PIAGGIO Runner 125, Runner 200 Service Station Manual

SERVICE STATION MANUAL
633616 (IT)-633617(EN)-633618 (FR)-633619
(DE)-633620 (ES)- 633621 (PT)- 633622 (NL)- 633623
(EL)
Runner 125 - 200
SERVICE STATION
Runner 125 - 200
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.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
SERVICE STATION MANUAL
Runner 125 - 200
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special 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 VIRGIN CIRCUIT DIAGNOSTIC CODES DIAGNOSTIC CODE - 1 FLASH DIAGNOSTIC CODE - 2 FLASHES DIAGNOSTIC CODE - 3 FLASHES IGNITION CIRCUIT BATTERY RECHARGE CIRCUIT STATOR CHECK VOLTAGE REGULATOR CHECK RECHARGE SYSTEM VOLTAGE CHECK TURN SIGNALS SYSTEM CHECK FUSES DASHBOARD SEALED BATTERY DRY-CHARGE BATTERY BATTERY INSTALLATION
PUMP ELECTRICS CHECK 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
This section describes the general specifications of the vehicle.
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 naked 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 sizes. 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.
Characteristics Runner 125 - 200
CHAR - 8
Vehicle identification
Vehicle 125 Chassis prefix: ZAPM46300 ÷ 1001 Engine prefix: M463M Vehicle 200 Chassis prefix: ZAPM46400 ÷ 1001 Engine prefix: M464M
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification
Desc./Quantity
Kerb weight 137 ± 5 kg
Maximum load Driver + passenger + baggage (180 Kg)
Wheelbase 1340 mm Saddle height 815 mm Overall length 1890 mm
Overall width 750 mm
Overall height 1260 mm
Runner 125 - 200 Characteristics
CHAR - 9
Engine
TECHNICAL DATA 125
Specification
Desc./Quantity
Engine single-cylinder, four-stroke
Bore x stroke 57 x 48.6 mm
Cubic capacity 124 cm³
Compression ratio 11.5 ÷ 12.5 : 1
Ignition advance (before TDC)
From 10° ± 1° at 2000 rpm to 34° ± 1° at 6500 rpm
Kehin Carburettor CVEK-30
Max. speed 108 km/h
Timing system single overhead camshaft driven by a chain on the left-hand
side, 4 valves, three-arm rocking lever with set screw.
intake valve clearance 0.10 mm
Valve clearance: discharge 0.15 mm
Air filter sponge, impregnated with mixture (50% oil and 50% unleaded
petrol).
Starting system Electric starter with Bendix gear
Lubrication With lobe pump (inside crankcase) controlled by a chain with
double filter: mesh and paper
Fuel supply With unloaded petrol, carburettor and electric pump Engine - wheel ratio Short: 1/28.02 Engine - wheel ratio Long: 1/8.41
TECHNICAL DATA 200
Specification
Desc./Quantity
Engine single-cylinder, four-stroke
Bore x stroke 72 x 48.6 mm
Characteristics Runner 125 - 200
CHAR - 10
Specification Desc./Quantity
Cubic capacity 198 cm³
Compression ratio 11 ÷ 12 : 1
Ignition advance (before TDC)
From 10° ± 1° at 2000 rpm to 32° ± 1° at 6500 rpm
Kehin Carburettor CVEK-30
Max. speed 120 km/h
Timing system single overhead camshaft driven by a chain on the left-hand
side, 4 valves, three-arm rocking lever with set screw.
intake valve clearance 0.10 mm
Valve clearance: discharge 0.15 mm
Air filter sponge, impregnated with mixture (50% oil and 50% unleaded
petrol).
Starting system Electric starter with Bendix gear
Lubrication With lobe pump (inside crankcase) controlled by a chain with
double filter: mesh and paper
Fuel supply With unloaded petrol, carburettor and electric pump Engine - wheel ratio Short: 1/19.36 Engine - wheel ratio Long 1/6.54
Transmission
TRANSMISSIONS
Specification Desc./Quantity
Transmission With automatic expandable pulley variator, V belt, automatic
clutch, gear reduction unit and transmission housing with
forced-circulation air cooling.
Capacities
CAPACITY
Specification
Desc./Quantity
Engine oil 1.1 lt. dry; 1.0 lt. at oil change
Fuel tank (including a ~ 1.7 l reserve) 8.5 lt. (approx. value)
Rear hub approx. 150 cc
Cooling system fluid ~ 2.100 ÷ 2.150 l
Electrical system
ELECTRICAL COMPONENTS 125
Specification
Desc./Quantity
Electronic ignition Consisting of a capacitor discharge ignition microprocessor
with a built-in AT coil and variable advance
Battery 12V -10 Ah
Spark plug CHAMPION RG 4HC - NGK CR 8 EB
Generator Three-phase alternating current
ELECTRICAL COMPONENTS 200
Specification
Desc./Quantity
Generator Three-phase alternating current
Battery 12V -10 Ah
Spark plug
CHAMPION RG 6YC - NGK CR 8 EB
Electronic ignition Consisting of a capacitor discharge ignition microprocessor
with a built-in AT coil and variable advance
Runner 125 - 200 Characteristics
CHAR - 11
Frame and suspensions
FRAME AND SUSPENSIONS
Specification Desc./Quantity
Chassis Modular double cradle frame made of welded tubular steel with
sheet metal reinforcement. Front suspension hydraulic double-acting telescopic fork with 35 mm stems Rear suspension With coaxial spring and hydraulic shock absorber. Chassis to
engine support with swinging arm.
Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 240 mm disc brake (vehicle LHS), with hydraulic control ac-
tivated by handlebar right lever.
Rear brake
Ø 220 mm disc brake with twin plunger callipers, with hydraulic control by a handlebar left lever.
Wheels and tyres
WHEELS AND TYRES
Specification
Desc./Quantity
Front wheel
3.00 x 14" light alloy rim
Front tyre Tubeless, 120/70-14'' 55P
Rear wheel
3.50 x 13" light alloy rims
Rear tyre Tubeless, 140/60 - 13'' 63P
TYRE PRESSURE
Specification
Desc./Quantity
Front wheel pressure: 1.7 bar
Rear tyre pressure 2 bar
Rear tyre pressure - driver and passenger 2.2 bar
Carburettor
125cc Version
Kehin
KEHIN CVEK-30 CARBURETTOR
Specification
Desc./Quantity
Depression carburettor CVEK-30
Body stamping CVK
Stamping 306D
Max. jet 98
Minimum jet 35
Max. air jet 70
Minimum air jet 130
Throttle valve spring 100 ÷ 160 g
Characteristics Runner 125 - 200
CHAR - 12
Specification Desc./Quantity
Minimum mixture set screw initial opening 2
Tapered pin stamping
NDYA
Diffuser nozzle Ø 2.8
Starter air jet Ø 1.5 (body)
Starter diffuser nozzle Ø 1.5 (body)
Starter jet 42
Starter device resistance ~ 20 (at 24°)
Diffuser Ø 29
200cc Version
Kehin
KEHIN CVEK-30 CARBURETTOR
Specification Desc./Quantity
Depression carburettor CVEK-30
Body stamping CVK
Stamping 309C
Max. jet 90
Minimum jet 35
Max. air jet 70
Minimum air jet 115
Throttle valve spring 150 ÷ 250 g
Minimum mixture adjustment screw initial opening 2±½
Tapered pin stamping
NDYC
Diffuser nozzle Ø 2.8
Starter air jet Ø 1.5 (body)
Starter diffuser jet Ø 1.2
Starter jet 42
Starter device resistance ~ 20 (at 24°)
Diffuser Ø 29
N.B.
THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE
Tightening Torques
TORQUE IN NM BY TYPE OF TIGHTENED MATERIAL
Name
Torque in Nm
M4 Ø 8.8 steel screw on plastic with metallic spacers 2
M4 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys
2
M4 Ø 8.8 steel screw Iron, steel 3
M5 Ø 8.8 steel screw on plastic with metallic spacers 4
M5 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys
4
M5 Ø 8.8 steel screw Iron, steel 6
M6 Ø 8.8 steel screw on plastic with metallic spacers 6.5
M6 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys
6.5
M6 Ø 8.8 steel screw Iron, steel 10.5
M7 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys
10.5
M7 Ø 8.8 steel screw Iron, steel 17
M8 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys
16
M8 Ø 8.8 steel screw Iron, steel 26 M10 Ø 8.8 steel screw Iron, steel 52 M12 Ø 8.8 steel screw Iron, steel 100
Runner 125 - 200 Characteristics
CHAR - 13
Name Torque in Nm
M14 Ø 8.8 steel screw Iron, steel 145
REAR BRAKE
Name Torque in Nm
Rear brake disc screws(°) 5 ÷ 6.5
Rear brake calliper-pipe fitting 20 ÷ 25
Rigid / flexible pipe fitting 13 ÷ 18
Rear brake pump-pipe fitting 16 ÷ 20
Rear brake calliper fixing screws 20 ÷ 25
FRONT BRAKE
Name Torque in Nm
Oil bleed screw 8÷12
Disc tightening screw (°) 5 ÷ 6.5
Brake fluid pipe-calliper fitting 20 ÷ 25
