PIAGGIO Liberty 125, Liberty 200 4tempi Workshop Manual

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WORKSHOP MANUAL

633120

Liberty 125 - 200 4tempi

WORKSHOP

MANUAL

Liberty 125 - 200 4tempi

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

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

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

required for manufacturing or construction reasons.

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

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

Liberty 125 - 200 4tempi

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

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

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

Safety rules

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

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

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

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

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

Maintenance rules

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

- Use only the appropriate tools designed for this vehicle.

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

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

- 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 vehicle.

- 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.

Liberty 125 - 200 4tempi Characteristics

CHAR - 7

Vehicle identification

VEHICLE IDENTIFICATION (125)

Specification Desc./Quantity

Chassis prefix (125) ZAPM38100 ÷ 1001

Engine prefix (125) M381M ÷ 1001

VEHICLE IDENTIFICATION (200)

Specification Desc./Quantity

Chassis prefix (200) ZAPM38400 ÷ 1001

Engine prefix(200) M384M ÷ 1001

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification

Desc./Quantity

Dry weight 99 kg

Width 735 mm

Length 1935 mm

Wheelbase 1335 mm

Saddle height 775 mm

Characteristics Liberty 125 - 200 4tempi

CHAR - 8

Engine

ENGINE

Specification

Desc./Quantity

Engine Single-cylinder, 4-stroke Piaggio LEADER

Timing system Single overhead camshaft (SOHC) with 2 valves

Valve clearance intake 0.10

outlet 0.15 Bore x stroke (125) 57 x 48.6 mm Bore x stroke (200) 72 x 48.6 mm

Cubic capacity (125) 124 cm³

Cubic capacity (200) 197 cm³ Compression ratio (125) 10.6 : 1 Compression ratio (200) 9,5:1

Carburettor KEIHIN CVEK26

Engine idle speed approx. 1.600 ÷ 1.800 rpm

Start-up Electric Maximum power to crankshaft (125) 10.5 CV at 8000 rpm Maximum power to crankshaft (200) 12.5 CV at 6500 rpm

Cooling Forced air circulation.

Liberty 125 - 200 4tempi Characteristics

CHAR - 9

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator with torque server,

V belt, automatic clutch, gear reduction unit and transmission

housing with forced air circulation cooling.

Capacities

CAPACITIES

Specification Desc./Quantity

Engine oil 61 in³ (1,000 cm³)

Rear hub oil ~ 200 cm³

Fuel tank capacity (125) ~ 6 litres (of which 1.5 litres is reserve)

Fuel tank (200 cc.) ~ 9 litres (including 1,5 litre reserve)

Electrical system

ELECTRICAL COMPONENTS

Specification

Desc./Quantity

Start-up Electric

Spark plug (125) Champion RG6YC- NGK CR7EB

Spark plug Champion RG6YC

Frame and suspensions

FRAME AND SUSPENSIONS

Specification

Desc./Quantity

Chassis Steel tube chassis Front suspension Ø 32 Hydraulic telescopic fork - travel: 76 mm Rear suspension Hydraulic single shock absorber and spring adjustable to 4 po-

sitions at preloading; travel: 85.5 mm.

Brakes

BRAKES

Specification

Desc./Quantity

Front brake Ø 220 mm disc with calliper with counteracting pistons. Rear brake Drum brake, Ø 140 mm

Wheels and tyres

WHEELS AND TYRES

Specification

Desc./Quantity

Front wheel rim Die-cast aluminium alloy, 2.15 x16" Rear wheel rim Die-cast aluminium alloy, 2.75 x14" Front tyre (125) Tubeless 90/80 - 16 Rear tyre (125) Tubeless 110/80-14" Front tyre (200) Tubeless 100/80-16" Rear tyre (200) Tubeless 120/70 - 14"

Characteristics Liberty 125 - 200 4tempi

CHAR - 10

Specification Desc./Quantity

Front tyre pressure 2 bar

Rear tyre pressure 2.2 bar

Rear tyre pressure (rider and luggage) 2.5 bar

Secondary air

In order to reduce polluting emissions, the vehicle is furnished with a catalytic converter in the muffler. To favour the catalytic process, an extra amount of oxygen is added via a secondary air system (SAS). This system allows more oxygen to be added to the unburned gases before they reach the converter, thus improving the action of the catalytic converter. The air enters the exhaust duct from the head, and is purified by a black filter. The system is fitted with a control valve that disables operation while decelerating to avoid unwanted noise. To ensure the best functioning of the SAS system, every 12,000 km the scooter should be taken to an Authorised Piaggio Service Centre to have the filter cleaned (Scheduled maintenance operations section). The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air.

CAUTION

CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE TO CARRY OUT THESE OPERATIONS.

Carburettor

125cc Version

Liberty 125 - 200 4tempi Characteristics

CHAR - 11

Kehin

CARBURETTOR SETTING

Specification Desc./Quantity

Type CVEK26

Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4

Setting stamping 262A

Maximum jet 82

Maximum air jet (on the body) 85

Tapered pin stamping NELA

Throttle valve spring 130 ÷ 180 gr.

