Piaggio WORKSHOP Beverly 125 250, Beverly 125 250 workshop Workshop Manual

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WORKSHOP MANUAL

618162

B 125-250

WORKSHOP

B 125-250

MANUAL

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/models shown in this publication are available in all countries. The availability of single

versions should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

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

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

WORKSHOP MANUAL

B 125-250

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

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

B 125-250 Characteristics

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 solvents. 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.

CHAR - 7

Characteristics B 125-250

Vehicle identification

VEHICLE IDENTIFICATION (125)

Specification Desc./Quantity

Chassis prefix (125) ZAPM 28400 ÷ 1001

Engine prefix (125) M284M

VEHICLE IDENTIFICATION (250)

Specification Desc./Quantity

Chassis prefix (250) ZAPM 28500 ÷ 1001

Engine prefix (250) M285M

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity

Kerb weight in running order 149 kg

Width (over mirrors) 837 mm

Length 2100 mm

Wheelbase 1455 mm

Saddle height 785 mm

Engine

ENGINE

Specification

Engine type Single-cylinder, four-stroke, four-valve, liquid-cooled.

Timing system Single overhead camshaft driven by chain on left side, three-

Bore x stroke (125) 57 x 48,6 mm

Bore x stroke 72 x 60 mm

Cubic capacity (125) 124 cm³

Cubic capacity 244,290 cm3 Compression ratio (125) 12:1 Compression ratio (250) 10,5 - 11,5 : 1

Keihin Carburettor (125 - 250) CVEK-30

Walbro Carburettor (125) WVF 7G* Ø 29 Walbro Carburettor (250) WVF-7S*

Engine idle speed 1650 ± 50 rpm

CO adjustment 3,8 ± 07%

Air filter Sponge-type damped with a 50% Selenia Air Filter Oil - 50%

Starter System Electric starter motor

Lubrication Engine lubrication with lobe pump (inside crankcase) controlled

by a chain with double filter: mesh and paper.

Fuel supply with unleaded petrol; carburettor and vacuum pump. Max. power (crankshaft) 125cc 11 kw (15 CV) at 9700 rpm Max. power (crankshaft) 250cc 16,18 Kw (22CV) a 8250 g/min.

Top speed (125) 105 Km/h Top speed (250) 124 Km/h

*The identification marking may change whenever the carburettor is updated

Desc./Quantity

arm rockers with threaded adjuster.

unleaded petrol mixture

CHAR - 8

B 125-250 Characteristics

Transmission

TRASMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator with torque server,

Capacities

CAPACITIES

Specification Desc./Quantity

Engine oil (125) ~ 1100 cc Engine oil (250) ~ 1200 cc

Petrol tank approx. 10 l (including reserve approx. 2.5 l)

Rear hub oil 250 cc

V belt, self-ventilating automatic centrifugal dry clutch, gear reduction unit and transmission housing with forced air circulation

cooling.

Electrical system

ELECTRICAL COMPONENTS

Specification

Ignition type Electronic capacitive discharge ignition (CDI) and variable ad-

variable ignition advance (before T.D.C.) 125 10°±1° at 2000 rpm - 34°±1° at 6000 rpm

Ignition advance (before T.D.C) 10° ± 1 at 2000 rpm.

Spark plug (125) NGK CR 8EB Spark plug (250) CHAMPION RG4HC

Battery 12V-12Ah

Fuses N° 2 15A, N°1 10A, N° 2 7,5A, N° 3 4A

Generator alternating current

BV 125: spark-plug

We inform you that the spark-plug NGKCR8EB has been replaced by the CHAMPION RG4HC starting with engine number M281M14016 , in order to improve the general performance of the engine. The distance between the electrodes does not change and is still at 0,7 ÷ 0,8 mm.

Desc./Quantity

vance, with separate HV coil.

28° ± 1 at 6500 rpm.

Frame and suspensions

FRAME AND SUSPENSIONS

Specification

Type of chassis Welded tubular steel chassis with stamped sheet reinforce-

Front suspension Hydraulic telescopic fork with advanced wheel pin and Ø 35

Front fork max. stroke 104 mm

Rear suspension Engine with swinging fork attached to frame by means of an

arm with 2 degrees of freedomPair of double-acting hydraulic

shock absorbers and coaxial springs with preloading adjust-

Rear shock absorber max. travel 95.5 mm

Desc./Quantity

ments.

mm stem

ment in four positions.

CHAR - 9

Characteristics B 125-250

Brakes

BRAKES

Specification Desc./Quantity

Front brake Disc brake, diameter 260 mm and floating calliper with twin

Rear brake Disc brake, diameter 260 mm and calliper with two counteract-

plungers and hydraulic control (lever on the far right of the han-

dlebar)

ing plungers and hydraulic control (lever on the far left of the

handlebar)

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheel rim Light alloy, 3.00 x 16" Rear wheel rim Light alloy, 3.50 x 16"

Front tyre 110/70-16" M/C 52P Tubeless

Rear tyre 140/70-16" M/C 65P Tubeless Front wheel tyre pressure (when cold) 2.1 bar Rear wheel tyre pressure (when cold) 2.3 bar

Rear wheel tyre pressure (with driver and passenger) (when

cold)

N.B.

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

2.5 bar

Secondary air

The SAS for 125cc leader engines operates in a similar manner to the SAS for 2T engines. The differences are the following: instead of entering through the muffler as for 2T engine, the secondary air enters directly in the discharge pipe on the head.

CHAR - 10

B 125-250 Characteristics

The 2T reed valve has a diaphragm. The unit, indicated by an arrow in the figure, has a cut-off connected to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions in the muffler.

Air is drawn through the opening «A», goes through the first filter and is channelled through the opening «B».

Air gets to the second filter «B» through the opening shown in the figure. Now, the filtered air enters the diaphragm device, and then is channelled to the head.

The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reaction of the catalytic converter.

CHAR - 11

Characteristics B 125-250

The working principle of the SAS for Quasar 250 cc Euro 2 engines is entirely similar to the SAS employed on 2-stroke engines. The main differences are the following: Secondary air enters directly into the exhaust duct on the cylinder head, instead of entering through the exhaust pipe as in two-stroke engines. The reed valve found on 2-stroke engines is here replaced by a membrane. Unit «A», shown in the figure, is provided with a cut-off connected to the vacuum inlet on the intake manifold to shut air inlet during deceleration, so to prevent detonations in the silencer. Air is sucked in through hole «B» and flows inside the duct into air-box «C» where it is filtered by filtering element «D». The filtered air now enters membrane device «A», through duct «E» and is then guided towards the head. Flowing through pipe «F», flanged to the head, secondary air reaches the exhaust duct thus providing oxygen addition to the unburnt gases just before they enter the catalytic converter. The efficiency of the catalyzing process is therefore increased.

CHAR - 12

B 125-250 Characteristics

Carburettor

125cc Version

Kehin

Walbro

KEIHIN CARBURETTOR 125

Specification

Depression type CVEK30

Printing on the body CVK

Device CUT-OFF Not present

Max. jet 105

Minimum jet 35

Max. air jet 70

Minimum air jet 130

Minimum mixture set screw initial opening 2 ± ¼

Conical pin Ø 2,450

Diffuser nozzle Ø 2.8

Starter air jet Ø 1,5

Starter jet 42

Starter device resistance ~ 20 Ω

Venturi choke Ø 29

Throttle valve Ø 30,5

Choke maximum cone Ø 47

Desc./Quantity

WALBRO CARBURETTOR

Specification

Type to depression WVF-7G*

Body stamping 7GO

Device CUT-OFF Not present

Max. jet 108

Minimum jet 36

Max. air jet 115

Minimum air jet 100

Throttle valve spring 100 g

Minimum mixture set screw initial opening 2 5/8 ± 1/2

Tapered pin stamping 51C

Tapered pin notches from above 2

Diffuser nozzle Ø 2.7

Gasoline inlet hole Ø 1.5

Starter air jet 200

Desc./Quantity

CHAR - 13

Characteristics B 125-250

Specification Desc./Quantity

Starter diffuser jet 130

Starter jet 50

Starter pin diameter Ø 1,78

Starter device resistance ~ 40 Ω

Venturi diffuser Ø 29 (30.3x27)

Throttle valve Ø 33

Choke maximum cone Ø 48,0

250cc Version

Keihin

KEIHIN CARBURETTOR 250

Specification Desc./Quantity

Depression type CVEK30

Printing on the body CVK

CUT-OFF device Present

Max jet 100

Minimum jet 38

Max. air jet 70

Minimum air jet 115

Idle mixture adjustment screw initial opening 2½ ± ¼

Conical pin Ø 2,530

Diffuser nozzle Ø 2.8

Starter air jet Ø 1,5

Starter jet 42

Starter device resistance ~ 20 Ω

Venturi choke Ø 29

Throttle valve Ø 30,5

Choke maximum cone Ø 47

Walbro

WALBRO CARBURETTOR250

Specification

Depression type WVF-7S*

Printing on the body 7S

CUT-OFF device Present

Max. jet 118

Minimum jet 34

Max. air jet 150

Minimum air jet 31

Throttle valve spring 120 g

Idle mixture adjustment screw initial opening 3 ± ½

Conical pin 465

Conical pin top notches 3

Diffuser nozzle Ø 2.7

Gasoline inlet hole Ø 1.5

Starter air jet 200

Starter diffuser jet 130

Starter jet 50

Starter pin diameter Ø 1,78

Starter device resistance ~ 40 Ω

Venturi diffuser Ø 29 (30.3x27)

Throttle valve Ø 33

Choke maximum cone Ø 48,0

*The identification letter can vary every time the carburettor is updated.

