PIAGGIO Runner 125, Runner 200 Service Station Manual

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SERVICE STATION MANUAL

633616 (IT)-633617(EN)-633618 (FR)-633619

(DE)-633620 (ES)- 633621 (PT)- 633622 (NL)- 633623

(EL)

Runner 125 - 200

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SERVICE STATION

MANUAL

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.

in whole or in part is prohibited."

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

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

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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.

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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

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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

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INDEX OF TOPICS

CHARACTERISTICS

CHAR

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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

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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

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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

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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

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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

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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 Ω (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 Ω (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

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

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

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

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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

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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

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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

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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

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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

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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.

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

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Page 20

N.B.

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

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Page 21

N.B.

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

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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

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Page 23

Products

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

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

Characteristic

Rear hub oil

Capacity ~ 150 cm³

Locking torques (N*m)

Hub oil drainage screw 15 ÷ 17 Nm

Runner 125 - 200 Maintenance

MAIN - 43

Page 44

Air filter

Remove the air cleaner cap after undoing the retainer screws, then extract the filter.

- Wash with water and neutral soap.

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

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

-Drip dry the filter and then squeeze it between the hands without wringing.

CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,

THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.

CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER

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

Engine oil

In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Replace oil and filter every 6,000 km. The engine must be drained by running off the oil from drainage cap "B" of the flywheel side mesh pre-filter; furthermore to facilitate oil drainage, loosen the cap/dipstick "A". Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter "C" and remove it. Make sure the pre-filter and discharge tap O-rings are in good condition. Lubricate them and refit the gauze filter and oil drainage tap, screwing them up to the specified torque.

Maintenance Runner 125 - 200

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Page 45

Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from cap "A". Then start up the scooter, leave it running for a few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

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

Characteristic

Engine oil top-up

600 ÷ 650 cc

Check

This operation must be carried out with the engine cold and following the procedure below:

1. Place the vehicle on its centre stand and on flat ground.

2. Undo cap/dipstick "A", dry it off with a clean cloth and replace it, screwing down completely.

3. Remove the cap/dipstick again and check that the level is between the min and max. marks; top up if necessary.

The MAX level mark indicates a quantity of around 1100 cc of oil in the engine. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level.

Runner 125 - 200 Maintenance

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Page 46

Oil top up

The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. The restoration level between the MIN and MAX levels implies a quantity of oil of approx. 400 cc.

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.

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.

Maintenance Runner 125 - 200

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Page 47

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) Discharge: 0.15 mm (when cold)

Level check

- Remove the front grille

- Check that the coolant level is between the min and max reference marks. Top up with recommended coolant, if necessary.

Recommended products

AGIP PERMANENT PLUS Coolant

Monoethylene glycol antifreeze fluid, CUNA NC 956-16

Level check

Proceed as follows:

- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;

- Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the pads.

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Top-up

Proceed as follows:

1. rest the vehicle on its centre stand with the handlebars perfectly horizontal;

2. remove the rear-view mirrors;

3. remove the front handlebar cover;

4. remove the tank cover «A» loosening the two

fixing screws «B» and restore the level using only the prescribed fluid without exceeding the maximum level. Under normal climatic conditions, the liquid should be replaced every two years. This operation must be carried out by trained technicians, please contact an Authorised Piaggio-Gilera Service Cen-

tre

CAUTION

TOP UPS SHOULD ONLY BE CARRIED OUT WITH DOT 4 CLASSIFIED BRAKE FLUID.

CAUTION

THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE. THEREFORE, WHEN TOPPING IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL RESULT IN INEFFICIENT BRAKING.

WARNING

IN NORMAL CLIMATIC CONDITIONS IT IS ADVISABLE TO REPLACE THE ABOVE-MENTIONED FLUID EVERY 2 YEAR. NEVER USE BRAKE FLUID CONTAINED IN CONTAINERS WHICH ARE ALREADY OPEN OR PARTIALLY USED.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

Maintenance Runner 125 - 200

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Page 49

Headlight adjustment

Proceed as follows:

1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen;

2. Turn on the headlight and check that the borderline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and higher than 7/10;

3. Otherwise, regulate the headlight by adjusting the screw «A», after removing the front grille.

N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.

SAS filters inspection and cleaning

the SAS for leader engines 125 cm³ - 200 cm³ Euro 2 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. 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.

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System description:

The air is drawn through a passage behind the secondary air box cover, passes through that cover and flows towards the valve. Now the filtered air enters the diaphragm valve to be channelled towards 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.