Minimum jet 35

Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 1 ¾

Starter jet 42

Starter air jet (on the body) Ø 1.5

Starter pin travel 10 mm (at 24°)

Starter resistance 20 Ohm (at 24°)

200cc Version

Kehin

CARBURETTOR SETTING

Specification

Desc./Quantity

Type CVEK26

Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4

Setting stamping 265A

Maximum jet 82

Maximum air jet (on the body) 85

Tapered pin stamping NELA

Throttle valve spring 130 ÷ 180 gr.

Minimum jet 35

Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 1 ¾

Starter jet 42

Starter air jet (on the body) Ø 1.5

Starter pin travel 10 mm (at 24°)

Starter resistance 20 Ohm (at 24°)

Tightening Torques

MOTORE

Name

Torque in Nm

Ignition spark plug 10 ÷ 15 Nm

Head cover screws 8 ÷ 10

Head-cylinder stud bolt nuts 6 ÷ 7 + 90° + 90° *

Screws fixing head and cylinder to crankcase 8 ÷ 10

Chain tensioner pad screw 5 ÷ 7 Nm

Timing chain tensioner screws 8 ÷ 10 Nm

Timing chain tensioner central screw 5 - 6

Camshaft pulley screw 12 ÷ 14

Rocking lever axle and camshaft bearing screw 3 ÷ 4 Nm

Valve clearance adjustment lock nuts 7 ÷ 9 Nm

Engine oil pre-filter cover: 25 ÷ 28 Nm

Engine oil drainage cap 25 ÷ 28

Characteristics Liberty 125 - 200 4tempi

CHAR - 12

Name Torque in Nm

Alternator flywheel nut 40 ÷ 44 Nm

Stator screws 3 ÷ 4

Pick-up screws 3 ÷ 4

Oil pump bulkhead screw 4 ÷ 5

Timing chain/oil pump compartment cover screws 4 ÷ 5 Nm

Oil decantation labyrinth sheet screws 7 ÷ 8

Oil pump crown screw 8 ÷ 10

Screws fixing oil pump to crankcase 5 ÷ 6

Oil pump coupling screws 7 ÷ 9 Nm

Oil sump screws 8 ÷ 10 Nm

Inlet manifold screw 7 ÷ 9

Carburettor/manifold clamp screw 1.2 ÷ 1.5 Nm

Screws fixing cables to starter motor 1.5 ÷ 2.5

Starter motor screws 11 ÷ 13

Transmission cover screws 11 ÷ 13 Nm Crankcase cooling cover screw 2 ÷ 2.5 Nut locking clutch unit on pulley 55 ÷ 60 Nm

Crankshaft pulley nut 18 to 20 + 90° Nm

Driven pulley shaft nut 40 ÷ 44 Nm

Hub oil drainage screw 3 ÷ 5 Nm

Rear hub cap screws 24 ÷ 26 Nm

Wheel axle nut 115 ÷ 125

Crankcase half union screw 8 ÷ 10

Per assicurare una corretta coppia di bloccaggio lubrificare i dadi prima del montaggio. * Montando dei nuovi prigionieri, l'operazione di serraggio dei dadi comprende l'effettuazione di 3 rotazioni di 90° dopo il primo bloccaggio a 6÷7 Nm, pertanto: 6÷7 Nm + 90° + 90° + 90° a passaggi incrociati.

STEERING ASSEMBLY

Name

Torque in Nm

Upper steering ring nut 35 ÷ 40 Steering lower ring nut 12 ÷ 14

handlebar fixing screw 45 ÷ 55

FRAME ASSEMBLY

Name

Torque in Nm

Engine-swinging arm bolt 33 ÷ 41

Frame-swinging arm bolt 64 - 72

Shock absorber - chassis nut 20 ÷ 25

Shock absorber/engine pin 33 - 41 N.m

Rear wheel axle 104 ÷ 126

Stand bolt 20 ÷ 25

Front mudguard fixing screw 4 ÷ 6

FRONT SUSPENSION

Name

Torque in Nm

Fork bottom screw 20 ÷ 25

Front wheel axle 45 ÷ 50

Odometer drive screw 6 ÷ 7

FRONT BRAKE

Name

Torque in Nm

Brake fluid pump-hose fitting 20 ÷ 25

Brake fluid pipe-calliper fitting 20 ÷ 22

Calliper tightening screw 20 ÷ 25

Disc tightening screw (Apply LOCTITE 243 medium-strength

threadlocker)

8 ÷ 12 Nm

Oil bleeding valve 8 ÷ 12

Overhaul data

Liberty 125 - 200 4tempi Characteristics

CHAR - 13

Assembly clearances

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER

(125)

Name Initials Cylinder Piston Play on fitting

Coupling A 56.980 ÷ 56.987 56.933 ÷ 56.940 0.040 - 0.054 Coupling B 56.987 ÷ 56.994 56.940 ÷ 56.947 0.040 - 0.054 Coupling C 56.994 ÷ 57.001 56.947 ÷ 56.954 0.040 - 0.054