Brake fluid pump-hose fitting 16 ÷ 20
Tightening screw for calliper support to the fork 20 ÷ 25
Screw tightening calliper to the support 42 ÷ 52
REAR SUSPENSION
Name Torque in Nm
Upper shock absorber clamp 33 ÷ 41 Lower shock absorber clamp 33 ÷ 41
Shock absorber-crankcase attachment bracket 20 ÷ 25
Rear wheel axle 104 ÷ 126
Muffler arm clamping screws 27 ÷ 30
FRONT SUSPENSION
Name
Torque in Nm
Fork leg screw 6 ÷ 7 Front wheel axle 45 ÷ 50 Fork plate screw 25 ÷ 34
CHASSIS
Name
Torque in Nm
Centre stand bolt 25 ÷ 30
Side stand bolt (°) 35 ÷ 40
Engine arm bolt - frame arm 33 ÷ 41
Swinging arm buffer nut 64 - 72 Frame-swinging arm bolt 64 - 72 Engine-swinging arm bolt 64 - 72
STEERING
Name
Torque in Nm
Upper steering ring nut 30 ÷ 33 Steering lower ring nut 10 ÷ 13 then loosen by 90° Handlebar fixing screw 50 ÷ 55
Fixing screws for handlebar control assembly U-bolts 7 ÷ 10
ENGINE - COOLING
Product
Description Specifications
(°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength
threadlock
CRANKCASE AND CRANKSHAFT
Name
Torque in Nm
Internal engine crankcase bulkhead (transmission-side half
shaft) screws
4 ÷ 6
Engine-crankcase coupling screws 11 ÷ 13
Starter motor screws 11 ÷ 13
Characteristics Runner 125 - 200
CHAR - 14
Name Torque in Nm
Crankcase timing system cover screws (°) 3.5 ÷ 4.5
ENGINE - FLYWHEEL
Name Torque in Nm
Pick-Up clamping screws 3 ÷ 4
Stator assembly screws (°) 3 ÷ 4
Flywheel cover fixing screws 5 - 6
Flywheel nut 94 ÷ 102
Screw fixing freewheel to flywheel 13 ÷ 15
ENGINE - TRANSMISSION
Name Torque in Nm
Rear hub cover screws 24 ÷ 27
Driven pulley shaft nut 54 ÷ 60
Transmission cover screws 11 ÷ 13
Drive pulley nut 75 ÷ 83
Clutch unit nut on driven pulley 55 ÷ 60
Belt support roller screw 11 ÷ 13
ENGINE - CYLINDER HEAD
Name Torque in Nm
Manifold-silencer retaining bolt 15 ÷ 20
Nut fixing muffler to cylinder head 16 ÷ 18
Camshaft retention plate screw 4 ÷ 6
Timing chain tensioner central screw 5 - 6
Timing chain tensioner support screw 11 ÷ 13
Starter ground support screw 11 ÷ 15
Timing chain tensioner slider screw 10 ÷ 14
Inlet manifold screws 11 ÷ 13
Tappet set screw lock nut 6 ÷ 8
Starter ground screw 7 ÷ 8.5
Head fixing side screws 11 ÷ 12
Nuts fixing head to cylinder (*) 27 ÷ 29
Tappet cover screws 6 ÷ 7
Spark plug 12 ÷ 14
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
NOTE
Product
Description Specifications
(°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength
threadlock
Overhaul data
Assembly clearances
Runner 125 - 200 Characteristics
CHAR - 15
Cylinder - piston assy.
ENGINE 200 COUPLING CATEGORIES
Name
Initials Cylinder Piston Play on fitting
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
Characteristics Runner 125 - 200
CHAR - 16
ENGINE 125 COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
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 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
Piston rings
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo
Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Crankshaft to crankcase axial
clearance
Crankshaft to crankcase axial clearance
CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE
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 18 -0.10 -0.15 C D = 0.20 - 0.50
Runner 125 - 200 Characteristics
CHAR - 17
Name Description Dimensions Initials Quantity
Spacer tool 51.4 +0.05 E D = 0.20 - 0.50
Slot packing system
200 models
Characteristic
Compression ratio, 200 models
11.5 ± 0.5 : 1
Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover 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 200 WITH FIBRE HEAD GASKET (1.1)
Name
Measure A Thickness
Shimming 200 - Cylinder 67 - Head gas-
ket 1.1 - Base gasket 0.4
1.70 ÷ 1.60 0.4 ± 0.05
Shimming 200 - Cylinder 67 - Head gas-
ket 1.1 - Base gasket 0.6
1.60 ÷ 1.40 0.6 ± 0.05
Shimming 200 - Cylinder 67 - Head gas-
ket 1.1 - Base gasket 0.8
1.40 ÷ 1.30 0.8 ± 0.05
Characteristics Runner 125 - 200
CHAR - 18
Characteristic
Compression ratio, 125 models
12 ± 0.5: 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 METAL HEAD GASKET (0.3)
Name
Measure A Thickness
Shimming 125 - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.4
1.40 ÷ 1.65 0.4 ± 0.05
Shimming 125 - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.6
1.65 ÷ 1.90 0.6 ± 0.05
Version 125
Characteristic
Compression ratio, 125 models
12 ± 0.5: 1
Runner 125 - 200 Characteristics
CHAR - 19
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
Measure A Thickness
Shimming 125 - Cylinder 67 - Head gas-
ket 1.1 - Base gasket 0.4
2.20 ÷ 2.45 0.4 ± 0.05
Shimming 125 - Cylinder 67 - Head gas-
ket 1.1 - Base gasket 0.6
2.45 ÷ 2.70 0.6 ± 0.05
Characteristic
Compression ratio, 200 models
11.5 ± 0.5 : 1
Characteristics Runner 125 - 200
CHAR - 20
Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover 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 200 WITH METALLIC HEAD GASKET (0.3)
Name
Measure A Thickness
Shimming 200 - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.4
2.50 ÷ 2.40 0.4 ± 0.05
Shimming 200 - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.6
2.40 ÷ 2.20 0.6 ± 0.05
Shimming 200 - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.8
2.20 ÷ 2.10 0.8 ± 0.05
Runner 125 - 200 Characteristics
CHAR - 21
Oversizes
ENGINE 125 OVERSIZE
Name
Description Dimensions Initials Quantity
Compression ring 57 x 1 A 0.15 ÷ 0.30
Oil scraper ring 57 x 1 A 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35
Compression ring 1st
oversize
57.2 x 1 A 0.15 ÷ 0.30
Oil scraper ring 1st
Oversize
57.2 x 1 A 0.10 ÷ 0.30
Oil scraper ring 1st
Oversize
57.2 x 2.5 A 0.15 ÷ 0.35
Compression ring 2nd
Oversize
57.4 x 1 A 0.15 ÷ 0.30
Oil scraper ring 2nd
Oversize
57.4 x 1 A 0.10 ÷ 0.30
Oil scraper ring 2nd
Oversize
57.4 x 2.5 A 0.15 ÷ 0.35
Compression ring 3rd
Oversize
57.6 x 1 A 0.15 ÷ 0.30
Oil scraper ring 3rd
Oversize
57.6 x 1 A
Oil scraper ring 3rd
Oversize
57.6 x 2.5 A 0.15 ÷ 0.35
ENGINE 200 OVERSIZE
Name
Description Dimensions Initials Quantity
Oil scraper ring 72 x 2.5 A 0.20 ÷ 0.40 Oil scraper ring 72 x 1 A 0.20 ÷ 0.40
Compression ring 72 x 1.5 A 0.15 ÷ 0.30
Characteristics Runner 125 - 200
CHAR - 22
Products
RECOMMENDED PRODUCTS TABLE
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 Four-stroke engine oil Lubricating oil for flexible shafts (throttle
control)
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the
requirements of API SL, ACEA A3, JASO
MA specifications
AGIP GP 330 Grease for brake control levers, throttle,
stand
White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing
NLGI 2 Molybdenum disulphide; ISO-L-
XBCHB2, DIN KF2K-20
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
MONTBLANC MOLYBDENUM
GREASE
Grease for driven pulley shaft adjusting ring and movable driven pulley housing
Grease with molybdenum disulphide
AGIP GREASE PV2 Grease for the steering bearings, pin
seats and swinging arm
White anhydrous-calcium based grease
to protect roller bearings; temperature
range between -20 C and +120 C; NLGI
2; ISO-L-XBCIB2.
Runner 125 - 200 Characteristics
CHAR - 23
INDEX OF TOPICS
TOOLING TOOL
APPROPRIATE TOOL
Stores code Description
020151Y Air heater
020331Y Digital multimeter
020333Y Single battery charger
020334Y Multiple battery charger
001467Y014 Pliers to extract ø 15-mm bearings
Runner 125 - 200 Tooling
TOOL - 25
Stores code Description
020412Y 15 mm guide
020335Y Magnetic support for dial gauge
020565Y Flywheel lock calliper spanner
020439Y 17 mm guide
020359Y 42x47-mm adaptor
Tooling Runner 125 - 200
TOOL - 26
Stores code Description
020363Y 20 mm guide
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
Runner 125 - 200 Tooling
TOOL - 27
Stores code Description
020382Y011 adapter for valve removal tool
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
Tooling Runner 125 - 200
TOOL - 28
Stores code Description
020364Y 25-mm guide
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020444Y Tool for fitting/ removing the driven pulley
clutch
020330Y Stroboscopic light to check timing
001467Y035 Belle for OD 47-mm bearings
Runner 125 - 200 Tooling
TOOL - 29
Stores code Description
020368Y driving pulley lock wrench
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
Tooling Runner 125 - 200
TOOL - 30
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