- Detach the vehicle electric cable harness from its attachment fitting on the crankcase.

- Remove the 2 fixing screws, the gasket and the pipe connecting the SAS valve to the head.

- Disconnect the depression pipe from the SAS valve

- Unscrew the 3 fixing screws of the SAS valve cover from the flywheel cover and remove it together with the whole valve.

- Unscrew the 2 fixing screws of the SAS valve and separate all the components.

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Page 51

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

- Check the integrity of the rubber gasket between the valve and the sas air filter support.

- Clean the filter thoroughly. Replace the filter if it is damaged or distorted.

- Check that the coupling connecting the secondary air to the metal pipe does not have any dents, overheating or warping. If there is, replace it.

- Check that the metal pipe does not have any dents

CAUTION

INADEQUATE TIGHTNESS BETWEEN THE SAS VALVE AND ITS SUPPORT INCREASES NOISE IN THE SAS SYSTEM.

To refit, follow the removal procedure in reverse order being careful to respect the direction of the rubber coupling connecting the SAS valve and the discharge system

CAUTION

NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR FILTER

CAUTION

WHEN RIDING ON DUSTY STREETS, THE SECONDARY AIR FILTER MUST BE CLEANED MORE OFTEN THAN WHAT IS INDICATED IN THE SCHEDULED MAINTENANCE CHART.

Insert the filter into its housing. Fit the valve support with the 3 screws Insert the rubber spacer on the valve and proceed with the assembly on the support. Fix the valve with 2 screws. Insert the coupling and the depression pipe into the valve. Lock the upper clamp.

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Page 52

Fix the metal tube to the head using the gasket and the 2 screws. Lock the lower clamp connecting manifold / pipe.

Maintenance Runner 125 - 200

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Runner 125 - 200 Maintenance

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 55

This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given.

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-

place

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. Remove the sponge, wash with water and car shampoo, then

soak it in a mixture of 50% petrol and 50% specific oil. Press

with your hand without squeezing, allow it to drip dry and refit.

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 movable guide of the driven pulley

with specific grease.

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

sary

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

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

valve

Rear wheel spins at idle

Starting difficulties

DIFFICULT STARTING

Possible Cause

Operation

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

Check the starter motor, the system and the torque limiter

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 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.

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

supply, replace if required.

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

soak it in a mixture of 50% petrol and 50% specific oil. Press

with your hand without squeezing, allow it to drip dry and refit.

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-

place

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Possible Cause Operation

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

replace and use the new battery following the instructions

shown in the chapter

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

ened

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

valve

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

Fuel pump fault Check the pump control device

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

LOW 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 adding the recommended oil type

Engine tends to cut-off at full throttle

ENGINE STOP FULL THROTTLE

Possible Cause

Operation

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

vacuum intake and the pipe sealing

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.

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

ENGINE STOP IDLING

Possible Cause

Operation

Incorrect timing Time the system and check the timing system components

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

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

the sponge filter is clean too

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

movement and power supply; replace if necessary

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Page 57

Possible Cause Operation

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

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

Replace the pipe

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

High fuel consumption

HIGH FUEL CONSUMPTION

Possible Cause Operation

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.

Loose nozzles Check the maximum and minimum nozzles are adequately

fixed in their fittings

Fuel pump failure Check that there is no fuel in the low-pressure duct

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

power supply

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

soak it in a mixture of 50% petrol and 50% specific oil. Press

with your hand without squeezing, allow it to drip dry and refit.

SAS malfunctions

ANOMALIES IN THE SECONDARY AIR DEVICE

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

Replace the pipe

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

Transmission and brakes

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

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

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Insufficient braking

INSUFFICIENT BRAKING

Possible Cause Operation

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

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.

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

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.

Electrical system

Battery

BATTERY

Possible Cause

Operation

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

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 (Orange) on the control unit

connector.

If by operating the turn indicator control the lights

are not steadily on, replace the control unit; other-

wise, check the cable harness and the switch.

Steering and suspensions

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Page 59

Rear wheel

REAR WHEEL ROTATES WITH ENGINE AT IDLE

Possible Cause Operation

Idling rpm too high Adjust the engine idle speed.

Clutch fault Check the springs / clutch masses

Controls

STEERING CONTROLS AND SUSPENSIONS

Possible Cause Operation

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

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.

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

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.

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

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.

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

steering covers and the adjustments.

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 61

KEY (With electric pump)

1. Electronic ignition device

2. Immobilizer aerial

3. Magneto flywheel - Pick-up

4. Voltage regulator

5. Fuses

6. Battery

7. Starter motor

8. Start-up remote control switch

9. Start-up button

10. Stop button on rear brake

11. Stop button on front brake

12. Turn indicator switch

13. License plate light

14. Rear left turn indicator

15. Rear light

A. Tail light bulbs B. Stop light bulbs

16. Rear right turn indicator

17. Left front turn indicator

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18. Headlight assembly A. Tail light bulbs B. High-beam light bulbs C. Low-beam light bulb

19. Right front turn indicator

20. Horn

21. Horn button

22. Thermistor

23.Wheel turning sensor

24. Instrument panel

1. +Battery

2. +Key

3. Ground

4. -Hall

5. +Hall

6. Hall

7. Lighting

8. Enable gauge

10. Rev counter

11. Coolant level

12. Fuel level

13. High-beam warning light

14. Right turn indicator

15. Left turn indicator

16. Oil reserve warning light

17. Low fuel warning light

20. Immobilizer LED

25. Engine oil pressure sensor

26. Fuel level transmitter

27. Light switch

28. Thermoswitch

29. Electric fan

30. Fuel pump

31. Electric pump control device

1. +Key

3. Pump ground connection

4. +Pump

5. Ground

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Page 63

6. Engine revs

32. Automatic starter

33. Key switch

34. Starter control winding

35. Spark plug

36. HV coil

KEY (Without electric pump)

1. Electronic ignition device

2. Immobilizer aerial

3. Magneto flywheel - Pick-up

4. Voltage regulator

5. Fuses

6. Battery

7. Starter motor

8. Start-up remote control switch

9. Start-up button

10. Stop button on rear brake

11. Stop button on front brake

12. Turn indicator switch

13. License plate light

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14. Rear left turn indicator

15. Rear light

A. Tail light bulbs B. Stop light bulbs

16. Rear right turn indicator

17. Left front turn indicator

18. Headlight assembly

A. Tail light bulbs B. High-beam light bulbs C. Low-beam light bulb

19. Right front turn indicator

20. Horn

21. Horn button

22. Thermistor

23.Wheel turning sensor

24. Instrument panel

1. +Battery

2. +Key

3. Ground

4. -Hall

5. +Hall

6. Hall

7. Lighting

8. Enable gauge

10. Rev counter

11. Coolant level

12. Fuel level

13. High-beam warning light

14. Right turn indicator

15. Left turn indicator

16. Oil reserve warning light

17. Low fuel warning light

20. Immobilizer LED

25. Engine oil pressure sensor

26. Fuel level transmitter

27. Light switch

28. Thermoswitch

29. Electric fan

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Page 65

30. Fuel pump

31. Automatic starter

32. Key switch

33. Starter control winding

34. Spark plug

35. HV coil KEY Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Conceptual diagrams

Ignition

KEY (With electric pump)

1. Electronic ignition device

2. Immobilizer aerial

5. Fuses

6. Battery

33. Key switch

35. Spark plug

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Page 66

36. HV coil

KEY (Without electric pump)

1. Electronic ignition device

2. Immobilizer aerial

5. Fuses

6. Battery

32. Key switch

34. Spark plug

35. HV coil

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Headlights and automatic starter section

KEY (With electric pump)

1. Electronic ignition device

5. Fuses

6. Battery

13. License plate light

15. Rear light

A. Tail light bulbs B. Stop light bulbs

18. Headlight assembly A. Tail light bulbs B. High-beam light bulbs C. Low-beam light bulb

24. Instrument panel

1. +Battery

2. +Key

3. Ground

4. -Hall

5. +Hall

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Page 68

6. Hall

7. Lighting

8. Enable gauge

10. Rev counter

11. Coolant level

12. Fuel level

13. High-beam warning light

14. Right turn indicator

15. Left turn indicator

16. Oil reserve warning light

17. Low fuel warning light

20. Immobilizer LED

27. Light switch

32. Automatic starter

33. Key switch

34. Starter control winding

KEY (Without electric pump)

1. Electronic ignition device

5. Fuses

6. Battery

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Page 69

13. License plate light

15. Rear light

A. Tail light bulbs B. Stop light bulbs

18. Headlight assembly A. Tail light bulbs B. High-beam light bulbs C. Low-beam light bulb

24. Instrument panel

1. +Battery

2. +Key

3. Ground

4. -Hall

5. +Hall

6. Hall

7. Lighting

8. Enable gauge

10. Rev counter

11. Coolant level

12. Fuel level

13. High-beam warning light

14. Right turn indicator

15. Left turn indicator

16. Oil reserve warning light

17. Low fuel warning light

20. Immobilizer LED

27. Light switch

31. Automatic starter

32. Key switch

33. Starter control winding

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Battery recharge and starting