Coupling D 57.001 ÷ 57.008 56.954 ÷ 56.961 0.040 - 0.054 Coupling 1st increase A1 57.180 ÷ 57.187 57.133 ÷ 57.140 0.040 - 0.054 Coupling 1st increase B1 57.187 ÷ 57.194 57.140 ÷ 57.147 0.040 - 0.054 Coupling 1st increase C1 57.194 ÷ 57.201 57.147 ÷ 57.154 0.040 - 0.054 Coupling 1st increase D1 57.201 ÷ 57.208 57.154 ÷ 57.161 0.040 - 0.054

Coupling 2nd increase A2 57.380 ÷ 57.387 57.333 ÷ 57.340 0.040 - 0.054 Coupling 2nd increase B2 57.387 ÷ 57.394 57.340 ÷ 57.347 0.040 - 0.054 Coupling 2nd increase C2 57.394 ÷ 57.401 57.347 ÷ 57.354 0.040 - 0.054 Coupling 2nd increase D2 57.401 ÷ 57.408 57.354 ÷ 57.361 0.040 - 0.054 Coupling 3rd oversize A3 57.580 ÷ 57.587 57.533 ÷ 57.540 0.040 - 0.054 Coupling 3rd oversize B3 57.587 ÷ 57.594 57.540 ÷ 57.547 0.040 - 0.054 Coupling 3rd oversize C3 57.594 ÷ 57.601 57.547 ÷ 57.554 0.040 - 0.054 Coupling 3rd oversize D3 57.601 ÷ 57.608 57.554 ÷ 57.561 0.040 - 0.054

PISTON TO CAST IRON CYLINDER COUPLING (125)

Name

Initials Cylinder Piston Play on fitting

Coupling M 56.997 ÷ 57.004 56.944 ÷ 56.951 0.046 ÷ 0.060

Coupling N 57.004 ÷ 57.011 56.951 ÷ 56.958 0.046 ÷ 0.060

Coupling O 57.011 ÷ 57.018 56.958 ÷ 56.965 0.046 ÷ 0.060

Coupling P 57.018 ÷ 57.025 56.965 ÷ 56.972 0.046 ÷ 0.060 Coupling 1st oversize M1 57.197 ÷ 57.204 57.144 ÷ 57.151 0.046 ÷ 0.060 Coupling 1st oversize N1 57.204 ÷ 57.211 57.151 ÷ 57.158 0.046 ÷ 0.060 Coupling 1st oversize O1 57.211 ÷ 57.218 57.158 ÷ 57.165 0.046 ÷ 0.060 Coupling 1st oversize P1 57.218 ÷ 57.225 57.165 ÷ 57.172 0.046 ÷ 0.060

Coupling 2nd oversize M2 57.397 ÷ 57.404 57.344 ÷ 57.351 0.046 ÷ 0.060 Coupling 2nd oversize N2 57.404 ÷ 57.411 57.351 ÷ 57.358 0.046 ÷ 0.060 Coupling 2nd oversize O2 57.411 ÷ 57.418 57.358 ÷ 57.365 0.046 ÷ 0.060 Coupling 2nd oversize P2 57.418 ÷ 57.425 57.365 ÷ 57.372 0.046 ÷ 0.060 Coupling 3rd oversize M3 57.597 ÷ 57.604 57.544 ÷ 57.551 0.046 ÷ 0.060 Coupling 3rd oversize N3 57.604 ÷ 57.611 57.551 ÷ 57.558 0.046 ÷ 0.060 Coupling 3rd oversize O3 57.611 ÷ 57.618 57.558 ÷ 57.565 0.046 ÷ 0.060 Coupling 3rd oversize P3 57.618 ÷ 57.625 57.565 ÷ 57.572 0.046 ÷ 0.060

COUPLING BETWEEN PISTON AND CYLINDER (200)

Name

Initials Cylinder Piston Play on fitting

[p] A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 [p] B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044 [p] C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044 [p] D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044

Piston rings

SEALING RINGS (125)

Name

Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 ÷ 0.30

Oil scraper ring 57x1 A 0.10 ÷ 0.30 Oil scraper ring 57x2.5 A 0.10 ÷ 0.35

Compression ring 1st

oversize

57.2 x 1 A 0.15 ÷ 0.30

Characteristics Liberty 125 - 200 4tempi

CHAR - 14

Name Description Dimensions Initials Quantity

Oil scraper ring 1st

oversize

57.2x1 A 0.10 ÷ 0.30

Oil scraper ring 1st

oversize

57.2x2.5 A 0.10 ÷ 0.35

Compression ring 2nd

oversize

57.4x1 A 0.15 ÷ 0.30

Oil scraper ring 2nd

oversize

57.4x1 A 0.10 ÷ 0.30

Oil scraper ring 2nd

oversize

57.4x2.5 A 0.10 ÷ 0.35

Compression ring 3rd

oversize

57.6x1 A 0.15 ÷ 0.30

Oil scraper ring 3rd

oversize

57.6x1 A 0.10 ÷ 0.30

Oil scraper ring 3rd

oversize

57.6x2.5 A 0.10 ÷ 0.35

Maximum clearance after use: 1 mm

SEALING RINGS (200)