Desc./Quantity

CHAR - 14

B 125-250 Characteristics

Tightening Torques

STEERING

Name Torque in Nm

Upper steering ring nut 30 ÷ 36

Steering lower ring nut 10 ÷ 13 then loosen by 90°

Handlebar fixing screw (*) 45 ÷ 50

Fixing screws for handlebar control assembly U-bolts 7 ÷ 10

FRAME ASSEMBLY

Name Torque in Nm

Engine-swinging arm bolt 64 - 72

Chassis-swinging arm pin nut 64 - 72

Spacer locking threaded bushing 13 ÷ 17

Spacer locking threaded bushing lock nut 90 ÷ 110

Frame arm-engine arm coupling pin nut 33 ÷ 41

Bolt of the Silent block support plate 64 - 72

Centre stand bolt 25 ÷ 30

Side stand fixing bolt 35 ÷ 40

Side stand switch screw 5 ÷ 7

FRONT SUSPENSION

Name

Fixing screw for pumping elements to lower fork plate 20 ÷ 25

Front wheel axle 45 ÷ 50

Fork leg screw 6 ÷ 7

front mudguard to plate fixing screw 4.5 ÷ 7

Fixing screw for mudguard plate to fork 9 ÷ 11

Torque in Nm

FRONT BRAKE

Name

Brake fluid pump-hose fitting 16 ÷ 20

Brake fluid pipe-calliper fitting 16 ÷ 20

Calliper to fork tightening screw 20 ÷ 25

Disc tightening screw (°) 5 - 6

Oil bleed screw 12 - 16

Pad fastening pin 19.6 ÷ 24.5

Torque in Nm

REAR SUSPENSION

Name

Left lower shock absorber support bolt 20 ÷ 25

Upper shock absorber clamp 33 ÷ 41 Lower shock absorber clamp 33 ÷ 41

Rear wheel axle 104 ÷ 126

Fixing screw for wheel rim to hub 34 ÷ 38

Muffler support arm to engine screws (*) 20 ÷ 25

Torque in Nm

REAR BRAKE

Name

Brake fluid pump-hose fitting 16 ÷ 20

Brake fluid pipe-calliper fitting 16 ÷ 20

Flexible/ rigid oil pipe coupling 9 ÷ 11

Rear disc tightening bolt 11 ÷ 13

Oil bleed screw 12 - 16

Screw tightening calliper to the support 20 ÷ 25

Screw fixing rear brake calliper support to engine 20 ÷ 25

Pad fastening pin 20 ÷ 25

Torque in Nm

CHAR - 15

Characteristics B 125-250

MUFFLER

Name Torque in Nm

Screw fixing manifold to muffler 15.5 ÷ 18.5

Muffler heat guard fixing screw 5 - 6

Exhaust fumes inlet screw 22 ÷ 26

Screw fixing muffler support arm to crankcase 33 ÷ 41

Nuts fixing muffler to support arm 27 ÷ 30

Nut fixing muffler to cylinder head 16 ÷ 18

LUBRICATION

Name Torque in Nm

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/mesh filter 24 ÷ 30

Oil filter 4 ÷ 6

Oil pump cover screws 0.7 ÷ 0.9

Screws fixing oil pump to crankcase 5 - 6

Oil pump control crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

CYLINDER HEAD

Name Torque in Nm

Spark plug 12 ÷ 14

Nuts fixing head to cylinder (1) (^) 9 ÷ 11 + 180°

Head fixing side screws 11 ÷ 12

Starter ground screw 7 ÷ 8.5

M5 side screw fastening washers on cam shaft (125 cc) 7 ÷ 8,5

Tappet set screw lock nut 6 ÷ 8

Timing chain tensioner slider screw 10 ÷ 14

Starter ground support screw 11 ÷ 15

M6 central screw fastening washers on cam shaft (125 cc) 11 ÷ 15

Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 4 ÷ 6

TRANSMISSION

Name

Belt support roller screw 11 ÷ 13

Clutch unit nut on driven pulley 45 ÷ 50

Drive pulley nut 75 ÷ 83

Transmission cover screws 11 ÷ 13 Nm

Driven pulley shaft nut 54 ÷ 60

Rear hub cover screws 24 ÷ 27

Torque in Nm

FLYWHEEL

Name

Flywheel cover fixing screws 5 - 6

Stator assembly screws (°) 3 ÷ 4

Flywheel nut (125) 52 ÷ 58 Flywheel nut (250) 94 ÷ 102

Pick-Up clamping screws 3 ÷ 4

Screw fixing freewheel to flywheel 13 ÷ 15

Torque in Nm

CRANKCASE AND CRANKSHAFT

Name

Internal engine crankcase bulkhead (transmission-side half

shaft) screws

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing system cover screws (°) 3.5 ÷ 4.5

CHAR - 16

Torque in Nm

4 ÷ 6

B 125-250 Characteristics

COOLING

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

Screws for water pump rotor driving link 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Bleed screw: 3

(°) Apply LOCTITE 242 medium-strength threadlock (*) The two screws must be tightened to the prescribed torque after having done so with the rear wheel axle nut. Safety locks: see "Pre-delivery operations". (^) Fasten the nuts in two crossed passes. (1) Before fitting the nuts lubricate them with engine oil

Overhaul data

Assembly clearances

Cylinder - piston assy.

ENGINE 125 COUPLING CATEGORIES

Name

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059

Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059 Cylinder 1st Oversize A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059 Cylinder 1st Oversize B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059

Piston 1st Oversize C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059 Piston 1st Oversize D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059

Initials Cylinder Piston Play on fitting

CHAR - 17

Characteristics B 125-250

Name Initials Cylinder Piston Play on fitting

Cylinder 2nd Oversize A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059 Cylinder 2nd Oversize B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059

Piston 2nd Oversize C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059

Piston 2nd Oversize D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059 Cylinder 3rd Oversize A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059 Cylinder 3rd Oversize B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059

Piston 3rd Oversize C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059 Piston 3rd Oversize D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

COUPLING CATEGORIES ENGINE 250

Name

Cylinder / piston A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 Cylinder / piston B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044 Cylinder / piston C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044 Cylinder / piston D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044

Initials Cylinder Piston Play on fitting

Piston rings

UPRATING TABLE MOTOR 125

Name

Compression ring 57 x 1 A 0.15 ÷ 0.30

Description Dimensions Initials Quantity

CHAR - 18

B 125-250 Characteristics

Name Description Dimensions Initials Quantity

Oil scraper ring 57 x 1 A 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35

OVERSIZES MOTOR 250

Name Description Dimensions Initials Quantity

Compression ring 72 x 1.5 A 0.15 ÷ 0.30

Oil scraper ring 72 x 1 A 0.20 ÷ 0.40 Oil scraper ring 72 x 2.5 A 0.20 ÷ 0.40

Crankcase - crankshaft - connecting rod

CRANKCASE - CRANKSHAFT- CRANKSHAFT HALF-BEARINGS

Name Description Dimensions Initials Quantity

Crankshaft half-bearing Type A - red 1.970 ÷ 1.973 Crankshaft half-bearing Category B - blue 1.973 ÷ 1.976 Crankshaft half-bearing Type C - yellow 1.976 ÷ 1.979

Crankshaft class 1 -

Crankcase class 1

Crankshaft class 1 -

Crankcase class 2

Crankshaft class 2 -

Crankcase class 1

Crankshaft class 2 -

Crankcase class 2

Crankshaft Category 1 28.998 ÷ 29.004 Crankshaft Class 2 29.004 ÷ 29.010 Crankcase Category 1 32.959 ÷ 32.965 Crankcase Class 2 32.953 ÷ 32.959

C - C B - B B - B A - A

Fitting clearance

Crankshaft/ crankcase axial clearance 0.15 - 0.40 mm (when cold)

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name

Half-shaft, transmission

side

Description Dimensions Initials Quantity

16.6 +0-0.05 A D = 0.20 - 0.50

CHAR - 19

Characteristics B 125-250

Name Description Dimensions Initials Quantity

Flywheel-side half-shaft 16.6 +0-0.05 B D = 0.20 - 0.50

Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50

Spacer tool 51.4 +0.05 E D = 0.20 - 0.50

Slot packing system

Characteristic

Compression ratio, 125 models

Cr: 11.50 ÷ 13:1

Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa.

N.B.

NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND ON A RECTIFIED PLANE.

VERSION 125 WITH FIBRE HEAD GASKET (1.1)

Name

Shimming 125 - Cylinder 67 - Head gas-

ket 1.1 - Base gasket 0.4

Shimming 125 - Cylinder 67 - Head gas-

ket 1.1 - Base gasket 0.6

Measure A Thickness

2.20 ÷ 2.45 0.4 ± 0.05

2.45 ÷ 2.70 0.6 ± 0.05

Characteristic

Compression ratio, 125 models

CHAR - 20

B 125-250 Characteristics

Cr: 11.50 ÷ 13:1

N.B.

VERSION 125 WITH METAL HEAD GASKET (0.3)

Name

Shimming 125 - Cylinder 67.8 - Head

gasket 0.3 - Base gasket 0.4

Shimming 125 - Cylinder 67.8 - Head

gasket 0.3 - Base gasket 0.6

Measure A Thickness

1.40 ÷ 1.65 0.4 ± 0.05

1.65 ÷ 1.90 0.6 ± 0.05

Characteristic

Compression ratio 250 version

CR: 10.5 ÷ 11.5 : 1

CHAR - 21

Characteristics B 125-250

N.B.

MEASUREMENT "A" TO BE TAKEN IS A VALUE OF PISTON RE-ENTRY, IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER. THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER, THE LESS THE BASE GASKET IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA.

ENGINE 250 SHIMMING

Name

shimming 3.70 - 3.60 0.4 ± 0.05 shimming 3.60 - 3.40 0.6 ± 0.05 shimming 3.40 - 3.30 0.8 ± 0.05

CHAR - 22

Measure A Thickness

B 125-250 Characteristics

Oversizes

Name

Compression ring 1st

oversize

Oil scraper ring 1st

Oversize

Oil scraper ring 1st

Oversize

Compression ring 2nd

Oversize

Oil scraper ring 2nd

Oversize

Oil scraper ring 2nd

Oversize

Compression ring 3rd

Oversize

Oil scraper ring 3rd

Oversize

Oil scraper ring 3rd

Oversize

Products

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

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-

AGIP GP 330 Calcium complex soap-based grease

AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the

Product

OVERSIZES

Description Dimensions Initials Quantity

57.2 x 1 A 0.15 ÷ 0.30

57.2 x 1 A 0.10 ÷ 0.30

57.2 x 2.5 A 0.15 ÷ 0.35

57.4 x 1 A 0.15 ÷ 0.30

57.4 x 1 A 0.10 ÷ 0.30

57.4 x 2.5 A 0.15 ÷ 0.35

57.6 x 1 A 0.15 ÷ 0.30

57.6 x 1 A

57.6 x 2.5 A 0.15 ÷ 0.35

PRODUCT

Description Specifications

quirements of API GL3 specifications

creased adhesiveness

with NLGI 2; ISO-L-XBCIB2

Grease (brake control levers, throttle

grip)

requirements of API SL, ACEA A3, JASO

MA specifications

CHAR - 23

Characteristics B 125-250

Product Description Specifications

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze

MONTBLANC MOLYBDENUM

GREASE

AGIP GREASE PV2 Grease for steering bearings and spindle

AGIP CITY HI TEC 4T Four-stroke engine oil Lubricating oil for flexible shafts (throttle

Grease for driven pulley shaft adjusting ring and movable driven pulley housing

seats

fluid, CUNA NC 956-16

Grease with Molybdenum disulphide

Soap-based lithium and zinc oxide

grease containing NLGI 2; ISO-L-

XBCIB2 of the swinging arm

control)

CHAR - 24

INDEX OF TOPICS

TOOLING TOOL

Tooling B 125-250

APPROPRIATE TOOLS

Stores code Description

020151Y Air heater

020331Y Digital multimeter

020648Y Single battery charger

001467Y014 Pliers to extract ø 15-mm bearings

020412Y 15 mm guide

TOOL - 26

B 125-250 Tooling

Stores code Description

020335Y Magnetic support for dial gauge

020565Y Flywheel lock calliper spanner

020439Y 17 mm guide

020359Y 42x47-mm adaptor

020363Y 20 mm guide

TOOL - 27

Tooling B 125-250

Stores code Description

020459Y Punch for fitting bearing on steering tube

020458Y Puller for lower bearing on steering tube

005095Y Engine support

008564Y Flywheel extractor

020434Y Oil pressure control fitting

020382Y011 adapter for valve removal tool

TOOL - 28

B 125-250 Tooling

Stores code Description

020424Y Driven pulley roller casing fitting punch

020431Y Valve oil seal extractor

020193Y Oil pressure gauge

020306Y Punch for assembling valve seal rings

020360Y Adaptor 52 x 55 mm

020364Y 25-mm guide

TOOL - 29

Tooling B 125-250

Stores code Description

020375Y Adaptor 28 x 30 mm

020376Y Adaptor handle

020444Y Tool for fitting/ removing the driven pulley

020330Y Stroboscopic light to check timing

001467Y035 Belle for OD 47-mm bearings

clutch

TOOL - 30

020368Y driving pulley lock wrench

B 125-250 Tooling

Stores code Description

020319Y Immobilizer check tester

020287Y Clamp to assemble piston on cylinder

020263Y Sheath for driven pulley fitting

020262Y Crankcase splitting strip

020430Y Pin lock fitting tool

020428Y Piston position check support

TOOL - 31

Tooling B 125-250

Stores code Description

020426Y Piston fitting fork

020425Y Punch for flywheel-side oil seal

020423Y driven pulley lock wrench

020414Y 28-mm guide

020393Y Piston fitting band

020382Y Valve cotters equipped with part 012 re-

moval tool

TOOL - 32

B 125-250 Tooling

Stores code Description

020455Y 10-mm guide

020442Y Pulley lock wrench

020440Y Water pump service tool

020329Y MityVac vacuum-operated pump

020357Y Adaptor 32 x 35 mm 020409Y Multimeter adaptor - Peak voltage detec-

tion

TOOL - 33

Tooling B 125-250

Stores code Description

020456Y Ø 24 mm adaptor

020332Y Digital rev counter

020074Y Support base for checking crankshaft

020055Y Wrench for steering tube ring nut

002465Y Pliers for circlips

alignment

TOOL - 34

001330Y Tool for fitting steering seats

B 125-250 Tooling

Stores code Description

020454Y Tool for fitting piston pin stops (200 - 250)

020622Y Transmission-side oil guard punch

020444Y011 adapter ring

020444Y009 46x55 Wrench

001467Y Extractor for bearings for holes

001467Y013 Pliers to extract ø 15-mm bearings

TOOL - 35

Tooling B 125-250

Stores code Description

020444Y010 adapter ring

020244Y 15-mm diameter punch

020115Y Ø 18 punch

020271Y Tool for removing-fitting silent bloc

020627Y Flywheel lock wrench

020467Y Flywheel extractor

TOOL - 36

B 125-250 Tooling

Stores code Description

020626Y Driving pulley lock wrench

020628Y Water pump service kit

TOOL - 37

INDEX OF TOPICS

MAINTENANCE MAIN

B 125-250 Maintenance

Maintenance chart

EVERY 3,000 KM

10'

Action

Engine oil - level check/ top-up

EVERY 2 YEARS

Action

Coolant - change Brake fluid - change Secondary air filter (external/internal) - cleaning (125)

AFTER 1000 KM

80'

Action

Engine oil - replacement Hub oil - change Engine oil - change Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test

(*) See instructions in «Idle speed adjustment» section

AT 6,000 KM OR 12 MONTHS

engine oil- change(125) Hub oil level - check Spark plug/ electrode gap - check Air filter - clean oil filter - change(125) valve clearance 125 - check Sliding blocks / variable speed rollers - check Driving belt - checking Coolant level - check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test

AT 12,000 KM OR 24 MONTHS 60,000 KM

100'

Engine oil - replacement Hub oil level - check Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change Idle speed (*) - adjustment Sliding block / variable speed rollers - change Throttle lever - adjustment

Action

MAIN - 39

Maintenance B 125-250

Action

Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test Driving belt - checking

(*) See regulations in section «Idling speed adjustment»

AT 18,000 KM AND AT 54,000 KM

Action

Engine oil - change Hub oil level - check Spark plug/ electrode gap - check Air filter - clean Oil filter -Replacement Valve clearance - check Sliding blocks / variable speed rollers - check Coolant level - check Radiator - external cleaning/ check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test Driving belt - checking

AT 24,000 KM AND 48,000 KM

Engine oil - replacement Hub oil - change Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change Idle speed (*) - adjustment Sliding block / variable speed rollers - change Throttle lever - adjustment Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test Transmission Belt - Check (250) Transmission Belt (125 cc) - Replacement

(*) See regulations in section «Idling speed adjustment»

AFTER 30,000 KM, 42,000 KM, 66,000 KM

90' (125) - 80' (250)

Hub oil level - check Spark plug/ electrode gap - check

Action

MAIN - 40

B 125-250 Maintenance

Action

Air filter - clean Variable speed rollers - check or replacement Driving belt - checking Coolant level - check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test engine oil- change(125) oil filter - change(125)

AT 36,000 KM

Action

Engine oil - replacement Hub oil level - check Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change valve clearance 125 - check 250 cc Valve Play - Check Idle speed (*) - adjustment Sliding block / variable speed rollers - change Throttle lever - adjustment Driving belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid hoses - replacement Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Secondary air filter (250) - Cleaning Vehicle and brake test - road test

(*) See regulations in section «Idling speed adjustment»

270'

Engine oil - replacement Hub oil - change Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change valve clearance 125 - check 250 cc Valve Play - Check Idle speed (*) - adjustment Sliding block / variable speed rollers - change Throttle lever - adjustment Driving belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid hoses - replacement Brake fluid level - check Transmission elements - lubrication Safety locks - check

A 72000 KM

Action

MAIN - 41

Maintenance B 125-250

Action

Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Secondary air filter (250) - Cleaning Vehicle and brake test - road test

(*) Vedere norme della sezione «Regolazione del minimo»

Carburettor

- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning.

- Check carefully that the parts are in good condition.

- The throttle valve should move freely in the chamber. Replace it in case of excessive clearance due to wear.

- If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it is new), replace the carburettor.

- It is advisable to replace the gaskets at every refit

WARNING

PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS

1. Diaphragm cover - 2. Throttle valve spring - 3.

Conical needle support - 4. Conical needle spring

- 5. Conical needle - 6. Throttle valve diaphragm -

7. Automatic starting device - 8. Idle speed adjusting screw - 9. Accelerating pump rocker - 10. Idle mixture adjusting screw - 11. Float pin - 12. Accelerating pump assembly - 13. Float - 14. Float chamber - 15. Idling jet - 16. Main jet - 17. Diffuser

- 18. Float chamber drain screw.

Checking the spark advance

- To check ignition advance, use the stroboscopic light with induction pincers connected to the spark plug power wire.

- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug).

- Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines).

MAIN - 42

B 125-250 Maintenance

- Start the engine and check that the light works properly and the rpm indicator can read also the high rpm (e.g. 8000 rpm).

- If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive load on the spark plug power line (10 ÷ 15 KΩ in series to HV wire).

Version 125:

- Remove the slit plastic cap on the flywheel cover.

- Adjust the lamp flash dephasing corrector to make the reference on the flywheel cover collimate with the level on the water pump drive. Read the advance degrees indicated by the stroboscopic lamp.

Characteristic

Check ignition advance 125

10° ± 1° at 2000 rpm - 34° ± 1° at 6000 rpm

Version 250:

- Remove the spark plug.

- Remove the plastic cover from the slotted hole on the flywheel cover, indicated in the picture.

- Remove the transmission compartment air intake cover shown in the photograph.

MAIN - 43

Maintenance B 125-250

- Using a screwdriver rotate the fan, mounted onto the drive pulley, until the marking on the flywheel is aligned with that stamped on the flywheel cover, as shown in the picture.

- Mark the alignment between fan and transmission cover on the transmission side, as shown in the picture.

- Refit the spark plug.

- Refit the plastic cover on the flywheel cover.

Characteristic

Spark advance check, 250cc

from 10°± 1° to 2000 rpm

through 28°±1° to 6500 rpm

- Check that the advance degrees match the revolution speed as indicated in the tables.

- In case of abnormal values, check the Pick-Up and the control unit supplies (positive-negative); replace the control unit, if required.

- A new control unit prevents the engine from rotating at over 2,000 rpm.

- The programmed control unit allows the engine revolution within the prescribed limits.

Specific tooling

020330Y Stroboscopic light to check timing

Spark advance variation

VERSION 125

Specification

Operation threshold First threshold : 10700 ±50

Reactivation threshold First threshold : 10600±50

Spark elimination First threshold : 1 spark on 7

Second threshold : 2 sparks on 3

Desc./Quantity

Second threshold : 11000 ±50 Second threshold : 10900±50

MAIN - 44

B 125-250 Maintenance

VERSION 250

Specification

Operation threshold First threshold : 9600±50

Reactivation threshold First threshold : 9500±50

Spark elimination First threshold : 1 spark on 7

Second threshold : 2 sparks on 3

Desc./Quantity

Second threshold : 9800±50 Second threshold : 9700±50

MAIN - 45

Maintenance B 125-250

Spark plug

- Put the vehicle on the central stand.

- Open the door on the left side of the vehicle by levering in the recess in the lower part of the door after removing the screw.

- Disconnect the spark plug HV cable cap. - Unscrew the spark plug with the spanner provided.

- Check the spark plug to see if the insulator is cracked, the electrodes are worn out or excessively sooty. Also check the condition of the seal washer and measure the spark gap with a suitable thickness gauge.

- If necessary adjust the spark gap by carefully bending the side electrode. If the spark plug has any of the defects mentioned above, replace it with a plug of the recommended type.

MAIN - 46

B 125-250 Maintenance

- Insert the plug into the hole with the proper inclination, screw it in fully by hand and then tighten it with the specially designed spanner.

- Push the spark plug cap all the way down onto the spark plug and then proceed to the reassembly.

CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MO-

TOR IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 12,000 KM. THE USE OF NON CONFORMING IGNITION CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.

Characteristic

Spark plug (125)

NGK CR 8EB

Spark plug (250)

CHAMPION RG4HC

Spark plug: electrode distance

0.7 mm ÷ 0.8 mm

Locking torques (N*m)

Spark plug 12 ÷ 14

Hub oil

Check

-Stand the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tighten- ing it completely; -Take out the dipstick checking that the oil level reaches the dipstick bottom notch (see figure); if the level is under the MAX. mark, it needs to be filled with the right amount of hub oil.

-Screw up the oil dipstick again and make sure it is locked properly into place. The notches on the hub oil level dipstick, except for the notch indicating the MAX level, refer to other manufacturer's models and have no specific function for this model.

MAIN - 47

Maintenance B 125-250

Replacement

-Remove the oil filler cap «A». - Unscrew the oil drainage plug «B » and drain out all the oil. - Screw the drainage plug again and fill the hub with oil.

Recommended products

AGIP ROTRA 80W-90 rear hub oil

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

Locking torques (N*m)

Hub oil drainage screw 15 ÷ 17 Nm

Air filter

- Remove the left side panel.

- Remove the air cleaner cover after unscrewing the 9 fixing screws.

- Take out the filtering element.

- Replace the air filter with a new one.

N.B. EVERY 6,000 KM CHECK THE AIR FILTER AND IF RE-

QUIRED, CLEAN IT WITH COMPRESSED AIR. THE AIR JET MUST BE DIRECTED FROM THE INSIDE TO THE OUTSIDE OF THE FILTER (I.E. OPPOSITE TO THE SENSE THE AIR FLOWS AT REGULAR ENGINE RUNNING). EVERY 6,000 KM, UPON SERVICING, REMOVE THE RETAINER AND RUBBER COVER UNDER THE FILTER HOUSING AS SHOWN IN THE FIGURE AND DRAIN ALL POSSIBLE OIL DEPOSITS.

Cleaning (Every 12,000 km):

- Wash with water and car shampoo.

- Dry with short blasts of compressed air and a clean cloth.

- Soak with a 50% mixture of gasoline and oil.

- Drip dry the filtering element and then squeeze it with your hands without wringing.

- Refit the filtering element.

CAUTION

NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WILL RESULT IN AN EXCESSIVE CYLINDER AND PISTON WEAR AND ALSO IN CARBURETTOR DAMAGE.

CAUTION

WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Locking torques (N*m)

Engine oil drainage plug 24 ÷ 30

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Oil pressure warning light

The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the "ON" position. However, this light should switch off once the engine has been started.

MAIN - 50

B 125-250 Maintenance

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

Checking the ignition timing

-Remove the 4 fixing screws and move away from the engine the flywheel cover fitted with a water pump and cooling manifolds.

-Rotate the flywheel until the reference matches the crankcase operation end as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference mark is opposite the indicator on the head, make the crankshaft turn once more.

-The TDC reference mark is repeated also between the flywheel cooling fan and the flywheel cover. To use this reference mark, remove the spark plug and turn the engine in the opposite direction to the normal direction using a calliper spanner applied to the camshaft command pulley casing.

N.B. TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.

Checking the valve clearance

-To check valve clearance, centre the reference marks of the timing system

- Use a thickness gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve clearance values, intake and drainage respectively, are different from the ones indicated below, adjust them by loosening the lock nut and operate on the register with a screwdriver as shown in the figure. Intake: 0.10 mm (when cold)

MAIN - 51

Maintenance B 125-250

Discharge: 0.15 mm (when cold)

Cooling system

Level check

- To check the level, it is necessary to look inside the expansion tank: a mark on the side of the filler indicates MIN and MAX levels.

Top-up

The fluid level inspection should be carried out every 6,000 km when the motor is cold, following the methods indicated below: Place the scooter on its centre stand and on flat ground.

- Undo the screw shown in the figure and remove the expansion tank cap on RHS.

- Remove the cap of the expansion tank and top up the fluid level if it is near or below the MIN mark inside the tank. The coolant level must always be between MIN and MAX. level.

-The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised water- antifreeze solution mix.

CAUTION

DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE vehicle IS IN USE.

MAIN - 52

B 125-250 Maintenance

Braking system

Level check

The brake fluid tanks for the front and rear brakes are located on the pumps under the handlebar cover. Proceed as follows:

- Bring the scooter onto the centre stand and with the handlebar centred; - check the fluid level at the sight glass as shown in the figure. A certain lowering of the level is caused by wear on the pads.

Top-up

- Remove the cap on the handlebar cover as shown in the photograph.

MAIN - 53

Maintenance B 125-250

- Remove the tank cap by loosening the two screws, remove the gasket and top up using only the liquid specified without exceeding the maximum level.

CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.

CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE

SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.

CAUTION THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS,

IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

Headlight adjustment

- Place the unloaded vehicle on a level surface, 10 metres from a half-lit white screen, with the tyres inflated to the prescribed pressure. Ensure that the axis of the vehicle is perpendicular to the screen.

- Draw a horizontal line on the screen 69 ÷ 72 cm above the ground.

- Switch on the headlight, turn on the low beam and check that the horizontal line that divides the dark area from the lighted area is not above the line previously drawn on the screen. To shift the headlight, turn the adjusting screw in the glove compartment (see figure).

MAIN - 54

B 125-250 Maintenance

CO check

- Remove RHS footrest.

- Remove the gas cap on the exhaust pipe.

- Using the original washer, install the exhaust gas collection kit as shown in the picture.

- Suitably orientate all the components.

- Shut the gas outlet terminal of the tool.

- Start the engine and let it warm up until the electric fan activates.

- Stop the engine.

- Disconnect the SAS check valve vacuum hose shown in the figure.

- Seal the connection using a conical a cap.

- Connect the Mitivac vacuum pump to the SAS control valve.

- Start the vacuum pump up to a pressure of -0.6 ÷ -0.8 bar so to close the valve and cut off the SAS system.

- Remove the exhaust gas collection kit cap and connect the analyzer adequately pre-heated.

- Check the analyser output and the engine rpm.

- Adjust the CO concentration.

N.B.

MAIN - 55

Maintenance B 125-250

CHECK THAT THE RESULT IS OBTAINED WITH THE VALVE GAS IN CLOSED POSITION.

N.B. ALSO CHECK THE CARBURETION ADJUSTMENT IS OB-

TAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS.

N.B. OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN

THE TANK AND THE FUEL CIRCUIT. N.B. IN CASE OF UNSTABLE CO, CHECK THAT THE CARBU-

RETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYSTEM AND THE DEPRESSION SEALS WORK ADEQUATELY

N.B. IN CASE OF 1000 PPM UNBURNED HYDROCARBONS

(HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYSTEM, THE VALVE CLEARANCE AND THE EXHAUST VALVE TIGHTNESS.

Specific tooling

020329Y MityVac vacuum-operated pump 020332Y Digital rev counter 494929Y Exhaust fumes analyser 020625Y Kit for sampling gas from the exhaust

manifold

Characteristic

CO Check

3.8±0.7 to 1650±50 RPM

SAS filters inspection and cleaning

ENGINE 250

- Remove LHS footrest.

- Remove the air-box/crankcase fixing screws.

- Remove the three fixings shown in the figure.

- Detach the oil vapours recovery line and the choke cable harness from the clamp shown in the picture.

- Remove the plastic fairing.

MAIN - 56

B 125-250 Maintenance

- Remove the two screws shown in the picture.

- Remove the filter indicated in the photograph

- Check that the gasket is in good conditions

- Check the SAS filter housing for dents or deformations

- Clean the SAS filter carefully. Replace the filter if it is damaged or deformed. To refit, carry out the removal operations but in reverse order.

CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER

MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

CAUTION NEVER RUN THE ENGINE WITHOUT THE SECONDARY

AIR FILTER

See also

Footrest

- Remove the flywheel cover.

- Remove the two screws fixing the SAS valve as shown in the figure and remove the SAS valve and the O-ring from the support

MAIN - 57

Maintenance B 125-250

- Remove the plastic support and the gasket as shown in the photograph

- Check that the SAS valve plastic support is not dented or distorted

- Check that the gasket is in good conditions

- Carefully clean the inside and outside filters. Replace them if damaged or abnormally distorted.

- Make sure the coupling connecting the secondary air to the head is not dented, overheated or distorted. If there is, replace it.

- Check that the metal pipe does not have any dents To refit, follow the removal procedure but in reverse order, being careful to respect the direction of the rubber coupling connecting the SAS valve to the discharge system

CAUTION INADEQUATE TIGHTNESS BETWEEN THE SAS VALVE

AND ITS SUPPORT INCREASES NOISE IN THE SAS SYSTEM.

CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER

MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

CAUTION NEVER RUN THE ENGINE WITHOUT THE SECONDARY

AIR FILTER

MAIN - 58

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Troubleshooting B 125-250

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-

Excess of encrustations in the combustion chamber Descale the cylinder, the piston, the head and the valves

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Muffler obstructed Replace

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to

drip dry and then reassemble.

Automatic starter failure Check: mechanical movement, electric connection and fuel

supply, replace if required.

Oil level exceeds maximum Check for causes and fill to reach the correct level

Lack of compression: parts, cylinder and valves worn Replace the worn parts

Transmission belt worn Replace

Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-

aged parts and lubricate the driven pulley moveable guide with

Montblanc Molybdenum Grease

Clutch slipping Check the clutch system and/or the bell and replace if neces-

Overheated valves Remove the head and the valves, grind or replace the valves

Wrong valve adjustment Adjust the valve clearance properly

Valve seat distorted Replace the head assembly

Air filter dirty Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to

drip dry and then reassemble.

Defective floating valve Check the proper sliding of the float and the functioning of the

place

sary

valve

Rear wheel spins at idle

REAR WHEEL ROTATES WITH ENGINE AT IDLE

Possible Cause

Idling rpms too high Adjust the engine idle speed and the CO%, if necessary.

Clutch fault Check the springs / clutch masses

Starting difficulties

DIFFICULT STARTING

Possible Cause

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill

Rpm too low at start-up or engine and start-up system dam-

aged

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance

- Engine flooded. Try starting-up with the throttle fully open. If the engine fails to

Automatic starter failure Check: mechanical movement, electric connection and fuel

TROUBL - 60

Operation

Check the starter motor, the system and the torque limiter

start, remove the spark plug, dry it and before refitting, make

the motor turn so as to expel the fuel excess taking care to

connect the cap to the spark plug, and this in turn to the ground.

If the fuel tank is empty, refuel and start up.

supply, replace if required.

B 125-250 Troubleshooting

Possible Cause Operation

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components

The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-

Battery flat Check the charge of the battery, if there are any sulphur marks,

Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-

Defective floating valve Check the proper sliding of the float and the functioning of the

Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation

Worn valve guides Check and replace the head unit if required

Worn valve oil guard Replace the valve oil guard

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn or broken piston rings or piston rings that have not been

fitted properly

soak it in a mixture of 50% petrol and 50% of specific oil (Se-

lenia Air Filter Oil), then hand dry without squeezing, allow to

drip dry and then reassemble.

place

replace and use the new battery following the instructions

shown in the chapter

ened valve

Replace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the

Oil pump with excessive clearance Perform the dimensional checks on the oil pump components

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level using the recommended oil type (Selenia HI

Engine tends to cut-off at full throttle

ENGINE STOP FULL THROTTLE

Possible Cause

Faulty fuel supply Check or replace the pump and the vacuum valve, check the

Incorrect float level Restore the level in the tank by bending on the float the thrust-

Water in the carburettor Empty the tank through the appropriate bleed nipple.

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air

Engine tends to cut-off at idle

Operation

By-Pass area.

Scooter 4 Tech)

Operation

vacuum intake and the pipe sealing

ing reed of the petrol inlet rod so as to have the float parallel to

the tank level with the carburettor inverted.

ENGINE STOP IDLING

Possible Cause

Incorrect timing Time the system and check the timing system components

Operation

TROUBL - 61

Troubleshooting B 125-250

Possible Cause Operation

Cut off device failure Check that the following parts work properly: valve; diaphragm;

Incorrect idle adjustment Adjust using the rpm indicator

Pressure too low at the end of compression Check the thermal group seals and replace worn components

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components

The starter remains on Check: electric wiring, circuit not interrupted, mechanical

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air

spring; and that the air calibration elements are clean; check if

the sponge filter is clean too

movement and power supply; replace if necessary

Excessive exhaust noise

EXCESSIVE EXHAUST NOISE

Possible Cause Operation

Secondary air device cut-off valve not working Replace the secondary air device

Depression intake pipe of the secondary air device disconnec-

ted or dented Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the

head pipe

Replace the device and the coupling

Replace the pipe

High fuel consumption

HIGH FUEL CONSUMPTION

Possible Cause

Float level Restore the level in the tank by bending on the float the thrust-

Loose nozzles Check the maximum and minimum nozzles are adequately

Fuel pump failure Check that there is no fuel in the low-pressure duct Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then

SAS malfunctions

ANOMALIES IN THE SECONDARY AIR DEVICE

Possible Cause

Secondary air device cut-off valve not working Replace the secondary air device

Depression intake pipe of the secondary air device disconnec-

ted or dented Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the

head pipe

Operation

ing reed of the petrol inlet rod so as to have the float parallel to

the tank level with the carburettor inverted.

fixed in their fittings

power supply

soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to

drip dry and then reassemble.

Operation

Replace the pipe

Replace the device and the coupling

Transmission and brakes

TROUBL - 62

B 125-250 Troubleshooting

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Faulty clutch Check that there is no grease on the masses. Check that the

Insufficient braking

INSUFFICIENT BRAKING

Possible Cause Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

clutch mass contact surface with the casing is mainly in the

centre with equivalent characteristics on the three masses.

Check that the clutch casing is not scored or worn in an anom-

alous way

not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.

Brakes overheating

Possible Cause

Rubber gaskets swollen or stuck Replace gaskets.

Compensation holes on the pump clogged Clean carefully and blast with compressed air

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

Defective piston sliding Check calliper and replace any damaged part.

Braking vibrations or noise

VIBRATIONS OR NOISE WHEN BRAKING

Possible Cause

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

Electrical system

Battery

BRAKES OVERHEATING

Operation

a wheel mounted on the vehicle to measure the axial shift of

the disc.

Operation

a wheel mounted on the vehicle to measure the axial shift of

the disc.

BATTERY

Possible Cause

Battery This is the device in the system that requires the most frequent

attention and the most thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 3 months. If the battery is fitted on a motorcycle,

be careful not to invert the connections, keeping in mind that

Operation

TROUBL - 63

Troubleshooting B 125-250

Possible Cause Operation

the black ground wire is connected to the negative terminal

while the red wire is connected to the terminal marked+.

Turn signal lights malfunction

TURN INDICATOR NOT WORKING

Possible Cause Operation

Electronic ignition device failure With the key switch set to "ON" jump the contacts 1 (Blue -

Black) and 5 (Red/Blue) on the control unit connector. If by

operating the turn indicator control the lights are not steadily

on, replace the control unit; otherwise, check the cable harness

and the switch.

Steering and suspensions

Heavy steering

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-

Excessive steering play

Possible Cause

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-

Noisy suspension

Possible Cause

Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front

STEERING HARDENING

larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

EXCESSIVE STEERING BACKLASH

Operation

larities in turning the steering continue even after making the above adjustments, check the seats on which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

NOISY SUSPENSION

Operation

shock absorbers; the condition of the ball bearings and relevant

lock-nuts, the limit switch rubber buffers and the movement

bushings. In conclusion, check the tightening torque of the

wheel hub, the brake calliper, the shock absorber disk in the

attachment to the hub and the steering tube.

TROUBL - 64

B 125-250 Troubleshooting

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Seal fault or breakage Replace the shock absorber Check the condition of wear of the

steering covers and the adjustments.

TROUBL - 65

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

B 125-250 Electrical system

Legend:

1. Front left hand-side turn signal light; two (2) bulb lights for each lamp

2. Immobiliser antenna

3. Electronic ignition device with integrated choke and turn signal controls (ECU)

4. Horn button

5. Turn signal switch

6. Headlight switch

7. Stop light switch on rear brake

8. Double filament bulb 12V - 55/60W

9. Taillight bulb

10. High beam signal light

11. Engine oil pressure warning light

12. Turn signal warning light (RHS)

ELE SYS - 67

Electrical system B 125-250

13. Low fuel warning light

14. Turn signal warning light (LHS)

15. Instrument panel light bulb

16. Headlamp signal light

17. Odometer with warning lights and level gauges with 7 and 2 light bulbs.

18. Headlight

19. Two (2) fuse holders with four (4) fuses (7.5 A)

20. Stop light switch on front brake

21. Starter button

22. Immobiliser diagnostic tool port

23. Key-switch

24. Front right hand-side turn signal light

25. Centre and side-stand, and frame assembly

26. Fuel level sensor

27. Fuse holder assembly

28. Rear right hand-side turn signal light

29. License plate light bulb

30. License plate lamp

31. Battery

32. Starter relay

33. Starter motor

34. Engine oil pressure sensor

35. Pick-up

36. Automatic choke

37. Carburettor heater

38. H.T. coil

39. Taillight assembly

40. Taillight and stop light bulb

41. Voltage regulator

42. Rear left hand-side turn signal light

43. Two (2) amber light bulbs for turn signal lamp

44. Relay

45. Horn Wires colour coding: B = White Bl = Blue G = Yellow Mr = Brown

ELE SYS - 68

B 125-250 Electrical system

N = Black BV = White-Green GN = Yellow-black Gr = Grey Rs = Pink R = Red Vi = Purple V = Green VN = Green-Black BN = White-Black BBl = White-Blue GV = Yellow-Green Ar = Orange Az = Light blue GrBl = Grey-Blue GrN = Grey-Black RBl = Re-Blue GR =Yellow-Red BlN = Blue-Black

Electrical system installation

ELE SYS - 69

Electrical system B 125-250

Front side

INSTALLING THE ELECTRICAL CIRCUIT

Specification

1 Installing the electrical circuit Front fuse holder 2 Installing the electrical circuit Two relays 3 Installing the electrical circuit Intercom master-box pre-wiring 4 Installing the electrical circuit To seat opening button 5 Installing the electrical circuit Insert in the appropriate hole 6 Installing the electrical circuit Insert in the appropriate hole 7 Installing the electrical circuit To radiator thermal switch 8 Installing the electrical circuit To electric fan 9 Installing the electrical circuit Clamp 10 Installing the electrical circuit To fuel level gauge 11 Installing the electrical circuit Seat opening cable 12 Installing the electrical circuit Earth cable fixing onto frame. 13 Installing the electrical circuit To side-stand switch 14 Installing the electrical circuit Horn

ELE SYS - 70

Desc./Quantity

B 125-250 Electrical system

INSTALLING THE ELECTRICAL CIRCUIT

Specification

1 Installing the electrical circuit To antenna 2 Installing the electrical circuit Clamp 3 Installing the electrical circuit Ignition master-box (ECU) 4 Installing the electrical circuit To headlight

Desc./Quantity

ELE SYS - 71

Electrical system B 125-250

INSTALLING THE ELECTRICAL CIRCUIT

Specification

1 Installing the electrical circuit To engine cut-off switch 2 Installing the electrical circuit To instrument panel 3 Installing the electrical circui To headlight switch 4 Installing the electrical circuit To turn signal switch 5 Installing the electrical circuit To horn button 6 Installing the electrical circuit To LHS stop light switch 7 Installing the electrical circuit Clamp 8 Installing the electrical circuit Red binding 9 Installing the electrical circuit Key-switch cap 10 Installing the electrical circuit To RHS stop light switch 11 Installing the electrical circuit To starter button

Desc./Quantity

ELE SYS - 72

B 125-250 Electrical system

Back side

INSTALLING THE ELECTRICAL CIRCUIT

Specification

1 Installing the electrical circuit Retaining spring 2 Installing the electrical circuit Guide the battery breathing tube through the frame hole,

Desc./Quantity

as shown.

ELE SYS - 73

Electrical system B 125-250

INSTALLING THE ELECTRICAL CIRCUIT

Specification

1 Installing the electrical circuit To battery (-) 2 Installing the electrical circuit To the plafoniera 3 Installing the electrical circuit Clamp 4 Installing the electrical circuit To actuator 5 Installing the electrical circuit To license plate light 6 Installing the electrical circuit To taillight 7 Installing the electrical circuit To 12V - 180W power outlet underneath the seat 8 Installing the electrical circuit Clamp 9 Installing the electrical circuit To battery (+) 10 Installing the electrical circuit Battery 12 V/12 Ah

Desc./Quantity

ELE SYS - 74

B 125-250 Electrical system

INSTALLING THE ELECTRICAL CIRCUIT

Specification

1 Installing the electrical circuit To the plafoniera 2 Installing the electrical circuit Choke device diagnostic port 3 Installing the electrical circuit Battery restraining belt 4 Installing the electrical circuit Seat opening actuator

Desc./Quantity

ELE SYS - 75

Electrical system B 125-250

INSTALLING THE ELECTRICAL CIRCUIT

Specification

1 Installing the electrical circuit Secure the metallic clamp on the red binding so that the

cable harness remains underneath the frame tube. 2 Installing the electrical circuit To 12V - 180W power outlet underneath the seat 3 installing the electrical circuit The clamp must be placed on the aft hole 4 Installing the electrical circuit Starter relay, 12V - 80A 5 Installing the electrical circuit Rear fuse-holder 6 Installing the electrical circuit Clamp 7 Installing the electrical circuit Rear fuse-holder 8 Installing the electrical circuit Clamp 9 Installing the electrical circuit HT coil 10 Installing the electrical circuit To thermistor 11 Installing the electrical circuit Insert in the appropriate hole 12 Installing the electrical circuit Battery breathing tube

