GILERA COGUAR User Manual
WORKSHOP MANUAL
COGUAR
Reproduced by
OWNERS CLUB
OF BRITAIN
from information obtained from original or copied
manuals originally issued by
Piaggio/Gilera
Whilst every care has been taken to ensure
accuracy of the contents, I Gotta Gilera does not
accept any liability of any type due to any errors or
omissions, and use of this manual will denote
acceptance of this condition.
NOTES:
We have found one obvious error within the original manual, but have copied it
exactly as it originally appeared together with a note advising that it is an error.
If you find any other errors, please email pppdrive@talktalk.net so that this manual
can be updated to be as accurate as is possible.
COGUAR WORKSHOP MANUAL
This manual was written by Piaggio-Gilera for use in Piaggio-Gilera
dealers and authorised servicing workshops. It is assumed that the
person using this manual for maintenance and repairs on Piaggio-Gilera
Coguar models has a basic knowledge of mechanical principles and
procedures concerning vehicle repair techniques.
Information concerning important variations in vehicle characteristics or in
certain repair operations will be communicated as an update to this
manual.
However, it is not possible to carry out a completely satisfactory job
without the necessary systems and tools. Therefore, please consult the
pages in this manual dealing with special tools and the special equipment
catalogue.
NOTE This indicates a note that gives important information to make the
………..procedure clearer and easier to carry out.
Important note
Warning
This indicates certain precautions that are to be taken to avoid
injuries to the person repairing the vehicle.
NOTE - For all that concerns the specific operations on the Coguar
………….engine, see the “SERVICE STATION MANUAL 4T SPEED
………….125cc ENGINE.”
This indicates special procedures that are to be followed
to avoid damaging the vehicle.
GENERAL INFORMATION
Safety regulations
If it is necessary to work on the vehicle with the engine running, make sure that the
environment is well ventilated, if necessary using a suitable exhaust system. Never
run the engine in closed places since the exhaust gasses are toxic.
The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin.
Sulphuric acid is highly corrosive; if it comes into contact with the eyes or skin, wash
with plenty of water and go immediately to a Doctor.
The battery produces hydrogen which can be highly explosive. Do not smoke and
avoid naked flames and sparks near the battery, especially when recharging it.
Petrol is very inflammable and under some conditions can explode. Do not smoke
in the work area and keep clear of naked flames and sparks.
Clean the brake shoes, drums and pads in well ventilated areas directing the
compressed air jet to avoid taking in the dust caused by the wear on the shoes.
Although the brake lining does not contain asbestos, inhalation of the dust is still
harmful.
Maintenance rules
Use original PIAGGIO-GILERA spare parts and lubricants recommended by the
manufacturer. Spare parts other than originals or that do not conform can damage
the vehicle.
Only use the special tools designed for this vehicle.
Always use new seals, seal rings and split pins when assembling.
After disassembly, clean the components with non flammable solvent. Lubricate all
working surfaces before reassembling, except for the bevel pairs.
After reassembly, check that all the components have been installed correctly and
operate perfectly.
For disassembly, overhaul and reassembly operations, only use tools with metric
measurements. The metric screws, nuts and bolts are not interchangeable with
English measurement couplings. The use of unsuitable tools or couplings could
damage the vehicle.
When working on the vehicle electrical system, check the correct assembly of the
electrical connections, especially those connecting the to earth and the battery.
Vehicle identification
Vehicle
COGUAR 125 cc
Frame prefix
ZAPM1700000001001
Engine prefix
JD09E
INDEX
Specifications
Vehicle overhaul data
Special equipment
Maintenance and troubleshooting
Electrical system
Front suspension
Rear suspension
Braking system
Pre-delivery operations
Section
1
1
1
2
3
4
5
6
7
GENERAL INFORMATION 1
SUB INDEX
Specifications
Torque settings
Section - Page
1 - 1
1 - 2
1
SPECIFICATIONS
Dimensions and weight
Width
Length
Wheelbase
Height
Dry weight
760mm
2020mm
1500mm
1130mm
141kg
Engine
Type
4 stroke
Cylinders
Bore
Stroke
Capacity
Comp. Ratio
56.5mm
49.5mm
124cc
9.2±0.5:1
Timing: single shaft with cams
in head, two valves, chain
driven on right-hand side.
Carburettor
Air Cleaner
Start up
Lubrication
Fuel supply
Cooling
KEIHIN PDC3F
Paper
Electric starter
Forced, wet sump
Unleaded petrol,
carburettor,
gravity system
Air
Performance
Engine idling
Max power at
shaft
Max torque at
shaft
Max speed
1400±100rpm
7.9kW/8250rpm
10Nm/7000rpm
102kph
Transmission
Geared primary, chain secondary.
Capacities
Petrol (inc reserve) 12 lt
Reserve 2.2 lt
Engine oil
Sump 1.0 lt
Total system capacity 1.2 lt
Fork oil 280cc
Frame
1
Single tube with double closed cradle.
Suspension
Front: Hydraulic fork with 35mm rod
………..and 130mm stroke.
Rear: Dual shock-absorbing element
………...with 84mm stroke.
Brakes
Front: 260mm diameter disc, with
…………hydraulic control dual floating
…………shoe, lever on r-h handlebar.
Rear: 160mm diameter drum, with
…………mechanically controlled
…………expansion calliper.
Wheels
Stainless steel spokes aluminium rims
Front: 2.50 X 17”
Rear: .3.00 X 17”
Tyres
Front: .100/80 - 17”
Rear: 130/70 - 17”
Pressures (cold):
Front: 1.8 bar (1.9 with passenger)
Rear: 2.0 bar (2.2 with passenger)
Electrical components
Generator
Ignition
3 phase, ac
Electronic with
variable spark
Spark advance
(before TDC)
Spark plug
Battery
15° at 1400rpm
32° at 3450rpm
NGK DPR8EA-9
ND X204EPR-U9
12V - 9Ah
advance
1-1
TORQUE SETTINGS
FASTENING
Engine to frame (rear)
Engine (front & upper)
Side stand to frame
Stand fastening nut
Pedal plate to frame
Chain guard
Handlebar to upper plate
Fork upper plate to rods
Fork lower plate to rods
Fork lower ring
Fork upper ring
Front brake shoe to fork
Shoe/pump fitting
Front wheel axle
Front wheel fastening bolt
Rear shock absorber to frame
Fork to frame
Rear wheel axle
Block retainer
Front brake pump fastening U-bolt
L-H lever holder fastening U-bolt
Throttle grip
Light/indicators device
Saddle to frame
Tank to frame
Filter casing to frame front
Filter casing to frame rear
Tool box to frame
R-H & L-H tube cover
Headlight bracket to upper plate
Km cntr bracket to headlight plate
Headlight to bracket
Front mudguard to fork
Rear light to mudguard
Breather
Handles to frame front
Handles to frame rear
Spray guard to frame
Pinion guard
Exhaust pipe to frame
Exhaust pipe to engine
Gear lever
THREAD
Screw M10x1.25
Screw M8
Screw M10x1.25
Nut M10x1.25
Screw M10
Screw M6
Nut M10
Screw M8
Screw M10x1.25
M25x1
M24x1
Screw M8
Screw M10
M 12x1.25
Screw M8
Screw M12
Screw M12x1.25
Screw M14x1.5
Screw M10x1.25
Screw M6
Screw M6
Screw M5
Screw M5
Screw M6
Screw M6
Screw M6
Screw M6
Screw M6
Screw M5
Screw M5
Screw M5
Screw M5
Screw M6
Nut M6
Screw M6
Screw M6
Screw M8
Screw M6
Screw M6
Screw M10x1.25
Nut M6
Screw M6
TORQUE in
Nm (kgm)
32÷40 (3.2÷4.0)
20÷25 (2.0÷2.5)
40÷45 (4.0÷4.5)
40÷45 (4.0÷4.5)
20÷22 (2.0÷2.2)
4÷7 (0.4÷0.7)
45÷50 (4.0÷5.0)
20÷22 (2.0÷2.2)
35÷40 (3.5÷4.0)
27÷33 (2.7÷3.3)
37÷43 (3.7÷4.3)
20÷22 (2.0÷2.2)
13÷17 (1.3÷1.7)
65÷70 (6.5÷7.0)
20÷22 (2.0÷2.2)
70÷80 (7.0÷8.0)
65÷70 (6.5÷7.0)
60÷70 (6.0÷7.0)
40÷45 (4.0÷4.5)
6÷7 (0.6÷0.7)
6÷7 (0.6÷0.7)
3÷4 (0.3÷0.4)
3÷4 (0.3÷0.4)
4÷7 (0.4÷0.7)
4÷7 (0.4÷0.7)
4÷7 (0.4÷0.7)
4÷7 (0.4÷0.7)
4÷7 (0.4÷0.7)
4÷7 (0.4÷0.7)
5÷8 (0.5÷0.8)
5÷8 (0.5÷0.8)
5÷8 (0.5÷0.8)
8÷10 (0.8÷1.0)
4÷7 (0.4÷0.7)
4÷7 (0.4÷0.7)
7÷10 (0.7÷1.0)
20÷22 (2.0÷2.2)
8÷10 (0.8÷1.0)
4÷7 (0.4÷0.7)
40÷45 (4.0÷4.5)
10÷12 (1.0÷1.2)
4÷7 (0.4÷0.7)
1-2,1
Tightening torque Nm (kgm) according to type of material tightened
Steel screw
8.8 diam.
M4
M5
M6
M7
M8
M10
M12
M14
Plastic with
metal spacer
2 (0.2)
4 (0.4)
6.5 (0.65)
Brass, Copper,
aluminium and
alloys
2 (0.2)
4 (0.4)
6.5 (0.65)
10.5 (1.05)
16 (1.6)
Iron, steel
3 (0.3)
6 (0.6)
10.5 (1.05)
17 (1.7)
26 (2.6)
52 (5.2)
100 (10.0)
145 (14.5)
1-2,2
MAINTENANCE AND TROUBLESHOOTING 2
SUB INDEX
Schedule Servicing times
Troubleshooting
Section - Page
2 - 1
2 - 2
2
SCHEDULED SERVICE
CHECK
REPLACE
Km X 1,000
Months
Nuts, bolts & fastenings
Spark Plug
Drive Chain (clean & lubricate)
Engine oil vapour recovery circuit
Engine idling speed
Air Cleaner
Engine oil mesh filter (clean)
Centrifuge engine oil filter (clean)
Brake Shoes (adjust)
Valve clearance (adjust)
Electrical system & battery
Brake & Clutch Levers (grease)
Front Brake fluid level
1 6 12 18 24 30 36 42 48 54 60
4 12 24 36
Drain at each of scheduled times in header above
Check/adjust at each of sched times in header above
Every 500 kms
Brake Fluid
Engine Oil
Front Brake Pads
Tyre pressure & wear
Headlight (check & adjust)
Drive chain guard, check for wear
Vehicle & brake test (road test)
Km counter transmission (lube)
Suspension (check operation)
Steering (adjust)
Throttle transmission (adjust)
Clutch transmission (adjust)
Transmission (lubricate)
Front Brake Pipe
Coupon labour time
65 75
Replace Every 2 Years
Replace Every 3,000 kms
130
75
130
90
130
75
130
75
155
Engine oil
Cable lube oil
Km counter
Trans. Grease
Joint/pin grease
Brake fluid
Specifications
SAE 20W/50 synthetic oil exceeding API SG
Four-stroke engine oil
Lithium-based soap grease, NLG13
Complex calcium-based soap grease NLG12
SAE J1703, NHTSA 116 DOT4, ISO 4925
Recommended
Selenia HI Scooter 4T
Selenia HI Scooter 4T
JOTA 3 FS
Arexons system TW249
TUTELA TOP 4
2-1
SYMPTOM
Engine turns
but does not
start.
Irregular idling
ratio, poor
performance,
the engine
stops.
The engine
misfires when
accelerating.
Fuel delay on
accelerating.
Poor
performance
or high fuel
consumption
Backfire.
Lean mixture.
Rich mixture.
Idling speed
too high.
TROUBLESHOOTING
FUEL FEED
POSSIBLE CAUSE
No fuel in tank.
Engine flooded.
No spark (faulty ignition
system).
Air cleaner clogged up.
Intake air leakage.
Faulty throttle control.
Faulty starter.
Faulty ignition system.
Dirt in fuel
Irregular air intake.
Incorrect idling ratio.
Incorrect idling mixture
screw calibration.
Poor compression in
cylinder.
Starter jammed.
Rich mixture.
Lean mixture.
Carburettor clogged up
Faulty ignition system.
Lean mixture.
Faulty ignition system.
Lean mixture.
Fuel feed clogged up.
Faulty ignition system.
Air cleaner clogged up.
Faulty ignition system.
Faulty carburettor.
Lean mixture.
Rich mixture.
Fuel nozzles clogged up.
Faulty float valve.
Fuel tank breather
clogged up.
Fuel filter clogged up.
Fuel feed tube squeezed.
Breather clogged up.
Incorrect air intake.
Air cleaner clogged up.
Taper pin or taper nozzle
worn.
Faulty float valve.
Float level too high.
Starter jammed.
Irregular air intake.
REMEDY
Refuel.
Turn the starter to position 3 (off). Open the throttle
fully and turn engine for a few seconds. Do not
persist in turning starter motor.
Check the connections and the battery charge.
Possible problems may concern the coil, the control
unit or the impulse generator.
Replace the air cleaner.
Check the air cleaner and the carburettor.
Check the throttle control free travel. If required
adjust the cable tension.
Check the starter (and lubricate if required).
Check the battery, the ignition coil, the control unit,
the spark plug and all connections.
Drain and wash out the tank & the carburettor.
Check the air cleaner, the carburettor & the intake
manifold.
Adjust.
Adjust.
Check the head and spark plug fastening. Replace
the gas rings or the head gasket if, required.
Release and lubricate the starter.
Check the air cleaner condition.
Check the air cleaner condition.
Overhaul the carburettor.
Check the battery, the ignition coil, the control unit,
the spark plug and the respective connections.
Check the air cleaner condition.
Check the battery, the ignition coil, the control unit,
the spark plug and the respective connections.
Check the air cleaner condition.
Clean the tube.
Check the battery, the ignition coil, the control unit,
the spark plug and the respective connections.
Replace the air cleaner.
Check the battery, the ignition coil, the control unit,
the spark plug and the respective connections.
Check and replace if required.
Check the air cleaner condition.
Check the air cleaner condition.
Overhaul the carburettor.
Replace the complete float.
Clean the hole.
Replace the filter.
Clean the tube.
Clean the tube.
Check the cleaner, the carburettor and the intake
manifold.
Replace the air cleaner.
Replace.
Replace the complete float.
Adjust.
Release and lubricate the starter.
Check the air cleaner, the carburettor & the intake
manifold.
2-2,1
CLUTCH AND GEARBOX LINKAGES
SYMPTOM
Clutch lever
is too stiff.
Clutch does not
disengage or bike
moves slowly with
clutch disengaged.
Clutch slips.
The gears
are difficult
to engage.
The gears
slip
POSSIBLE CAUSE
The clutch cable is damaged, twisted
or dirty.
Incorrect clutch cable route.
Faulty clutch disengagement plate
bearing.
Damaged clutch disengagement
mechanism.
Excessive clutch lever play.
Deformed clutch metal plates.
Loose clutch hub fastening nut.
Seized or worn clutch
disengagement mechanism.
Engine oil level too high or incorrect
viscosity.
Worn clutch friction plates.
Worn clutch springs.
No clutch lever play.
Incorrect clutch operation or
adjustment.
Bent or damaged gearbox fork.
Bent gearbox fork shaft.
Bent or damaged gearbox control
shaft.
Damaged gearbox drum grooves.
Worn gears or engagement cavities.
Bent gearbox fork shaft.
Broken gearbox drum retainer.
Worn or bent gearbox forks.
Broken gearbox linkage return
spring.
REMEDY
Check cable and replace it if required.
Re-route.
Replace damaged components.
Check cable route.
Adjust.
Replace.
Fasten.
Release, check wear and replace the
component, if required.
Check engine oil level and viscosity.
Replace complete plate assembly.
Replace clutch springs.
Adjust lever play.
Check if fault is adjustment or worn
component.
Replace damaged/worn parts.
Replace damaged/worn parts.
Replace damaged/worn parts.
Replace damaged/worn parts.
Replace damaged/worn parts.
Replace damaged/worn parts.
Replace damaged/worn parts.
Replace damaged/worn parts.
Replace damaged/worn parts.
2-2,2
CYLINDER HEAD AND VALVES
Head related problems generally have a considerable influence of engine
performance. Such problems can be diagnosed by checking
compression either with a sound sensor or a stethoscope to identify any
incorrect noise.
If the low ratio performance is poor, check whether there is white smoke
in the crankcase breather tube. The white smoke is the symptom of a
seized segment.
SYMPTOM
Poor
compression:
Valves
Poor
Compression:
Head
Excessive
smoke
Excessive
noise
Irregular idling
POSSIBLE CAUSE
Incorrect valve clearance.
Burnt or bent valve.
Incorrect timing.
Worn valve spring.
Imperfect head gasket tightness or
damaged gasket.
Deformed or cracked head.
Damaged valve stem oil seal.
Cracked head.
Damaged head gasket.
Incorrect valve clearance.
Seized valve or broken valve spring.
Worn or damaged rocker arm or
camshaft.
Loose or worn timing chain.
Worn or damaged timing chain
take-up device.
Worn camshaft gears.
Poor compression.
Air intake leakage.
Incorrectly adjusted decompressor.
REMEDY
Adjust.
Replace.
Adjust.
Replace.
Replace the gasket.
Replace the head and respective gasket.
Replace the part.
Replace.
Replace.
Adjust.
Replace.
Replace worn or damaged parts.
Replace worn or damaged parts.
Replace worn or damaged parts.
Replace the camshaft.
Check the head and spark plug fastening
Replace the piston rings and head gasket
Check air cleaner and carburettor.
Adjust.
2-2,3
Loading...