Name Description Dimensions Initials Quantity

Compression ring 72x1.5 A 0.15 ÷ 0.30

Oil scraper ring 72x1 A 0.20 ÷ 0.40 Oil scraper ring 72x2.5 A 0.20 ÷ 0.40

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (125)

Name

Description Dimensions Initials Quantity

Half-shaft, transmission

side

16,6 +0-0,05 A D = 0.20 ÷ 0.50

Flywheel-side half shaft 16,6 +0-0,05 B D = 0.20 ÷ 0.50 Connecting rod with PP 18 -0.10 -0.15 C 0.20 ÷ 0.50

Crank pin width 51.400 E

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS

(125)

Name

Description Dimensions Initials Quantity

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

Crankcase Category 2 32.959 ÷ 32.965 Crankshaft half-bearing Category B - blue 1.973 ÷ 1.976 Crankshaft half-bearing Type C - yellow 1.976 ÷ 1.979 Crankshaft half-bearing Category E - green 1.979 ÷ 1.982 Crankshaft category 1 -

Crankcase category 1

E - E

Crankshaft category 1 -

Crankcase category 2

C - C

Liberty 125 - 200 4tempi Characteristics

CHAR - 15

Name Description Dimensions Initials Quantity

Crankshaft category 2 -

Crankcase category 1

C - C

Crankshaft category 2 -

Crankcase category 2

B - B

Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (200)

Name

Description Dimensions Initials Quantity

Half-shaft, transmission

side

16,6 +0-0,05 A D = 0.20 ÷ 0.50

Flywheel-side half shaft 16,6 +0-0,05 B D = 0.20 ÷ 0.50 Connecting rod with PP 18 -0.10 -0.15 C 0.20 ÷ 0.50

Crank pin width E 51.4 +0.050

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS

(200)

Name

Description Dimensions Initials Quantity

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 Crankshaft half-bearing Category B - blue 1.973 ÷ 1.976 Crankshaft half-bearing Type C - yellow 1.976 ÷ 1.979 Crankshaft half-bearing Category E - green 1.979 ÷ 1.982 Crankshaft category 1 -

Crankcase category 1

E - E

Crankshaft category 1 -

Crankcase category 2

C - C

Crankshaft category 2 -

Crankcase category 1

C - C

Crankshaft category 2 -

Crankcase category 2

B - B

Crankshaft/crankcase axial clearance: 0.15 ÷ 0.43

Characteristics Liberty 125 - 200 4tempi

CHAR - 16

Products

TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications

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

quirements of API GL3 specifications

AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions

(brakes, throttle control and odometer)

Oil for 4-stroke engines

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

creased adhesiveness

AGIP GP 330 Grease (brake control levers, throttle

grip)

Calcium complex soap-based grease

with NLGI 2; ISO-L-XBCIB2

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA

Synthetic oil

AGIP GREASE MU3 Grease for odometer transmission gear

case

Soap-based lithium grease with NLGI 3;