Desc./Quantity

ELE SYS - 76

B 125-250 Electrical system

INSTALLING THE ELECTRICAL CIRCUIT

Specification

1 Installing the electrical circuit Starter motor earth cable 2 Installing the electrical circuit Starter motor positive (+) cable 3 Installing the electrical circuit Screw - tighten up to 10 ÷ 13 Nm 4 Installing the electrical circuit Screw - tighten up to 6 ÷ 8 Nm 5 Installing the electrical circuit To automatic choke connection 6 Installing the electrical circuit Thermistor 7 Installing the electrical circuit To oil sensor 8 Installing the electrical circuit To cable harness 9 Installing the electrical circuit Metallic clamp 10 Installing the electrical circuit Flywheel connection 11 Installing the electrical circuit Clamp 12 Installing the electrical circuit Air filter/carburettor bellow

Desc./Quantity

Conceptual diagrams

ELE SYS - 77

Electrical system B 125-250

Ignition

IGNITION

Specification

1 Pick - up 2 Magneto flywheel 3 Fuse 15A (N° 7) 4 Electronic ignition device 5 Spark plug 6 HV coil 7 Voltage regulator 8 Battery 12V - 10Ah

Desc./Quantity

ELE SYS - 78

B 125-250 Electrical system

Headlights and automatic starter section

HEADLIGHTS AND AUTOMATIC STARTER SECTION

Specification

1 Electronic ignition device 2 Fuse 10 A (N°6) 3 Battery 12V - 12Ah 4 Fuse 15 A (N°7) 5 Key switch contacts 6 Dipped beam light 12V-55W 7 Light remote control switch 8 Fuse 4 A (N°4) 9 Bulb for upper beams 12V-55W

Desc./Quantity

ELE SYS - 79

Electrical system B 125-250

Specification Desc./Quantity

10 High beam warning light bulb 12V - 1,2W 11 Lights switch with high beam flash 12 Automatic starter 13 Fuse 7,5 A (N°3) 14 Number-plate light bulb 12V 5W 15 Two front parking light bulbs 12V - 5W 16 Two (2) taillight bulbs 12V - 5W 17 N° 5 light bulbs for instrument panel illumination 12V - 2W

Battery recharge and starting

ELE SYS - 80

B 125-250 Electrical system

BATTERY RECHARGE AND START-UP

Specification Desc./Quantity

1 Electronic ignition device 2 Voltage regulator 3 Magneto flywheel 4 Pick - up 5 Fuse 15 A (N°7) 6 Battery 12V-12Ah 7 Key switch contacts 8 Fuse 4A (N° 2) 9 Front and rear brake light button 10 Brake light bulbs 12V-10W 11 Start up button 12 Diodo 13 Remote starter switch 14 Starter motor 15 Engine stop remote control switch 16 Fuse 7,5A (N°1) 17 Engine disabled warning light bulb 12V - 1,2W 18 Side stand switch 19 Engine stop switch

ELE SYS - 81

Electrical system B 125-250

Level indicators and enable signals section

LEVEL INDICATORS AND ENABLE SIGNALS SECTION

Specification

1 Electronic ignition device 2 Fuse 4A (N° 5) 3 Fuse 7,5A (N°1) 4 Key switch contacts 5 Fuse 15 A (N°7) 6 Battery 12V-12Ah 7 Radiatore electric fan motor 8 Thermal switch for electric fan 9 Thermistor

ELE SYS - 82

Desc./Quantity

B 125-250 Electrical system

Specification Desc./Quantity

10 Oil Pressure Warning Light Bulb 12V - 1,2W 11 Motor Oil pressure sensor 12 Reserve Fuel Warning Light Bulb 12V - 1,2W 13 Fuel level sender 14 Fuel gauge 15 Digital clock 16 Coolant temperature gauge

Thermal switch

We inform you that a new thermal switch has been introduced starting with frame number ZAPM2300003507739 (X9) ZAPM3620000003383 (X8) ZAPM2850000001025 (Beverly), in order to prevent possible malfunctioning of the thermal switch.

ELE SYS - 83

Electrical system B 125-250

Turn signal lights

DIRECTION INDICATORS, HORN , UTILITIES

Specification

1 Turn indicator switch 2 Rh turn indicator warning light bul 12V - 1,2W 3 Lh turn indicator warning light bulb 12V - 1,2W 4 Four turn indicator bulbs N°4 12V-10W 5 Electronic ignition device 6 Horn button 7 Horn 12V 8 Fuse 7,5 A (N°3) 9 Key switch contacts 10 Fuse 15 A (N°7)

ELE SYS - 84

Desc./Quantity

B 125-250 Electrical system

Specification Desc./Quantity

11 Saddle electrical opening button 12 Saddle opening actuator 13 Plug socket 12 V - 180 W MAX 14 Fuse 15 A (N°8) 15 Battery 12V-12Ah 16 Helmet compartment lighting button 17 Helmet compartment lamp bulb 12V-5W

Checks and inspections

Immobiliser

The electric ignition system is fed with direct current and is protected by an antitheft immobilizer integrated to the control unit. The ignition system consists of:

- electronic control unit

- immobilizer aerial

- master and service keys with built-in transponder

- H.V. coil

- diagnosis LED The diagnosis LED also works as a blinking light to deter theft. This function is activated every time the key switch is set to «OFF», when the side stand is lowered or the engine emergency cut-off switch is set to «OFF». It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to «ON», the deterring blinker function is deactivated. Subsequently, a flash confirms the switching to « ON». The duration of the flash depends on the electronic control unit program (see figure).

In case the LED turns off and remains so even when switching over to «ON», check if:

- there is battery voltage

- 15A main fuse (No. 7) is in working order. If the deterring LED remains off, check the control unit power supply as follows:

- Disconnect the control unit connector. Check if:

ELE SYS - 85

Electrical system B 125-250

- There is battery voltage between terminal No. 4 (Red/Black) and the ground lead

- There is battery voltage between the terminal No. 4 (Red/Black) and terminal No. 8 (Negative) as shown in the figure.

- There is battery voltage between the terminals No. 5 and No. 8 with the key switch set to «ON», the side stand folded up and the emergency cutoff switch set to «RUN». If no faults are found, replace the control unit; otherwise, check the wiring and the following components:

- Engine stop remote control;

- Emergency cut-off switch;

- Side stand contacts;

- Key switch contacts.

Virgin circuit

If the ignition system has not been programmed, the engine can be started but it will run limited to 2000 rpm. When trying to accelerate, some evident loss of power may be felt. Program the system with the MASTER (Brown) and SERVICE (Black) keys as follows:

- Insert the MASTER key, turn it to "ON" and keep it in that position for 2 seconds (limit values: 1 ÷ 3 seconds).

- Alternately insert all the available black keys and turn each one of them to "ON" for 2 seconds.

- Insert the MASTER key again and turn it to "ON" for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 (Black) service keys can be programmed at one time.

ELE SYS - 86

B 125-250 Electrical system

Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start. Once the control unit has been programmed, the control unit is inseparably matched with the MASTER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stored one is deleted. If a service key setting is lost, it is essential to carefully check the efficiency of the high voltage system: Shielded cap resistance ~ 5000 Ω. In any case it is advisable to use resistive spark plugs.

Diagnostic codes

The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings. That is, the led is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-second flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:

Diagnostic code - 2 flashes

When the 2-flash code is detected, carry out the following checks:

- Check if the failure continues after changing key (MASTER key included). If the failure persists with any key, disconnect the aerial connector from the control unit and check the aerial for continuity with the recommended tool. If non-conforming values are measured, replace the aerial. If no failures are found in the aerial, replace the control unit.

CAUTION

BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT

Specific tooling

020331Y Digital multimeter

Electric characteristic

immobilizer aerial

~ 7 ÷ 9 Ohm

ELE SYS - 87

Electrical system B 125-250

2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial. Ignition disabled-Vehicle immobilised

Diagnostic code - 3 flashes

If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the key switch.

- If the failure disappears when the MASTER key is used, proceed with coding a new service key (Blue).

- If the failure persists, it means that the MASTER key and the control unit are not linked; in this case, replace the control unit and then encode the keys. The immobilizer system is efficient when, after switching over to «ON», only a 0.7-sec flash is detected (see diagram). In this case, the engine can be started.

Example with programmed control unit, transponder, programmed key and working aerial. The

ignition is enabled (regular use conditions)

3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans- ponder code. Ignition disabled-Vehicle immobilised

Ignition circuit

Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a spark in the spark plug. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition system.

ELE SYS - 88

B 125-250 Electrical system

The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control unit is connected to the Pick-Up by the chassis and the engine ground lead. To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.

No spark plug

Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure:

- Pick-Up check. Disconnect the control unit connector and check the resistance value between terminal No. 2 (Green) and terminal No. 8 (Black). Check the Pick-Up and its power line:

Electric characteristic

Pick-up resistance value

Pick-up resistance value: 105 ÷ 124 Ohm

If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine manual). If non-conforming values are measured, replace the Pick-Up; otherwise, repair the cable harness. In case conforming values are measured, try replacing the control unit (without programming) and make sure the failure has been solved by checking sparks are produced in the spark plug; only then program the control unit.

- HV primary coil check Disconnect the control unit connector and check that the cable between terminals No. 3 and No. 8 is not interrupted (see figure). If non-conforming values are measured, check again the HV primary coil directly on the positive and negative terminals. If non-conforming values are measured, repair the cable harness or else replace the HV coil.

Electric characteristic

High voltage coil primary resistance value

High voltage coil primary resistance value: 0.4 ÷

0.5 Ohm

ELE SYS - 89

Electrical system B 125-250

HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.

Electric characteristic

Resistance value

High voltage coil secondary resistance value ~ 2000 ± 300 ohm

Pick-Up.

- Disconnect the control unit connector and connect the positive wire to connector No. 2 and the negative wire to connector No. 8 (see figure).

- The multimeter end of a scale should be 200V. Use the start-up system to run the engine and measure the voltage produced by the Pick-Up.

- Replace the Pick-Up if non-conforming values are measured.

N.B. THE MULTIMETER MUST BE SELECTED TO DETECT

CONTINUOUS VOLTAGE.

Specific tooling

020409Y Multimeter adaptor - Peak voltage detection

Electric characteristic

Voltage value

> 5 Volt

- HV coil With the control unit and HV coil connected, measure the voltage of the coil primary during the startup test with the voltage peak adaptor and connecting the positive terminal to the ground one and the negative to the coil positive connector.

ELE SYS - 90

B 125-250 Electrical system

If non-conforming values are measured, replace the control unit.

N.B. THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE

HV COIL PRIMARY IS BLACK AND THE NEGATIVE TERMINAL ONE IS GREEN.

Electric characteristic

High voltage coil voltage value

High voltage coil voltage value: > 100 Volt

Stator check

Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.

Electric characteristic

Ohm value:

0.7 ÷ 0.9 Ohm

Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.

Voltage regulator check

With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator. In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.

ELE SYS - 91

Electrical system B 125-250

Recharge system voltage check

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. In turn, the latter is directly connected to the ground lead and to the battery positive terminal passing through the 15A protection fuse (No. 7). This system therefore requires no connection to the key switch. The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed. Connect an ammeter induction pliers to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current generated by the system with lights on and a high running engine. In case the generated current value is lower than 10A, repeat the test using a new regulator and/ stator alternatively.

Choke Inspection

Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals receive battery voltage with the engine on (see figure).

ELE SYS - 92

B 125-250 Electrical system

If there is no voltage, connect the multimeter's negative terminal to earth and the positive terminal to the white wire on the automatic choke device. With the ignition switch turned onto the «ON» position, check for the presence of battery voltage. If no voltage is detected, check the wiring connected with the ignition switch and the two fuses 15A (no.

8). If voltage is present, repeat the check from the ignition control unit connector. After disconnecting the choke device, start the engine and keep it idling. Check for the presence of voltage by connecting the multimeter's positive terminal to terminal no. 5 (white/green) and its negative terminal to terminal no. 7 (white/black) (see figure). If no voltage is detected, replace the control unit after verifying the integrity of the fuses, otherwise check the wiring between the choke and the electronic control unit and if necessary proceed by replacing the choke device.

Turn signals system check

If the turn signal lights fail to operate, proceed as follows:

- Detach the control unit connector and check for potential difference at terminal no. 4 (red/black) with respect to earth (p.d. must be equal to battery voltage).

- Check that the same p.d. (battery voltage) is present between terminals no. 4 and no. 8 (black).

- Repeat the same check between terminals no. 5 (white/green) and no. 8 (black) with the ignition switch turned to the «ON» position, the side-stand retracted, and the emergency cut-off switch in the «RUN» position.

ELE SYS - 93

Electrical system B 125-250

If no voltage is detected, check the wiring, the connections and the integrity of the main 15A fuse; otherwise proceed as follows:

- Use a jumper to connect terminals no. 1 (black/blue) and no. 4 (red/black) (see figure) and, operating the turn signal switch, alternating left and right hand-side, ensure that the turn signal lights light up.

- If so, the control unit is defective and must be replaced. Otherwise check the wiring between the control unit and the turn signal switch, and then repeat the test

- If the wiring is intact and the turn signal lights still fail to operate correctly, replace the turn signal switch.

Lights list

LIGHT BULB TABLE

Specification

1 High-beam light bulb Type: HALOGEN (H7)

2 Low-beam bulb Type: HALOGEN (H1)

3 Front tail light bulb Type: ALL GLASS

ELE SYS - 94

Desc./Quantity

Power: 12V - 55W

Quantity: 1

Power: 12V - 55W

Quantity: 1

Power: 12V - 5W

Quantity: 2

B 125-250 Electrical system

Specification Desc./Quantity

4 Instrument panel bulb Type: ALL GLASS

5 Front turn indicator bulb Type: Spherical

6 Helmet compartment light bulb Type: CYLINDRIC

7 Rear turn indicator light bulb Type: Spherical

8 Taillight bulb Type: SPHERICAL

9 Stop light bulb Type: ALL GLASS

10 License plate light bulb Type: ALL GLASS

Fuses

Power: 12V - 2W

Quantity: 5

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

Power: 12V - 5W

Quantity: 1

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

Power: 12V - 3W

Quantity: 2

Power: 12V - 10W

Quantity: 1

Power: 12V - 5W

Quantity: 1

The electrical equipment is protected by:

1. Four fuses "A" protecting the outside electrical socket, located under the right-hand side panel.

2. Four fuses "B" protecting the different circuits, located in the upper left portion of the glove compartment. The tables show the positions and specifications of the fuses installed on the vehicle.

CAUTION BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE

THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE USING ANY OTHER MATERIAL (A PIECE OF ELECTRICAL WIRE, FOR EXAMPLE) OR A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED.

FUSES A

Specification

1 Diagnostic LED, Clock N.1 4A 2 Headlight (high/low beam bulb) N.1 10A 3 General N.1 15A 4 Helmet compartment lamp, 12V socket, saddle electrical

opening actuator

Desc./Quantity

N.1 15A

ELE SYS - 95

Electrical system B 125-250

FUSES B

Specification Desc./Quantity

1 Electric stand prewiring, starter relay switch coil, engine

stop relay coil, engine disabled warning light, oil pres-

sure warning light, reserve fuel warning light, coolant

temperature warning light 2 Brake light bulb, starter relay switch inhibitor N.1 4A 3 Horn, passing function N.1 7,5A 4 Analogue instrument panel light bulbs, number-plate

light bulb, front and rear parking light bulbs

N.1 7,5A

N.1 4A

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and, afterwards, every six months. INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE

1) Voltage check

Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 ÷ 14.70V

- Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity

- Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the nominal capacity of the battery

- Charge time: 5 h

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. CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDS TO BE RECHARGED PERIODICALLY. THE BATTERY RUNS DOWN COMPLETELY IN THE COURSE OF THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE VEHICLE, BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL

ELE SYS - 96

B 125-250 Electrical system

WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL MARKED WITH THE +POSITIVE SIGN

WARNING

WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

Normal bench charging must be carried out using the specific battery charger 020333Y (single) or 020334 (multiple), setting the battery charge selector to the type of battery that needs recharging (i.e., at a current equal to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to - ).

Dry-charge battery

COMMISSIONING A NEW DRY-CHARGED BATTERY

- Remove the battery air pipe stop cap and each single cell cap.

- Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an ambient temperature not below 15°C, until it reaches the upper level indicated on the block.

- Tilt the battery slightly to remove any air bubbles formed during filling.

- Place the caps on each single cell filling hole without screwing them and leave the battery to rest. During this stage, the battery is subjected to a gasification phenomenon and temperature increases.

- Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes).

- Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level using the same filling electrolyte Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled water;

- Before 24 hours elapse, recharge the battery following these steps:

- Connect the battery charger terminals observing the correct polarity;

- Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity;

- Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge. Note: Batteries that have been stored for a long time may take a longer charging time. The battery chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the activation of the safety system and not the end of the charge.

- Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester.

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Electrical system B 125-250

- If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging.

- Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary, clean battery properly, close each single cell cap tightly and install it on the vehicle.

- If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.

Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the Check function. The value indicated on the display must be higher than the value indicated on the chart;

otherwise, recharge the battery again in the same way indicated above.

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle B 125-250

Exhaust assy. Removal

- Undo the two exhaust manifold fixings on the head.

- Undo the three screws fixing the muffler to the support arm.

- Remove the full muffler unit.

To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.

Locking torques (N*m)

Nuts fixing muffler to support arm 27 ÷ 30 Nut fixing muffler to cylinder head 16 ÷ 18

Removal of the engine from the vehicle

- Disconnect the battery.

- Remove seat, side fairings, and footrests.

- Drain coolant.

- Remove the silencer assembly.

- Remove the silencer mounting bracket.

- Remove the rear wheel.

- Remove the shock-absorbers lower fixings.

- Remove the throttle cable.

- Detach the air filter bellow and manifold shown in the figure.

- Detach engine earth cable.

- Disconnect the electrical devices on the carburettor and the starter motor power cord.

ENG VE - 100

Piaggio WORKSHOP Beverly 125 250, Beverly 125 250 workshop Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual