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.
This indicates special procedures that are to be followed
Important note to avoid damaging the vehicle.
|
This indicates certain precautions that are to be taken to avoid |
Warning |
|
|
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.”
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 |
Frame prefix |
Engine prefix |
COGUAR 125 cc |
ZAPM1700000001001 |
JD09E |
INDEX
|
Section |
Specifications |
1 |
Vehicle overhaul data |
1 |
Special equipment |
1 |
Maintenance and troubleshooting |
2 |
Electrical system |
3 |
Front suspension |
4 |
Rear suspension |
5 |
Braking system |
6 |
Pre-delivery operations |
7 |
GENERAL INFORMATION |
1 |
SUB INDEX |
|
|
Section - Page |
Specifications |
1 - 1 |
Torque settings |
1 - 2 |
1
SPECIFICATIONS
Dimensions and weight
Width |
760mm |
Length |
2020mm |
Wheelbase |
1500mm |
Height |
1130mm |
Dry weight |
141kg |
Engine |
|
Type |
4 stroke |
Cylinders |
1 |
Bore |
56.5mm |
Stroke |
49.5mm |
Capacity |
124cc |
Comp. Ratio |
9.2±0.5:1 |
Timing: single shaft with cams in head, two valves, chain driven on right-hand side.
Carburettor |
KEIHIN PDC3F |
|
Air Cleaner |
Paper |
|
Start up |
Electric starter |
|
Lubrication |
Forced, wet sump |
|
Fuel supply |
Unleaded petrol, |
|
|
carburettor, |
|
|
gravity system |
|
Cooling |
Air |
|
Performance |
|
|
Engine idling |
1400±100rpm |
|
Max power at |
7.9kW/8250rpm |
|
shaft |
||
|
||
Max torque at |
10Nm/7000rpm |
|
shaft |
||
|
||
Max speed |
102kph |
|
Electrical components |
||
Generator |
3 phase, ac |
|
|
Electronic with |
|
Ignition |
variable spark |
|
Spark advance
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
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) |
|
advance |
|
(before TDC) |
15° at 1400rpm |
|
32° at 3450rpm |
||
|
||
Spark plug |
NGK DPR8EA-9 |
|
ND X204EPR-U9 |
||
|
||
Battery |
12V - 9Ah |
1-1
TORQUE SETTINGS
FASTENING |
THREAD |
TORQUE in |
|
|
|
Nm (kgm) |
|
Engine to frame (rear) |
Screw M10x1.25 |
32÷40 |
(3.2÷4.0) |
(front & upper) |
Screw M8 |
20÷25 (2.0÷2.5) |
|
Side stand to frame |
Screw M10x1.25 |
40÷45 (4.0÷4.5) |
|
Stand fastening nut |
Nut M10x1.25 |
40÷45 |
(4.0÷4.5) |
Pedal plate to frame |
Screw M10 |
20÷22 (2.0÷2.2) |
|
Chain guard |
Screw M6 |
4÷7 (0.4÷0.7) |
|
Handlebar to upper plate |
Nut M10 |
45÷50 (4.0÷5.0) |
|
Fork upper plate to rods |
Screw M8 |
20÷22 |
(2.0÷2.2) |
Fork lower plate to rods |
Screw M10x1.25 |
35÷40 (3.5÷4.0) |
|
Fork lower ring |
M25x1 |
27÷33 |
(2.7÷3.3) |
Fork upper ring |
M24x1 |
37÷43 |
(3.7÷4.3) |
Front brake shoe to fork |
Screw M8 |
20÷22 (2.0÷2.2) |
|
Shoe/pump fitting |
Screw M10 |
13÷17 (1.3÷1.7) |
|
Front wheel axle |
M 12x1.25 |
65÷70 |
(6.5÷7.0) |
Front wheel fastening bolt |
Screw M8 |
20÷22 (2.0÷2.2) |
|
Rear shock absorber to frame |
Screw M12 |
70÷80 |
(7.0÷8.0) |
Fork to frame |
Screw M12x1.25 |
65÷70 (6.5÷7.0) |
|
Rear wheel axle |
Screw M14x1.5 |
60÷70 |
(6.0÷7.0) |
Block retainer |
Screw M10x1.25 |
40÷45 |
(4.0÷4.5) |
Front brake pump fastening U-bolt |
Screw M6 |
6÷7 (0.6÷0.7) |
|
L-H lever holder fastening U-bolt |
Screw M6 |
6÷7 |
(0.6÷0.7) |
Throttle grip |
Screw M5 |
3÷4 |
(0.3÷0.4) |
Light/indicators device |
Screw M5 |
3÷4 |
(0.3÷0.4) |
Saddle to frame |
Screw M6 |
4÷7 (0.4÷0.7) |
|
Tank to frame |
Screw M6 |
4÷7 (0.4÷0.7) |
|
Filter casing to frame front |
Screw M6 |
4÷7 |
(0.4÷0.7) |
Filter casing to frame rear |
Screw M6 |
4÷7 (0.4÷0.7) |
|
Tool box to frame |
Screw M6 |
4÷7 |
(0.4÷0.7) |
R-H & L-H tube cover |
Screw M5 |
4÷7 (0.4÷0.7) |
|
Headlight bracket to upper plate |
Screw M5 |
5÷8 (0.5÷0.8) |
|
Km cntr bracket to headlight plate |
Screw M5 |
5÷8 |
(0.5÷0.8) |
Headlight to bracket |
Screw M5 |
5÷8 |
(0.5÷0.8) |
Front mudguard to fork |
Screw M6 |
8÷10 |
(0.8÷1.0) |
Rear light to mudguard |
Nut M6 |
4÷7 |
(0.4÷0.7) |
Breather |
Screw M6 |
4÷7 (0.4÷0.7) |
|
Handles to frame front |
Screw M6 |
7÷10 (0.7÷1.0) |
|
Handles to frame rear |
Screw M8 |
20÷22 (2.0÷2.2) |
|
Spray guard to frame |
Screw M6 |
8÷10 (0.8÷1.0) |
|
Pinion guard |
Screw M6 |
4÷7 |
(0.4÷0.7) |
Exhaust pipe to frame |
Screw M10x1.25 |
40÷45 |
(4.0÷4.5) |
Exhaust pipe to engine |
Nut M6 |
10÷12 |
(1.0÷1.2) |
Gear lever |
Screw M6 |
4÷7 (0.4÷0.7) |
|
1-2,1
Tightening torque Nm (kgm) according to type of material tightened
|
|
|
Brass, Copper, |
|
|
|
Steel screw |
Plastic with |
aluminium and |
Iron, steel |
|||
8.8 diam. |
metal spacer |
alloys |
|
|
||
M4 |
2 |
(0.2) |
2 |
(0.2) |
3 |
(0.3) |
M5 |
4 |
(0.4) |
4 |
(0.4) |
6 |
(0.6) |
M6 |
6.5 |
(0.65) |
6.5 |
(0.65) |
10.5 |
(1.05) |
M7 |
|
|
10.5 |
(1.05) |
17 |
(1.7) |
M8 |
|
|
16 |
(1.6) |
26 |
(2.6) |
M10 |
|
|
|
|
52 |
(5.2) |
M12 |
|
|
|
|
100 |
(10.0) |
M14 |
|
|
|
|
145 |
(14.5) |
1-2,2
MAINTENANCE AND TROUBLESHOOTING 2
SUB INDEX
|
Section - Page |
Schedule Servicing times |
2 - 1 |
Troubleshooting |
2 - 2 |
2
SCHEDULED SERVICE
|
CHECK |
Km X 1,000 |
1 |
6 |
12 |
18 |
24 30 36 42 48 54 60 |
|
|||||||
|
REPLACE |
Months |
4 |
12 |
24 |
36 |
|
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)
Every 500 kms 
Drain at each of scheduled times in header above Check/adjust at each of sched times in header above
Front Brake fluid level
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
Replace Every 2 Years
Replace Every 3,000 kms
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65 |
75 130 |
75 |
130 |
90 |
130 |
75 |
130 |
75 155 |
||||||||||||||||||
Engine oil Cable lube oil Km counter Trans. Grease Joint/pin grease Brake fluid
Specifications |
Recommended |
SAE 20W/50 synthetic oil exceeding API SG |
Selenia HI Scooter 4T |
Four-stroke engine oil |
Selenia HI Scooter 4T |
Lithium-based soap grease, NLG13 |
JOTA 3 FS |
Complex calcium-based soap grease NLG12 |
Arexons system TW249 |
SAE J1703, NHTSA 116 DOT4, ISO 4925 |
TUTELA TOP 4 |
2-1
TROUBLESHOOTING
FUEL FEED
SYMPTOM |
POSSIBLE CAUSE |
REMEDY |
|
|
|
|
No fuel in tank. |
Refuel. |
|
|
|
|
|
Turn the starter to position 3 (off). Open the throttle |
|||
|
Engine flooded. |
fully and turn engine for a few seconds. |
Do not |
||
Engine turns |
|
persist in turning starter motor. |
|
|
|
|
Check the connections and the battery |
charge. |
|||
but does not |
No spark (faulty ignition |
||||
Possible problems may concern the coil, the control |
|||||
start. |
system). |
||||
unit or the impulse generator. |
|
|
|||
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|
||
|
Air cleaner clogged up. |
Replace the air cleaner. |
|
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|
Intake air leakage. |
Check the air cleaner and the carburettor. |
|
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|
|
Check the throttle control free travel. If required |
|
||
|
Faulty throttle control. |
adjust the cable tension. |
|
|
|
|
Faulty starter. |
Check the starter (and lubricate if required). |
|
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|
|
Faulty ignition system. |
Check the battery, the ignition coil, the control unit, |
|
||
|
the spark plug and all connections. |
|
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||
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|
||
|
Dirt in fuel |
Drain and wash out the tank & the carburettor. |
|||
|
Irregular air intake. |
Check the air cleaner, the carburettor & the intake |
|
||
Irregular idling |
manifold. |
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|
||
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|
|||
Incorrect idling ratio. |
Adjust. |
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|
||
ratio, poor |
|
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Incorrect idling mixture |
|
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|
||
performance, |
Adjust. |
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|
||
screw calibration. |
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|
|||
the engine |
|
|
|
||
Poor compression in |
Check the head and spark plug fastening. |
Replace |
|||
stops. |
|||||
cylinder. |
the gas rings or the head gasket if, required. |
|
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||
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|||
|
Starter jammed. |
Release and lubricate the starter. |
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Rich mixture. |
Check the air cleaner condition. |
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Lean mixture. |
Check the air cleaner condition. |
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Carburettor clogged up |
Overhaul the carburettor. |
|
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|
The engine |
Faulty ignition system. |
Check the battery, the ignition coil, the control unit, |
|
||
misfires when |
the spark plug and the respective connections. |
||||
accelerating. |
Lean mixture. |
Check the air cleaner condition. |
|
|
|
Fuel delay on |
Faulty ignition system. |
Check the battery, the ignition coil, the control unit, |
|
||
the spark plug and the respective connections. |
|||||
accelerating. |
|
||||
Lean mixture. |
Check the air cleaner condition. |
|
|
||
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|
|||
Poor |
Fuel feed clogged up. |
Clean the tube. |
|
|
|
performance |
Faulty ignition system. |
Check the battery, the ignition coil, the control unit, |
|
||
or high fuel |
the spark plug and the respective connections. |
||||
|
|||||
consumption |
Air cleaner clogged up. |
Replace the air cleaner. |
|
|
|
|
Faulty ignition system. |
Check the battery, the ignition coil, the control unit, |
|
||
|
the spark plug and the respective connections. |
||||
Backfire. |
|
||||
Faulty carburettor. |
Check and replace if required. |
|
|
||
|
Lean mixture. |
Check the air cleaner condition. |
|
|
|
|
Rich mixture. |
Check the air cleaner condition. |
|
|
|
|
Fuel nozzles clogged up. |
Overhaul the carburettor. |
|
|
|
|
Faulty float valve. |
Replace the complete float. |
|
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|
|
Fuel tank breather |
Clean the hole. |
|
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|
|
clogged up. |
|
|
||
Lean mixture. |
|
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|
||
Fuel filter clogged up. |
Replace the filter. |
|
|
||
|
Fuel feed tube squeezed. |
Clean the tube. |
|
|
|
|
Breather clogged up. |
Clean the tube. |
|
|
|
|
Incorrect air intake. |
Check the cleaner, the carburettor and the intake |
|
||
|
manifold. |
|
|
||
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|
||
|
Air cleaner clogged up. |
Replace the air cleaner. |
|
|
|
|
Taper pin or taper nozzle |
Replace. |
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worn. |
|
|
||
Rich mixture. |
|
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|
||
Faulty float valve. |
Replace the complete float. |
|
|
||
|
Float level too high. |
Adjust. |
|
|
|
|
Starter jammed. |
Release and lubricate the starter. |
|
|
|
Idling speed |
Irregular air intake. |
Check the air cleaner, the carburettor & the intake |
|
||
too high. |
manifold. |
|
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||
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|||
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|
|
2-2,1
CLUTCH AND GEARBOX LINKAGES
SYMPTOM |
POSSIBLE CAUSE |
|
REMEDY |
|
|||||
|
|
The clutch cable is damaged, twisted |
Check cable and replace it if required. |
||||||
Clutch lever |
or dirty. |
|
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Incorrect clutch cable route. |
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Re-route. |
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is too stiff. |
Faulty |
clutch disengagement |
plate |
Replace damaged components. |
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bearing. |
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Damaged |
clutch |
disengagement |
Check cable route. |
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mechanism. |
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Clutch does not |
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Excessive clutch lever play. |
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Adjust. |
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Deformed clutch metal plates. |
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Replace. |
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disengage or bike |
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Loose clutch hub fastening nut. |
Fasten. |
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moves slowly with |
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clutch disengaged. |
S e i z e d |
o r w o r n c l u t c h |
Release, check wear and replace the |
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disengagement mechanism. |
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component, if required. |
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Engine oil level too high or incorrect |
Check engine oil level and viscosity. |
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Clutch slips. |
viscosity. |
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|
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Worn clutch friction plates. |
|
Replace complete plate assembly. |
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Worn clutch springs. |
|
|
Replace clutch springs. |
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|
|
No clutch lever play. |
|
|
Adjust lever play. |
|
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|
|
Incorrect |
clutch |
operation or |
Check if fault is adjustment or worn |
|
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The gears |
adjustment. |
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component. |
||||
Bent or damaged gearbox fork. |
Replace damaged/worn parts. |
|
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are difficult |
Bent gearbox fork shaft. |
|
Replace damaged/worn parts. |
|
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to engage. |
Bent or damaged gearbox control |
Replace damaged/worn parts. |
|
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|
|
shaft. |
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Damaged gearbox drum grooves. |
Replace damaged/worn parts. |
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|
|
Worn gears or engagement cavities. |
Replace damaged/worn parts. |
|
|||||
The gears |
Bent gearbox fork shaft. |
|
Replace damaged/worn parts. |
|
|||||
Broken gearbox drum retainer. |
|
Replace damaged/worn parts. |
|
||||||
slip |
Worn or bent gearbox forks. |
|
Replace damaged/worn parts. |
|
|||||
|
|
Broken |
gearbox |
linkage |
return |
Replace damaged/worn parts. |
|||
|
|
spring. |
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|
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|
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|
|
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|
|
|
|
|
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 |
POSSIBLE CAUSE |
REMEDY |
||
Poor |
Incorrect valve clearance. |
Adjust. |
||
Burnt or bent valve. |
Replace. |
|||
compression: |
||||
Incorrect timing. |
Adjust. |
|||
Valves |
||||
Worn valve spring. |
Replace. |
|||
|
||||
Poor |
Imperfect head gasket tightness or |
Replace the gasket. |
||
Compression: |
damaged gasket. |
|
|
|
Head |
Deformed or cracked head. |
Replace the head and respective gasket. |
|
|
Excessive |
Damaged valve stem oil seal. |
Replace the part. |
|
|
Cracked head. |
Replace. |
|||
smoke |
||||
Damaged head gasket. |
Replace. |
|||
|
||||
|
Incorrect valve clearance. |
Adjust. |
||
|
Seized valve or broken valve spring. |
Replace. |
||
Excessive |
Worn or damaged rocker arm or |
Replace worn or damaged parts. |
||
camshaft. |
|
|
||
noise |
|
|
||
Loose or worn timing chain. |
Replace worn or damaged parts. |
|||
|
||||
|
Worn or damaged timing chain |
Replace worn or damaged parts. |
||
|
take-up device. |
|
|
|
|
Worn camshaft gears. |
Replace the camshaft. |
||
|
Poor compression. |
Check the head and spark plug fastening |
||
Irregular idling |
|
Replace the piston rings and head gasket |
||
Air intake leakage. |
Check air cleaner and carburettor. |
|||
|
Incorrectly adjusted decompressor. |
Adjust. |
||
|
|
|
|
|
2-2,3
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