Page 1
Page 2
Index
1 Vespa GT 200 16
2 Characteristics 17
2.1 Various 17
2.1.1 Workshop Safety 17
2.1.2 Service Recommendations 17
2.2 Vehicle Identification 18
2.2.1 Frame No. 18
2.2.2 Engine No. 18
2.3 Technical Specifications 19
2.3.1 Weight and Dimensions 19
2.4 Engine 20
2.4.1 General 20
2.4.2 Walbro carburetor 21
2.4.3 Kehin carburetor 22
2.5 Transmission 23
2.6 Capacities 23
2.7 Electrical Components 23
2.8 Frame, Suspensions, Brakes and Tires 24
2.8.1 Frame and Suspension 24
2.8.2 Brakes 24
2.8.3 Wheels and Tires 24
3 Tightening Torques 25
3.1 Steering Unit 25
3.2 Frame 25
3.3 Front Suspension 25
3.4 Front Brake 26
3.5 Rear Suspension 26
3.6 Rear Brake 27
3.7 Silencer 27
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3.8 Hydraulic Components 27
3.9 Cylinder Head 28
3.10 Transmission 29
3.11 Flywheel 29
3.12 Engine Crankcase and Shaft 29
3.13 Cooling 30
4 Assembly Clearances 31
4.1 Piston–Cylinder Mating 31
4.2 O Rings 32
4.3 Compression Ratio Limiting Shimming System: (11-12:1) 33
4.4 Crankshaft End-Play 34
4.5 Crankshaft Alignment 35
5 Recommended Lubricants 36
6 Special Tools 37
6.1 Steering Bearing Seat Installer – 001330Y 37
6.2 Pliers – 001467Y014 37
6.3 Bell – 001467Y017 37
6.4 Steering Column Ball- Cage Bearing Removing Punch – 020004Y 37
6.5 Front Suspension Overhaul Tool – 020021Y 38
6.6 Punch – 020036Y 38
6.7 Punch - 020038Y 38
6.8 Ring Nut Spanner - 020055Y 38
6.9 Crankshaft Aligner - 020074Y 39
6.10 Heat Gun Support - 020150Y 39
6.11 Heat Gun - 020151Y 39
6.12 Oil Pressure Gauge - 020193Y 39
6.13 Crankcase Detacher - 020262Y 40
6.14 Half-Pulley Assembler - 020263Y 40
6.15 Fitting Punch - 020306Y 40
6.16 Vacuum Pump - 020329Y 40
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6.17 Timing Light - 020330Y 41
6.18 Digital Multimeter - 020331Y 41
6.19 Digital Tachometer - 020332Y 41
6.20 Single Battery Charger - 020333Y 42
6.21 Multiple Battery Charger - 020334Y 42
6.22 Dial Gauge - 020335Y 42
6.23 Adapter (42×47 mm) - 020359Y 43
6.24 Adapter (52×55 mm) - 020360Y 43
6.25 Guide (20 mm) - 020363Y 43
6.26 Guide (25mm) - 020364Y 43
6.27 Guide (22 mm) - 020365Y 44
6.28 Adapter (28×30 mm) - 020375Y 44
6.29 Handle - 020376Y 44
6.30 Valve Half-Cone Remover - 020382Y 44
6.31 Bushing - 020382Y011 44
6.32 Piston Assembly Band - 020393Y 45
6.33 Multimeter Adapter - 020409Y 45
6.34 Guide (15 mm) - 020412Y 46
6.35 Clutch Drum Lock Wrench - 020423Y46
6.36 Punch - 020424Y 46
6.37 Punch - 020425Y 46
6.38 Piston Fitting Fork - 020426Y 47
6.39 Piston Support - 020428Y 47
6.40 Valve O-Ring Remover - 020431Y 47
6.41 Oil Pressure Gauge - 020434Y 47
6.42 Guide (17 mm) - 020439Y 48
6.43 Water Pump Overhaul Tool - 020440Y 48
6.44 Adapter (26×28 mm) - 020441Y 48
6.45 Stop Wrench - 020442Y 48
6.46 Driven Pulley Spring Tool - 020444Y 49
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6.47 Guide (30 mm) - 020483Y 49
6.48 Pivot Retainers Installer - 020488Y49
6.49 Hub Cover support - 020489Y 49
6.50 Flywheel Wrench - 020565Y 50
6.51 Engine Support - 002095Y 50
6.52 Pliers - 002465Y 50
6.53 Punch - 06029Y 50
6.54 Flywheel Extractor - 08564Y 51
6.55 Gas Analyzer - 494929 51
7 Maintenance 52
7.1 Maintenance Schedule 52
7.2 Carburetor 54
7.3 Checking and Replacing the Spark Plug 55
7.4 Air Filter 56
7.5 Engine Oil 58
7.5.1 Checking the Engine Oil Level 58
7.5.2 Topping-Up the Engine Oil 59
7.5.3 Replacing the Oil and Oil Filter 59
7.6 Hub Oil 61
7.6.1 Checking the Hub Oil Level 61
7.6.2 Replacing the Hub Oil 61
7.7 Topping-Up the Engine Cooling Liquid 62
7.8 Brake Fluid 63
7.8.1 Checking the Brake Fluid Level 63
7.8.2 Topping-Up the Brake Fluid Level 64
7.9 Removing the Steering Lock 65
7.9.1 Removing the Steering Lock when on «OFF» Position 65
7.9.2 Removing the Steering Lock when on «LOCK» Position 66
7.10 Headlight Adjustment 67
7.11 Checking the Spark Advance 68
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7.12 Spark Advance Variation Curve 69
7.13 Evaporative emission system 70
Checking the CO Concentration 71
7.14 SAS (Secondary Air System) 73
7.14.1 General 73
7.14.2 Description 73
7.14.3 Removing the SAS 74
8 Troubleshooting 77
8.1 Engine 77
8.1.1 Poor Performance 77
8.1.2 Rear Wheel Spins at Idle 78
8.1.3 Rich Mixture 78
8.1.4 Weak Mixture 79
8.1.5 Low Compression 79
8.1.6 Starting Problems 80
8.1.7 Excessive Oil Consumption/Excessive Smoke from Exhaust 81
8.1.8 Insufficient Lubrication Pressure 81
8.1.9 Engine Tends to Cut Out at Full Throttle 82
8.1.10 Engine Tends to Stop at Idle 82
8.1.11 Excessive Fuel Consumption 83
8.2 Transmission and Brakes 83
8.2.1 Irregular Clutch Operation or Grapping 83
8.2.2 Poor Braking Performance 84
8.2.3 Brakes Overheating 84
8.3 Electrical System 85
8.3.1 Battery 85
8.3.2 Turn Signal Lights Not Working 85
8.4 Steering Controls and Suspension 85
8.4.1 Excessive Steering Stiffness 85
8.4.2 Excessive Steering Play 85
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8.4.3 Noisy Suspension 86
8.4.4 Suspension Oil Leaking 86
Electrical System 87
9.1 Electrical Diagrams 89
9.1.1 Ignition Section 89
9.1.2 Turn Signal Lights, Horn, Services and Accessory Pre - Wiring 90
9.1.3 Level Indicators and Safety Switches92
9.1.4 Battery Recharge and Starting Section 93
9.1.5 Headlight and Automatic Choke Section 94
9.2 Electrical Equipment 95
9.2.1 Electronic Ignition (Immobilizer System) 95
9.2.2 Un-Coded Electronic Ignition System97
9.2.3 Diagnostic Codes 98
9.2.4 2-Flash Diagnostic Code 98
9.2.5 3-Flash Diagnostic Code 99
9.2.6 Ignition System 99
9.2.7 Spark Plug Power Supply Failure 100
9.2.8 Battery Charging System 101
9.2.9 Checking the Voltage Regulator 102
9.2.10 Stator check 102
9.2.11 Checking the Regulator 103
9.2.12 Checking the Automatic Choke Section 103
9.2.13 Turn Signal Lights Fail to Operate 104
9.2.14 Fuses 105
9.2.15 Instrument Panel 106
9.2.16 Battery 107
9.2.16.1 Preparing the Battery 107
9.2.16.2 Checking the Electrolyte Level 107
9.2.16.3 Checking the Electrolyte Density 107
9.2.16.4 Checking the Battery Charge Level108
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9.2.16.5 Cleaning the Battery 108
9.2.16.6 Installing the Battery 108
10 Engine 111
10.1 Disassembling the Engine from the Frame 111
10.2 Removing the Silencer 116
10.3 Refitting the Engine onto the Frame 116
10.4 Removing the Rocker Cover 117
10.5 Refitting the Rocker Cover 117
10.6 Checking the Compression 117
10.7 Transmission 118
10.7.1 Removing the Transmission Cover118
10.7.2 Removing the Fan Case 118
10.7.3 Removing the Transmission Cooling Intake 119
10.7.4 Removing the Driven Pulley Shaft Bearing 119
10.7.5 Fitting the Driven Pulley Shaft Bearing 119
10.7.6 Removing the Belt Support Roller 120
10.7.7 Refitting the Belt Support Roller 120
10.7.8 Removing the Driving Pulley 121
10.7.9 Removing the Driven Pulley 121
10.7.10 Inspecting the Clutch Drum 122
10.7.11 Checking the Clutch Drum Surface Eccentricity 122
10.7.12 Removing the Clutch 123
10.7.13 Disassembling the Fixed Driven Half - Pulley Bearings 123
10.7.14 Checking the Fixed Driven Half- Pulley 124
10.7.15 Checking the Moving Driven Half-Pulley 125
10.7.16 Fitting the Fixed Driven Half-Pulley Bearings 125
10.7.17 Refitting the Driven Pulley 126
10.7.18 Checking the Moving Driven Half-Pulley Spring 127
10.7.19 Checking the Drive Belt 127
10.7.20 Checking the Clutch Friction Material128
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10.7.21 Fitting the Clutch 128
10.7.22 Checking the Moving Driving Half-Pulley 129
10.7.23 Fitting the Fixed Driving Half-Pulley and Bushing Assembly 130
10.7.24 Fitting the Moving Half-Pulley Assembly 131
10.7.25 Fitting the Clutch Drum 132
10.7.26 Fitting the Transmission Cover 133
10.7.27 Removing the Rear Hub Cover 133
10.7.28 Removing the Rear Wheel Axle 134
10.7.29 Checking the Hub Casing Bearings 134
10.7.30 Removing the Wheel Axle Bearing from the Cover 135
10.7.31 Removing the Driven Pulley Shaft 136
10.7.32 Checking the Hub Cover 136
10.7.33 Fitting the Hub Casing Bearings 136
10.7.34 Fitting the Wheel Axle Bearing on the Cover 137
10.7.35 Checking the Hub Shafts 138
10.7.36 Fitting the Hub Gears 139
10.7.37 Fitting the Hub Cover 139
10.8 Flywheel 140
10.8.1 Removing the Flywheel Cover Assembly 140
10.8.2 Removing the Flywheel 143
10.8.3 Removing the Stator 144
10.8.4 Checking the Stator 144
10.8.5 Checking the Low Oil Pressure Switch 145
10.8.6 Checking the Pick-Up 145
10.8.7 Checking the Flywheel 145
10.8.8 Fitting the Stator Assembly 145
10.8.9 Fitting the Flywheel 146
10.8.10 Fitting the Flywheel Cover Assembly 146
10.9 Checking the Secondary Air Box Valve 148
10.9.1 Checking the One- Way Valve 149
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10.10 Lubrication Circuit 151
10.10.1 Checking the Oil Pressure 152
10.10.2 Removing the Oil Sump and Pressure Adjusting By-Pass Valve 153
10.10.3 Checking the By-Pass Valve 153
10.10.4 Removing the Oil Pump 154
10.10.5 Checking the Oil Pump 155
10.10.6 Fitting the Oil Pump 156
10.10.7 Fitting the Chain Cover Oil Seal 157
10.10.8 Fitting the By- Pass and the Oil Sump 159
10.10.9 Removing the Intake Manifold 159
10.10.10 Thermostat Removal 160
10.10.11 Removing the Timing Chain Sprockets 160
10.10.12 Removing the Camshaft and Rockers 161
10.10.13 Removing the Cylinder Head 162
10.10.14 Removing the Valves 163
10.10.15 Removing the Cylinder and Piston Assembly 163
10.10.16 Inspecting the Small End 164
10.10.17 Inspecting the Wrist Pin Diameter165
10.10.18 Inspecting the Piston and Cylinder Diameters 165
10.10.19 Inspecting the Piston 166
10.10.20 Checking the Piston Ring Gap 167
10.10.21 Fitting the Piston 168
10.10.22 Choosing the Base Gasket Thickness 168
10.10.23 Fitting the Piston Rings 170
10.10.24 Fitting the Cylinder 170
10.10.25 Inspecting the Cylinder Head 171
10.10.26 Checking the Valve Seals 171
10.10.27 Inspecting the Valve Seats 172
10.10.28 Inspecting the Valves 172
10.10.29 Testing the Valve Seals 174
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10.10.30 Checking the Valve Spring Plates and Half-cones 174
10.10.31 Fitting the Valves 174
10.10.32 Inspecting the Timing Components175
10.10.33 Inspecting the Camshaft 176
10.10.34 Fitting the Cylinder Head 177
10.10.35 Fitting the Timing Components 178
10.10.36 Fitting the Thermostat 181
10.10.37 Fitting the Intake Manifold 181
10.11 Crankshaft 182
10.11.1 Preparing the Engine for Crankcase Separation 182
10.11.2 Separating the Crankcase Halves 183
10.11.3 Checking the Crankshaft 184
10.11.4 Checking the Crankcase Halves 186
10.11.5 Checking the Main Bearings 187
10.11.6 Assembling the Crankcase Halves 188
10.11.7 Fitting the Starter Motor 190
10.11.8 Removing the Carburetor 191
10.11.8.1 Kehin CVK 30 Carburetor 191
10.11.8.2 Walbro WVF-7P Carburetor 197
10.11.9 Re-assembling the carburetor 204
10.11.9.1 Kehin CVK 30 Carbu retor 204
10.11.9.2 Walbro WFV-7P Carburetor 206
10.11.10 Checking the Float Height 208
10.11.10.1 Kehin CVK 30 Carburetor 208
10.11.10.2 Walbro WVF-7P Carburetor 210
10.11.11 Checking the Vacuum Valve and the Needle 212
10.11.11.1 Kehin CVK 30 Carburetor 212
10.11.11.2 Walbro WVF-7P Carburetor 214
10.11.12 Checking the Automatic Choke Device 215
10.11.12.1 Kehin CVK 30 Carburetor 215
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10.11.12.2 Walbro WVF-7P Carburetor 217
10.12 Cooling System 219
10.12.1 Cooling Circuit 219
10.12.2 Removing the Water Pump 220
10.12.3 Checking the Components 221
10.12.4 Fitting the Water Pump 222
10.12.5 Checking the Thermostat 224
11 Suspensions 225
11.1 Removing and Refitting the Front Wheel 226
11.2 Removing and Refitting the Rear Wheel 226
11.3 Removing the Steering Column 227
11.4 Removing the Front Wheel Hub 230
11.5 Front Wheel Hub Overhaul 230
11.6 Removing the Front Brake Caliper-Shock Absorber Bracket 232
11.7 Front Brake Caliper-Shock Absorber Bracket Overhaul 233
11.8 Removing the Front Shock Absorber235
11.9 Front Swing Arm Overhaul 235
11.10 Steering Column Ball-Cage Bearings Overhaul 237
11.11 Removing the Rear Shock Absorber-Silencer Bracket 240
11.12 Rear Shock Absorbers 241
11.12.1 Removing the Rear Shock Absorbers 241
11.12.2 Refitting the Rear Shock Absorbers 242
11.13 Central Stand 242
11.14 Inspecting the Rear Swing Arm 242
11.15 Swing Arm Overhaul 245
11.16 Silent - Block Overhaul 247
12 Bodywork 250
12.1 Removing the Seat 250
12.2 Removing the Steering Column Cover 250
12.3 Removing the Front Handlebar Cover250
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12.4 Removing the Rear Handlebar Cover251
12.5 Removing the Instrument Panel 251
12.6 Removing the Glove-box Panel 252
12.7 Removing the Battery Compartment Cover 254
12.8 Removing the Side Fairings 254
12.9 Removing the Footrest 254
12.10 Removing the Luggage Carrier 256
12.11 Removing the Taillight 257
12.12 Removing the Helmet Compartment 257
12.13 Removing the Front Fender 258
12.14 Removing the Fuel Tank 258
12.15 Removing the Radiators and the Cooling Fan 260
12.16 Removing the Rear Mudguard 261
12.17 Removing the Turn Signal Lights 261
12.18 Removing the Electrical Opening Seat System 262
13 Pre- Delivery Inspections 264
13.1 Checking the Vehicle Appearance 264
13.2 Checking the Tightening Torques 264
13.3 Checking the Electrical Circuit 264
13.4 Checking the Levels 265
13.5 Road Test 265
13.6 Static Test 265
13.7 Functional Check 266
Time Sheets 267
14.1 Engine 267
14.2 Crankcase 267
14.3 Crankshaft 267
14.4 Piston- Cylinder Assembly 268
14.5 Cylinder Head and Valves 268
14.6 Camshaft 268
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14.7 Valve Cover 269
14.8 Chain Tensioner - By-Pass Valve 269
14.9 Oil Filter 269
14.10 Driven Pulley 270
14.11 Pump Assembly - Oil Sump 270
14.12 Rear Wheel Axle 271
14.13 Driving Pulley 271
14.14 Electric Starter 272
14.15 Kick-Starter, Transmission Cover, and Transmission Cooling 272
14.16 Transmission Cooling Air Inlet 272
14.17 Flywheel Magneto 273
14.18 Carburetor 273
14.19 Air Filter 274
14.20 Silencer 274
14.21 Frame 275
14.22 Central Stand 275
14.23 Footrest and Battery 276
14.24 Glove- Box 276
14.25 Helmet Compartment and Rear Fender 277
14.26 Front Fender and Rear Mudguard 277
14.27 Fuel Tank 277
14.28 Cooling System 278
14.29 Fuel Pump 278
14.30 Steering Column 279
14.31 Front Suspension 279
14.32 Rear suspension 280
14.33 Handlebar Covers 280
14.34 Handlebar, and Brake and Throttle Controls 281
14.35 Swing Arm 281
14.36 Brakes 282
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14.37 Saddle and Rear Rack 283
14.38 Locks and Immobilizer 283
14.39 Mirrors, Electric Controls, and Instrument Panel 284
14.40 Lights 285
14.41 Electrical Devices 286
14.42 Front Wheel 287
14.43 Rear Wheel 287
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1 Vespa GT 200
This manual has been prepared by Piaggio USA, Inc., a subsidiary of Piaggio & C. S.p.A., for
use in the workshops of authorized Piaggio ® dealers and sub-agents
It is assumed that the person utilizing this manual for servicing or repairing Piaggio® vehicles
has a knowledge of the principles of mechanics and standard procedures required for general
vehicle repair, therefore information regarding routine procedures has been deliberately
omitted. Any relevant changes concerning the vehicle characteristics or specific repair
operations will be divulged in the form of updates to this manual.
Satisfactory repair or service cannot be achieved without the necessary equipment and tools.
Refer to the pages of this manual concerning specific tools and equipment and the special tools
catalogue.
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2 Characteristics
This section describes the general characteristics of the vehicle.
2.1 Various
2.1.1 Workshop Safety
For tests performed with the engine running ensure the work is carried out in a well-ventilated
place and, if necessary, using appropriate extractors. Never run the engine in an enclosed
space; exhaust gases are toxic.
Some types of battery use sulphuric acid as an electrolyte. Protect eyes, clothing and skin.
Sulphuric acid is highly corrosive; if it comes into contact with the eyes or the skin, rinse
thoroughly with water and seek immediate medical attention.
The battery produces hydrogen gas, which is extremely explosive. Do not smoke and do not
allow flames or sparks near the battery, especially whilst it is being recharged.
Gasoline is extremely flammable and, under certain conditions, explosive. Do not smoke and do
not allow flames or sparks in the work area.
Cleaning of brake shoes, drums and pads should be done in a well-ventilated area, aiming
compressed air so as to avoid inhaling the dust produced by wear in the friction material. Even
the dust from asbestos- free linings can damage the health.
2.1.2 Service Recommendations
Use genuine Piaggio ® spare parts and recommended lubricants. Use of non-genuine spare
parts may damage the vehicle.
For operations requiring special tools, use only those designed specifically for this engine.
Always replace seals, gaskets and split pins with new ones, during reassembly.
After removing components, clean them with a non-flammable or high flash-point solvent.
Lubricate all contacting surfaces, inspect for taper fit couplings, before reassembling.
Check all components have been correctly fitted and test that they work properly after
reassembly.
Use only Metric - sized tools for removing, repairing and refitting operations. Metric screw
fasteners, nuts and bolts are not interchangeable or compatible with Imperial-sized fasteners.
Use of Imperial-sized tools or fasteners can damage the vehicle.
For repairs that involve disconnecting the vehicle’s electrics, test the connections after
reassembly, especially those to ground and to the battery.
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2.2 Vehicle Identification
2.2.1 Frame No.
Vehicle Frame prefix
Granturismo 200 cc ZAPM3120000001001
2.2.2 Engine No.
Vehicle Engine prefix
Granturismo 200 cc M312M1001
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2.3 Technical Specifications
2.3.1 Weight and Dimensions
Characteristics Descriptions
Dry weight 308 lbs. (140 Kg)
Width (at handgrips) 2.48 ft. (755 mm)
Length 6.36 ft. (1,940 mm)
Wheel base 4.58 ft. (1,395 mm)
Saddle height 2.62 ft. (800 mm)
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2.4 Engine
2.4.1 General
Characteristics Descriptions
Type Single-cylinder, four-stroke, four-valve, liquid-
cooled
Timing system Single overhead camshaft driven by chain on
L.H., 3-arm rockers with threaded adjuster
Bore 2.83 in. (72.0 mm)
Stroke 1.91 in. (48.6 mm)
Piston displacement 12.06 cu. in. (197.775 cm3)
Compression ratio 11-12: 1
Walbro carburetor WVF-7P
Keihin carburetor CVK 30
Engine idle 1650±50 rpm
CO value 3.8±0.7%
Air filter Sponge air filter, soaked in fuel-oil mixture (50%
gasoline - 50% oil)
Starter system Electric starter motor with torque limiter
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Lubrication By chain driven lobe pump in crankcase, mesh
strainer and cartridge filter
Fuel system Gasoline supplied by carburetor with vacuum
pump
Max power (shaft) 21 hp (15.4 kW) @ 8,500 rpm
Max speed 75 mph (120 km/h)
2.4.2 Walbro carburetor
Characteristics Descriptions
Vacuum type WVF- 7P*
Printing on body 7P
CUT- OFF device Present
Max jet 95
Slow running jet 33
Main air jet 120
Idling air jet 55
Throttle valve spring 0.264 lbs (1.18 N)
Initial opening of idle speed mixture
adjusting screw
Conical needle 495
Notches from top of conical needle 2
Diffuser nozzle Ø 0.106 in (2.7 mm)
Fuel inlet hole Ø 0.059 in (1.5 mm)
Starting air jet 200
Starting diffuser jet 110
Starter jet 45
Starter pin diameter Ø 0.070 in (1.78 mm)
2±½
Starter device resistance ~40 O
Venturi tube Ø 1.142 in (29.0 mm) - (30.3×27.0 mm)
Throttle valve Ø 1.299 in (33.0 mm)
Tube maximum choke Ø 1.890 in (48.0 mm)
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2.4.3 Kehin carburetor
Characteristics Descriptions
Vacuum type CVK 30
Printing on body CVK
CUT- OFF device present
Max jet 92
Slow running jet 38
Main air jet 70
Idling air jet 115
Throttle valve spring 0.330–0.551 lbs (1.47–2.45 N)
Initial opening of idle speed mixture
adjusting screw
Conical needle NDAA
Notches from top of conical needle Single-notch needle
Diffuser nozzle Ø 1.969 in (5.0 mm)
Fuel inlet hole Ø 0.059 in (1.5 mm)
Starting air jet
Starting diffuser jet -
Starter jet 42
Choke pin diameter -
Choke device resistance ~ 20 O
Venturi tube Ø 1.142 in (29.0 mm) (47×30.9 mm)
Throttle valve Ø 1.201 in (30.5 mm)
Tube maximum choke -
2¼±¼
-
*The identification letter may vary every time the carburetor is updated.
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2.5 Transmission
Characteristics Descriptions
Transmission By automatic variator, with expanding pulleys,
torque converter, V-belt, automatic clutch, gear
reducer and transmission compartment cooled
by forced air circulation
2.6 Capacities
Characteristics Descriptions
Engine oil ~1.06 quarts (~1,000 cm3)
(recommended oil: Selenia HI Scooter 4 Tech)
Fuel tank
(including reserve ~0.5 gal)
Rear hub ~0.16 quarts (~150 cm3)
Cooling system fluid ~0.55-0.57 gallons (~ 2.10–2.15 liters)
~2.5 gallons (~9.5 liters)
(recommended oil: TUTELA ZC 90)
(recommended: PARAFLU 11FE (diluted))
2.7 Electrical Components
Characteristics Descriptions
Ignition type Electronic ignition by capacitive discharge, with
variable advance and separate H.T. coil
Variable ignition advance
(before T.D.C.)
Spark plug Champion RG 6 YC
Battery 12V-12Ah
Fuses 1×15A, 1×10A, 3×7.5A, 2×5A
From 10°±1° @ 2,000 rpm
to 32°±1° @ 6,500 rpm
Generator In alternating current (AC)
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2.8 Frame, Suspensions, Brakes and Tires
2.8.1 Frame and Suspension
Characteristics Descriptions
Type Pressed steel, mono-coque type
Front suspension Single-arm suspension equipped with dual-effect
hydraulic shock absorber with coaxial spring
Front shock absorber travel 3.4 in (86.5 mm)
Rear suspension Engine mounted on oscillating fork pivoted to the
frame by means of an arm with 2 degrees of
freedom. Pair of dual effect hydraulic shock
absorbers and coaxial springs with 3 preload
adjustment positions
Rear shock absorber travel 3.52 in (89.5 mm)
2.8.2 Brakes
Characteristics Descriptions
Front Ø 8.66 in (220 mm) disc and hydraulically
operated floating caliper (via RH lever) with two
Ø 0.98 in (25 mm) pistons
Rear Ø 8.66 in (220 mm) disc and hydraulically
operated floating caliper (via LH lever) with two
Ø 1.18 in (30 mm) pistons
2.8.3 Wheels and Tires
Characteristics Descriptions
Aluminum alloy rims Front: 3.00×12”
Rear: 3.00×12”
Tires Front: 120/70-12” Tubeless
Rear: 130/70-12” Tubeless
Tire pressure (when cold): Front: 26.1 psi (1.8 bars)
Rear (rider only): 29.0 psi (2.0 bars)
Rear (rider + passenger): 31.9 psi (2.2 bars)
Note: The tire inflation pressure should be checked and adjusted when the tires are at
ambient temperature. Pressure should be adjusted according to the weight of the driver,
accessories, and/or passenger.
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3 Tightening Torques
3.1 Steering Unit
Component Qty Torque [lbs·ft (N·m)]
Steering upper ring nut 1
Steering lower ring nut 1
Handlebar clamping screw (*) 1
Handlebar control unit U-bolts fixing screws 2
22.1–29.5
(30–40)
5.9–7.4
(8–10)
33.1–36.8
(45–50)
5.1–7.4
(7–10)
3.2 Frame
Component Qty Torque [lbs·ft (N·m)]
Swing arm-engine pivot nut 1
Swing arm-frame pivot nut 1
Frame –engine link nut 1
47.1–53.0
(64–72)
56.0–61.1
(76–83)
24.3–30.2
(33–41)
Silent- block support plate bolt 2
Center stand bolt 1
30.9–38.3
(42–52)
18.4–22.1
(25–30)
3.3 Front Suspension
Component Qty Torque [lbs·ft (N·m)]
Shock absorber plate–caliper fixing screw 2
Wheel axle nut 1
Wheel screw 5
Mudguard–fork fixing screw 3
25
14.7–19.9
(20–27)
55.2–66.3
(75–90)
14.7–18.4
(20–25)
3.7–4.8
(5-6.5)
Page 26
3.4 Front Brake
Component Qty Torque [lbs·ft (N·m)]
Pump–oil tube connection 1
Caliper-oil tube connection 1
Caliper-shock absorber plate fixing screw 2
Disk clamping screw (°) 6 4.4 (6)
Oil bleeder screw 1
Pad clamping pin 2
Brake pump basin screw 2
13.7–18.4
(20–25)
13.7–18.4
(20–25)
13.7–18.4
(20–25)
8.8–11.8
(12–16)
13.6–18.4
(19.6-25)
9.6–13.7
(15–20)
3.5 Rear Suspension
Component Qty Torque [lbs·ft (N·m)]
L.H. side shock absorber support platecrankcase fixing screw
2
13.7–18.4
(20–25)
Shock absorber top fastening 2
Shock absorber bottom fastening 2
Rear wheel axle 1
Wheel–hub fixing screw 5
Silencer-shock absorber support arm screws on
engine (*)
26
2
13.7–18.4
(20–25)
24.3–30.2
(33–41)
76.5–92.6
(104–126)
13.7–18.4
(20–25)
13.7–18.4
(20–25)
Page 27
3.6 Rear Brake
Component Qty Torque [lbs·ft (N·m)]
Pipe-oil tube connection 1
Caliper–oil tube connection 2
Rear disk clamping screw (°) 6
Oil bleeder screw 1
Caliper–engine fixing screw 2
Brake pump basin screw 2
Caliper coupling screw 2
13.7–18.4
(20–25)
13.7–18.4
(20–25)
8.1–9.6
(11–13)
8.8–11.8
(12–16)
13.7–18.4
(20–25)
11.0–14.7
(15–20)
22.1–24.3
(30–33)
3.7 Silencer
Component Qty Torque [lbs·ft (N·m)]
Silencer heat shield fixing screw 4
Exhaust gas inlet screw 1
Silencer–support arm fixing screw 3
3.7–4.4
(5–6)
9.6–11.0
(13–15)
13.7–18.4
(20–25)
3.8 Hydraulic Components
Component Qty Torque [lbs·ft (N·m)]
Hub oil bleeder cap 1
Oil filter–crankcase fixing screw 1
Engine oil-net filter bleeder cap 1
27
11.0–12.5
(15–17)
19.9–24.3
(27–33)
17.7–22.1
(24–30)
Page 28
Oil filter 1
Oil pump cover screw 2
Oil pump–crankcase fixing screw 2
Oil pump control rim screw 1
Oil pump cover plate screws 2
Oil sump screw 7
Minimum oil pressure sensor 1
5.9–7.4
(8–10)
5.2–6.6
(7–9)
3.7–4.4
(5–6)
7.4–10.3
(10–14)
2.9–4.4
(4–6)
7.4–10.3
(10–14)
8.8-10.3
(12–14)
3.9 Cylinder Head
Component Qty Torque [lbs·ft (N·m)]
Spark plug 1
Head cover screw 5
Head-cylinder fixing nut (*) (§) 4
Head fixing side screw 2
Start up mass screw 1
Adjustment tappet lock-nut 2
Intake manifold screw 2
Timing chain tightening sliding block screw 1
Start up mass bell screw 1
8.8–10.3
(12–14)
4.4–5.2
(6–7)
5.2±0.7 +½ rotation
(7±1 +180°)
8.1–9.6
(11–13)
5.2–6.3
(7-8.5)
4.4–5.9
(6–8)
8.1–9.6
(11–13)
7.4–10.3
(10–14)
8.1–11.0
(11–15)
Timing belt tightening support screw 2
28
8.1–9.6
(11–13)
Page 29
Timing belt tightening central screw 1
Camshaft retain plate screw 2
3.7-4.4
(5–6)
2.9–4.4
(4–6)
3.10 Transmission
Component Qty Torque [lbs·ft (N·m)]
Belt support roller screw 1
Clutch assy. nut 1
Driving pulley nut 1
Transmission cover screw 13
Driven pulley axle nut 1
8.1–9.6
(11–13)
40.5–44.2
(55–60)
55.2–61.1
(75–83)
8.1–9.6
(11–13)
39.8–44.4
(54–60)
Rear hub cover screw 7
17.7–19.9
(24–27)
3.11 Flywheel
Component Qty Torque [lbs·ft (N·m)]
Flywheel cover fixing screw 4
Stator unit screw (°) 2
Flywheel nut 1
Pick-up fixing screw 2
3.7–4.4
(5–6)
2.2–2.9
(3–4)
38.3–42.7
(52–58)
2.2–2.9
(3–4)
3.12 Engine Crankcase and Shaft
Component Qty Torque [lbs·ft (N·m)]
Engine crankcase inside head screws
(transmission side half shaft)
2
2.9–4.4
(4–6)
Engine crankcase coupling screws 11
29
8.1–9.6
(11–13)
Page 30
Starter motor screws 2
Crankcase timing chain cover screw (°) 3
8.1–9.6
(11–13)
2.5-3.2
(3.5-4. 5)
3.13 Cooling
Component Qty Torque [lbs·ft (N·m)]
Water pump impeller cover 3
Water pump impeller driving joint screws 3
Thermostat cover screws 2
2.2–2.9
(3–4)
2.2–2.9
(3–4)
2.2–2.9
(3–4)
30
Page 31
00 0 5
4 Assembly Clearances
4.1 Piston–Cylinder Mating
1.3 in (33mm)
Part Dimensions
00 0 70
.
+
00 0 30
.
−
8352
Cylinder
Piston
.
(
72.00
.
(
0.018
+
0.010
−
0
.
±
8332
±
97.71
1.3 in (33mm)
[in (mm)]
Coupling Classes
Class Cylinder Piston
A
)
014.0
)
B
C
D
2.8342–2.8345
(71.990-71.997)
2.8345–2.8347
(71.997-72.004)
2.8347–2.8350
(72.004-72.011)
2.8350–2.8353
(72.011-72.018)
2.8327–2.8330
(71.953-71.960)
2.8330–2.8333
(71.960-71.967)
2.8333–2.8336
(71.967-71.974)
2.8336–2.8338
(71.974-71.981)
Assembly
Clearance
0.00118–0.00173
(0.030-0.044)
31
Page 32
4.2 O Rings
[in (mm)]
Compression ring
Scraper ring
Scraper ring
Part Dimensions
2.834×0.059
(72.0×1.5)
2.834×0.039
(72.0×1.0)
2.834×0.098
(72.0×2.5)
Clearance
Class
A
A
A
Assembly
Clearance
0.005–0.011
(0.15-0.30)
0.007–0.015
(0.20-0.40)
0.007–0.015
(0.20-0.40)
32
Page 33
4.3 Compression Ratio Limiting Shimming System: (11-12:1)
1. Measure «A» (with piston at T.D.C.).
Note: Measure «A» must be taken without any gasket installed between the crankcase and the
cylinder and after resetting the comparator, complete with support, on a rectified surface.
2. Install according to the measure «A» taken.
Note: The «A» value to be measured is referred to the piston recess. It indicates the amount
by which the surface formed by the piston crown lowers, compared to the surface formed by
the cylinder upper part. The more the piston descends into the cylinder, the less the base
gasket to be applied (to recover the compression ratio) will be and vice versa.
[in (mm)]
Measure «A» Gasket thickness
(1.7-1. 6) 0.015±0.0019 (0.4±0.05)
(1.6-1. 4) 0.023±0.0019 (0.6±0.05)
(1.4-1. 3) 0.031±0.0019 (0.8±0.05)
33
Page 34
00 1 9
00 0 0
00 1 9
00 0 0
4.4 Crankshaft End-Play
Standard clearance:
Crankshaft/crankcase axial clearance 0.005-0.015 in
(engine cold) (0.15-0.40 mm)
[in (mm)]
Part Dimensions
0
.
+
0
.
−
6530
Half-shaft transmission side
Half-shaft flywheel side
Connecting rod
Spacing tool
.
(
16.60
6530
.
(
16.60
7080
.
(
18.00
0232
.
(
18.00
−
−
+
−
0.000
+
0.050
−
0
+
0
−
0.000
+
0.050
−
0.150
−
0.100
−
0.150
−
0.100
−
)
.
.
)
00 5 90
.
00 4 00
.
)
00 1 00
.
00 0 00
.
)
Clearance
Class
A
B
C
D
Assembly
Clearance
D= 0.007–0.019
(0.20-0.50)
34
Page 35
4.5 Crankshaft Alignment
Measure the diameters on both X and Y axes
Class Standard diameter (mm)
1
2
Maximum allowable misalignment:
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
Specific tools and equipment:
Support and comparator 020335Y
Crankshaft aligning tool 020074Y
Crankcase
1.1416–1.1418
(28.998-29.004)
1.1418–1.1421
(29.004-29.010)
Crankcase – Crankshaft – Half crankshaft bearings
Class 1 Class 2
1.2973–1.2978
(32.953–32.963)
Half
crankshaft
bearing
Note: Spare crankcases are selected
with half-crankcases of the same
category and mounted with category
B bearings (blue colored).
Match the shaft with two category 1
shoulders with category 1 crankcase
(or cat. 2 with cat. 2).
A spare crankcase cannot be
combined with a crankshaft with
mixed categories. Spare shafts have
half-shafts of the same category.
A type - Red B type - Blue C type - Yellow
0.0776–0.0777
(1.970–1.973)
0.0777–0.0778
(1.973–1.976)
Half-crankcase Half crankshaft Bearing
Cat. 1 Cat. 1 B
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 A
Cat. 2 Cat. 1 C
35
0.0778–0.779
(1.976–1.979)
Page 36
5 Recommended Lubricants
Use Characteristics Recommended Product
Rear hub
Air filter sponge
Brake levers, throttle handgrip
Engine oil
Brake fluid
Coolant
Grease for driven pulley shaft
compensating ring and
moveable driven pulle y sliding
seat
SAE 80W/90 oil, exceeding
API GL3 specifications
Mineral oil with specific
additives to increase
adhesion ISO VG 150
Complex calcium soap
grease NLGI 1-2
SAE 5W/40 synthetic oil,
exceeding API SJ
specifications
Synthetic fluid SAE J1703,
NHTSA 116 DOT 4,
ISO 4925
Monoethylene glycol-based
anti-freezer,
CUNA NC 956-16
Molybdenum disulphide
grease
TUTELA ZC 90
SELENIA Air Filter Oil
SYSTEM TW 249 AREXONS
SELENIA HI Scooter 4
Tech
TUTELA TOP 4
PARAFLU 11 FE (Diluted)
MONTBLANC
MOLYBDENUM GREASE
(498345)
Grease for wheel bearings, pivot
housings and swing arm
Lithium soap and zinc oxide
grease NLG12 for the
oscillating arm
36
TUTELA ZETA 2
Page 37
6 Special Tools
6.1 Steering Bearing Seat Installer – 001330Y
Description Notes Part No.
Steering bearing seat installer; to
be fitted with parts:
001330Y009- For bottom housing
001330Y010- For top housing
6.2 Pliers – 001467Y014
Description Notes Part No.
NECESSARY 001330Y
0.59 in (15mm) Pliers NECESSARY
001467Y
014
6.3 Bell – 001467Y017
Description Notes Part No.
Bell NECESSARY
001467Y
017
6.4 Steering Column Ball-Cage Bearing Removing Punch – 020004Y
Description Notes Part No.
Punch for removing steering
column ball-cage bearings from
steering head
RECOMMENDED
020004Y
37
Page 38
6.5 Front Suspension Overhaul Tool – 020021Y
Description Notes Part No.
Front suspension overhaul tool NECESSARY 020021Y
6.6 Punch – 020036Y
Description Notes Part No.
Punch NECESSARY 020036Y
6.7 Punch - 020038Y
Description Notes Part No.
Punch NECESSARY 020038Y
6.8 Ring Nut Spanner - 020055Y
Description Notes Part No.
Steering column ring nut spanner
38
NECESSARY
020055Y
Page 39
6.9 Crankshaft Aligner - 020074Y
Description Notes Part No.
Crankshaft aligning tool
6.10 Heat Gun Support - 020150Y
Description Notes Part No.
“Metabo hg 1500/2” hot air gun
support
6.11 Heat Gun - 020151Y
Description Notes Part No.
“Metabo hg 1500/2” hot air gun
RECOMMENDED
RECOMMENDED
RECOMMENDED
020074Y
020150Y
020151Y
6.12 Oil Pressure Gauge - 020193Y
Description Notes Part No.
Oil pressure gauge
39
NECESSARY
020193Y
Page 40
6.13 Crankcase Detacher - 020262Y
Description Notes Part No.
Crankcase detachment plate
6.14 Half-Pulley Assembler - 020263Y
Description Notes Part No.
Half pulley assembly sheath NECESSARY 020263Y
RECOMMENDED
020262Y
6.15 Fitting Punch - 020306Y
Description Notes Part No.
Retaining ring fitting punch
6.16 Vacuum Pump - 020329Y
Description Notes Part No.
Mitivac- like vacuum pump
40
NECESSARY
RECOMMANDED
020306Y
020329Y
Page 41
6.17 Timing Light - 020330Y
Description Notes Part No.
Timing light for two and fourstroke engines
6.18 Digital Multimeter - 020331Y
Description Notes Part No.
Digital multimeter
RECOMMANDED
RECOMMANDED
020330Y
020331Y
6.19 Digital Tachometer - 020332Y
Description Notes Part No.
Digital tachometer
RECOMMANDED
020332Y
41
Page 42
6.20 Single Battery Charger - 020333Y
Description Notes Part No.
Single battery charger
6.21 Multiple Battery Charger - 020334Y
Description Notes Part No.
Multiple battery charger
6.22 Dial Gauge - 020335Y
Description Notes Part No.
RECOMMANDED
RECOMMANDED
020333Y
020334Y
Dial gauge (0.001 mm) with
magnetic stand
RECOMMANDED
020335Y
42
Page 43
6.23 Adapter (42×47 mm) - 020359Y
Description Notes Part No.
42×47 mm Adapter NECESSARY 020359Y
6.24 Adapter (52×55 mm) - 020360Y
Description Notes Part No.
52×55 mm Adapter NECESSARY 020360Y
6.25 Guide (20 mm) - 020363Y
Description Notes Part No.
20 mm guide NECESSARY 020363Y
6.26 Guide (25mm) - 020364Y
Description Notes Part No.
25 mm guide NECESSARY 020364Y
43
Page 44
6.27 Guide (22 mm) - 020365Y
Description Notes Part No.
22 mm guide NECESSARY 020365Y
6.28 Adapter (28×30 mm) - 020375Y
Description Notes Part No.
28×30 mm adapter NECESSARY 020375Y
6.29 Handle - 020376Y
Description Notes Part No.
Handle for adapters NECESSARY 020376Y
6.30 Valve Half-Cone Remover - 020382Y
Description Notes Part No.
Tool for valve half-cone removal
NECESSARY
020382Y
6.31 Bushing - 020382Y011
Description Notes Part No.
44
Page 45
Bushing (for valve removal) NECESSARY
6.32 Piston Assembly Band - 020393Y
Description Notes Part No.
Piston assembly band NECESSARY 020393Y
6.33 Multimeter Adapter - 020409Y
020382Y
011
Description Notes Part No.
Multimeter adapter (peak voltage
measurement)
RECOMMENDED
020409Y
45
Page 46
6.34 Guide (15 mm) - 020412Y
Description Notes Part No.
15 mm guide NECESSARY 020412Y
6.35 Clutch Drum Lock Wrench - 020423Y
Description Notes Part No.
Clutch drum lock wrench NECESSARY 020423Y
6.36 Punch - 020424Y
Driven pulley-roller housing
installing punch
6.37 Punch - 020425Y
Description Notes Part No.
NECESSARY 020424Y
Description Notes Part No.
Oil seal (flywheel-side) punch NECESSARY 020425Y
46
Page 47
6.38 Piston Fitting Fork - 020426Y
Description Notes Part No.
Piston fitting fork NECESSARY 020426Y
6.39 Piston Support - 020428Y
Description Notes Part No.
Piston projection support NECESSARY 020428Y
6.40 Valve O-Ring Remover - 020431Y
Description Notes Part No.
Valve o- ring removing tool NECESSARY 020431Y
6.41 Oil Pressure Gauge - 020434Y
Description Notes Part No.
Oil pressure gauge NECESSARY 020434Y
47
Page 48
6.42 Guide (17 mm) - 020439Y
Description Notes Part No.
17 mm guide for shock absorber
support bearing assembly
6.43 Water Pump Overhaul Tool - 020440Y
Description Notes Part No.
Water pump overhaul tool NECESSARY 020440Y
NECESSARY 020439Y
6.44 Adapter (26×28 mm) - 020441Y
Description Notes Part No.
26×28 mm adapter
NECESSARY
020441Y
6.45 Stop Wrench - 020442Y
Description Notes Part No.
Driving pulley wrench NECESSARY 020442Y
48
Page 49
6.46 Driven Pulley Spring Tool - 020444Y
Description Notes Part No.
Driven pulley spring compressing
tool
6.47 Guide (30 mm) - 020483Y
Description Notes Part No.
30 mm guide for hub bearing
assembly
6.48 Pivot Retainers Installer - 020488Y
Description Notes Part No.
NECESSARY 020444Y
NECESSARY 020483Y
Pivot retainers installation tool NECESSARY 020488Y
6.49 Hub Cover support - 020489Y
Description Notes Part No.
Hub cover support tool kit NECESSARY 020489Y
49
Page 50
6.50 Flywheel Wrench - 020565Y
Description Notes Part No.
Adjustable wrench for flywheel
fixing
6.51 Engine Support - 002095Y
Description Notes Part No.
Engine support; to be fitted with
parts:
002095Y015 – Tube
002095Y022 – Cross member
002095Y023 – Nut
002095Y044 – Plate
002095Y046 - Clamp
6.52 Pliers - 002465Y
NECESSARY 020565Y
RECOMMENDED
002095Y
6.53 Punch - 06029Y
Description Notes Part No.
Snap-ring pliers
Description Notes Part No.
Steering column ball- cage bearing
installing punch
RECOMMENDED
RECOMMENDED
002465Y
006029Y
50
Page 51
6.54 Flywheel Extractor - 08564Y
Description Notes Part No.
Flywheel removing tool NECESSARY 008564Y
6.55 Gas Analyzer - 494929
Description Notes Part No.
Exhaust gas analyzer
RECOMMENDED
494929
51
Page 52
7 Maintenance
This section provides information on periodical maintenance.
7.1 Maintenance Schedule
1
×625 miles
(×1,000 km)
6 1
2 18 24 30 36 42 48 54 60 66 72
Months
4 12 24 3
- - - - - - - - -
6
Check: V
Replacement: S
Engine oil - Check level/Top up V
Engine oil – Replace S S S S S S S S S S S S S
Hub oil level - Check/Replace S V V V S V V V S V V V S
Spark plug/Electrodes distance - Check
/Replace
Air filter – Clean
Secondary air filter (external internal) – Clean Every 2 years
Oil filter – Replace S S S S S S S S S S S S S
Valve clearance - Check
Idle speed (*) – Adjust
Gas control – Adjust
V S V S V S V S V S V S
V V V V V V V V V V V V
V
V
V
V
V
Every 1,875 mile (3,000 km)
V
V
V
V
V
V
V
V
V
V
V
V
V
V
Variator rollers – Check/Replace
Driving belt - Check/Replace
Cooling fluid level - Check
Cooling fluid – Replace Every 2 years
Radiator – Clean exterior/Check
Steering – Adjust
Brake levers – Lubricate
Brake pads - Check condition and wear V V V V V V V V V V V V V
Brake fluid piping – Replace
Brake fluid level - Check V V V V V V V V V V V V V
Brake fluid - Replace Every 2 years
V V V V V V V V V V V V
V S V S V S V S V S V S
V V V V V V V V V V V V
V
V
V
V
V
V
V
V
V
V
S
V
V
V
V
V
52
V
V
V
S
Page 53
Transmissions- Lubricate
Safety locks – Check
Suspensions – Check
Electrical system and Battery - Check V V V V V V V V V V V V V
Headlight - Check/Adjust
Tires pressure and wear - Check
Vehicle and braking system performance - Road
test
Labor time 70'
V
V
V
V
V
V
V V V V V V V V V V V V
V V V V V V V V V V V V
130' 135' 140' 150' 90' 245' 90' 150' 140' 135' 90' 260'
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
Safety tightenings: refer to the chapter “Pre -delivery Operations”.
(*) See rules
V
V
V
V
53
Page 54
7.2 Carburetor
-
Disassemble all carburetor components, ac-
curately wash them in solvent, and then dry
them with compressed air. To ensure
thorough cleaning, pay particular attent ion
to the passages in the carburetor body.
-
Carefully check the conditions of each
component.
-
The throttle valve must slide freely into the
chamber; in case of excessive play due to
wear, replace the valve.
-
Replace the carburetor if the chamber shows
excessive signs of wear as to preclude the
valve’s regular seal or free sliding (even if
new).
-
Gaskets should be replaced every time the
carburetor is reassembled.
Warning - Fuel is highly explosive. Always re place gaskets to prevent leakage.
1. Diaphragm cover - 2. Throttle valve spring -
3. Conical needle support - 4. Conical needle
spring -5. Conical needle - 6. Throttle valve
diaphragm - 7. Automatic choke - 8. Idle speed
adjusting screw - 9. Return valve rockers -
10. Idle mixture adjusting screw - 11. Float pin
- 12.Return pump unit - 13. Float - 14. Float
chamber - 15. Idling jet - 16.Main jet -
17. Diffuser - 18. Float chamber drain screw.
54
Page 55
7.3 Checking and Replacing the Spark Plug
Warning – Remove the spark plug when the
engine is cold. Replace the spark plug every
7,500 miles (12,000 km). The use of nonconforming ignition controllers, and spark
plugs other than those prescribed can
seriously damage the engine.
Recommended spark plug:
Champion RG6YC
-
Rest the vehicle on the centra l stand
-
Open the saddle and extract the helmet
compartment
-
Disconnect the spark plug H.T. cable cap.
-
Unscrew the spark plug, using the spanner
provided.
-
Inspect the spark plug, to ensure that the
insulator is in good conditions and no signs
of cracks are visible. Also check the
condition of the seal washer and make sure
that the electrodes are not worn out or
excessively sooty.
-
Measure the spark gap with a suitable
thickness gauge
Standard dimension:
Spark gap 0.028-0.031 in.
(0.7–0.8 mm)
-
If necessary adjust the spark gap by
carefully bending the side electrode.
-
If the spark plug shows any of the defects
mentioned above, replace it with a plug of
the recommended type.
-
Insert the spark plug with the proper
inclination, and screw it thoroughly by
hand, then tighten it using the supplied
spanner.
Tightening torque:
Spark plug 8.9-10.3 lbs·ft
(12-14 N·m)
Insert the cap over the spark plug thoroughly
and proceed to the reassembly
55
Page 56
7.4 Air Filter
Note: Every 3,726 miles (6,000 km) it is
necessary to check the air filter and blow it, if
required. The jet should be directed from the
inside outwards of the filter (i.e., opposite to the
air flow direction during normal engine
operation).
-
Remove the left hand-side fairing by releasing
the two screws, as shown in the figure
-
Remove the helmet compartment
-
Remove the three fastening screws that can
be reached after the removal of the helmet
compartment, from inside the frame
-
Remove the five fixing screws shown in the
figure
-
Remove the filtering element.
-
Replace the air filter with a new one.
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must be cleaned more
Note: Every 3,726 miles (6,000 km), during
servicing, it is necessary to remove the stops
and the rubber caps located below the filter
box, as shown in the figure, and drain any oil
accumulation.
Cleaning (Every 7,452 miles, or 12,000 km ):
Wash with water and shampoo.
Dry with light jets of compressed air and wipe wit h a clean cloth.
Soak with a 50% fuel-oil mixture (use SELENIA AIR FILTER OIL).
Let the filtering element drip and squeeze it with hands without wringing.
Replace the filtering element.
Caution – If the vehicle is mostly used on dusty roads, the air filter
frequently than what indicated in the scheduled maintenance table.
Caution – Never let the engine run without air filter. This would cause an excessive wear of
cylinder and piston and would damage the carburetor.
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7.5 Engine Oil
Engine oil is used in 4- stroke engines to lubricate the valve gear components, the
crankshaft bearings and the power plant. An insufficient quantity of oil can cause
serious damage to the engine itself.
In all 4-stroke engines, oil deterioration and consumption are, to some extent, normal,
especially during running-in. Consumption partly depends on the riding style (e.g.: when
riding constantly at full throttle, oil consumption increases).
7.5.1 Checking the Engine Oil Level
Perform the following operations when the
engine is cold:
-
Rest the vehicle on the central stand and
on a flat surface.
-
Unscrew dipstick «A», dry it with a clean
cloth and reinsert it, by screwing it
completely.
-
Remove the dipstick again and check that
the level is between the MAX and MIN
levels; top up, if required.
The MAX level mark means that in the engine
there is an oil quantity of approximately
1.164 quarts (1,100 cm3).
Note: The level will be lower if checked after
using the vehicle (i.e. when the engine is
hot). To obtain a correct indication of the oil
level, wait at least 10 minutes after switching
off the engine.
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7.5.2 Topping-Up the Engine Oil
The oil should be topped up after having
checked the level and in any case by adding
oil without ever exceeding the MAX mark.
Restoring the level between MIN and MAX
requires a quantity of oil of ~0.4 quarts
(~400 cm3).
Oil pressure warning light
The vehicle is equipped with a warning light
on the instrument panel which comes on
when the ignition key is turned to the “ON”
position. However, this light should switch off
once the engine has started.
Note: Should the light turn on while braking,
idling or cornering, check the oil level and the
lubrication system as soon as possible.
7.5.3 Replacing the Oil and Oil Filter
-
Oil and filter should be replaced every
3,726 mi (6,000 km). The engine should
be emptied by draining the oil from the
pre- filter drainage tap «B» of the net pre filter on the flywheel side. To facilitate the
oil drainage, loosen dipstick «A». Once
the oil has been drained from the drainage
tap, loosen the oil filter cartridge «C» and
remove it as described below.
-
Check that the O-rings of the pre-filter and
drainage cap are not worn out and in good
conditions.
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-
Lubricate the O-rings and replace net filter
and oil drainage cap; tighten at the
prescribed torque.
-
Install the new cartridge filter after
lubricating the O-ring.
-
Fill with fresh engine oil.
-
Since a certain quantity of oil still remains
in the circuit, the fill- up should be carried
out with about 0.64 quarts (600-650 cm3)
of oil from cap «A». Subsequently, start
up the engine, let it idle for a few minutes
and then switch it off. After about 5
minutes, check the level and top up if
necessary without ever exceeding the
MAX mark. The cartridge filter must be
replaced every time the oil is changed. For
top ups and replacements, use fresh
Selenia HI Scooter 4 Tech oil.
Note: Engine oil should be replaced when the
engine is hot.
Tightening torque:
Engine oil drainage cap 17.6- 22.1 lbs·ft
(24-30 N·m)
Recommended oil:
Selenia HI Scooter 4 Tech
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7.6 Hub Oil
7.6.1 Checking the Hub Oil Level
-
Position the vehicle on its central stand on
a flat surface
-
Unscrew the oil dipstick «A», dry it with a
clean cloth and reinsert it, screwing it in
completely.
-
Pull out the dipstick and check that the oil
level reaches the lower notch (see figure);
if the level is below the MAX mark, restore
the proper amount of oil in the hub.
-
Reinsert the dipstick and screw it tightly.
The notches on the hub oil dipstick, with the
exception of the MAX mark, refer to other
PIAGGIO models and have no specific
function as far as this vehicle is concerned.
7.6.2 Replacing the Hub Oil
-
Remove oil filler cap «A».
-
Unscrew oil drain cap «B» and let the oil
drain out completely.
-
Retighten the oil drain cap and then fill the
hub with fresh oil
Recommended oil: TUTELA ZC 90
Oil capacity:
Rear hub ~0.16 quarts
(~150 cm3)
Tightening torques:
Hub oil draining screw 11.0- 12.5 lbs·ft
(15-17 N·m)
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7.7 Topping-Up the Engine Cooling Liquid
Note: The liquid level inspection should be
carried out every 3,726 mi. (6,000 km) when
the engine is cold. The following steps should
be followed:
-
Rest the vehicle on its central stand level
ground.
-
Loosen the screw shown in the figure and
remove the plastic flap on the right hand
side of the vehicle’s leg-shield, in order to
access the cooling liquid expansion tank
-
Remove the expansion tank cap and top
up, if the coolant level is below or near the
MIN level in the expansion tank. The fluid
level should always be between the MIN
and MAX marks.
-
The coolant consists of a 50% mixture of
demineralized water and antifreeze
solution with a base of ethylene glycol and
corrosion inhibitors.
Warning – To prevent leaks of the cooling
fluid from the expansion tank during the use
of the vehicle, never exceed the MAX mark
upon filling.
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7.8 Brake Fluid
7.8.1 Checking the Brake Fluid Level
The front and rear brake fluid reservoirs are
located on the pumps installed on the
handlebar.
In order to check the brake fluid level in the
reservoirs, follow these steps:
-
Rest the vehicle on its central stand on
level ground and turn the handlebar to the
central position.
-
Remove the brake pump cover.
-
Check the fluid level through the sight
shown in the figure.
Note: A certain decrease in the level of the
fluid occurs as a result of pad wear.
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7.8.2 Topping-Up the Brake Fluid Level
Caution - Only use brake fluid classified as
DOT 4.
-
If the level is below minimum, loosen the
two screws shown in the figure.
-
Remove the reservoir cap, remove the
gasket and top up, only using the
prescribed fluid and without exceeding the
maximum level.
Recommended brake fluid:
TUTELA TOP 4
Warning – Keep the brake fluid away from
the skin, the eyes and clothing. In case of
contact, rinse thoroughly with water.
Warning – The brake fluid is highly
corrosive. Do not let it come into contact with
the paintworks.
Warning – The brake fluid is hygroscopic, i.e.
it absorbs humidity from the surrounding air.
If the concentration of humidity in the fluid
exceeds a certain value, the braking action
becomes insufficient.
Warning - Never use braking fluid drawn
from open or partly empty containers.
In normal climatic conditions, the fluid should
be replaced every 12,420 mi (20,000 km ) or
in any case every 2 years.
Note: Change brake fluid and bleed system
as described in chapter “Braking System”.
Tightening torque
Reservoir screws: 11.0-14.7 lbs·ft
(15-20 N·m)
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7.9 Removing the Steering Lock
7.9.1 Removing the Steering Lock when on «OFF» Position
-
Remove the leg- shield as described in
chapter “Bodywork”.
-
Remove the immobilizer antenna shown in
the figure.
-
Disconnect the wiring.
-
Pull out the retaining spring shown in the
figure and remove the ignition switch.
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-
Push the bolt lightly and extract the
retainer from the milled part shown in the
figure.
-
Extract the bolt assembly from the lock
body.
-
To refit, follow the reverse procedure.
7.9.2 Removing the Steering Lock when on «LOCK» Position
The bolt retaining spring is not accessible in
the «LOCK» position. It is then necessary to
drill the bolt as shown in the figure to eject it.
Note: To refit the bolt from this position, first
disengage the steering lock by putting the
lock body (inner and outer part) in the OFF
position.
To refit, proceed as described in the previous
paragraph.
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7.10 Headlight Adjustment
-
Place the unloaded vehicle on a flat
surface, 32.8 ft (10 m) from a half lit white
screen, with the tires inflated to the
prescribed pressure. Ensure that the axis
of the vehicle is perpendicular to the
screen.
-
Trace a horizontal line on the screen 27.2-
28.3 in (67-70 cm) above ground.
-
Remove the steering cover by loosening
the screw shown in the figure.
-
Switch on the headlight, turn on the low
beam and check that the horizontal line,
which separates the lighted area from the
dark area, is not above the line previously
drawn on the screen. To shift the
headlight, operate on the adjusting screw
immediately below the headlight, as shown
in the figure.
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7.11 Checking the Spark Advance
-
To check the spark advance, use the
stroboscopic light with the induction clamp
connected toe the spark plug feeder cable.
-
Connect the induction clamp paying
attention to the polarity (the arrow on the
clamp must be facing the spark plug).
-
Set the lamp selector to the central position
(1 spark = 1 crankshaft revolution as in 2
stroke engines).
-
Start the engine and check that the lamp
works properly and that the revolution
counter can als o read high engine speeds
(e.g. 8,000 rpm).
-
If flashing or rpm reading instabilities are
noted, increase the resistive load on the
spark plug feeder cable (10- 15 kO in series
with the H.T. cable).
-
Remove the plastic cover from the slotted
hole on the flywheel cover.
-
Using the lamp flash phase shift corrector,
align the reference mark on the flywheel
cover with the level on the water pump
drive. Read the degrees of advance on the
stroboscopic light.
-
Check the revolving speed corresponding to
the degrees of advance in the tables below.
-
If any discrepancy is found, check the pick-
up and the control unit feeders (positivenegative). If necessary, replace the control
unit.
-
An un-programmed control unit prevents
the engine from exceeding 2,000 rpm.
-
A programmed control unit allows the
engine to revolve within the prescribed
limits.
Spark advance:
from 10°±1° @ 2,000 rpm
to 32°±1° @ 6,000 rpm
Specific tools and equipment:
Timing Light 020330Y
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7.12 Spark Advance Variation Curve
Rev limiter
First threshold First threshold
Tripping threshold 9,900±50 rpm 9,900±50 rpm
Restore threshold 9,800±50 rpm 9,800±50 rpm
Spark suppression 1 spark out of 7 2 sparks out of 3
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7.13 Evaporative emission system
A = Canister
B = Uni-directional valve
C = Air intake membrane
D = Cylinder head
E = Carburetor
F = Air intake float chamber
G = Pump
H = Fuel output
I = Fuel tank
L = Plug
M = Fuel breather pipe
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N = Roll-over valve
O = Union “T”
P = Enviornment
Checking the CO Concentration
This test may be re quired when engine operation is irregular or while adjusting the idle.
The test must be carried out after washing all carburetor components and making sure that the
air filter is clean and the spark plug is in good condition.
-
Remove the side fairing and then the trans-
mission cooling air inlet duct so as to easily
reach the flow adjustment screw.
-
Remove the gas cap on the exhaust.
-
Using the original washer, install the exhaust
gas collection kit onto the exhaust.
-
Suitably orientate all the components.
-
Close the gas outlet terminal of the tool.
-
Start the engine and let it warm up until the
electric fan activates.
-
Stop the engine.
-
Disconnect the SAS (Secondary Air System)
check valve vacuum pipe from the ‘T’
connection shown in the figure.
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-
Seal the connection using a cap or a pipe
portion with conical a cap.
-
Connect the Mitivac vacuum pump to the
control pipe and to the SAS valve.
-
Start the vacuum pump up to a pressure of
-8.7 ÷ -11.6 psi (-0.6 ÷ -0.8 bar) so as to
close the valve and cut off the SAS system.
Remove the exhaust gas collection kit closing cap and connect the analyzer properly pre heated.
Check the conditions displayed by the analyzer and the engine rpm and adjust the CO
value to:
3.8±0.7 @ 1,650±50 rpm
Special equipment and tools:
Mityvac-like vacuum pump 020329Y
Digital tachometer 020332Y
Exhaust gas analyzer 494929Y
Note: Check that the result is obtained with the gas valve in the closest position.
Also check that the carburetion adjustment is obtained with the flow screw open by 2 to 4
turns.
If not, check the fuel level adjustment in the basin and check the fuel circuit.
In case of unsteady CO, check the carburetor cleaning, the feeding system efficiency and
the vacuum seals.
In case of unburnt hydrocarbons (HC) > of 1,000 p.p.m., check the ignition system, the
timing, the valve clearance and the drainage valve seal.
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7.14 SAS (Secondary Air System)
7.14.1 General
The Secondary Air System (SAS) on the 200cc
L.E.AD.E.R. engines is similar, in principle, to the
SAS employed on PIAGGIO’s 2-stroke engines.
Here, however, the secondary air enters directly
into the exhaust duct from the head.
The bleed valve found on the 2- stroke engine is here replaced by a membrane. The unit,
indicated by an arrow in the figure, is provided with a cut - off connected to the vacuum inlet
on the intake manifold to shut the air inlet during deceleration, to prevent explosions in the
silencer.
7.14.2 Description
Air is sucked through hole «A» and flows through
the first filter into hole «B».
Passing through the hole indicated in the figure,
air reaches the second filter «B».
At this point, the filtered air enters into the
membrane device to be channeled towards the
head.
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Flowing through a stiff duct, flanged to the head,
the secondary air reaches the exhaust duct thus
providing oxygen addition to the unburnt gases
just before they enter the catalytic converter. The
efficiency of he catalyzing process is therefore
increased.
7.14.3 Removing the SAS
Warning – This operation must be performed
with the engine cold.
Remove the silencer.
Remove the R.H. fairing.
Loosen the clamps and remove the cooling fluid
inlet and outlet sleeves from the pump cover and
drain the cooling system.
Remove the top strip fixing the SAS valve
connection sleeve to the drainage as shown in the
figure.
Remove the 2 fixing screws, the gasket and the
pipe connecting the SAS valve to the head. Then,
remove the pipe.
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Release the electric wiring fixing from the
flywheel cover as shown in the figure
Disconnect the vacuum pipe from the SAS valve
Remove the pump support bracket and the fuel
filter
Remove the flywheel cover with the SAS valve by
releasing the 4 hexagon screws as shown in the
figure
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Remove the two SAS valve fixing screws and
remove the valve with the O- ring from the
support
Remove the plastic support with the gasket
Check that the secondary air box valve plastic
support is free from cracks and deformations
Check the integrity of the gasket
Warning - An impaired seal between secondary
air box valve and flywheel cover causes an
increase of noise of the system.
Carefully clean the internal and external filter. If
they exhibit damages or abnormal deformations,
proceed to the replacement.
Check that the sleeve connecting the secondary
air to the head exhibits no cracks or
deformations. Replace them, if necessary. Check
that the metal duct is free from cracks.
For re- assembly, perform the operations for
removal in the reverse order respecting the
orientation of the rubber sleeve connecting the
SAS valve to the exhaust system.
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8 Troubleshooting
This section provides troubleshooting guidance. All faults are provided with a list of possible
causes and remedies.
8.1 Engine
8.1.1 Poor Performance
Symptom Possible Cause Operation
Poor
performance
Carburetor dirty. Fuel pump or
one-way valve faulty
Timing failure or timing system
parts worn
Exhaust blocked Replace
Air filter clogged or dirty Remove the sponge, wash it in water
Automatic choke failure Check the mechanical sliding and the
Clutch slipping Check and if necessary replace the
Remove, wash with solvent and dry
with compressed air, or replace
Reset timing phase or replace any
worn parts
and shampoo, and then soak it in a
50% mixture of fuel and oil
(recommended: Selenia Air Filter
Oil). Squeeze the sponge without
twisting, allow it to drip and then
replace it
electrical connection and ensure that
power is supplied. Replace if
necessary
clutch assembly and/or the clutch
drum housing
Automatic transmission faulty Check correct pulley sliding and
rollers. Replace any faulty
components and lubricate the
movable driven pulley guide with
Montblanc Molybdenum Grease
Worn driving belt Replace
Low compression: piston rings,
cylinder, valves and valve seats
worn
Engine oil level exceeding MAX
mark
77
Replace any worn parts
Find out the cause and adjust the oil
level
Page 78
8.1.2 Rear Wheel Spins at Idle
Symptom Possible Cause Operation
Idle speed too high Adjust the engine idle speed and, if
Rear wheel spins
at idle
Faulty clutch Check clutch springs/weights
necessary, the CO concentration
8.1.3 Rich Mixture
Symptom Possible Cause Operation
Rich mixture
Calibrated air holes on
carburetor clogged or
obstructed
Float valve faulty Check the proper sliding of the float
Level in float bowl too high Restore the level in the float chamber
Automatic choke remains
activated
Air filter clogged or dirty Remove the sponge, wash it in water
Remove, wash in solvent and dry
with compressed air.
and the operation of the valve.
by bending the fuel inlet needle
thrust blade on the float so that the
float is parallel to the chamber
surface when the carburetor is in an
upside-down position.
Check the correct sliding of the
mechanical component and the
electrical connection and ensure that
power is supplied. If necessary
replace.
and shampoo, and then soak it in a
50% mixture of fuel and oil
(recommended: Selenia Air Filter
Oil). Squeeze the sponge without
twisting, allow it to drip and then
replace it.
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8.1.4 Weak Mixture
Symptom Possible Cause Operation
Carburetor jets clogged Remove, wash in solvent and dry
with compressed air.
Float valve faulty Check the proper sliding of the float
and the operation of the valve.
Level in float bowl too low Restore the level in the float bowl
bending the fuel inlet needle thrust
blade on the float so that the float is
Weak mixture
Tank breather clogged Restore proper tank aeration.
Feed pipes choked or throttle Restore proper fuel flow.
parallel to the chamber surface when
the carburetor is in an up-side down
position.
Intake manifold cracked or
clamps poorly tightened
Replace the intake connection and
check for any abnormal air leakage.
8.1.5 Low Compression
Symptom Possible Cause Operation
Incorrect valve adjustment Adjust valve clearance
Valves overheated Remove the cylinder head and the
Low
compression
Valve seat deformed/worn Replace the head assembly
Cylinder worn; piston rings
worn or broken
valves, then grind or replace the
valves
Replace cylinder-piston assembly or
piston rings
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8.1.6 Starting Problems
Symptom Possible Cause Operation
Flat battery Check the battery charge level. If the
battery shows any sign of sulphation,
replace it with a new one
Starting
problems
Carburetor dirty or fuel pump
faulty
Spark plug faulty or spark
advance incorrect
Air filter clogged or dirty Remove the sponge, wash it in water
Automatic choke failure Check the mechanical sliding and the
Engine flooded Open the throttle wide and try to
Remove, wash with solvent and dry
with compressed air, or replace
Replace the spark plug or check the
ignition circuit components
and shampoo, and then soak it in a
50% mixture of fuel and oil
(recommended: Selenia Air Filter
Oil). Squeeze the sponge without
twisting, allow it to drip and then
replace it
electrical connection and ensure that
power is supplied. Replace if
necessary
start the engine. If the engine does
not start, remove the spark plug, dry
it and, before replacing it, crank the
engine to expel the excess of fuel,
keeping the cap connected to the
spark plug and the latter to earth. If
the fuel has run out, refuel and then
start the engine
Incorrect valve seal or wrong
valve adjustment
Starting speed too low or
starting system and motor
faulty
Altered fuel characteristics Drain worn fuel and refuel
80
Inspect the head and/or set the
correct clearance
Check starter motor, starting system
and torque limiter
Page 81
8.1.7 Excessive Oil Consumption/Excessive Smoke from Exhaust
Symptom Possible Cause Operation
Excessive oil
consumption/ex
cessive smoke
from exhaust
Piston rings worn or broken or
improperly fitted
Oil leaks from joints or gaskets Check and replace the gaskets or
Oil retainer worn Replace valve oil retainer
Valve guides worn Check and, if necessary, replace the
Replace cylinder-piston assembly or
piston rings
restore the joint seal
head assembly
8.1.8 Insufficient Lubrication Pressure
Symptom Possible Cause Operation
Oil level too low Restore to the required level by
topping up with fresh oil
(recommended oil: Selenia HI
Scooter 4 Tech)
Insufficient
lubrication
pressure
Oil filter excessively dirty Replace the cartridge filter
Oil pump play excessive Perform dimensional checks on the oil
pump components
By-pass re mains open. Check the by-pass and replace if
required. Carefully clean the by-pass
area
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8.1.9 Engine Tends to Cut Out at Full Throttle
Symptom Possible Cause Operation
Main jet dirty; lean carburetion Wash the jet in solvent and dry with
compressed air
Water in carburetor Empty the float chamber by using the
drain screw
Engine tends to
cut out at full
throttle
Float level incorrect Restore the level in the float chamber
by bending the fuel inlet needle
thrust blade on the float so that the
float is parallel to the chamber
surface when the carburetor is in an
up-side down position
Fuel supply circuit faulty Check and, if necessary, replace the
fuel pump. Check the vacuum intake
and the duct seal
8.1.10 Engine Tends to Stop at Idle
Symptom Possible Cause Operation
Idling jet dirty Wash in solvent and dry with
compressed air
Choke device remains activated Check: electrical connections, circuit
continuity, mechanical sliding and
power supply; replace if required
Spark plug faulty or spark
advance incorrect
Replace the spark plug or check the
ignition circuit components
Engine tends to
stop at idle
Compression end pressure too
low
Idle adjustment incorrect Adjust using a rev counter
Cut- off device fault y Check the operation of the valve,
Incorrect timing Restore correct timing and check
82
Check thermal unit seals and replace
worn components
membrane and spring; check if the
air adjusters and the sponge filter are
clean
timing system components
Page 83
8.1.11 Excessive Fuel Consumption
Symptom Possible Cause Operation
Air filter clogged or dirty Remove the sponge, wash it in water
and shampoo, and then soak it in a
50% mixture of fuel and oil
(recommended: Selenia Air Filter
Oil). Squeeze the sponge without
twisting, allow it to drip and then
replace it.
Automatic choke device faulty Check electrical connections, circuit
continuity, mechanical sliding, and
Excessive fuel
consumption
Fuel pump faulty Check vacuum duct seal
Jets loose Check that the main and idling jets
Float level Restore the level in the float chamber
power supply
are securely seated
by bending the fuel inlet needle
thrust blade on the float so that the
float is parallel to the chamber
surface when the carburetor is in an
up-side down position
8.2 Transmission and Brakes
8.2.1 Irregular Clutch Operation or Grapping
Symptom Possible Cause Operation
Faulty clutch Check that the clutch weights are
free from grease
Clutch irregular
operation or
grapping
Check that the contact surface of the
clutch weights with the drum housing
is mainly at the centre and equivalent
for the three weights
Check that the drum housing exhibits
no abnormal wear or scratches
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8.2.2 Poor Braking Performance
Symptom Possible Cause Operation
Poor braking
performance
Pads or disk excessively worn;
brake fluid quantity insufficient
or hydraulic system faulty
Brake disk loose or distorted Check the tightening of the brake
Check the pads wear;
MIN allowable dimension:
Brake pads wear 0.06 in
(1.5 mm)
Ensure that the brake disks are not
worn, scratched or deformed
Check the brake fluid level in the
pumps and, if necessary, replace the
brake fluid
Check that there is no air in the
circuit and bleed as necessary
Check that the front brake caliper
moves correctly along the front disk
axis
disk screws. Using a comparator and
with the wheel mounted onto the
vehicle, measure the disk’s axial
deviation
Brake fluid leakage from the
hydraulic system
Replace faulty flexible connections,
piston, or brake pump gaskets as
necessary
8.2.3 Brakes Overheating
Symptom Possible Cause Operation
Defective piston sliding Check caliper and replace any
damaged parts
Brake disk loose or distorted Check the tightening of the brake
disk screws. Using a comparator and
with the wheel mounted onto the
Brakes
overheating
Pump compensation holes
clogged
Rubber gaskets swollen or
sealed
vehicle, measure the disk’s axial
deviation
Clean thoroughly and blow with
compressed air
Replace gaskets
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8.3 Electrical System
8.3.1 Battery
Symptom Possible Cause Operation
The battery requires regular maintenance.
If the vehicle is not used for long periods (1 month or more), the battery
Battery
8.3.2 Turn Signal Lights Not Working
Symptom Possible Cause Operation
Turn signal
lights not
working
must be charged from time to time. Over a period of disuse of 3 months,
the battery will discharge completely. When installing the battery, make
sure the black ground lead is connected to the negative terminal and the
red lead to the positive terminal
Electronic control unit faulty With the ignition switch set to «ON»,
jumper contacts 1 (Blue- Black) and 5
(Red-Blue) on the electronic control
unit connector. If turn indicators do
not light up and stay lit when the
related switch is operated, replace
the regulator, otherwise check the
wiring and the switch
8.4 Steering Controls and Suspension
8.4.1 Excessive Steering Stiffness
Symptom Possible Cause Operation
Irregular tightening Check the tightening of the upper
Excessive
steering
stiffness
8.4.2 Excessive Steering Play
Symptom Possible Cause Operation
Excessive
steering play
Irregular tightening. As above
and lower ring nuts. If steering
rotation is still uneven, check the
bearing ball rolling seats. Replace if
the seats appear to be recessed or if
the balls are flattened
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8.4.3 Noisy Suspension
Symptom Possible Cause Operation
Anomalies in the suspension
system
Noisy
suspension
If the front suspension is noisy, check
the operation of the front shock
absorber, the condition of the ball
bearings and of the related locknuts,
the rubber stops and the sliding
bushes
Also check the tightening torques of
the wheel hub, the brake caliper, the
disk and the shock absorber on the
hub and steering column connections
8.4.4 Suspension Oil Leaking
Symptom Possible Cause Operation
Faulty seal Replace the shock absorber
Suspension oil
leaking
Check the wear of the steering caps
and adjusters
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9 Electrical System
1 Front left- hand side turn signal light
(with 2 bulbs)
2 Rear brake light switch
3 Headlight switch
4 Turn signal lights switch
5 Horn button
6 Radio- intercom fitting
7 Saddle opener button
8 Thermostat
9 Electric fan
10 Saddle opening actuator
11 Voltage regulator
12 Rear left-hand side turn signal light
(with bulb)
13 Number plate light (with bulb)
14 Complete tail light (with low beam
bulb and 6 brake light bulbs)
15 Rear right-hand side turn signal light
(with bulb)
16 Fuel level transmitter
17 Engine earth
18 Starter motor
19 Oil pressure sensor
20 Magneto flywheel
21 Automatic choke device
22 Thermostat
23 H.T. coil
24 Starting relay
25 Fuse holder with 2 fuses
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26 Battery 12V 12Ah
27 Anti-theft alarm fitting
28 Immobilizer antenna
29 Key switch
30 Start-up button
31 Horn
32 Front right-hand side turn signal light
(with 2 bulbs)
33 Analogue instrument panel with 9
bulbs, warning lights, fuel reserve
warning light, oil pressure warning
light, upper beam indicator, RH turn
signal light indicator, LH turn signal
light indicator, LED for immobilizer, 3
bulbs for instrument illumination
34 Relay switch
35 Complete right or left- hand
asymmetric headlight with bulb for
headlight and 1 bulb for position
36 Fuse holder box
37 Anti-theft alarm fitting
38 Electronic ignition device (CDI)
39 Engine stop deviator
40 L.H. lever brake light switch
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9.1 Electrical Diagrams
9.1.1 Ignition Section
1 Pick-up 5 Spark plug
2 Flywheel magneto 6 H.T. coil
3 15A Fuse (No. 7) 7 Voltage regulator
4 Electronic ignition device (CDI) 8 12V-12Ah Battery
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9.1.2 Turn Signal Lights, Horn, Services and Accessory Pre-Wiring
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1 Direction indicators 12V- 2W 12 Ignition switch contact
No. 4 Front turn signal light bulbs
2
12V-5W
No. 2 Rear turn signal light bulbs
3
12V-10W
4 Horn 12V 15 Anti-theft alarm pre-wiring
5 Saddle opening button 16 Radio-intercom pre -wiring
6 Horn button 17 10A Fuse
7 Turn signal lights switch 18 Immobilizer LED
8 Saddle opening actuator 19 Battery (12V-12Ah)
9 7.5A Fuse 20 15A Fuse
10 7.5A Fuse 21 Immobilizer antenna
11 Anti-theft alarm pre- wiring 22 Electronic ignition device (CDI)
13 Ignition switch contact
14 7.5A Fuse
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9.1.3 Level Indicators and Safety Switches
1 Cooling fluid temperature indicator 7 Oil pressure sensor
2 Fuel level indicator 8 Fuse 7.5A
3 Fuel level transmitter 9 Key switch contacts
4 Thermostat 10 Battery 12V-12Ah
5 Fuel indicator 12V–1.2W 11 Fuse 15A
6 Oil pressure indicator 12V–1.2W 12 Electronic ignition device
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9.1.4 Battery Recharge and Starting Section
1 Engine stop deviator 8 No. 8 bulbs for stop light 12V–2.3W
2 Key switch contacts 9 Fuse 15A
3 Fuse 5A 10 Battery 12V / 12Ah
4 Stop buttons 11 Electronic ignition device
5 Start- up button 12 Voltage regulator
6 Starter motor 13 Magneto flywheel
7 Starting relay 14 Pick-up
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9.1.5 Headlight and Automatic Choke Section
1 Starting relay 7 Fuse 8A
2 Light switch 8 Key switch contacts
3
4 Upper beam indicator 12V–1.2W 10 Fuse 15A
5
6
Dipped beam/upper bulb 12V55/60W
No. 3 bulbs for instrument lighting +
side/taillights indicator 12V- 2W
No. 3 number plate position bulbs
12V-5W
9 Automatic starter
11 Battery 12V- 12Ah
12 Electronic ignition device
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9.2 Electrical Equipment
9.2.1 Electronic Ignition (Immobilizer System)
The electronic ignition system is DC - fed and
is equipped with an immobilizer antitheft
system built into the electronic control unit.
The ignition system consists of:
-
Electronic control unit (CDI)
-
Immobilizer antenna
-
Master and service key with built- in
transponder
-
H.T. coil
-
Diagnostic LED
1 = Un-programmed control unit
2 = Programmed control unit
3 = LED on
4 = LED off
Note: The diagnostic LED also works as a deterring blinker. This function is activated every
time the ignition switch is turned to the «OFF» position, or the 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 the «ON» position the deterring blinker function is
deactivated. Subsequently, a flash confirms the switching to the «ON» status.
This duration of the flash depends on the programming of the electronic control unit prog
(see figure above).
If the LED is off and stays off even when the
ignition switch is turned to «ON», check if:
-
Battery voltage is present, i.e. the battery
is not flat
-
The fuses are in working order; main fuse
15A (no. 7)
If both battery and fuses are working
properly and the deterring LED still remains
off, diskonnect the electronic control unit
connector and follow these steps to check
that power is supplied to the electronic
control unit:
Rs = Red
Ne = Black
-
Ensure that the potential difference
between terminal no. 4 (red/black) and
ground (see figure) is equal to the battery
voltage
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-
Check that battery voltage is present
between terminals no. 4 (red/black) and
no. 8 (black), as shown in the figure
-
Check that battery voltage is present
between terminals no. 5 (green/white) and
no. 8 (black) with the ignition switch
turned to the «ON» position and the
emergency cut- off switch set to «RUN»
(see figure).
Rs = Red
Ne = Black
If no faults are found, replace the control
unit; otherwise, check the wiring and the
following components:
If no malfunction is found, replace the control
unit and, otherwise check the wiring and the
following components:
-
Engine stop relay switch
-
Emergency cut- off switch
-
Ignition switch contacts
Bi = White
Ve = Green
Ne = Black
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9.2.2 Un-Coded Electronic Ignition System
When the ignition system is not coded, the engine can be run at a maximum speed of 2,000
rpm. Any attempt to rev up causes the engine to misfire.
To code the system, set the emergency cut- off switch to the «RUN» position and use the
MASTER (brown) and SERVICE (black) keys as follows:
-
Insert the MASTER key; turn the ignition switch to the «ON» position for approximately 2
seconds (strictly between 1 and 3 seconds) and then turn it back to the «OFF» position
-
Insert all the SERVICE keys available in succession, each time turning the ignition switch
to «ON» for 2 seconds
-
Insert the MASTER key again and turn it to «ON» for 2 seconds
Note: The time needed to change keys must not exceed 10 seconds.
Note: A maximum of three SERVICE keys can be programmed within the same coding
session.
It is essential to observe the sequence and time limits as described above. If at any time
during the programming session these are not observed, the procedure will have to be
restarted from the beginning.
Once the control unit has been coded, an unbreakable relation is created between the
control unit and the MASTER key transponder.
This relation allows new SERVICE keys to be
coded in case of loss, replacement, etc. Each
new storing operation cancels the previous
one.
Should the SERVICE keys lose the data stored
in them it is essential to carefully check the
shielding of the high-voltage system:
Standard resistance:
Shielded cap ~5 kO
The use of resistive spark plugs is
recommended (see figure).
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9.2.3 Diagnostic Codes
After the flash that denotes the switching to the «ON» status, the system may output a
number of malfunction codes.
The LED stays initially off for 2 seconds, and then the diagnostic codes are displayed in the
form of 0.5-second flashes.
Once the malfunction code has been displayed, the LED turns on to indicate that ignition is
impossible (see graph below).
2-Flash code
Example – electronic control unit programmed, transponder absent and/or antenna
malfunctioning.
Ignition disabled – Vehicle immobilized
3-Flash code
Example - electronic control unit programmed, aerial in working conditions and
transponder code unknown.
1 = LED on
2 = LED off
3 = LED remains lit
Ignition disabled – Vehicle immobilized
9.2.4 2-Flash Diagnostic Code
If the 2- flash diagnostic code is displayed, check if the malfunction persists when the key
(including the MASTER key) is changed. If the anomaly persists with any key, detach the
control unit aerial connector and check the continuity of the antenna by using the
recommended multimeter 020331Y.
Standard resistance:
Immobilizer antenna ~ 7-9 O
If the value is not as specified, replace the antenna.
If no anomaly is found, replace the control unit.
Warning – Before performing the storing procedure on the new control unit, check that no
malfunction code is signaled. This is precaution is needed to avoid wasting a new control
unit.
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9.2.5 3-Flash Diagnostic Code
If the 3-flash diagnostic code is displayed, check if the anomaly persists even after inserting
the MASTER key into the ignition switch.
If the malfunction disappears when the MASTER key is used, proceed to a new coding of the
SERVICE (black) keys.
If the anomaly persists, then the MASTER key and the control unit are not matched. In that
case, replace the control unit and proceed to code the keys.
The immobilizer system is in working order when, after turning the ignition switch to «ON»,
a single 0.7-second flash is emitted (see graph below).
In that case, ignition is possible.
Example – electronic control unit
programmed, transponder present key
programmed and aerial in working order.
Ignition enabled
(standard operating conditions)
1 = LED on
2 = LED off
3 = No flashing
4 = LED remains off
9.2.6 Ignition System
Once the immobilizer system has been enabled, it is possible to obtain a spark at the plug
through the H.T. coil and the signals coming from the pick- up.
The basic power supply is represented by the battery. The system is calibrated in such a
way that any voltage drops in the battery are detected by the starting system and is
therefore virtually harmless to the ignition system.
The pick- up is connected to the control unit by a single wire. As a result, the pick- up ground
is connected to the control unit through the frame and the earth wire from the engine.
To avoid hampering the ignition system during the starting process, it is important that the
engine/frame ground connection is as efficient as possible.
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9.2.7 Spark Plug Power Supply Failure
If no power is supplier to the spark plug and the
LED signals that ignition is possible, follow these
steps:
-
Run a pick-up check: detach the control unit
connector and check continuity between
terminals no. 2 (green) and no. 8 (black). This
check involves the pick up and its supply:
Standard resistance:
Pick-Up 105-124 O
If the circuit is interrupted, repeat the check between the flywheel connector and the engine
ground (see engine manual). If the measured values are not as specified, replace the pick-
up, otherwise repair the wiring.
If, on the other hand, the values are as specified, try replacing the control unit (without
programming it) and ensure that the problem has been solved by checking that a spark is
produced at the plug, then proceed to program the control unit.
H.T. coil primary circuit check
Detach the control unit connector and check
continuity between terminals no. 3 and no. 8 (see
figure).
Standard resistance:
H.T. coil secondary circuit 0.4-0.5O
If the resistance is not as specified, repeat the check
directly on the positive and negative terminals of the
H.T. coil primary circuit.
If the measured resistance is as specified, proceed by
repairing the wiring or restoring the connections,
otherwise replace the H.T. coil.
Ve = Green, Ne = Black
Vi = Purple
Ne = Black
H.T. coil secondary circuit check
Disconnect the spark plug cap from the H.T. cable
and measure the resistance between the end of the
H.T. cable and the negative terminal of the H.T. coil
(see figure).
Standard resistanc e:
H.T. coil secondary circuit ~3,000±300 O
1 = Black cap
If the measured values are not as specified, replace
the H.T. coil. To obtain a more accurate diagnosis
proceed to verify the peak voltage using the
multimeter adaptor.
Specific equipment and tools:
Multimeter adaptor 020409Y
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2 = Green cap
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