ISO-L-XBCHA3, DIN K3K-20

Liberty 125 - 200 4tempi Characteristics

CHAR - 17

INDEX OF TOPICS

TOOLING TOOL

TOOLS

Stores code Description

001330Y Tool for fitting steering seats

001467Y009 Driver for OD 42-mm bearings

001467Y013 Pliers to extract ø 15-mm bearings

002465Y Pliers for circlips

005095Y Engine support

008564Y Flywheel extractor

Liberty 125 - 200 4tempi Tooling

TOOL - 19

Stores code Description

020004Y Punch for removing fifth wheels from

headstock

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crankshaft

alignment

020150Y Air heater support

020151Y Air heater

020193Y Oil pressure gauge

Tooling Liberty 125 - 200 4tempi

TOOL - 20

Stores code Description

020262Y Crankcase splitting strip

020263Y Driven pulley assembly sheath

020287Y Clamp to assemble piston on cylinder

020306Y Punch for assembling valve sealing rings

020329Y MityVac vacuum-operated pump

020330Y Stroboscopic light to check timing

Liberty 125 - 200 4tempi Tooling

TOOL - 21

Stores code Description

020331Y Digital multimeter

020332Y Digital rev counter

020333Y Single battery charger

020334Y Multiple battery charger

Tooling Liberty 125 - 200 4tempi

TOOL - 22

Stores code Description

020335Y Magnetic support for dial gauge

020357Y 32x35-mm Adaptor 020359Y 42x47-mm Adaptor

020360Y 52x55-mm Adaptor

020363Y 20 mm guide

020364Y 25-mm guide

Liberty 125 - 200 4tempi Tooling

TOOL - 23

Stores code Description

020368Y driving pulley lock wrench

020375Y Adaptor 28 x 30 mm

020376Y Adaptor handle

020382Y011 adapter for valve removal tool

020409Y Multimeter adaptor - Peak voltage detec-

tion

Tooling Liberty 125 - 200 4tempi

TOOL - 24

Stores code Description

020412Y 15 mm guide

020414Y 28-mm guide

020423Y Driven pulley lock wrench

020424Y Driven pulley roller casing fitting punch

020425Y Punch for flywheel-side oil seal

020426Y Piston fitting fork

Liberty 125 - 200 4tempi Tooling

TOOL - 25

Stores code Description

020427Y Piston fitting band

020428Y Piston position check support

020430Y Pin lock fitting tool

020431Y Valve oil seal extractor

020434Y Oil pressure control fitting

020444Y Tool for fitting/ removing the driven pulley

clutch

Tooling Liberty 125 - 200 4tempi

TOOL - 26

Stores code Description

020565Y Flywheel lock calliper spanner

020622Y Transmission-side oil guard punch

494929Y Exhaust fumes analyser

020625Y Kit for sampling gas from the exhaust

manifold

Liberty 125 - 200 4tempi Tooling

TOOL - 27

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

EVERY 2 YEARS

Action

Brake fluid - change

EVERY 3000 KM

Action

Engine oil - level check/ top-up

AFTER 1000 KM

80'

Action

Engine oil - replacement Hub oil - change Oil filter (net filter) - clean 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 the «Idle speed adjustment» section

AFTER 6000 KM, 18000 KM, 54000 KM

150'

Action

Engine oil - replacement Hub oil level - check Spark plug electrode gap - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Variable speed rollers/pads - check Driving belt - checking Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - road test

AFTER 12000 KM, 60000 KM

160'

Action

Engine oil - replacement Hub oil level - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement

Liberty 125 - 200 4tempi Maintenance

MAIN - 29

Action

Driving belt - replacement Odometer gear - greasing 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 Centre stand - lubrication Secondary air filter - cleaning Tyre pressure and wear - check Vehicle and brake test - road test

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

AFTER 24000 KM, 48000 KM

175'

Action

Engine oil - replacement Hub oil - change Air filter - clean Engine oil - change Oil filter (net filter) - clean Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Cylinder ventilation system - cleaning Odometer gear - greasing 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 Secondary air filter - cleaning Centre stand - lubrication Vehicle and brake test - road test

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

AFTER 30000 KM, 42000 KM, 66000 KM

95'

Action

Engine oil - replacement Hub oil level - check Spark plug electrode gap - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Slide pads and variator rollers - check Driving belt - checking Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - road test

Maintenance Liberty 125 - 200 4tempi

MAIN - 30

AFTER 36000 KM

270'

Action

Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Flexible brake tubes - replacement Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Secondary air filter - cleaning Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - road test

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

AFTER 72,000 KM

270'

Action

Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment Cylinder ventilation system - check Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Flexible brake tubes - replacement Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Secondary air filter - cleaning Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - road test

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

Liberty 125 - 200 4tempi Maintenance

MAIN - 31

CO check

- Remove the exhaust gases outlet cap on the exhaust pipe

- Using the supplied washer, install the exhaust gases collection kit fitting onto the pipe, as shown in the figure.

- Correctly orientate the components as shown in the picture

- Shut the gas outlet on the tool

- Start the engine and let it warm up

- Shut the engine down

- 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.

Maintenance Liberty 125 - 200 4tempi

MAIN - 32

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

Liberty 125 - 200 4tempi Maintenance

MAIN - 33

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

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. Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed air Dirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol and wash the

tank, if necessary. Replace the cock as a last resource.

Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace

if necessary.

Excessive driving belt wear Check it and replace, if necessary

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

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

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

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

Wrong valve adjustment Adjust the valve clearance properly

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

Valve seat distorted Replace the head assembly

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings

Rear wheel spins at idle

REAR WHEEL ROTATES WITH ENGINE AT IDLE

Possible Cause

Operation

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

Clutch fault Check the springs / clutch masses

Starting difficulties

DIFFICULTY STARTING UP

Possible Cause

Operation

Battery flat Check the state of the battery. If it shows signs of sulphation

replace it and bring the new battery into service charging it for

eight hours at a current of 1/10 of the capacity of the battery

itself

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

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

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

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

aged

Check the starter motor and the kick-starter unit

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

Vacuum operated cock failure Check that fuel is adequately supplied through the pipe by ap-

plying a vacuum to the suction pipe

Liberty 125 - 200 4tempi Troubleshooting

TROUBL - 35

Possible Cause Operation

Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace

if necessary.

Start-up enabling buttons failure Check continuity using an Ohm meter, with the switch pressed;

replace if necessary

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

Air filter obstructed 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.

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

Replace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause

Operation

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

By-Pass area.

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

Scooter 4 Tech)

Engine tends to cut-off at full throttle

THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE

Possible Cause

Operation

Maximum jet clogged Remove the carburettor, wash with solvent and dry with com-

pressed air

Water or condensate in the carburettor tank Remove the tank, wash with solvent and dry with compressed

air

Level in tank too low Restore the level in the tank by bending on the float the thrust-

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

the tank level with the carburettor inverted.

Engine tends to cut-off at idle

THE ENGINE TENDS TO STOP AT IDLE SPEED

Possible Cause

Operation

Incorrect idle adjustment Adjust using the rpm indicator

Incorrect timing Time the system and check the timing system components

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

movement and power supply; replace if necessary

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

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

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

Troubleshooting Liberty 125 - 200 4tempi

TROUBL - 36

High fuel consumption

EXCESSIVE FUEL CONSUMPTION

Possible Cause Operation

Air filter blocked or dirty. Clean according to the procedure

Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

power supply

Loose nozzles Check the maximum and minimum nozzles are adequately

fixed in their fittings

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

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

the tank level with the carburettor inverted.

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Slippage or irregular functioning Check that there is no grease on the masses.

Check that the faying surface between the clutch masses and the clutch bell is mainly in the middle and with equivalent spec-

ifications on the three masses.

Check that the clutch bell is not scored or worn abnormally

Never run the engine without the clutch bell

Insufficient braking

INEFFICIENT OR NOISY BRAKING

Possible Cause

Operation

Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk or

drum wear conditions.

Front brake disk loose or deformed Check the brake disc screws are locked; use a dial gauge and

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

the disc.

Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be

no flexible movement of the brake lever).

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

Excessive backlash in the rear brake control cable Adjust the backlash with the appropriate adjuster located on

the back part of the crankcase.

Brakes overheating

BRAKES OVERHEATING

Possible Cause

Operation

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

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

the disc.

Defective piston sliding Check calliper and replace any damaged part.

Liberty 125 - 200 4tempi Troubleshooting

TROUBL - 37

Electrical system

Battery

BATTERY

Possible Cause Operation

Battery The battery is the electrical device in the system that requires

the most frequent inspections and thorough maintenance. 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 5 ÷ 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keep-

ing in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+. Follow the instructions in the ELECTRICAL SYSTEM

chapter for the recharging of the batteries.

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 (Orange) on the control unit connector.

If by operating the turn indicator control the lights are not stead-

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

harness and the switch.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause

Operation

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

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

them.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause

Operation

Excessive steering clearance Check the tightening of the top ring nut. If irregularities continue

in turning the steering even after making the above adjust-

ments, check the seats in which the ball bearings rotate: re-

place if they are recessed.

Troubleshooting Liberty 125 - 200 4tempi

TROUBL - 38

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

Noisy suspension If the front suspension is noisy, check: that the front shock ab-

sorber works properly and the ball bearings are good condition.

Finally, check the locking torque of the wheel axle nut, the

brake calliper and the disc. Check that the swinging arm con-

necting the engine to the chassis and the rear shock absorber

work properly.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Oil leakage from suspension Replace the rear shock absorber or the front fork cartridge.

Liberty 125 - 200 4tempi Troubleshooting

TROUBL - 39

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Legend:

1. Front LHS turn signal lights (2 bulbs for each lamp)

2. Immobiliser antenna

3. Electronic ignition device with integrated turn signal and choke controller.

4. Horn button

5. Turn signal switch

6. Light switch

7. Stop light switch on rear brake

8. Dual-setting light bulb 12V - 55/60W

9. Headlamp light bulb

10. High beam warning light

11. Low oil pressure warning light

12. Turn signal warning light (RHS)

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 41

13. Low fuel warning light

14. Turn signal warning light (LHS)

15. Dashboard light bulbs

16. Headlamp warning light

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

18. Headlight

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

20. Front brake stop light switch

21. Starter button

22. Immobiliser diagnostic port

23. Key-switch

24. Front RHS turn signal light

25. Cable harness

26. Fuel level sender

27. Fuse holder assembly

28. Rear RHS turn signal light

29. License plate light bulb

30. License plate lamp

31. Battery

32. Starter relay

33. Starter motor

34. Low oil pressure sensor

35. Pick-up

36. Automatic choke device

37. Carburettor heater

38. H.T. coil

39. Taillight assembly

40. Stop and taillight bulb

41. Voltage regulator

42. Rear LHS turn signal light

43. Two amber bulbs for turn signal

44. Relay

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

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 42

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 = Red-Blue GR =Yellow-Red BlN = Blue-Black

Conceptual diagrams

Ignition

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 43

IGNITION

Specification Desc./Quantity

1 electronic control unit 2 Magneto flywheel 3 Pick - up 4 HV coil 5 Spark plug 6 Voltage regulator

Headlights and automatic starter section

HEADLIGHTS AND AUTOMATIC STARTER SECTION

Specification

Desc./Quantity

1 electronic control unit 2 Carburettor heater 3 Automatic starter 4 Key switch 5 Main fusible 15A 6 Battery (125) 12V - 9Ah 7 Battery (200) 12V - 12Ah 8 Headlamp relay 9 Light switch 10 High-beam fuse 7,5A 11 Low-beam and dashboard lights fuse 7,5A 12 Low-beam light bulb 12V - 55W 13 High-beam light bulb 12V-55W 14 High-beam lamp warning light 12V - 1.2W 15 Front side-light bulb 12V - 5W 16 Four dashboards illuminating bulbs 12V - 1,2W 17 Taillight bulb 12V - 5W 18 License plate bulb 12V - 5W 19 Low-beam fuse 7,5A