KEY (With electric pump)

1. Electronic ignition device

3. Magneto flywheel - Pick-up

4. Voltage regulator

5. Fuses

6. Battery

7. Starter motor

8. Start-up remote control switch

9. Start-up button

10. Stop button on rear brake

11. Stop button on front brake

15. Rear light

A. Tail light bulbs B. Stop light bulbs

33. Key switch

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Page 71

KEY (Without electric pump)

1. Electronic ignition device

3. Magneto flywheel - Pick-up

4. Voltage regulator

5. Fuses

6. Battery

7. Starter motor

8. Start-up remote control switch

9. Start-up button

10. Stop button on rear brake

11. Stop button on front brake

15. Rear light

A. Tail light bulbs B. Stop light bulbs

32. Key switch

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Level indicators and enable signals section

KEY (With electric pump)

1. Electronic ignition device

2. Immobilizer aerial

5. Fuses

6. Battery

22. Thermistor

23.Wheel turning sensor

24. Instrument panel

1. +Battery

2. +Key

3. Ground

4. -Hall

5. +Hall

6. Hall

7. Lighting

8. Enable gauge

10. Rev counter

11. Coolant level

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12. Fuel level

13. High-beam warning light

14. Right turn indicator

15. Left turn indicator

16. Oil reserve warning light

17. Low fuel warning light

20. Immobilizer LED

25. Engine oil pressure sensor

26. Fuel level transmitter

33. Key switch

KEY (Without electric pump)

1. Electronic ignition device

2. Immobilizer aerial

5. Fuses

6. Battery

22. Thermistor

23.Wheel turning sensor

24. Instrument panel

1. +Battery

2. +Key

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3. Ground

4. -Hall

5. +Hall

6. Hall

7. Lighting

8. Enable gauge

10. Rev counter

11. Coolant level

12. Fuel level

13. High-beam warning light

14. Right turn indicator

15. Left turn indicator

16. Oil reserve warning light

17. Low fuel warning light

20. Immobilizer LED

25. Engine oil pressure sensor

26. Fuel level transmitter

32. Key switch

Devices and accessories

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Page 75

KEY (With electric pump)

1. Electronic ignition device

5. Fuses

6. Battery

12. Turn indicator switch

14. Rear left turn indicator

16. Rear right turn indicator

17. Left front turn indicator

19. Right front turn indicator

20. Horn

21. Horn button

24. Instrument panel

1. +Battery

2. +Key

3. Ground

4. -Hall

5. +Hall

6. Hall

7. Lighting

8. Enable gauge

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Page 76

10. Rev counter

11. Coolant level

12. Fuel level

13. High-beam warning light

14. Right turn indicator

15. Left turn indicator

16. Oil reserve warning light

17. Low fuel warning light

20. Immobilizer LED

28. Thermoswitch

29. Electric fan

30. Fuel pump

31. Electric pump control device

1. +Key

3. Pump ground connection

4. +Pump

5. Ground

6. Engine revs

33. Key switch

KEY (Without electric pump)

Electrical system Runner 125 - 200

ELE SYS - 76

Page 77

1. Electronic ignition device

5. Fuses

6. Battery

12. Turn indicator switch

14. Rear left turn indicator

16. Rear right turn indicator

17. Left front turn indicator

19. Right front turn indicator

20. Horn

21. Horn button

24. Instrument panel

1. +Battery

2. +Key

3. Ground

4. -Hall

5. +Hall

6. Hall

7. Lighting

8. Enable gauge

10. Rev counter

11. Coolant level

12. Fuel level

13. High-beam warning light

14. Right turn indicator

15. Left turn indicator

16. Oil reserve warning light

17. Low fuel warning light

20. Immobilizer LED

28. Thermoswitch

29. Electric fan

30. Fuel pump

32. Key switch

Checks and inspections

This section is devoted to the checks on the electrical system components.

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Page 78

Immobiliser

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobiliser system consists of the following components:

- electronic control unit

- immobilizer aerial

- master key with built-in transponder (red key) with big handgrip

- service key with built-in transponder (red key with small handgrip)

- H.V. coil

- Diagnostic LED The diagnosis led also works as a blinking light to deter theft. This function is activated every time the ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to the "ON" position, the deterring blinker function is deactivated. Subsequently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition-key switch and/or the instrument panel is not initiated, check if:

•

there is battery voltage

•

fuses 2 and 4 are working properly

•

there is power to the control unit as specified below:

Remove the front shield to access the control unit. Disconnect the two connectors and check the following conditions:

With the key switch in the OFF position:

•

there is battery voltage between terminals 4-8 and terminal 6- large chassis earth connector (fixed power supply). If there is no voltage check that fuse 4 and its cable are in working order.

With the key switch in the OFF position:

•

there is battery voltage between terminals 5-8 and terminals 5-large chassis earth connector (power supply under panel). If there is no voltage, check the key switch contacts, that fuse no. 4 and its cable are working order.

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Page 79

INDEX OF TOPICS

VIRGIN CIRCUIT

Page 80

When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly. The data storage procedure for a previously unprogrammed control unit provides for the recognition of the master as the first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys. The master and service keys must be used to code the system as follows:

- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits 1 to 3 seconds).

- Insert the service key and turn it to "ON" for 2 seconds.

- If you have copies of the key, repeat the operation with each key.

- Insert the MASTER key again and turn it to "ON" for 2 seconds. The maximum time to change keys is 10 seconds. During a single data storage sequence a maximum of 7 service keys are allowed. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate keys, you must repeat the procedure using all the keys you intend to keep using. If a service key should become un-coded, the efficiency of the high voltage circuit shielding must be

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thoroughly inspected: In any case it is advisable to use resistive spark plugs.

Characteristic

MASTER key:

RED KEY WITH BIG HANDGRIP

SERVICE key.

RED KEY WITH SMALL HANDGRIP

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INDEX OF TOPICS

DIAGNOSTIC CODES

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The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the led remains on permanently, it means the ignition is inhibited:

1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after

which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs.

2. Previously unused control unit - transponder absent or cannot be used: The LED is per-

manently ON; in this condition, no operations are possible, including starting of the vehicle.

3. Programmed control unit - the service key in (normal condition of use): a single 0.7-second

flash is displayed, after which the LED remains off steadily. The engine can be started.

4. Programmed control unit - Master key in: a

0.7 sec. flash is displayed followed by the LED remaining off for 2 sec. and then by short 0.46 sec. flashes the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been completed, the LED remains permanently OFF. The engine can be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be transmitted are:

•

Code 1 flash

•

2-flash code

•

3-flash code

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Diagnostic codes Runner 125 - 200

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INDEX OF TOPICS

DIAGNOSTIC CODE - 1 FLASH

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The one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessary.

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INDEX OF TOPICS

DIAGNOSTIC CODE - 2 FLASHES

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A two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary. If this is not the case, replace the defective key and/or reprogram the control unit. Replace the control unit if the problem continues.

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INDEX OF TOPICS

DIAGNOSTIC CODE - 3 FLASHES

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A three-flash code indicates a system where the control unit does not recognise the key. Turn the switch to ON using several keys: if the error code is repeated even with the Master key, replace the control unit. If this is not the case, perform a reprogramming.

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INDEX OF TOPICS

IGNITION CIRCUIT

Page 92

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. 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.

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INDEX OF TOPICS

BATTERY RECHARGE CIRCUIT

Page 94

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery's positive terminal passing through the 20A protective fuse. The three-phase generator provides good recharge power and at low revs a good compromise is achieved between the generated power and idle speed stability.

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INDEX OF TOPICS

TATOR CHECK

Page 96

- With a tester, check the circuit between connections 5-3 and 5-1 is not interrupted.

- Check the earth isolation on the three phases of stators 5-earth, 3-earth, 1-earth. Stage indicative resistance: 0.7 - 0.9 Ω Minimum oil pressure switch check

- With a tester, check the circuit between connections 4 and ground (with engine off) is not interrupted. Pick-Up check

- Check that there is a resistance of about 105 ÷ 124 Ω at 20° C between connection 2 and ground.

- In case of values different from the ones stated, replace the defective parts.

N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A

CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.

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INDEX OF TOPICS

OLTAGE REGULATOR CHECK

Page 98

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.

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INDEX OF TOPICS

ECHARGE SYSTEM VOLTAGE CHECK

Page 100

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 10A, repeat the test using a new regulator and/ stator alternatively.

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PIAGGIO Runner 125, Runner 200 Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual