrication By oil leakage through pump with flow rate varying

according to the engine speed and throttle open-

ing.

Fuel supply Air-assisted direct fuel injection into the combus-

tion chamber. The electric pump is controlled by

the injection ECU.

Inlet By means of a compression valve on the casing

Max power (to the wheel)

Max torque ( to the wheel)

Cooling system Through circulation of cooling liquid

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With Automatic variator with expandable pulleys,

V belt, automatic clutch, reduction gear.

Runner Purejet Characteristics

CHAR - 3

Capacities

CAPACITY

Specification Desc./Quantity

Fuel tank (including reserve ~3 l) ~ 12 l

Oil mixer tank (indicative value) ~1,8 l

Rear hub ~75 cc

Cooling circuit ~ 0.90 l

Electrical system

ELECTRICS

Specification Desc./Quantity

1 Type of ignition Electronic ignition with H.V. coil controlled by

the ECU
2 Ignition advance (before the top dead centre) Variable integrated to the injection system
3 Spark plug CHAMPION RG6YCA
4 Battery 12V - 9Ah
5 Fuse N° 2 da 15A, N° 2 da 7,5A
6 Generator In star three-phase alternating current

Frame and suspensions

FRAME

Specification Desc./Quantity

Chassis type Welded tubular steel chassis with stamped sheet

reinforcements

Sospensione anteriore Forcella idraulica a steli rovesciati

Corsa forcella anteriore 73 mm

Avancorsa 66 mm

Sospensione posteriore Monoammortizzatore idraulico, molla elicoidale

coassiale. Attacco motore telaio con braccetto os-

cillante

Rear suspension stroke 60 mm

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 220 mm disc brake with hydraulic linkage (r.h.

brake lever).

Rear brake Ø 175 mm disc (hydraulically controlled via lever

on left hand-side of handlebar)

Characteristics Runner Purejet

CHAR - 4

Wheels and tyres

WHEELS AND TIRES

Specification Desc./Quantity

Front tire dimension 120/70-12"

Rear tire dimension 130/70-12"

Pressione pneumatici Ruota anteriore: 1,6 bar / Ruota posteriore: 1,8 bar

Circles 3,50 x 12" (light alloy)

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU­LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES

Tightening Torques

COPPIE DI SERRAGGIO IN N·M PER TIPO DI MATERIALE SERRATO

Name Torque in Nm

Ø Vite acc. 8,8 M4 su plastica con distanziali met-

allici

2

Ø Vite acc. 8,8 M4 su ottone, rame, alluminio e loro

leghe

2

Ø Vite acc. 8,8 M4 Ferro, acciaio 3

Ø Vite acc. 8,8 M5 su plastica con distanziali met-

allici

4

Ø Vite acc. 8,8 M5 su ottone, rame, alluminio e loro

leghe

4

Ø Vite acc. 8,8 M5 Ferro, acciaio 6

Ø Vite acc. 8,8 M6 su plastica con distanziali met-

allici

6,5

Ø Vite acc. 8,8 M6 su ottone, rame, alluminio e loro

leghe

6,5

Ø Vite acc. 8,8 M6 Ferro, acciaio 10,5

Ø Vite acc. 8,8 M7 su ottone, rame, alluminio e loro

leghe

10,5

Ø Vite acc. 8,8 M7 Ferro, acciaio 17

Ø Vite acc. 8,8 M8 su ottone, rame, alluminio e loro

leghe

16

Ø Vite acc. 8,8 M8 Ferro, acciaio 26
Ø Vite acc. 8,8 M10 Ferro, acciaio 52
Ø Vite acc. 8,8 M12 Ferro, acciaio 100
Ø Vite acc. 8,8 M14 Ferro, acciaio 145

GRUPPO STERZO

Name Torque in Nm

Upper steering ring nut 30 ÷ 40
Lower steering ring-nut 50 ÷ 60 (therefore to loosen by 90 ÷100)

Handlebars stud * 65 ÷ 70

GRUPPO TELAIO

Name Torque in Nm

Swinging arm - engine pin* 33 ÷ 41

Frame - swing arm bolt * 33 ÷ 41

Runner Purejet Characteristics

CHAR - 5

Name Torque in Nm

Shock-absorber - frame nut * 20 ÷ 25

Shock-absorber - engine bolt * 33 ÷ 41

Wheel axle pin* 100 ÷ 125

Stand pin 18.5 ÷ 19

Stand screws 18.5 ÷ 19

*: Bloccaggi di sicurezza.

SOSPENSIONE ANTERIORE

Name Torque in Nm

Dado forcella* 20 ÷ 25

Fork screw 20 ÷ 25

Front wheel axle * 45 ÷ 50

*: Bloccaggi di sicurezza.

FRENO ANTERIORE

Name Torque in Nm

Brake fluid pump - hose fitting 13 to 18 Nm

Brake fluid pipe-calliper fitting 20 ÷ 25

Support calliper tightening screw* 20 ÷ 25

Front disc tightening screw* 12 ÷ 15

Oil bleed screw 7 to 10 Nm

*: Bloccaggi di sicurezza.

FRENO POSTERIORE

Name Torque in Nm

Calliper tightening screw 20 ÷ 25

Brake fluid tube- calliper 13 ÷ 18

Brake fluid pump - hose fitting 13 to 18 Nm

Disc tightening screw 6 ÷ 6.5

Rear wheel axle 100 ÷ 125

Rear wheel hub screw 20 ÷ 25

Oil bleed screw 7 to 10 Nm

N.B.

PER ASSICURARE UNA CORRETTA COPPIA DI BLOCCAGGIO, LUBRIFICARE I DADI PRIMA
DEL MONTAGGIO.

GRUPPO MOTORE

Name Torque in Nm

Head tightening nut 10 ÷ 11

Vite spurgo liquido refrigerante 1 ÷ 2

Sensore temperatura 6 ÷ 8

Temperature sensor at the ECU 18 ÷ 22

Crankcase closure screw 12 ÷ 13

Transmission cover closing screw 12 ÷ 13

Pick-up screw 3 ÷ 4

Stator screw 3 ÷ 4

Vite raccordo aspirazione 7 ÷ 8

Starter screw 12 ÷ 13

Mixer screw 3 ÷ 5

Rear hub cap screw 12 ÷ 13

Driving pulley nut 40÷ 44*

Driven pulley nut 40÷ 44*

Characteristics Runner Purejet

CHAR - 6

Name Torque in Nm

Oil drain rear hub screw 3 ÷ 5

Clutch nut 55 ÷ 60

Mixer strip screw 3 ÷ 4
Ignition spark plug 11 ÷ 14
Head union screw 3 ÷ 4

Flywheel cover screw 1 ÷ 2

Flywheel tightening nut 40÷ 44*

Transmission strip cap screw 3 ÷ 4

Transmission cooling cap screw 3 ÷ 4

Water pump rotor 0.5 ÷ 0.4

Muffler -cylinder nut 9 ÷ 11

Engine - muffler screw 22 ÷ 24

Fuel injector to the head studs 3 ÷ 4

Crankcase compressor studs 3 ÷ 4

* Impiegare dadi nuovi.

Overhaul data

Assembly clearances

Cylinder - piston assy.

THE DIAMETER OF THE CYLINDER MUST BE MEASURED 15MM FROM THE HEAD RESTING
LEVEL.

ACCOPPIAMENTO TRA PISTONE E CILINDRO

Name Initials Cylinder Piston Play on fitting

Cilindro M 39,997-40,004 39,943-39,95 0,047-0,061
Cilindro N 40,004-40,011 39,95-39,957 0,047-0,061
Pistone O 40,011-40,018 39,957-39,964 0,047-0,061
Pistone P 40,018-40,025 39,964-39,971 0,047-0,061

Cilindro 1° mag-

giorazione

M1 40,197-40,204 40,143-40,15 0,047-0,061

Cilindro 1° mag-

giorazione

N1 40,204-40,211 40,15-40,157 0,047-0,061

Pistone 1° mag-

giorazione

O1 40,211-40,218 40,157-40,164 0,047-0,061

Pistone 1° mag-

giorazione

P1 40,218-40,225 40,164-40,171 0,047-0,061

Cilindro 2° mag-

giorazione

M2 40,397-40,404 40,343-40,35 0,047-0,061

Cilindro 2° mag-

giorazione

N2 40,404-40,411 40,35-40,357 0,047-0,061

Pistone 2° mag-

giorazione

O2 40,411-40,418 40,357-40,364 0,047-0,061

Pistone 2° mag-

giorazione

P2 40,418-40,425 40,364-40,371 0,047-0,061

Runner Purejet Characteristics

CHAR - 7

Piston rings

ANELLI DI TENUTA

Name Description Dimensions Initials Quantity

Anello di tenuta 40 A 0,10 ÷ 0,25

Anello di tenuta 1°

Magg.

40,2 A 0,10 ÷ 0,25

Anello di tenuta 2°

Magg.

40,4 A 0,10 ÷ 0,25

Crankcase - crankshaft - connecting rod

PISTON - TEST PROBE

Name Descrip

tion

Dimens

ions

Initials Quantit

y

Piston Ø 12

+0.007
+0.012

P 0.002 ÷

0.011

Test

probe

Ø 12
+0.005
+0.001

Q 0.002 ÷

0.011

AXIAL PLAY CONNECTING ROD - CRANKSHAFT

Name Description Dimensions Initials Quantity

Connecting rod 11.75 0 -0.05 A 0.25 ÷ 0.50

Characteristics Runner Purejet

CHAR - 8

Name Description Dimensions Initials Quantity

Shoulder washer 0.5 ±0.03 G 0.25 ÷ 0.50

Semi-shaft, trans.

side

13.75 +0.04 0 C 0.25 ÷ 0.50

Semi-shaft, fly-

wheel side

13.75 +0.04 0 D 0.25 ÷ 0.50

Spacer tool 40.64 H 0.25 ÷ 0.50

Casing 11.8 0 -0.35 B 0.20 ÷ 0.75

Shoulder washer 0.5 ±0.03 G 0.20 ÷ 0.75

Semi-shaft, trans.

side

13.75 +0.04 0 C 0.20 ÷ 0.75

Semi-shaft, fly-

wheel side

13.75 +0.04 0 D 0.20 ÷ 0.75

Spacer tool 40.64 H 0.20 ÷ 0.75

ROD SMALL END - ROLLER CASING -

TEST PROBE

Name Descrip

tion

Dimens

ions

Initials Quantit

y

Con-

necting

rod

Ø 17

+0.011

0.001

G 0.002 ÷

0.012

Roller

casing

Ø 2.5 0

0.007

F 0.002 ÷

0.012

Test

probe

Ø 12 +

0.005 +

0.001

H 0.002 ÷

0.012

FITTING CATEGORY ROD SMALL END -

ROLLER CASING - TEST PROBE

Name Descrip

tion

Dimens

ions

Initials Quantit

y

Rod

small

end

Cat. 3 Ø 17 + 0.011

+ 0.007

Rod

small

end

Cat. 2 Ø 17 + 0.007

+ 0.003

Rod

small

end

Cat. 1 Ø 17 +0.003

-0.001

Roller

casing

Cat. 1 Ø 2.5 0 -0.002

Runner Purejet Characteristics

CHAR - 9

Name Descrip

tion

Dimens

ions

Initials Quantit

y

Roller

casing

Cat. 2 Ø 2.5 -0.002

-0.004

Roller

casing

Cat. 3 Ø 2.5 -0.004

-0.006

Roller

casing

Cat. 1

Optional

Ø 2.5 -0.001

-0.003

Roller

casing

Cat. 2

Optional

Ø 2.5 -0.003

-0.005

Roller

casing

Cat. 3

Optional

Ø 2.5 -0.005

-0.007

Test

probe

+0.005
+0.001

Slot packing system

Montare il cilindro senza installare la guarnizione
alla base.
Applicare un comparatore centesimale sull'attrez­zo e azzerarlo su un piano rettificato.
Montare l'attrezzo sulla sommità del cilindro fis­sandolo con due dadi ai prigionieri, rispettando la
coppia di serraggio e portare il pistone al P.M.S.
Lo spessore della guarnizione da montare cam­bierà secondo il valore rilevato.
A tale scopo sono fornite n°3 guarnizioni aventi i
seguenti spessori:

Specific tooling

020272Y Piston position check tool

Locking torques (N*m)

Locking head nuts: 10 ÷ 11 N·m

SHIMMING SYSTEM

Name Measure A Thickness

Shimming 2.80 ÷ 3.04 0,4
Shimming 3.04 ÷ 3.24 0,6
Shimming 3.25 ÷ 3.48 0,8

Products

TABELLA PRODOTTI CONSIGLIATI

Product Description Specifications

AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the

requirements of API GL3 specifi-

cations

Characteristics Runner Purejet

CHAR - 10

Product Description Specifications

AGIP CITY HI TEC 4T Oil for flexible transmission lubri-

cation (acceleration control, mix-

er and odometer)

Synthetic oil that passes SAE

5W-40, API SL, ACEA A3, JASO

MA specifications

AGIP CITY HI TEC 4T Oil for air filter sponge Synthetic oil that passes SAE

5W-40, API SL, ACEA A3, JASO

MA specifications

AGIP GP 330 Grease for brake control levers,

throttle, stand

White calcium complex soap-

based spray grease with NLGI 2;

ISO-L-XBCIB2

AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines:

JASO FC, ISO-L-EGD

AGIP GREASE MU3 Grease for odometer transmis-

sion gear case

Soap-based lithium grease with

NLGI 3; ISO-L-XBCHA3, DIN

K3K-20

AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid

AGIP GREASE SM 2 Grease for compensating ring NLGI 2; ISO-L-XBCHB2, DIN

KF2K-20 Molybdenum disul-

phide grease and lithium soap

AGIP GREASE PV2 Grease for control levers on the

engine

White anhydrous-calcium based
grease to protect roller bearings;
temperature range between -20 °

C and +120 °C; NLGI 2; ISO-L-

XBCIB2

AGIP PERMANENT PLUS Coolant Monoethylene glycol antifreeze

fluid, CUNA NC 956-16

AGIP GREASE SM 2 Greasing the driven pulley bush-

ing

Soap-based lithium grease with

NLGI 2 Molybdenum Disulphide;

ISO-L-XBCHB2, DIN KF2K-20

Runner Purejet Characteristics

CHAR - 11

Characteristics Runner Purejet

CHAR - 12

INDEX OF TOPICS

TOOLING TOOL

TOOLING

Stores code Description

001330Y Tool for fitting steering seats

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Driver for OD 54 mm bearing

001467Y008 Pliers to extract 17 mm ø bear-

ings

001467Y009 Driver for OD 42 mm bearings

001467Y013 Pliers to extract ø 15-mm bear-

ings

001467Y014 Pliers to extract ø 15-mm bear-

ings

Tooling Runner Purejet

TOOL - 2

Stores code Description

001467Y017 Bell for bearings, outside Ø 39

mm

001467Y021 Extraction pliers for ø 11 mm

bearings

001467Y029 Bell for bearings, O.D. 38 mm

002465Y Pliers for circlips

004499Y Camshaft bearing extractor

Runner Purejet Tooling

TOOL - 3

Stores code Description

004499Y007 Half rings

006029Y Punch for fitting fifth wheel seat

on steering tube

020004Y Punch for removing fifth wheels

from headstock

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crank-

shaft alignment

020080Y Punch for removing 12-mm bear-

ings

020150Y Air heater support

Tooling Runner Purejet

TOOL - 4

Stores code Description

020151Y Air heater

020162Y Flywheel extractor

020163Y Crankcase splitting plate

020164Y Driven pulley assembly sheath

020166Y Pin lock fitting tool

020168Y Water seal punch mount on half-

crankcase

Runner Purejet Tooling

TOOL - 5

Stores code Description

020169Y Water pump crankshaft fitting

and removal spanner

020170Y Water pump/mixer command

gear extractor

020171Y Punch for driven pulley roller

bearing

020209Y Spring hook

020265Y Bearing fitting base

Tooling Runner Purejet

TOOL - 6

Stores code Description

020272Y Piston position check tool

020325Y Brake-shoe spring calliper

020329Y MityVac vacuum-operated pump

020330Y Stroboscopic light for timing con-

trol

020331Y Digital multimeter

Runner Purejet Tooling

TOOL - 7

Stores code Description

020332Y Digital rev counter

020334Y Multiple battery charger

020335Y Magnetic support for dial gauge

020340Y Flywheel and transmission oil

seals fitting punch

020357Y 32 x 35 mm adaptor
020358Y 37x40-mm adaptor
020359Y 42x47-mm adaptor

020362Y 12-mm guide

Tooling Runner Purejet

TOOL - 8

Stores code Description

020363Y 20 mm guide

020409Y Multimeter adaptor - Peak volt-

age detection

020376Y Adaptor handle

020412Y 15 mm guide

020439Y 17 mm guide

020444Y Test probe removal / fitting tool

Runner Purejet Tooling

TOOL - 9

Stores code Description

020456Y Ø 24 mm adaptor

020451Y Start-up crown lock

020452Y Tube for removing and refitting

the driven pulley shaft

020460Y Scooter diagnosis and tester

020481Y Control unit interface wiring

Tooling Runner Purejet

TOOL - 10

Stores code Description

020565Y Flywheel lock calliper spanner

020469Y Reprogramming kit for scooter

diagnosis tester

020614Y Diagnostic tester programming

software

020615Y Carbon dam ring fitting kit

020616Y Fuel pressure control kit

020617Y Air pressure check kit

Runner Purejet Tooling

TOOL - 11

Stores code Description

020620Y Water pump impeller stop

020621Y HV cable extraction adaptor

Tooling Runner Purejet

TOOL - 12

INDEX OF TOPICS

MAINTENANCE MAIN

Purejet engines use a very lean air-petrol mixture when running at idle, with its effective percentage
varying as a function of the engine temperature and power absorption.
The throttle body supplies large amounts of air and the idle speed is kept at 2,000 rpm by adequately
leaning down the mixture through the adjustment of the fuel injection timing.
The effective exhaust gases are leaned down even further by the additional air used for the cleaning
phase. The exhaust pipe is fitted with the special outlet for the gas collection kit.
Measuring the CO concentration at idle, values close to 0% (0.1-0.2%) will be found.
It is therefore necessary to carefully clean and calibrate the gas analyser.
These figures may be used for diagnostic purposes only as no carburetion adjustment is possible.

Maintenance chart

EVERY 2 YEARS

Action

Brake fluid - change
Coolant - change

AT 1,000 KM

Action

Hub oil level - Check / Replace
Oil mixer/throttle linkage - adjustment
Steering - adjustment
Brake control levers - greasing
Brake fluid level - check
Safety locks - check
Electrics - Check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 5,000 KM , 25,000 KM , 35,000 KM , 55,000 KM

Action

Hub oil level - Check / Replace
Spark plug - replacement
Oil mixer/throttle linkage - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Coolant level - check
Electrics - Check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 10,000 KM , 50,000 KM

Action

Hub oil level - Check / Replace
Spark plug - replacement
Fuel filter - replacement
Air filter - clean

Maintenance Runner Purejet

MAIN - 2

Action

Oil mixer/throttle linkage - adjustment
Variator rollers- Check wear
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Coolant level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrics - Check
Headlight - adjustment check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 15,000 KM , 45,000 KM

Action

Hub oil level - Check / Replace
Spark plug - replacement
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Coolant level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrics - Check
Headlight - adjustment check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 20,000 KM , 40,000 KM

Action

Hub oil level - Check / Replace
Spark plug - replacement
Fuel filter - replacement
Air filter - clean
Oil mixer/throttle linkage - adjustment
Variator rollers- Check wear
Mixer belt - replacement
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Coolant level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrics - Check
Headlight - adjustment check
Tyre pressure and wear - check

Runner Purejet Maintenance

MAIN - 3

Action

Vehicle and brake test - road test

AT 30.000 KM

Action

Hub oil level - Check / Replace
Spark plug - replacement
Fuel filter - replacement
Air filter - clean
Transmission gas mixer- adjust
Driving belt - replacement
Variator rollers- Check wear
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid hoses - replacement
Brake fluid level - check
Coolant level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrics - Check
Headlight - adjustment check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 60,000 KM

Action

Hub oil level - Check / Replace
Spark plug - replacement
Fuel filter - replacement
Air filter - clean
Transmission gas mixer- adjust
Driving belt - replacement
Variator rollers- Check wear
Mixer belt - replacement
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid hoses - replacement
Brake fluid level - check
Coolant level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrics - Check
Headlight - adjustment check
Tyre pressure and wear - check
Vehicle and brake test - road test

Maintenance Runner Purejet

MAIN - 4

Spark plug

We inform you that, in order to avoid water infiltra­tions through the spark plug cap, the following
modifications have been introduced:

1. The following parts have been discontinued:
a) Spark plug cap
b) Spark plug protective collar

2. A new spark plug cap has been introduced

- Disconnect the lug of the spark plug and remove
it.

- Examine it carefully and if the insulation coating
is splintered or damaged, replace it.

- Measure the distance between the electrodes
using a feeler gauge and if necessary regulate it
by carefully bending the external electrode.

- Ensure the seal washer is in good condition.

- Fit the spark plug, screw it on by hand and secure
it with a spark plug spanner to the prescribed tor­que.

Characteristic

Electrode gap

0.6 ÷ 0.7 mm

Recommended spark plug

RG 6 YCA

Locking torques (N*m)

Spark plug: 11 ÷ 14 Nm

Hub oil

Runner Purejet Maintenance

MAIN - 5

Replacement

- Remove the oil charging cap.

- Unscrew the oil drain plug "B" and allow the oil to flow out completely.

- Rescrew the drain plug "B" and refill the engine with oil until it touches the full hole (apporx. 75cc.).

- The level must correspond to the second notch starting from the bottom as shown in the picture.

WARNING

DO NOT REMOVE THE OIL PLUG STRAIGHT
AFTER AN ACTIVITY WITH THE ENGINE AT
FULL SPEED AND /OR WITH THE ENGINE
RUNNING.THE OVERHEATED OIL COULD
LEAK WITH DANGER OF BURNS

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications

Air filter

Removal

- Remove the 6 screws shown in the picture.

Cleaning

- Wash with soap and water.

- Dry.

Maintenance Runner Purejet

MAIN - 6

- Impregnate with fuel mixture of 50% fuel and oil.

CAUTION

NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE
WEAR OF THE PISTON AND CYLINDER.

Recommended products

AGIP CITY HI TEC 4T Oil for air filter sponge

Synthetic oil that passes SAE 5W-40, API SL, ACEA A3, JASO MA specifications

Fuel filter

To access the fuel filter remove the

•

left side.

•

Remove the filter from its support

•

Disconnect the tube from the fuel tank
taking care to arrange a bowl to collect
the fuel present in the tank. Please
note the tank is not fitted with a tap.

See also

Side fairings

transmissions

After mounting the transmissions, check that they
move perfectly within the sheath.

- Lubricate the cable with the recommended prod­uct, applying a plastic bag as shown in the picture.

- If the cable does not move perfectly due to pos­sible fraying replace both the cable and the sheath.

Recommended products

AGIP CITY HI TEC 4T Oil for flexible transmis­sion lubrication (acceleration control, mixer
and odometer)

Synthetic oil that passes SAE 5W-40, API SL,
ACEA A3, JASO MA specifications

Runner Purejet Maintenance

MAIN - 7

Grease the ends of the cable.

Transmission adjustment

Set the command cables:
Mix cable: see the following procedure "Mixer Timing".
Gas cable: adjust so there is no play in the sheathes.
Splitter command cable: adjust so there is no play in the gas knob.
All transmissions must be regulated so there is no play in the sheathes.

Mixer timing

Use the transmission register to adjust, with the
gas command released and the position of mixer
lever as shown in the picture.

N.B.

TO VERIFY THE CORRECT TIMING OF THE MIXER IT IS NECESSARY TO REMOVE THE AIR
CONDUIT OF THE TRANSMISSION COVER.

CAUTION

WHEN REMOVING OR WHERE THERE IS NO MORE OIL IN THE TANK, PROCEED WITH THE
BLEEDING ACTIVITIES OF THE MIXER AS FOLLOWS: WITH THE MIXER MOUNTED ON THE
VEHICLE AND WITH THE ENGINE OFF, DISCONNECT THE MIXER TUBE FROM THE CARBU­RETTOR AND LOOSEN THE BLEED VALVES (SEE ARROW IN PICTURE) UNTIL OIL STARTS TO
FLOW. TIGHTEN THE SCREW, START THE ENGINE AND WAIT FOR OIL TO COME OUT FROM
THE DELIVERY TUBE TO THE CARBURETTOR (ALREADY DISCONNECTED).

Reconnect the delivery tube to the carburettor and secure it with the appropriate clamp.
When doing this step, pour a small amount of the recommended product into the intake or in the blade
holder.

Recommended products

AGIP CITY TEC 2T Mixer oil

synthetic oil for 2-stroke engines: JASO FC, ISO-L-EGD

Maintenance Runner Purejet

MAIN - 8

Cooling system

Level check

- Remove the front grille

- Check that the coolant level is between the min
and max reference marks.
Top up with recommended coolant, if necessary.

Recommended products

AGIP PERMANENT PLUS Coolant

Monoethylene glycol antifreeze fluid, CUNA NC
956-16

See also

Legshield

Headlight adjustment

Place the vehicle with the driver on level ground
10 m from a white screen in the shadows (see side
picture) and ensure the vehicle axle is perpendic­ular to the screen.
Trace a horizontal line on the screen with a ground
height of 65 ÷ 67 cm; start the engine and block
the gas knob so the vehicle stays still, switch on
the headlight, engage the lower beam and direct it
so the horizontal demarkation line between the
area in shadow and lit up area does not go above
the horizontal line traced on the screen.
To access the adjusting screw of the headlight re­move the front cowling. Loosen the screw with star
notch. Before directing the headlight check the
tires are inflated to the correct pressure.

Runner Purejet Maintenance

MAIN - 9

Maintenance Runner Purejet

MAIN - 10

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Engine

Engine overheating

ENGINE OVERHEATING

Possible Cause Operation

No coolant in the cooling circuit Restore the level

Incorrect air bleeding Repeat the operation

Thermostat remains closed Replace

Fluid leak in the radiator Replace the radiator

Loss of fluid from the system Servicing the system

Coolant leaks from crankcase draining hole Replace coolant sealing ring on half-crankcase

from transmission-side

Shaft support bearings water rotor command and

mixer locked.

Replace the shaft complete with bearing

Breakage of mixer belt Replace belt

Transmission and brakes

Clutch grabbing or performing inadequately

FAULTY CLUTCH

Possible Cause Operation

Tear or irregular functioning Ensure the masses move at the touch of a finger

and return as normal.

Ensure there is no grease on the masses.

Ensure the seals work correctly (area of work at

the centre).

Ensure the clutch bell is not scored.

Check:

Rpm at start of drag: 4,000 revs per min.

Rpm on full throttle with rear wheel braked (3"÷ 6"

max.): 7000 - 7500 revs per min.

WARNING

NEVER ALLOW THE ENGINE TO REV WITHOUT THE CLUTCH BELL.

Insufficient braking

BRAKE SYSTEM

Possible Cause Operation

Insufficient braking Check wear of brake pads (1.5 mm MIN).

Check brake discs are not worn, scored or de-

formed.

Check the correct level of liquid in the pumps and

replace brake fluid if necessary.

Check there is no air in the circuits; if necessary,

bleed the air.

Troubleshooting Runner Purejet

TROUBL - 2

Possible Cause Operation

Check that the front brake calliper moves in axis

with the disc.

Brake disc slack or distorted Check the locking of the brake disc screws; use a

dial gauge and a wheel mounted on the vehicle to

measure the axial shift of the disc.

Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump break-

down, replace

Brakes overheating

OVERHEATING BRAKES

Possible Cause Operation

Defective sliding of pistons Check calliper and replace any damaged part.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial

gauge and a wheel mounted on the vehicle to

measure the axial shift of the disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Swollen or glued rubber gaskets Replace gaskets.

Electrical system

Battery

BATTERY

Possible Cause Operation

Battery The battery is the electrical device in the system

that requires the most frequent inspections and

thorough maintenance. Frequently check that the

fluid level fully covers the plates; otherwise, re-

store the level adding distilled water (never use

natural water, even if it is drinking water) and

check fluid density at the same time. If the vehicle

is not used for some time (1 month or more) the

battery needs to be recharged periodically. The
battery tends to discharge completely within three
months. If the battery is fitted on a motorcycle, be

careful not to invert the connections, keeping in
mind that the black ground wire is connected to the

negative terminal while the red wire is connected

to the terminal marked+.

N.B.

KEEP IN MIND THAT THE VEHICLE CANNOT RUN WITHOUT A BATTERY AND THAT THE BAT­TERY MUST NEVER BE DISCONNECTED WHILE THE VEHICLE IS RUNNING.

Turn signal lights malfunction

PROBLEMS WITH ELECTRICAL SYSTEM

Possible Cause Operation

Oil check doesn't work Check the turn indicator device and wiring.

Runner Purejet Troubleshooting

TROUBL - 3

Possible Cause Operation

Turn indicators not working Check the turn indicator device and wiring.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightness of the upper ring-nut. If irreg-

ularities continue to appear in rotating the steering

even after making the adjustments, check the

housings where the ball bearings rotate: replace if

not fitted.

Excessive steering play

EXCESSIVE STEERING PLAY

Possible Cause Operation

Excessive steering backlash Check the tightening of the top ring nut. If irregu-

larities continue in turning the steering even after

making the above adjustments, check the seats in

which the ball bearings rotate: replace if they are

recessed.

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

Noisy suspension If the front suspension is noisy, check: the efficien-

cy of the front suspension, the condition of the ball

bearings and relevant lock-nuts, the limit switch

rubber stoppers and the movement sleeves.

Suspension oil leakage

SUSPENSION GREASE LEAKS

Possible Cause Operation

Suspension grease leaks Replace the sealing rings.

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Oil leakage from suspension Replace the damper.

Troubleshooting Runner Purejet

TROUBL - 4

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

ELECRTRICS

Specification Desc./Quantity

1 Instrument panel
2 Headlight assembly
3 Stop switch on front brake
4 Plug with contacts
5 Starter button
6 Right front turn indicator
7 Ignition key-switch
8 Fuel level sender
9 Voltage regulator
10 Coil
11 Spark plug
12 Fuel injector
13 Air injector
14 Water temperature sensor
15 Throttle body pos.
16 Flywheel magneto

Electrical system Runner Purejet

ELE SYS - 2

Specification Desc./Quantity

17 Starter motor
18 15A fuse
19 Diagnostics outlet
20 Battery
21 Lampada per lampeggiatori
22 Stop light bulb
23 Direction indicator bulb
24 Oil mix warning light com.
25 Start-up relay
26 Electronic control unit
27 Resistance 27Ω
28 Fuel pump
29 Horn
30 7,5A fuse
31 Turn signal switch
32 Left front turn indicator
33 Horn button
34 Commutatore lampeggiatori
35 Light switch
36 Rear stop light switch

Conceptual diagrams

Ignition

Runner Purejet Electrical system

ELE SYS - 3

IGNITION SECTION

Specification Desc./Quantity

1 Battery 12V - 9Ah
2 Fuse 15A
3 Key switch contacts
4 Voltage regulator
5 15A fuse
6 HV coil
7 Ignition spark plug
8 Flywheel magneto
9 Pick - up

Headlights and automatic starter section

HEADLIGHTS AND TURN INDICATORS

Specification Desc./Quantity

1 Voltage regulator
2 Flywheel magneto
3 Turn indicator device com.
4 2 turn indicator warning light bulbs 12V-2w
5 4 turn indicator lamps 12V-10w
6 Turn signal switch
7 Plug with contacts
8 Parking light bulb 12V-5W

Electrical system Runner Purejet

ELE SYS - 4

Specification Desc./Quantity

9 Rear positioning bulbs 12V 5W
10 Service light warning light 12V-12W
11 3 bulbs for lighting instrument 12V 1,2W
12 Light switch
13 Low beam bulb 12V-35W
14 High beam bulb 12V-55W
15 High-beam warning light 12V - 1.2W
16 Fuse 7,5A
17 7.5A
18 Key switch contacts
19 Fuse 15A
20 Battery
21 Fuse 15A

Battery recharge and starting

RECHARGING BATTERY AND START SECTION

Specification Desc./Quantity

1 Voltage regulator
2 Flywheel magneto
3 CPU
4 7,5A fuse
5 15A fuse
6 Starter remote control
7 Starter motor

Runner Purejet Electrical system

ELE SYS - 5

Specification Desc./Quantity

8 Starter button
9 Brake light filament 12V-21W
10 Front brake stop light switch
11 Rear stop light switch
12 Battery 12V - 9Ah
13 Fuse 15A
14 Key switch contacts
15 Low-oil warning light switch

Level indicators and enable signals section

LEVEL INDICATORS AND HORN SCHEME

Specification Desc./Quantity

1 CPU
2 Water temperature sensor
3 Resistance 27Ω 0,5W
4 Water temperature gauge
5 7,5A fuse
6 Key switch contacts
7 Fuse 15A
8 Battery 12V - 9Ah
9 Horn button
10 Claxon in c.c.
11 Fuel resreve light

Electrical system Runner Purejet

ELE SYS - 6

Specification Desc./Quantity

12 Fuel indicator
13 Fuel level sending unit
14 Turn indicator device com.
15 Oil warning light
16 Oil mix warning light com.
17 Diagnostic light

Instruments and warning lights control board

CONTROL PANEL FOR INSTRUMENTS AND WARNING LIGHTS

Specification Desc./Quantity

1 Ground lead
2 Plug with contacts
3 Left turn indicator
4 High beam switch
5 Low-oil warning light switch
6 Fuel level sending unit
7 ECU
8 ECU
9 Fuel level sender
10 Turn indicator device com.
11 Low fuel warning light
12 Diagnostic light
13 Water thermometer
14 Fuel gauge
15 Low-oil warning light
16 High-beam warning light
17 Rhs turn signal warning light
18 Lhs turn signal warning light

Runner Purejet Electrical system

ELE SYS - 7

Specification Desc./Quantity

19 Headlamp warning light
20 Instrument lighting

Checks and inspections

Battery recharge circuit

The recharge circuit has a three phase generator with permanent magneto.
The generator is directly connected to the voltage regulator. The voltage regulator is connected directly
to the earth and battery positive passing through the 15A protection fuse. Therefore this system does
not have a connection to the key switch. The three phase generator provides a significant recharge
power and at low rpm, a good compromise is obtained between distributed power and idle stability.

Stator check

Disconnect the connector from the voltage regu­lator and check for continuity between each yellow
wire with the other two.
Ohm value: 0.7 - 0.9 Ohm.
Also check that each yellow wire is isolated from
the ground.
If non-conforming values are found, repeat the
checks on the stator; if incorrect values continue
to occur, replace the stator or repair the wiring.

Electrical system Runner Purejet

ELE SYS - 8

Voltage regulator check

With the battery fully charged, measure the volt­age in the battery poles with engine at high speed.
The voltage must not exceed 15.2 volt.
If higher voltage is found, replace the regulator.
At voltage less than 13 volt, proceed with checks
on the stator and relevant wiring.

Recharge system voltage check

Connect an ammeter induction clamp to the volt­age regulator positive cable. Measure the battery
voltage and turn on the lights with the engine off
and wait until the voltage settles at around 12 volts.
Start the engine and measure the current distrib­uted by the circuit with the lights on and engine at
high rpm.
If the current value is less than 10A, repeat the test
using a new regulator and/or stator instead.

Starter motor

Specifications

- Rated voltage 12V.

- Rated power 0.25 kW.

- Left rotation viewed from pinion side.

- Connection to engine with pinion and crown
wheel on transmission side crankshaft.

- Control with button

Tests to perform to check the electrical starter
Static test

Remove the left side panel.
Check the resistance of the induced brush unit.
Reference value: < or equal to 1 Ohm

- Use a lift to adequately support the vehicle.

- Remove the stand and support.

Runner Purejet Electrical system

ELE SYS - 9

- Use a multimeter to check the continuity of the
positive and negative power supply cable.

- Make sure the connections are good.
If no faults are found, replace the starter.

Specific tooling

020331Y Digital multimeter
Dynamic tests

Check the battery voltage after it has not been
used for a few hours.
Voltage < or equal to 12.5 V.
Check the density of the electrolyte of each ele­ment.
Bé = 30 ÷ 32
Specific weight: 1.25 ÷ 1.26
Make sure the negative terminals (battery nega­tive and starter negative) are correctly connected
to each other and to the frame.

- Connect the diagnostic tester.

- Connect an ammeter induction clamp to the neg­ative power supply cable of the starter.

- Disconnect the fuel injection connector.

- Turn to «ON».

- Select the «PARAMETERS» function.

- Start the engine (making sure the vehicle cannot
move) long enough to measure the rpm and starter
absorption.

- Absorption at drag rpm: from 15 to 25A.

- Drag rpm: from 500 to 550 rpm

N.B.

THE VALUE OF DECLARED RPM IS THAT IN­DICATED BY THE DIAGNOSTIC TESTER

Specific tooling

020460Y Scooter diagnosis and tester

Electrical system Runner Purejet

ELE SYS - 10

Carry out a no-load absorption test.
Remove the transmission cover.
Remove the starter pinion.
With the starter motor in no-load, maximum absorption must be 10 A with power supply voltage ≥ 12V.

STARTER MOTOR

Specification Desc./Quantity

Starter motor

Voltmeter

Starter motor contactor

Start button

Battery 12V-9Ah

Ammeter

See also

Centre-stand
Side fairings

Runner Purejet Electrical system

ELE SYS - 11

Turn signals system check

The turn indicator circuit is managed by an inter­mittent device. If there are any problems with this
circuit check:

- The 7,5A fuse indicated in the photograph after
removing the front cowling.

- Using a multimeter, that the BLACK-BLUE cable
to the turn indicator connector has a voltage of
+12V

- To check the efficiency of the bulbs, apply a ten­sion of +12V to the WHITE-BLUE cable of the
indicator switch for the right bulbs and to the PINK
cable for the left bulbs.

See also

Legshield

level indicators

Composed of fuel level transmitter, analogical
reading instrument and fuel reserve light.
If problems occur check:

- The fuel reserve light

- The 7,5A fuse in the photograph after having re­moved the front casing

The WHITE cable of the instrument group has a voltage of +12V
Using the current meter, the ohmic values of the fuel level transmitter moving the arm with the floater.
Limit values:
position of empty tank = 87 ÷ 97 Ω
position of ½ empty tank = 34 ÷ 42 Ω
position of full tank < 7 Ω

See also

Legshield

Electrical system Runner Purejet

ELE SYS - 12

The oil mix warning light performs a timed check
of 3" every time the key is turned to ON. The check
is managed by the turn indicator device which ap­plies a voltage of 12 v to the oil warning light bulb.
If on turning the key to ON the control is not carried
out check:

- Bulb efficiency

- The 7,5A fuse shown in the photograph after re­moving the front casing.

- Using a multimeter and turning the key to ON that the 2 YELLOW cables of the oil mix command light
have a voltage of +12V

- The efficiency of the oil mix command light.
To access the oil mix command light remove the rear hold. Remember that the voltage of +12V to the
2 YELLOW cables of the oil mix command light lasts 3" from the moment the key is turned to ON.

See also

Legshield
Rear rack

Lights list

The lighting system turns on when the key is
turned to ON.
It is possible to select the high beams using the
light switch.
If there are problems with the lighting system c h
e c k :

- Bulb efficiency

- The 7,5A fuse shown in the picture removing the
front casing

- Check using a multimeter that the GREY-RED cable of the plug with contacts has a voltage of +12V

- Check the GREY-BLUE cable of the light switch has a voltage of +12V

- Check efficiency of light switch

- Ensure the presence of earth to the bulb carriers.

See also

Legshield

Dry-charge battery

WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON­TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF

Runner Purejet Electrical system

ELE SYS - 13

COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP­PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF REACH OF CHILDREN

Characteristic

Battery

12V-9Ah

Commissioning dry-charge batteries:

1) Once the short closed tube and caps are removed, add sulphuric acid to the elements, of a type for
batteries with a specific gravity of 1.26, corresponding to 30° Bé at a temperature of at least 15°C until
reaching the upper level.

2) Let it sit for two hours.

3) Use the specific battery charger (single or multiple) to charge to an intensity equal to around 1/10 of
the capacity until the voltage has reached a value of around 2.7 V per element. The density of the acid
should be about 1.27, corresponding to 31° Bé, and the values have stabilised. The duration of the
charging operations must be 15 - 20 hours.

4) Once the charging is complete, level out the acid (add distilled water or remove excess acid), put
on the caps and clean carefully.

5) Once these operations have been completed, install the battery on the vehicle, correctly following
the connections described in point 3) «Battery charging».

WARNING

- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE
THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE­SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO
ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

Specific tooling

020333Y Single battery charger
020334Y Multiple battery charger

Battery maintenance

The battery is the electric device that requires the
most careful monitoring and diligent maintenance.
The maintenance rules are:

1) Check the level of the electrolyte

Check regularly that the electrolyte level is at up­per level. Use only distilled water to top up the
level.

Electrical system Runner Purejet

ELE SYS - 14

If the battery needs topping up very frequently,
check the vehicle electrics: the battery is probably
working in overload conditions which will lead to
rapid deterioration.

2) Check the charge

After topping up the electrolyte, check the density
using a densimeter (see figure).

CHECKING ELECTROLYTE DENSITY

Specification Desc./Quantity

Keep the tube vertical

Check with bare eye

The float must be released

When the battery is charged, the density should be 30 ÷ 32 Bé corresponding to a specific weight of

1.26 ÷ 1.28 at a temperature not under 15° C.
If the density falls below 20° Bé, the battery is completely run down and needs to be recharged. When
a battery is being charged the voltage of each element must be 2.6 ÷ 2.8V.
The discharge limit of each element is 1.8V.
When charging is completed, check the level and density of the electrolyte as well as the voltage of
each element. If the vehicle is not used for long periods of time (1 month or longer) the battery must be
periodically recharged.
The battery will completely discharge over three months. When the battery is refitted onto the vehicle,
be careful not to invert the connections: remember that the ground wire (black) needs to be connected
to the negative (-) terminal, while the red wire is connected to the terminal marked with the positive

(+) sign.

3) Recharging the battery

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
FIRST DETACH THE NEGATIVE LEAD BEFORE REMOVING THE BATTERY FROM THE VEHICLE.

Normal charging on the bench is done with the specific battery charger (single or multiple), positioning
the battery charger selector on the type of battery to recharge at a current of 0.9A for around 6 ÷ 8
hours. The connections with the power supply source must be made by connecting the corresponding
poles (+ with + and - with -). The battery caps must be removed during charging.

Specific tooling

020333Y Single battery charger
020334Y Multiple battery charger

4) Cleaning the battery

The battery should always be kept clean, especially the upper part, and the terminals protected with
vaseline.

Runner Purejet Electrical system

ELE SYS - 15

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.

CAUTION

IN EMERGENCIES, THE CHARGING TIME CAN BE DECREASED TO 5-6 HOURS.

CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.

CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST
USED SHORTENS THE LIFE OF THE BATTERY.

Electrical system Runner Purejet

ELE SYS - 16

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Removal of the engine from the vehicle

- Remove the side panels

- Remove the muffler
Remove the rear brake line clamps on the trans­mission cover as shown in the figure

- Loosen the 5 rear wheel clamping screws to re­move the brake calliper

- Remove the brake calliper using the 2 screws
shown in the figure.

- Remove the gas control cable from the throttle
body

Engine from vehicle Runner Purejet

ENG VE - 2

- Remove the generator cable connector

Remove the fuel connectors from the fuel injector,
as follows:

- Press the union pipe downwards

- Hold the pipe downwards and pull the safety ring
upwards

- Extract the connector from the fuel injector
If the connector is difficult to extract, do not force
it too much and combine the rotation movement
with pushing-pulling stresses.

Runner Purejet Engine from vehicle

ENG VE - 3

- Remove the screw fixing the fuel piping clamp to
the engine on the flywheel side

- Remove the electric connectors from the fuel and
air injector

- Remove the electric connector from the throttle
body

- Remove the plastic clamp connecting the electric
cable of the throttle body to the air pipe shown in
the figure

Engine from vehicle Runner Purejet

ENG VE - 4

- Remove the belt cooling cover

- Release the mixer control cable using the special
hole as shown

- Remove the starter wiring from the relay and from
the grounding wire

- Remove the plastic clamp connecting the starter
wiring to the swinging arm

- Remove the screw fixing the fuel piping clamp to
the engine on the transmission side

Runner Purejet Engine from vehicle

ENG VE - 5

- Remove the coolant temperature sensor con­nector

- Remove the cooling system piping from the en­gine and discharge the fluid

- Remove the air filter sucking sleeve

- Remove the lower suspension fixing

- Use two 17 mm Allen wrenches to remove the
engine/swinging arm fixing pin

- Remove the oil mixer pipe from the tank

Engine from vehicle Runner Purejet

ENG VE - 6

- To refit, perform the operations in the reverse di­rection and ensure that the electric wiring is prop­erly fixed to components such as: air injector, fuel
injector, throttle body, generator, coolant temper­ature sensor.

- Carefully clean the connectors removing any dirt
and foreign material

- Respect the clamps of the fuel lines to the engine.

- Make sure that the fuel line connectors are per­fectly inserted in the injector

- Check that the rubber buffers installed on the fuel
lines are properly placed to prevent damage to the
lines caused by rubbing.

CAUTION

THE FUEL PRESSURE IN THE SUPPLY SYS­TEM IS APPROX. 4 BAR. REPLACE THE FUEL
LINES IF DAMAGED.

Locking torques (N*m)

Swinging arm /engine: 33 - 41 Nm Rear brake
calliper: 20 - 25 Nm Rear wheel: 20 - 25 Nm
Lower shock absorber clamp: 33 - 41 Nm

See also

Side fairings

Runner Purejet Engine from vehicle

ENG VE - 7

Engine from vehicle Runner Purejet

ENG VE - 8

INDEX OF TOPICS

ENGINE ENG

Automatic transmission

Transmission cover

- Loosen the 15 screws and remove the transmis­sion cover with the aid of a mallet.

N.B.

THE CRANKCASE IS SLIGHTLY BLOCKED BY
THE TIGHT FIT BETWEEN THE SHAFT OF THE
DRIVEN HALF-PULLEY AND THE BEARING
HOUSED ON THE CRANKCASE.

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side
to avoid damaging the coated surface and use the
driven pulley shaft or a pin of the same diameter
to remove the bearing.

N.B.

IN CASE OF DIFFICULTY A STANDARD 8MM­INSIDE DIAMETER EXTRACTOR CAN BE
USED.

Refitting the driven pulley shaft bearing

-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.

N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.

CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED
SURFACE.

Engine Runner Purejet

ENG - 2

Removing the driven pulley

- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the
whole of the driven pulley assembly.

N.B.

THE UNIT CAN ALSO BE REMOVED WITH THE
DRIVE PULLEY MOUNTED.

Specific tooling

020565Y Flywheel lock calliper spanner

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the inner diameter of the clutch bell.

Characteristic

Clutch bell diameter/standard value

Ø 107+0.2 +0 mm

Clutch bell diameter/max. value allowed after
use

Ø 107.5 mm

Eccentricity measured /max.

0.20 mm

Removing the clutch

- Equip the tool with long pins screwed into position
«A» from the outside, insert the entire driven pulley
in the tool and put the central screw under stress.

CAUTION

THE TOOL WILL BE DEFORMED IF THE CEN­TRAL SCREW IS TIGHTENED UP TOO FAR.

Runner Purejet Engine

ENG - 3

- Using a 34 mm socket wrench remove the clutch
locking nut.

- Loosen the central screw thereby undoing the
driven pulley unit

- Separate the components.

Specific tooling

020444Y Tool for fitting/ removing the driven
pulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction
material.

- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.

N.B.

UPON RUNNING-IN, THE MASSES MUST EX­HIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE AN­OTHER.
VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.

CAUTION

DO NOT OPEN THE MASSES USING TOOLS
TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.

Characteristic

Check minimum thickness

1 mm

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

Engine Runner Purejet

ENG - 4

- Remove the three guide pins and the mobile half
pulley.

Removing the driven half-pulley bearing

- Remove the roller bearing with the special ex­tractor inserted from the bottom of the fixed half­pulley.

CAUTION

POSITION THE HOLDING EDGE OF THE EX­TRACTION PLIERS BETWEEN THE END OF
THE BEARING AND THE BUILT IN SEALING
RING.

Specific tooling

001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch
housing by means of the special tool.

N.B.

PROPERLY SUPPORT THE HALF-PULLEY SO
AS NOT TO DEFORM THE SLIDING SURFACE
OF THE DRIVING BELT

Specific tooling

020376Y Adaptor handle
020363Y 20 mm guide

Runner Purejet Engine

ENG - 5

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work
surface of the belt. If there are, replace the half­pulley..

- Make sure the bearings do not show signs of un­usual wear.

- Measure the external diameter of the pulley bush­ing.

Characteristic

Stationary driven half-pulley/Standard diame­ter

Ø 33.965 to 33.985 mm

Stationary driven half-pulley / Minimum diam­eter admitted after use

Ø 33.96 mm

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two O­rings.

- Measure the inside diameter of the mobile half­pulley bushing.

Characteristic

Mobile driven half-pulley/ Maximum diameter
allowed

Ø 34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile
half-pulley.

- Fitting the half-pulley on the bushing.

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel
revolving ring

Soap-based lithium grease containing NLGI 2 Mo­lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20

- Make sure the pins and collar are not worn, reassemble the pins and collar.

Engine Runner Purejet

ENG - 6

- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This
operation must be done through one of the holes inside the bushing until grease comes out of the
opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel revolving ring

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible
from the outside.

CAUTION

PROPERLY SUPPORT THE HALF-PULLEY TO
PREVENT DAMAGE TO THE THREADED END
WHILE THE BEARINGS ARE BEING FITTED.

Specific tooling

020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020362Y 12 mm guide
020171Y Punch for Ø 17 mm roller case

Refitting the driven pulley

• Check the surfaces contacting with the belt.

• Insert the new oil seals and the O-rings on the
mobile half-pulley.

• Fit the half-pulley on the bushing.

CAUTION

WHILE FITTING THE MOBILE DRIVEN HALF­PULLEY, TAKE CARE NOT TO DAMAGE THE
OIL SEALS.

• Check that pins and collar are not worn, refit pins and collar.

• Use a bent tip oiler to lubricate the pulley unit with approx. 6 gr grease. This operation must be per­formed through one of the holes into the bushing until the grease starts leaking from the opposite hole.
This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended products

AGIP GREASE SM 2 Grease for odometer transmission gear case

Lithium grease with NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Runner Purejet Engine

ENG - 7

• Measure the free length of the mobile driving half­pulley.

Characteristic

Standard length:

110 mm

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley
does not show signs of deformation

- Measure the free length of the spring

Characteristic

Standard length

118 mm

Minimum length allowed after use

XXXX

Refitting the clutch

- Preassemble the driven pulley group with spring,
sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the
spring being careful not to damage the plastic
sheath and the end of the threaded bar.

- Reassemble the nut securing the clutch and tight­en to the prescribed torque.

CAUTION

SO AS NOT TO DAMAGE THE CLUTCH NUT
USE A SOCKET WRENCH WITH SMALL
CHAMFER.

CAUTION

POSITION THE NON-CHAMFERED SURFACES
OF THE NUT IN CONTACT WITH THE CLUTCH

Locking torques (N*m)

Engine Runner Purejet

ENG - 8

Nut locking clutch unit on pulley 55 ÷ 60 Nm

Refitting the driven pulley

• Refit the driven pulley assembly, the clutch bell
and the nut using the specific tool.

Specific tooling

020565Y Flywheel lock calliper spanner

Locking torques (N*m)

Locking torque: 40 ÷ 44 N·m

Drive-belt

- Make sure the driving belt is not damaged and
does not have cracks in the toothed grooves.

- Check the width of the belt.

Characteristic

Transmission belt/Minimum width

17.5 mm

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer,
then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the
rollers and contrast plate fitted loosely on it do not come off.

Specific tooling

020451Y Start-up crown lock

Runner Purejet Engine

ENG - 9

Inspecting the rollers case

1) Check that the bushing and the sliding rings of
the mobile pulley do not show signs of scoring or
deformation.

2) Check the roller running tracks on the contact
pulley; there must not be signs of wear and check
the condition of the contact surface of the belt on
the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of
marked facetting on the sliding surface and that
the metallic insert does not come out of the plastic
shell borders.

4) Check the integrity of the sliding blocks of the
contact plate.

- Check that the internal bushing shown in the fig­ure is not abnormally worn and measure inside
diameter «A».

- Measure outside diameter «B» of the pulley slid­ing bushing shown in the figure.

CAUTION

DO NOT LUBRICATE OR CLEAN THE BUSH­ING.

Characteristic

Driving pulley / Maximum diameter:

20.12 mm

Driving pulley/ Standard diameter:

20.021 mm

Driving pulley bushing/ Diameter maximum:

XXX mm

Driving pulley bushing/ Standard diameter:

20 -0.020/-0.041mm

Engine Runner Purejet

ENG - 10

Refitting the driving pulley

- Manually move the mobile driven half-pulley
away pulling it towards the clutch unit and insert
the belt repeating the direction of rotation of the
first fitting.

N.B.

IT IS GOOD PRACTICE ALWAYS TO FIT THE
BELT SO THE WORDING CAN BE READ, IN
THE CASE THAT THIS DOES NOT SHOW A
FITTING SIDE.

- Refit the particular components of the assembly
(roller container assembly with bushing, limiting
washer, stationery half-pulley, cooling fan belt with
drive, washer and nut).

- Tighten the lock nut to torque 20 Nm and then
perform a final 90° lock preventing the rotation of
the drive pulley with the specific tooling.

N.B.

REPLACE THE NUT WITH A NEW ONE AT EV­ERY REFIT

CAUTION

IT IS MOST IMPORTANT WHEN FITTING THE
DRIVING PULLEY UNIT THAT THE BELT IS
FREE INSIDE IN ORDER TO AVOID MAKING A
WRONG TIGHTENING WITH THE POSSIBLE
LATER DAMAGE OF THE CRANKSHAFT
KNURLING.

Specific tooling

020451Y Start-up crown lock

Locking torques (N*m)

Crankshaft pulley nut 18 to 20 + 90° N.m

End gear

Runner Purejet Engine

ENG - 11

Removing the hub cover

• Remove the transmission cover

• Remove the clutch assembly

• Discharge the rear hub oil.

• Remove the 5 screws indicated in the figure.

• Remove the hub cover with driven pulley shaft.

See also

Refitting the clutch

Removing the wheel axle

- Remove the intermediate gear and the complete
gear wheel axle.

- When removing the intermediate gear pay atten­tion to the various shim adjustments.

Removing the wheel axle bearings

- Remove the oil seal and the seeger ring.

- Remove the bearing by pushing from the outside
towards the inside of the gear compartment, using
the appropriate punch.

Specific tooling

020363Y 20 mm guide
020376Y Adaptor handle
020358Y 37x40-mm adaptor

Engine Runner Purejet

ENG - 12

Removing the driven pulley shaft bearing

- Remove the seeger ring inside the cover.

- Remove the oil seal from the outside.

- Remove the centring dowels and position the
cover on a plane.

- Position the special tool on the internal track of
the bearing and remove said bearing with the aid
of a press.

Specific tooling

020452Y Tube for removing and refitting the
driven pulley shaft

- Position the special tube on the internal raceway
of the bearing and from the shaft toothed side as
indicated in the figure. Expel the driven pulley shaft
with the aid of a press.

Specific tooling

020452Y Tube for removing and refitting the
driven pulley shaft

Inspecting the hub shaft

- Check that the three shafts exhibit no wear or
deformation on the toothed surfaces, at the bear­ing housings and at the oil guards.

- In case of anomalies, replace the damaged com­ponents.

- Check that the fitting surface is not dented or dis­torted.

- If faults are found, replace the hub cover.

Runner Purejet Engine

ENG - 13

Refitting the driven pulley shaft bearing

- Support the inner track of the bearing from the
outside of the hub cover with the specific tool posi­tioned under the press and insert the driven pulley
axle.

- Refit the oil seal flush with the cover.

Specific tooling

020452Y Tube for removing and refitting the
driven pulley shaft

• Heat the hub cover and insert the bearing with
the specific punch.

• Fit the snap ring with the concave or radial part
on the bearing side.

N.B.

FIT THE BALL BEARING WITH THE SHIELD
FACING THE OIL SEAL.

Specific tooling

020151Y Air heater
020376Y Adaptor handle
020439Y 17 mm guide
020358Y 37x40-mm adaptor

Refitting the wheel axle bearing

- Heat the half crankcase on the transmission side
using a thermal gun.

- After lubricating its outer strip, insert the bearing
with the special adapter with the aid of a hammer.

- Refit the seeger ring and the oil seal using the 42
x 47 mm adapter and the handle.

Specific tooling

020151Y Air heater
020376Y Adaptor handle
020363Y 20 mm guide
020359Y 42x47-mm adaptor

Engine Runner Purejet

ENG - 14

Refitting the ub cover

• Refit the complete wheel axis.

• Refit the intermediate gear being careful of the
two shim adjustments.

• Apply LOCTITE 510 for surfaces on the hub cov­er and refit it with the complete pulley shaft.

• Insert the 5 screws and tighten them to the pre­scribed torque.

N.B.

CLEAN THE CONTACT SURFACES OF THE
HUB COVER AND THE HALF CRANKCASE OF
RESIDUE FROM PREVIOUS GASKETS BE­FORE APPLYING A NEW ONE.

Locking torques (N*m)

Locking torque: 11 to 13 Nm

Flywheel cover

Removing the stator

- Remove the flywheel cover.

• Use a specific compass wrench and a 15 mm
Allen wrench to remove the flywheel lock-nut.

Specific tooling

020565Y Flywheel lock calliper spanner

Runner Purejet Engine

ENG - 15

• Use a specific extractor to remove the flywheel

Specific tooling

020162Y Flywheel extractor

• Remove the two studs of the revolutions sensor
to the coolant inlet pipe.

• Remove the coolant inlet duct

• Remove the two stator fixing screws

• Remove the stator with wiring and revolution
sensor

Locking torques (N*m)

Flywheel nut 40 to 44 N.m

Refitting the stator

- To refit, perform the removal procedures in the reverse direction.

Engine Runner Purejet

ENG - 16

Refitting the flywheel cover

•

Fit the rubber seal on the flywheel con­nector and around the inlet coolant
hose.

•

Keeping the flywheel connector rubber
clamp on the coolant inlet hose, refit
the flywheel cover paying attention in
inserting the strap in the groove.

•

Tighten the 4 studs, noting that the two
longer golden screws are inserted in
the 2 top holes and are also responsi­ble for restraining the secondary air­box.

Cylinder assy. and timing system

• Remove the flywheel cover using the 4 screws
shown in the figure.

Runner Purejet Engine

ENG - 17

Removing the cylinder head

• Use a TORX 20 wrench to remove the air feeding
line from the injection head as shown in the figure.

• Remove the injection head, including the fuel in­jector and the pressure regulator, using the 2
screws shown in the figure

• Remove the spark plug

• Remove the temperature sensor shown in the
figure

To remove the air injector, extract the dust cover
and use a screwdriver to remove the injector as
shown in the figure

N.B.

BE CAREFUL NOT TO DAMAGE THE INJEC­TOR PLASTIC SUPPORT

Engine Runner Purejet

ENG - 18

• Remove the coolant outlet union from the head
with the relevant O-ring, using the two screws, as
shown in the figure.

• Remove the head inside recirculation duct as
shown in the figure.

• Remove the head using the 4 screws as shown
in the figure.

Runner Purejet Engine

ENG - 19

Removing the cylinder - piston assy.

• Remove the cylinder holding the piston in order
to prevent damage

• Remove the 2 plug stops by a screwdriver inser­ted into the special slits on the piston

• Remove piston pin and remove the piston

N.B.

USE PAPER OR A CLOTH TO CLOSE THE CYL­INDER HOUSING MOUTH ON THE CRANK­CASE TO PREVENT SLIPPAGE OF ONE OF
THE PIN LOCKING RINGS INTO THE CASE.

• Remove the roller from the connecting rod as
shown in the figure

• Remove the piston sealing rings

CAUTION

NOTE THE ASSEMBLY POSITIONS OF THE
LININGS TO PREVENT INVERTING THE POSI­TION IN CASE OF REUSE.

N.B.

BE CAREFUL NOT TO DAMAGE THE SEALING
RINGS DURING REMOVAL.

Engine Runner Purejet

ENG - 20

Inspecting the small end

- Measure the internal diameter of the small end
using an internal micrometer.

N.B.

IF THE DIAMETER OF THE ROD SMALL END
EXCEEDS THE MAXIMUM DIAMETER AL­LOWED, SHOWS SIGNS OF WEAR OR OVER­HEATING REPLACE THE CRANKSHAFT AS
DESCRIBED IN THE "CRANKCASE AND
CRANKSHAFT" CHAPTER".

Characteristic

Rod small end: standard diameter

17 +0.011-0.001

Rod small end: maximum allowable diameter

17,060 mm

Inspecting the wrist pin

- Check the wrist pin external diameter using a mi­crometer

Characteristic

Wrist pin: standard diameter

12 +0.005 +0.001 mm

Inspecting the piston

- Measure the bearings on the piston using a bore
meter

- Calculate the piston-pin coupling clearance.

Characteristic

Wrist pin housing: standard diameter

12 +0.007 +0.012

Wrist pin housing: standard clearance

0.002 ÷ 0.011 mm

Runner Purejet Engine

ENG - 21

- Measure the outer diameter of the piston, per­pendicular to the pin axis.

- Take the measurement in the position shown in
the figure
To classify the cylinder-piston fitting, check the ap­propriate table

See also

Cylinder - piston assy.

Inspecting the cylinder

• Check that the cylinder exhibits no seizure. If it
does, replace or adjust it, while respecting the al­lowable oversizes.

• Use a bore meter to measure the cylinder inside
diameter according to the directions shown in the
figure.

• Check that the fitting surface with the head is not worn or deformed
To classify the fitting, refer to the tables.

See also

Cylinder - piston assy.

Inspecting the piston rings

• Alternatively, insert the 2 sealing rings into the
cylinder.

• Insert the rings in an orthogonal position relative
to the cylinder axis, using the piston.

• Measure the sealing ring opening by a feeler
gauge, as shown in the figure.

• If the values are higher than those prescribed on the chart, replace the rings

Engine Runner Purejet

ENG - 22

Removing the piston

• Insert the roller in the connecting rod

• Fit piston and wrist pin on the connecting rod, with
piston facing the outlet

• Insert the wrist pin stop ring in the specific tool
with the aperture in the position shown on the tool,
as in the figure

• Place the wrist pin stop ring into position using a
punch

Specific tooling

020166Y Pin lock fitting tool

Runner Purejet Engine

ENG - 23

• Fit the wrist pin stop using the plug as shown in
the figure

Specific tooling

020166Y Pin lock fitting tool

Choosing the gasket

• Temporarily fit the cylinder on the piston, without
the basic gasket.

• Fit a dial gauge on the specific tool, using the
short union as shown in the figure.

Use a reference plane to reset the dial gauge with
a pre-load of a few millimetres.
Set the dial gauge.
Check that tracer slides smoothly.
Fit the tool on the cylinder without changing the
dial gauge position.
Lock the tool by the nuts used to secure the head.

Turn the engine shaft to the dead centre position (dial gauge rotation inversion point).
Measure the difference with the reset value.
Refer to the table to identify the thickness of the cylinder base gasket to use for refitting. The correct
identification of the thickness of the cylinder base gasket allows maintaining the correct compression
ratio.
Remove the specific tool and the cylinder.

Specific tooling

020272Y Piston position check tool

See also

Cylinder - piston assy.

Engine Runner Purejet

ENG - 24

Refitting the head and timing system components

• Carefully clean the head, removing any carbon
residues

• Check the perfect condition of the fitting surfaces

• Check that the O-rings are not broken, otherwise
replace them

• Screw the 4 head fixing nuts and tighten them in
crossed sequence to the prescribed torque

Locking torques (N*m)

Head fixing nuts: 10 ÷11 Nm

• Refit the head inside recirculation duct as shown
in the figure.

• Check that the O-Ring is in good working condi­tion.

• Fit the coolant outlet union on the head with rel­evant O-ring by tightening 2 screws to the prescri­bed torque.

Locking torques (N*m)

Coolant outlet union fixing screws: 3 ÷ 4 Nm

• Introduce the air injector into the head.

Runner Purejet Engine

ENG - 25

• Refit the dust cover onto the air injector.

N.B.

NOTE THAN WHEN THE AIR INJECTOR IS RE­FITTED, THE CARBON DAM O-RING MUST BE
NEW. IF A NEW AIR INJECTOR IS FITTED, THE
NEW CARBON DAM RING IS ALREADY
PRESENT. IF THE OLD AIR INJECTOR IS FIT­TED, THE CARBON DAM REQUIRES RE­PLACEMENT.

• Fit the spark plug

• Refit the temperature sensor shown in the figure
and tighten to the prescribed torque.

Locking torques (N*m)

Temperature sensor 18 ÷22 Nm Spark plug: 11
÷ 14 Nm

• Refit the injection head including the fuel injector
and pressure regulator and tighten to the prescri­bed torque.

Locking torques (N*m)

Injection head fixing screw: 3 ÷ 4 Nm

• Use a TORX 20 wrench to refit the air feeding
pipe from the injection head.

See also

air injector circuit

Air Injection

Carbon - dam replacement

Engine Runner Purejet

ENG - 26

- Remove the air injector

- The carbon dam ring must be broken to be re­moved.

- Carefully clean the air injector and the seat re­moving any carbon residues.

- Check that the sealing rings exhibit no wear, or
replace them.

- To refit, use a new carbon dam ring.

- Use the specific tool to fit the carbon dam ring.
We recommend doing this in several steps to en­sure a correct widening of the ring as shown in the
photo.

Specific tooling

020615Y Carbon dam ring fitting kit

- Position the specific tool with the rung facing the
injector as shown in the figure.

- Use the specific tool to tighten the carbon dam
ring seat as shown in the figure.

- Take several steps to ensure a correct insertion
into the seat.

- Refit the air injector in its seat on the head quickly
to prevent the carbon dam ring from expanding
again.

Specific tooling

020615Y Carbon dam ring fitting kit

Crankcase - crankshaft

• Remove flywheel and stator

- Remove the driving pulley

- Remove the driven pulley

- Remove the mixer

Runner Purejet Engine

ENG - 27

- Remove the throttle body with manifold, diaphragm, gasket and blade support

- Remove the volumetric compressor

- Remove the thermal unit

- Remove the starter

See also

Cylinder assy. and timing system
Removing the driving pulley
Removal
Removing the driven pulley

Splitting the crankcase halves

- Remove the 8 crankcase half clamping screws
shown in the figure

- Insert the guard on the crankshaft as shown in
the figure.

- Use the specific tool to remove the crankcase half
on the flywheel side. Place the tool being careful
to correctly centre it

- Use a 17 mm Allen wrench to remove the crank­case half on the flywheel side.

N.B.

IF SEPARATION REQUIRES FORCING, USE A
THERMAL GUN TO HEAT THE CRANKCASE IN
THE BENCH BEARING ZONE

Specific tooling

020151Y Air heater
020163Y Crankcase splitting plate

Engine Runner Purejet

ENG - 28

- Install the specific tool with relevant guard on the
transmission side crankcase half. Use four M6
screws of a suitable length.

- Use a 17 mm Allen wrench to remove the crank­shaft from the transmission side crankcase half.

Removing the crankshaft

- Install the specific tool on the half crankcase on
the transmission side using four M6 screws of an
adequate length.

- Remove the crankshaft from the transmission
side half crankcase

Specific tooling

020163Y Crankcase splitting plate

Removing the crankshaft bearings

- Bearings may be left on the crankcase halves or
on the crankshaft.

- Use the specific tool to remove any bearings left
on the crankshaft.

N.B.

HALF-RINGS MUST BE INSERTED ON THE
BEARINGS BY STRIKING THEM WITH A MAL­LET.

Specific tooling

004499Y Camshaft bearing extractor
004499Y007 Half rings

Runner Purejet Engine

ENG - 29

- Use the specific tool to remove any bearings left
on both crankcase halves.

Specific tooling

001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54 mm bearing

Refitting the crankshaft bearings

- This operation requires assembly by temperature

- Dip the bearings in oil bath when this is still cold.
Avoid contact between bearings and container.

- Use an appropriate amount of oil (approx.1 l)

- Gradually heat the container with a thermal gun
until the oil temperature reaches approx. 150°.

- Check the temperature using a multimeter provi­ded with thermal probe

N.B.

IF THE BEARINGS WERE IMMERSED INTO
HOT OIL, THEY WOULD BE IMMEDIATELY
DAMAGED.

- Place the crankshaft on the special support

- Alternately introduce the 2 bearings to insert
them home.

- If required, use a specific pipe to ensure their in­sertion.

N.B.

THIS OPERATION SHOULD BE PERFORMED
QUICKLY AND WITH PRECISE MOVES. OTH­ERWISE, START OVER.

Specific tooling

020265Y Bearing fitting base

Engine Runner Purejet

ENG - 30

008119Y009 Tube to assemble shafts and
axles

Inspecting the crankshaft components

- Check for any abnormal wear on the eccentric
track.

- To check using the dial gauge, see the section
«Checking crankshaft alignment»

Inspecting the crankshaft alignment

With the specific tool shown check that the eccen­tricity of the surfaces of diam. «A»-«B»-« C» are
within 0.03 mm. (reading limit on the dial gauge);
in addition, check the eccentricity of diam. «D», for
which a maximum reading of 0.02 mm is permitted.
In the case where eccentricity is not much above
prescribed levels, straighten the shaft by acting
on the counterweights with a shim or tighten them
in a clamp (with an aluminium bushing) as re­quired..

Specific tooling

020335Y Magnetic support for dial gauge
020074Y Support base for checking crankshaft

alignment

Runner Purejet Engine

ENG - 31

Inspecting the crankcase halves

- Remove the oil seals from both crankcase halves
using a screwdriver.

- Clean the fitting surfaces removing Loctite resi­dues and residues of the paper seal on the cylin­der.

- For this operation, use specific products available
on the market. Avoid any method that may impair
the crankcase fitting surfaces.

- To facilitate this operation, remove the rotor.
Please note that the threading is anticlockwise.

- Check the fitting surfaces and the bearing and oil
seal capacities.

- Check the cleaning and efficiency of the unidir­ectional valve of the oil supply to the pump case.

- Check the correct installation of the reference
dowels.

Engine Runner Purejet

ENG - 32