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 44

Battery recharge and starting

BATTERY RECHARGE AND START-UP SECTION

Specification

Desc./Quantity

1 Magneto flywheel 2 Voltage regulator 3 Pick - up 4 Main fusible 15A 5 Battery (125) 12V - 9Ah 6 Battery (200) 12V - 12Ah 7 Starter relay 8 Starter motor 9 Start up button 10 Front and rear brake light button 11 Brake light filament 12V-21W 12 Fuse 7.5 A 13 Key switch 14 electronic control unit

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 45

Level indicators and enable signals section

START PERMISSIVE BUTTONS AND LEVEL INDICATORS

Specification

Desc./Quantity

1 electronic control unit 2 Battery (200) 12V - 12Ah 3 Battery (125) 12V - 9Ah 4 Main fusible 15A 5 Key switch 6 Engine oil pressure sensor 7 Low oil pressure warning light 12V - 1,2W 8 Low fuel warning light 12V - 1.2W 9 Fuel gauge 10 Fuel level sender 11 Fuse 7.5 A 12 Immobilizer aerial 13 Low engine oil pressure sensor 14 Immobiliser LED 15 Front and rear brake light button 16 Taillight bulb 12V - 5W 17 Starter motor 18 Starter relay 19 Start up button

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 46

Turn signal lights

TURN INDICATORS AND HORN

Specification

Desc./Quantity

1 electronic control unit 2 Indicators switch 3 4 Turn indicator bulbs 12V-10W 4 Turn signal warning light bulbs 12V - 2W 5 Main fusible 15A 6 Battery (125) 12V - 9Ah 7 Battery (200) 12V - 12Ah 8 Horn 9 Fuse 7.5 A 10 Key switch 11 Horn button

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 47

Instruments and warning lights control board

4-PIN CONNECTOR

Specification

Desc./Quantity

1 Ground lead (-) 2 Left turn indicator 3 Right turn indicator 4 Contact not connected

6-PIN CONNECTOR

Specification

Desc./Quantity

1 Fuel gauge 2 High-beam warning light 3 Engine oil warning light 4 Fuse 7.5 A 5 Low fuel warning light 12V - 1.2W 6 Instrument panel lighting and headlamp warning light

Checks and inspections

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 48

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).

Whenever the LED is off and remains so, even when switching it to «ON», it is necessary to check if:

- the battery is charged

- 15A main fuse is working correctly. Connect the immobilizer tester to the diagnosis socket (see ET4 125 manual) located behind the front left fuse box flap. If the serial LED remains off, check the electronic control unit supply as follows:

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 49

Detach the connector from the ECU and check the following:

- Presence of battery potential difference between terminal 4 (Red/Blue) and earth

- Presence of battery potential difference between terminals 4 (Red/Blue) and 8 (black), as shown in the figure.

- Presence of battery potential difference between terminals 5 and 8 with the key-switch onto «ON». If no anomalies are found, replace the electronic control unit.

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 (Blue) 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).

- Alternatively 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 service keys (blue) can be programmed at one time. Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start.

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 50

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 as shown in the figure.

Diagnostic codes

The flash indicating the switching to "ON" (0.7-sec flash) 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-sec flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:

2-FLASH CODE

Example with programmed electronic control unit, no transponder and/or aerial malfunction

Ignition disabled-Vehicle immobilised 3-FLASH CODE

Example with programmed electronic control unit, aerial working properly and unknown transponder code.

Ignition disabled-Vehicle immobilised

Diagnostic code - 2 flashes

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

- Check if the failure continues even after changing key (including the MASTER key). If the failure persists with any key, disconnect the aerial connector from the electronic control unit and check the aerial continuity with the multimeter.

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 51

If it does not work, replace the aerial. If no faults are found, replace the control unit.

CAUTION

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

Specific tooling

020331Y Digital multimeter

Electric characteristic

Resistance value

~ 7 ÷ 9 Ohm

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)

Ignition circuit

All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected to the Pick-Up by the chassis and the engine ground lead.

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 52

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

When noticing no spark plug proceded as follows:

- Pick-Up inspection.

Detach the ECU connector and check for continuity between terminals 2 (Green) and 8 (Black). The inspection must include the pick-up and it's power cable. If an open circuit is found, repeat the inspection between the flywheel connector and earth. If unacceptable values are found, proceed by replacing the pick-up, otherwise repair the cable.

Electric characteristic

Pick-up resistance value

Pick-up resistance value: 105 ÷ 124 Ohm

- H.T. coil primary circuit inspection

Detach the connector from the ECU and check for continuity between terminals 3 (purple) and 8 (black) (see figure). If unacceptable values are found, repeat the inspection directly from the positive and negative terminals of the H.T. coil primary circuit. If the values are within the prescribed limit, proceed by repairing the wiring or reattaching all wirings, otherwise replace the H.T. coil.

Electric characteristic

High voltage coil primary resistance value

High voltage coil primary resistance value: 0.4 ÷

0.5 Ohm

- 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.

Specific tooling

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 53

020409Y Multimeter adaptor - Peak voltage detection

Electric characteristic

High voltage coil secondary resistance value

High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm

- Pick-Up

Detach the ECU connector and connect the positive terminal to connector no. 2 and the negative terminal to connector no. 8 (see figure). Crank the engine using the starter motor and check the tension produced by the pick-up. If unacceptable values are found, replace the PickUp.

N.B. THE MULTIMETER MUST BE SELECTED TO DETECT

CONTINUOUS VOLTAGE.

Electric characteristic

Pick-Up voltage value

Pick-Up voltage value: > 2 Volt

- H.V. coil

With the control unit and HV coil connected to the circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor and connect the positive terminal to the earth one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit.

THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK.

Electric characteristic

High voltage coil voltage value

High voltage coil voltage value: > 100 Volt

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 54

Battery recharge circuit

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 earth and to the battery positive passing through the 15A safety fuse. 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.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

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.

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 55

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.

Recharge system voltage check

Connect an ammeter induction clamp 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 8A, 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 when the engine is on (see figure). If no voltage is detected, connect the multimeter negative terminal to the ground lead and the positive terminal to the automatic starter orange cable;

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 56

with the key switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the key switch.

If battery potential is found, repeat the inspection from the connector to the ECU. After detaching the choke device, start the engine and, while at idle, check for tension connecting the positive terminal of the multimetre to terminal 5 (Orange) and the negative to terminal 7 (White/ Black) (see figure). If no tension is found, replace the ECU; otherwise check the wiring between the choke device and the ECU.

Turn signals system check

- If the turn signal lights are faulty, proceed as follows:

- Detach the ECU connector and check for battery tension between terminal 5 (Orange) and earth, with the key-switch onto «ON».

- Check the same is present between terminals 5 (Orange) and 8 (Black).

If no tension is measured, check the wiring, otherwise proceed as follows:

- Jumper terminals 1 (Black/Blue) and 5 (Orange), see figure, and alternately operate the turn signal switch towards left and right wit the key-switch onto «ON» and check the bulbs go off. If this happens, replace the ECU, as faulty. If this does not happen, check the wiring between the ECU and the turn signal switch, hence repeat the test.

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 57

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 RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1) Voltage check up

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 battery rated capacity

- Charge time: Maximum 5 h

Dry-charge battery

WARNING

- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about 15 minutes and seek immediate medical attention. In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Seek immediate medical attention Batteries produce explosive gases; keep clear of free flames, sparks or cigarettes; ventilate the area when recharging the battery indoors. Always protect your eyes when working close to batteries.

Keep out of the reach of children.

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 58

Commissioning dry-charged batteries :

1) - Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1.26, corresponding to 30 Be at a minimum temperature of 15°C until the upper level is reached.

2) - Leave to rest for at least 2 hours; then, restore the level with sulphuric acid.

3) - Within the following 24 hours, recharge using the specific battery charger (single) or (multiple) at a density of about 1/10 of the battery nominal capacity until fully charged; check that the acid density is about 27, corresponding to 31 Be, and that these values are stabilised.

4) - Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.

5) Once the above operations have been performed, install the battery on the vehicle ensuring that it is wired up properly.

1 Hold the vertical tube 2 Look at the level 3 The float must be freed

WARNING

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

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Battery maintenance

The battery is an electrical device which requires careful monitoring and careful maintenance. The maintenance rules are:

1) Electrolyte level check

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle electrical system: the battery works overcharged and is subject to quick wear.

2)Load status check

Liberty 125 - 200 4tempi Electrical system

ELE SYS - 59

After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. 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, remembering that the ground wire (black) marked (-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign.

3) Recharging the battery

Remove the battery from the vehicle removing the negative clamp first. Regular bench charging must be carried out with the specific battery charger, (single) or (multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).

4) Battery cleaning

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

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.

CAUTION

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

CAUTION

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

CAUTION

TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Electrical system Liberty 125 - 200 4tempi

ELE SYS - 60

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the head

- Undo the 2 screws fixing the muffler to the housing; then remove the whole muffler paying attention to the interference between its supporting bracket and the cooling cover.

Removal of the engine from the vehicle

•

Remove the spark plug access cover.

•

Remove the helmet compartment.

•

Remove the entire muffler assembly.

•

Disconnect the spark plug cap.

•

Remove the 3 screws on the transmission cover fixing the rear brake transmission.

•

Cut the fixing clamp and disconnect the transmission air pipe. Disconnect the engine ground lead after having unscrewed the specific screw on the cover.

Engine from vehicle Liberty 125 - 200 4tempi

ENG VE - 62

•

Detach the electrical connections from starter motor, choke device, carburettor heater and flywheel magneto.

•

Detach the throttle cable and the fuel hose from the carburettor.

•

Detach the vacuum tube from the fuel tap on the intake manifold.

•

Remove the rear shock absorber by loosening the top and bottom fixings.

•

Loosen the engine-swingarm fixing nut from the right hand side of the vehicle and then remove the bolt from the left.

WARNING BE VERY CAREFUL WHEN HANDLING FUEL. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSI-

TIVE LEAD FIRST AND THEN THE NEGATIVE ONE.

PIAGGIO Liberty 125, Liberty 200 4tempi Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual