Piaggio Vespa WORKSHOP NRG Power DD Workshop Manual

WORKSHOP MANUAL

633325

NRG Power DD

WORKSHOP

MANUAL

NRG Power DD

The descriptions and illustrations given in this publication are not binding. While the basic features 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 accessory supplies, which it considers necessary to improve the product or which

are required for manufacturing or construction reasons.

Not all versions shown in this publication are available in all Countries. The availability of individual

versions should be confirmed with the official Piaggio sales network.

"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."

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

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

WORKSHOP MANUAL

NRG Power DD

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio­Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a
basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are
unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along
with the specific tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Characteristics NRG Power DD

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 open flames or sparks.

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

Maintenance rules

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

- Use only the appropriate tools designed for this vehicle.

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

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

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.

CHAR - 2

NRG Power DD Characteristics

Vehicle identification

Frame prefix: ZAPC45100 ÷ 1001
Engine prefix: C451M

Dimensions and mass

Specification Desc./Quantity

Max length 1790 mm.

Max width 850 mm.
Seat height 795 mm.
Wheelbase 1280 mm

Dry weight 99 kg.

DIMENSIONS AND MASS

CHAR - 3

Characteristics NRG Power DD

Engine

ENGINE

Specification Desc./Quantity

Type of engine One-cylinder 2 speed Piaggio Hi-PER2 PRO

Bore x stroke 40 X 39.3 mm

Cubic capacity 49.40 cc

Compression ratio 11.3 ÷ 12.8 : 1

Carburettor DELL'ORTO PHVA 17.5 ID

CO adjustment 3.5% ± 0.5

Engine idle speed 1800 to 2000 r.p.m.

Air filter Sponge impregnated with fuel mixture (50% SE-

LENIA air filter oil and 50% unleaded petrol).

Starting system electric starter/kickstarter

Lubrication With blend and variable oil variable according to

the engine revolutions and the throttle valve open-

ing by means of a pump controlled by the driving

shaft with toothed belt.

Fuel supply: With the fuel pump in depression, lead-free gaso-

line (with 95 octane minimum) by means of the

carburettor

Cooling system Through circulation of cooling liquid

CHAR - 4

NRG Power DD Characteristics

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator, torque

server, V belt, automatic clutch, gear reduction

unit.

Capacities

CAPACITY

Specification Desc./Quantity

Rear hub oil Quantity : ~ 85 cc

Mixer oil 1.2 litres

Fuel tank capacity 6.5 litres (1.5 litres of reserve)

Electrical system

ELECTRIC SYSTEM

Specification Desc./Quantity

Type of ignition Capacitive discharge type electronic ignition, with

incorporated high voltage coil

Spark advance (Before T.D.C.) 20°±1 at 4000 rpm

Sparkplug (One-cylinder two-stroke liquid cooled) CHAMPION RN1C

Battery 12V-4Ah

Main fuse 7.5 A

Generator In alternate current with three output sections

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Chassis type Welded tubular steel chassis with stamped sheet

reinforcements

Front suspension upside-down hydraulic telescopic fork.

Front suspension travel 75 mm

Rear suspension With coaxial spring and hydraulic shock absorber.

Chassis to engine support with swinging arm.

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 220 mm disc brake with hydraulic linkage (r.h.

brake lever).

Rear brake Ø 175 mm disc (hydraulically controlled via lever

on left hand-side of handlebar)

CHAR - 5

Characteristics NRG Power DD

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front tyre Tubeless 120/70-13"

Rear tyre Tubeless 140/60 x 13''

Wheels With circles of 3.50 x 13" in light alloy.

Secondary air

To clean the sponge filters of the secondary air
system, proceed as follows:
Unscrew the two studs ( 2) of the aluminium lid of
the secondary air box to access the polyurethane
sponge contained inside the box; after cleaning
with water and neutral soap, dry the sponge with
a clean cloth and reassemble the system, check­ing that the steel blade is not warped and/or does
not guarantee the seal on its strike surface; re­place if necessary.

N.B.

UPON REFITTING, MAKE SURE TO CORRECT­LY FIT THE TAB IN ITS FITTING ON THE TWO
PLASTIC AND ALUMINIUM COVERS.

CAUTION

DURING THE OPERATION, CHECK THE IN­TEGRITY AND SEAL OF THE TWO SLEEVES
(3) IN RUBBER LOCATED AT THE ENDS OF
THE SECONDARY AIR HOSE; IF NECESSARY,
REPLACE THEM USING NEW CLAMPS TO
FASTEN.

Carburettor

50cc Version

Dell'Orto

Reference number of adjustment 8439

CHAR - 6

DELL'ORTO CARBURETTOR

Specification Desc./Quantity

Type PHVA 17.5 ID

Diffuser diameter Ø 17.5

NRG Power DD Characteristics

Specification Desc./Quantity

Maximum nozzle: 53

Maximum air nozzle (on the body): Ø 1.5

Tapered pin stamped code: A22

Pin position (notches from above): 1

Diffuser: 209 HA

Minimum nozzle: 32

Minimum air nozzle (on the body): Free

Secondary minimum air hole Ø 2.5

Initial minimum mix screw opening: 1 1/2

Starter jet 50

Starter air nozzle (on the body): Ø 1.5

Stroke of starter pin: 11 mm

Fuel inlet hole Ø 1.0

Tightening Torques

STEERING ASSEMBLY

Name Torque in Nm

Upper steering ring nut (safety locks) 35 to 40 Nm
Lower steering ring nut (safety locks) 8 to 10 Nm

Handlebar fixing pin (safety locks) 45 to 50 Nm

FRAME ASSEMBLY

Name Torque in Nm

Swinging arm-engine pin (safety locks) 33 to 41 Nm

Swinging arm-frame pin (safety locks) 64 to 72 Nm

Shock absorber - frame nut (safety locks) 20 to 25 Nm

Shock absorber-engine pin (safety locks) 33 to 41 Nm

Rear wheel axis (safety locks) 104 to 126 Nm

Bolt holding stand to the engine 18 to 19 Nm

Side stand fixing screw 12 ÷ 20

Side stand bracket fixing screw 15 ÷ 20

Rear rim fixing screw 20÷25

FRONT SUSPENSION

Name Torque in Nm

Front wheel axle nut (safety locks) 45 to 50 Nm

Wheel axle clamp screw 6 ÷ 7 Nm

Lower leg screw 15 to 20 Nm

Hydraulic cartridge stem nut 15 to 18 Nm

FRONT BRAKE

Name Torque in Nm

Viti fissaggio coperchio pompa freno 1,5 ÷ 2 Nm

Brake pump support fixing screw 7 to 10 Nm

Brake fluid pump - hose fitting 13 to 18 Nm

Brake fluid tube - calliper fitting 20 to 25 Nm

Calliper tightening screw 20 to 25 Nm

Disc tightening screw (safety locks - lock with

LOCTITE THREADLOCK MEDIUM TYPE 243)

Oil bleed screw 7 to 10 Nm

6 ÷ 7 Nm

CHAR - 7

Characteristics NRG Power DD

Name Torque in Nm

Calliper coupling screw 20 to 25 Nm

REAR BRAKE

Name Torque in Nm

Fastening screws calliper to the crankcase 20 - 25

Brake reservoir cover fixing screw 2÷4 N·m (Grimeca) - 0,8÷1,5 N·m (Brembo) -

1,5÷2 N·m (Hengtong)

Brake pump support fixing screw 7 to 10 Nm

Brake fluid pump - hose fitting 13 to 18 Nm

Brake fluid tube - calliper fitting 20 to 25 Nm

Oil bleed screw 7 to 10 Nm

ENGINE ASSEMBLY

Name Torque in Nm

Clutch bell nut 40 to 44 Nm

Clutch lock ring nut 55 ÷ 60

nut locking driving pulley on the crankshaft 40 to 44 Nm

Start-up lever screw 12 ÷ 13

Flywheel nut 40 to 44 Nm

Flywheel fan screws 3 ÷ 4

Half-crank case joint bolts 12 ÷ 13

Bolts holding exhaust pipe to the crankcase 22 ÷ 24

Screws holding the filter box to the crank case 4 ÷ 5

Head nuts 10 ÷ 11

Starter screws 12 ÷ 13

Ignition spark plug 25 ÷ 30
Hub oil drainage cap 3 ÷ 5
Oil hub level dipstick Manual

Rear hub cap screws 12 ÷ 13

Transmission cover screws 12 ÷ 13

Inlet manifold screws 8 ÷ 9

Flywheel hood fixing screws 1 ÷ 2

Cylinder hood fixing screws 3.5 ÷ 5

Stator clamping screws 3 ÷ 4

Pick-Up clamping screw 4 ÷ 5

Mixer clamping screws 3 ÷ 4

Screw fixing brake lever to the journal on the en-

gine

12 ÷ 13

Overhaul data

Assembly clearances

Cylinder - piston assy.

CYLINDER-PISTON FITTING

Name Initials Cylinder Piston Play on fitting

Standard fitting M 39.997-40.004 39.943-39.95 0.047-0.061
Standard fitting N 40.004-40.011 39.95-39.957 0.047-0.061

CHAR - 8

NRG Power DD Characteristics

Name Initials Cylinder Piston Play on fitting

Standard fitting O 40.011-40.018 39.957-39.964 0.047-0.061

Standard fitting P 40.018-40.025 39.964-39.971 0.047-0.061
1st oversize fitting M1 40.197-40.204 40.143-40.15 0.047-0.061
1st oversize fitting N1 40.204-40.211 40.15-40.157 0.047-0.061
1st oversize fitting O1 40.211-40.218 40.157-40.164 0.047-0.061
1st oversize fitting P1 40.218-40.225 40.164-40.171 0.047-0.061

2nd oversize fitting M2 40.397-40.404 40.343-40.35 0.047-0.061
2nd oversize fitting N2 40.404-40.411 40.35-40.357 0.047-0.061
2nd oversize fitting O2 40.411-40.418 40.357-40.364 0.047-0.061
2nd oversize fitting P2 40.418-40.425 40.364-40.371 0.047-0.061

Piston rings

SEALING RINGS

Name Description Dimensions Initials Quantity

Compression ring 40 A 0.10 to 0.25
Compression ring

1st oversize

Compression ring

2nd Oversize

40.2 A 0.10 to 0.25

40.4 A 0.10 to 0.25

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Connecting rod 11.750-0.05 A clearance E = 0.25

to 0.50

CHAR - 9

Characteristics NRG Power DD

Name Description Dimensions Initials Quantity

shoulder washer 0.5 ± 0.03 G clearance E = 0.25

to 0.50 - clearance

F = 0.20 to 0.75

Half-shaft, trans-

mission side

Flywheel-side half-

shaft

Lining between the

shoulders

Cage 11.800-0.35 B clearance F = 0.20

13.75+0.040 C clearance E = 0.25
to 0.50 - clearance

F = 0.20 to 0.75

13.75+0.040 D clearance E = 0.25
to 0.50 - clearance

F = 0.20 to 0.75

40.64 H clearance E = 0.25
to 0.50 - clearance

F = 0.20 to 0.75

to 0.75

Slot packing system

- Fit the cylinder without installing the basic gasket.

- Apply a centimetre dial gauge on the special tool and zero it on the ground plane

- Fit the tool to the top of the cylinder fixing it with two nuts to the studbolts and take the piston to the
T.D.C.

- The thickness of the gasket to fit will change depending on the value detected. For this purpose, there
are three with different thicknesses

Specific tooling

020272Y Piston position check tool

SLOT PACKING SYSTEM

Name Measure A Thickness

Shimming 2.80 ÷ 3.04 0,4
Shimming 3.04 ÷ 3.24 0,6

Spacing 3,24÷3,48 0,8

CHAR - 10

NRG Power DD Characteristics

Products

TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications

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

requirements of API GL3 specifi-

cations

AGIP CITY HI TEC 4T Oil to lubricate flexible transmis-

sions (brake, throttle control and

mixer, odometer)

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

AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines:

AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-

AGIP GREASE SM 2 Grease for the tone wheel revolv-

ing ring

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

MONTBLANC MOLYBDENUM

GREASE

AGIP GREASE PV2 Grease for the steering bearings,

SPECIAL AGIP PERMANENT

fluid

Grease for driven pulley shaft ad-

justing ring and movable driven

pulley housing

pin seats and swinging arm

coolant Monoethylene glycol-based anti-

Oil for 2-stroke engines: SAE

5W-40, API SL, ACEA A3, JASO

MA

for increased adhesiveness

JASO FC, ISO-L-EGD

based spray grease with NLGI 2;

ISO-L-XBCIB2

Soap-based lithium grease con-

taining NLGI 2 Molybdenum di-

sulphide; ISO-L-XBCHB2, DIN

KF2K-20

Grease with Molybdenum disul-

phide

White anhydrous-calcium based
grease to protect roller bearings;

temperature range between -20

C and +120 C; NLGI 2; ISO-L-

XBCIB2.

freeze fluid, CUNA NC 956-16

CHAR - 11

Characteristics NRG Power DD

CHAR - 12

INDEX OF TOPICS

TOOLING TOOL

Tooling NRG Power DD

TOOLING

Stores code Description

001330Y Tool for fitting steering seats

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Driver for OD 54 mm bearing

001467Y009 Driver for OD 42 mm bearings

001467Y013 Pliers to extract ø 15-mm bear-

ings

001467Y014 Pliers to extract ø 15-mm bear-

ings

TOOL - 2

NRG Power DD Tooling

Stores code Description

001467Y017 Bell for bearings, outside Ø 39

mm

001467Y021 Extraction pliers for ø 11 mm

bearings

002465Y Pliers for circlips

006029Y Punch for fitting fifth wheel seat

on steering tube

020004Y Punch for removing fifth wheels

from headstock

020209Y Spring hook

TOOL - 3

Tooling NRG Power DD

Stores code Description

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crank-

shaft alignment

020150Y Air heater support

020151Y Air heater

020162Y Flywheel extractor

020163Y Crankcase splitting plate

TOOL - 4

NRG Power DD Tooling

Stores code Description

020164Y Driven pulley assembly sheath

020165Y Start-up crown lock

020166Y Pin lock fitting tool

020167Y Arrest key for impeller pump

020168Y Water seal punch mount on half-

crankcase

020169Y Water pump crankshaft fitting

and removal spanner

TOOL - 5

Tooling NRG Power DD

Stores code Description

020170Y Water pump/mixer command

gear extractor

020261Y Starter spring fitting

020262Y Crankcase splitting strip

020265Y Bearing fitting base

020325Y Brake-shoe spring calliper

020329Y MityVac vacuum-operated pump

TOOL - 6

NRG Power DD Tooling

Stores code Description

020330Y Stroboscopic light for timing con-

trol

020331Y Digital multimeter

020332Y Digital rev counter

020334Y Multiple battery charger

TOOL - 7

Tooling NRG Power DD

Stores code Description

020335Y Magnetic support for dial gauge

020350Y Electrical system check instru-

ment

020357Y 32 x 35 mm adaptor
020359Y 42x47-mm adaptor

020376Y Adaptor handle

TOOL - 8

NRG Power DD Tooling

Stores code Description

020412Y 15 mm guide

020456Y Ø 24 mm adaptor

020483Y 30 mm guide

020565Y Flywheel lock calliper spanner

020625Y Kit for sampling gas from the ex-

haust manifold

494929Y Exhaust fumes analyser

TOOL - 9

Tooling NRG Power DD

TOOL - 10

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance NRG Power DD

Maintenance chart

EVERY 2 YEARS

Action

Brake fluid - change
Coolant - change

AFTER 1000 KM

50'

Action

Hub oil - change
Oil mixer/throttle linkage - adjustment
Odometer cable - greasing
Steering - adjustment
Brake control levers - greasing
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 5000 KM OR 12 MONTHS, 25000 KM, 35000 KM AND 55000 KM

40'

Hub oil level - check
Spark plug/electrode gap - replacement
Air filter - clean
Oil mixer/throttle linkage - adjustment
Coolant level - check
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 10000 KM OR 24 MONTHS AND 50000 KM

95'

Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Oil mixer/throttle linkage - adjustment
Variable speed rollers - replacement
Odometer cable - greasing
Driving belt - check
Coolant level - check
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear

Action

Action

MAIN - 2

NRG Power DD Maintenance

Action

Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle and brake test - road test

(*) See CO regulation in the «Adjusting the engine idle» section

AT 15000 KM AND 45000 KM

65'

Action

Hub oil level - check
Spark plug/electrode gap - replacement
Air filter - clean
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Coolant level - check
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test

(**) See the regulations of the "Secondary air system" section

AT 20000 KMS AND 40000 KMS

120'

Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Cylinder cooling system - check/cleaning
Oil mixer/throttle linkage - adjustment
Driving belt - check
Variable speed rollers - replacement
Mixer belt - replacement
Coolant level - check
Radiator - external cleaning/ check
Odometer cable - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check

Action

MAIN - 3

Maintenance NRG Power DD

Action

Vehicle and brake test - road test

(*) See CO regulation in the «Adjusting the engine idle» section

AT 30000 KM

130'

Action

Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Variable speed rollers - replacement
Coolant level - check
Odometer cable - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Flexible brake tubes - replacement
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test

(*) See CO regulation in the «Adjusting the engine idle» section
(**)See rules in the «Secondary Air System» section

160'

Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Variable speed rollers - replacement
Mixer belt - replacement
Coolant level - check
Radiator - external cleaning/ check
Odometer cable - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Flexible brake tubes - replacement
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check

AT 60000 KM

Action

MAIN - 4

NRG Power DD Maintenance

Action

Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test

(*) See CO regulation in the «Adjusting the engine idle» sectionp>
(**) Vedere norme della sezione «Sistema aria secondaria»

Checking the spark advance

- Check to be carried out at an engine speed of, or above, 4,000 rpm with timing light. The spark
advanced measured must be 20° before T.D.C.

- This figure is correct when the reference on the flywheel shroud is aligned with that on the cooling fan
and the out-of-phase on the light is set to 20°.

N.B.

IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS PROVIDED FOR IN THE ELECTRICAL
SYSTEM CHAPTER.

CAUTION

BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK THE CORRECT KEYING OF THE FLY­WHEEL ON THE CRANKSHAFT.

Specific tooling

020330Y Stroboscopic light for timing control

Spark plug

- Rest the vehicle on its centre-stand;

- Detach the spark plug flap by removing the two
fixing screws;

- Detach the H.T. cable cap from the spark plug;

- Remove the spark plug using the box-spanner
provided;

MAIN - 5

Maintenance NRG Power DD

- Examine the conditions of spark plug, the integ­rity of the insulator, and measure the spark gap
with the aid of a feeler gauge.

- If required, adjust the spark gap by carefully
bending the outer electrode.
In the event of defects, replace the spark plug with
one of the recommended type;

- Engage the thread, with the correct inclination,
and the screw the spark plug by hand as far as it
will go, then tighten it using the box-spanner pro­vided;

- Insert the spark plug cap;

- Refit the spark plug flap.

CAUTION

THE SPARK PLUG MUST BE REMOVED WHEN
THE MOTOR IS COLD. THE SPARK PLUG
MUST BE REPLACED EVERY 5000 KM. USE
OF STARTERS NOT CONFORMING OR SPARK
PLUGS NOT THOSE DESCRIBED CAN SERI­OUSLY DAMAGE THE ENGINE.

Characteristic

Spark plug

CHAMPION RN1C

Electric characteristic

Electrode gap

0.45 ÷ 0.55 mm

Locking torques (N*m)

Spark plug 25 - 30 Nm

Hub oil

MAIN - 6

NRG Power DD Maintenance

Check

Do the following to check the correct level:

1) Stand the vehicle on the centre-stand on flat
ground;

2) Remove the dipstick «A», and dry it with a clean
cloth. Reinsert it, screwing it in all the way;

3) Remove the stick and check that the oil level is
slightly over the second notch starting from the
lower end;

4) Screw the dipstick back in, checking that it is
locked in place.

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

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

Replacement

- Remove oil filler cap «A».

- Loosen oil draining cap «B» and allow for the
system to drain completely.

- Refit the draining cap and refill the hub with the
prescribed oil.

Characteristic

Rear hub oil

~ 85 cc

MAIN - 7

Maintenance NRG Power DD

Air filter

-Remove the cap of the purifier, unscrewing the six
clamping screws and removing the filter.
Cleaning:

-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.

-Let it dry and refit it again.

CAUTION

NEVER RUN THE ENGINE WITHOUT THE AIR
FILTER, THIS WOULD RESULT IN AN EXCES­SIVE WEAR OF THE PISTON AND CYLINDER.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased ad­hesiveness

transmissions

- Adjust the control cables:
Mix cable: see procedure indicated in "Mixer tim­ing".
Throttle cable: adjust the set screw on the carbu­rettor in such a way that the sheath has no back­lash.
Splitter control cable: adjust set screw on the throt­tle control to the handlebar in such a way that there
is no backlash on the throttle control.
Adjust all transmissions in such a way that their
sheathings show no sign of backlash.

Mixer Timing

- Using the transmission set screw on the crank­case, with throttle control untwisted, adjust the
reference mark on the rotating plate so that it is
lined up with the reference mark on the mixer
body, as shown in the figure.

MAIN - 8

NRG Power DD Maintenance

While doing this, the engine must be fuelled with a
2 % oil mixture (0.5 litre minimum if the reservoir
is empty).

CAUTION

IN CASE OF DISMANTLING OR RUNNING OUT
OF OIL IN THE RESERVOIR BLEED THE MIXER
AS FOLLOWS: REFILL THE OIL RESERVOIR
WHEN THE MIXER IS FITTED TO THE VEHICLE
AND THE ENGINE IS OFF, UNDO THE MIXER
PIPE FROM THE CARBURETTOR AND LOOS­EN THE BLEED SCREWS (SEE THE ARROW IN
THE FIGURE) UNTIL THE OIL BEGINS TO
FLOW OUT. TIGHTEN THE SCREWS, START
UP THE ENGINE AND WAIT FOR OIL TO FLOW
OUT OF THE TUBE. RECONNECT THE DELIV­ERY PIPE TO THE CARBURETTOR AND FIX IT
IN PLACE WITH THE RELEVANT METAL CLIP.

Recommended products

AGIP CITY TEC 2T Mixer oil

synthetic oil for 2-stroke engines: JASO FC, ISO­L-EGD

Braking system

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.

MAIN - 9

Maintenance NRG Power DD

Top-up

Proceed as follows:

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

CAUTION

ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.

CAUTION

MAKE SURE THE BRAKE FLUID DOES NOT
GET INTO YOUR EYES OR ON YOUR SKIN OR
CLOTHES. IF THIS HAPPENS ACCIDENTALLY,
WASH WITH WATER.

CAUTION

BRAKE CIRCUIT FLUID IS VERY CORROSIVE;
MAKE SURE THAT IT DOES NOT COME INTO
CONTACT WITH THE PAINTWORK.

CAUTION

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

N.B.

SEE THE BRAKING SYSTEM CHAPTER WITH
REGARD TO THE CHANGING OF BRAKE FLU­ID AND THE BLEEDING OF AIR FROM THE
CIRCUITS.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

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;

MAIN - 10

NRG Power DD Maintenance

2. Turn on the headlight and check that the bor-

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

CO check

In the event that the exhaust on the vehicle being
tested does not have an exhaust gases collection
port, proceed as follows:

- Remove the R.H. side fairing

- Remove the secondary air box cover with the
aluminium cap by acting upon the clamp shown in
the figure.

Attach the exhaust gas collection tube to the sec­ondary air rubber manifold. Such joint must be
sealed in order to guarantee accurate CO read­ings.

- Start the engine, adjust the idle speed to 1,700 ± 100 rpm and check the CO value is equal 3.5 ± 1%

- If the parameters found do not agree with the above figures, act upon the idle adjusting screw. Oth­erwise, check the automatic choke device

Specific tooling

020320Y Exhaust gases analyser
020332Y Digital rev counter

MAIN - 11

Maintenance NRG Power DD

The check must be carried out after having care­fully cleaned all carburettor components, with the
air filter clean, and the spark plug in good condi­tions.

- Remove the R.H. side fairing

- Warn-up the engine by riding the vehicle on the
road for at least 10 minutes

- Shut down the engine

- Remove the 2 secondary air box screws shown
in the figure

− Place a plastic sheet between the one-way valve
and the aluminium outlet as shown in the figure

− Ensure the one-way valve packing properly
seals the aluminium outlet fitting.

− Refit the aluminium outlet onto the SAS box as
shown in the picture.

- Attach the special tool and move the joints as
shown in the figure.

- Start the engine, adjust the idle speed to 1,700 ±
100 rpm and check the CO value is equal 3.5 ± 1%

- If the parameters found do not agree with the
above figures, act upon the idle adjusting screw.
Otherwise, check the automatic choke device.

Specific tooling

020320Y Exhaust gases analyser
020332Y Digital rev counter

MAIN - 12

NRG Power DD Maintenance

020625Y Kit for sampling gas from the exhaust
manifold

MAIN - 13

Maintenance NRG Power DD

MAIN - 14

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Troubleshooting NRG Power DD

This section makes it possible to find the solutions to use in troubleshooting.
For each breakdown, a list of the possible causes and respective interventions is given.

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

Defective fuel pump or damaged depression line Replace the pump or control lines

Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with com-

pressed air
Fuel filter on the tank outlet fitting dirty or clogged Clean the fitting filter
Excess of encrustations in the combustion cham-

ber

Lack of compression wear of the piston rings or

cylinder

Exhaust pipe clogged due to excessive encrusta-

tions

Air filter blocked or dirty Clean according to the procedure

Starter inefficient (stays on) Check the mechanical sliding, continuity of the cir-

Clutch slipping Check the centrifugal brake shoe assembly and /

Defective mobile pulley sliding Check the parts, change the faulty parts and lubri-

Transmission belt worn Replace

Roller wear; Presence of oil; Dirt Clean the speed variator, replace the rollers if worn

Replace the exhaust pipe and check the carbura-

cuit, the presence of power and electrical wiring

cate the driven pulley using only Montblanc-Mo-

Remove the encrustations

Check the worn parts and replace them

tion and mixer timer

or clutch bell and replace if necessary

libdenum Grease (dis. 498345) grease

out

Rear wheel spins at idle

REAR WHEEL

Possible Cause Operation

Idling rpms too high Check the idling speed and, if necessary, adjust

the C.O.

Clutch fault Check the spring/friction mass and the clutch bell

Air filter housing not sealed Correctly refit the filter housing and replace it if it

is damaged

Starting difficulties

DIFFICULTY STARTING

Possible Cause Operation

Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with com-

pressed air

Defective fuel pump or damaged depression line Replace the pump or control lines

TROUBL - 2

NRG Power DD Troubleshooting

Possible Cause Operation

Starter inefficient Check: electric wiring, circuit continuity, mechani-

cal sliding and power supply

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

sulphation replace it and bring the new battery into

service charging it for eight hours at a current of

1/10 of the capacity of the battery itself

- Engine flooded. Start up keeping the throttle fully open alternating
approximately five seconds of turning it with five

seconds still. If however it does not start, remove

the spark plug, the engine over with the throttle

open being careful to keep the cap in contact with

the spark plug and the spark plug grounded but

away from its hole. Refit a dry spark plug and start

the vehicle.

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

refill

Defective spark plug or with incorrect electrode

gap

Intake joint cracked or with a bad seal Replace the intake joint and check its tightness on

Purifier-carburettor fitting damaged Replace

Remove the encrustation, restore the plug gap or

replace being sure to use the types of spark plug
recommended at all times. Bear in mind that many
problems engines have, derive from the use of the

wrong spark plug

the crankcase and on the carburettor

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation

Excess of encrustations in the combustion cham-

ber

Engine tends to cut-off at full throttle

ENGINE STOP FULL THROTTLE

Possible Cause Operation

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

Dirty carburettor Wash the carburettor with solvent and dry with

Water in the carburettor Empty the tank through the appropriate bleed nip-

Air filter dirty Clean or replace

Defective floating valve Check the proper sliding of the float and the func-

Tank breather hole obstructed Restore the proper tank aeration

Remove the encrustations

pressed air

compressed air

ple.

tioning of the valve

TROUBL - 3

Troubleshooting NRG Power DD

Engine tends to cut-off at idle

ENGINE STOP IDLING

Possible Cause Operation

Minimum nozzle dirty Wash the nozzle with solvent and dry with com-

pressed air

Starter that stays open Check: electric wiring, circuit continuity, mechani-

cal sliding and power supply

Reed valve does not close Check / replace the reed pack

Wrong idling adjustment Correctly adjust the engine idling and check the

level of the C.O.

Spark plug defective or faulty Replace the spark plug with one with the specified

degree and check the plug gap

Excessive exhaust noise

INCREASED NOISINESS

Possible Cause Operation

Secondary metal air pipe deteriorated Check the seal of the piping on the crankcase and

on the housing, check the piping between the

housing and the muffler.

Good condition of the missing secondary air circuit

components

Check the individual components and the piping,

check the precision of the fitting. Replace the dam-

aged components

High fuel consumption

HIGH FUEL CONSUMPTION

Possible Cause Operation

Air filter blocked or dirty. Clean according to the procedure

Starter inefficient Check: electric wiring, circuit continuity, mechani-

cal sliding and power supply

Engine overheating

ENGINE OVERHEATING

Possible Cause Operation

Lack of liquid in the cooling circuit. Restore the level and check the absence of losses

from the circuit

Incorrect air bleeding Repeat the operation

Thermostat remains closed Replace

Liquid leak from the radiator Replace radiator

Liquid leak from the system Overhaul of the system

Coolant leaks from crankcase draining hole Replace coolant sealing ring on half-crankcase

from transmission-side

Bearings shaft support impeller blocked Replace the bearings and the shaft with impeller

Breakage of mixer belt Replace the belt and check that the thermal unit

has not been damaged

TROUBL - 4

NRG Power DD Troubleshooting

SAS malfunctions

SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-

FLER

Possible Cause Operation

Secondary air reed blocking Replace
Secondary air filter clogging Clean the filter and the housing

Blockage of the secondary air fitting on the muffler Remove the encrustations from the joint being

careful not to let the debris fall into the muffler

Transmission and brakes

Clutch grabbing or performing inadequately

CLUTCH

Possible Cause Operation

Tear or irregular functioning Check that the masses open and return normally

Check that there is no grease on the masses
Check that the clutch masses' contact surface with
the clutch bell is mainly in the middle with charac-

teristics equivalent on the three masses

Check that the clutch bell is not scored or worn

abnormally

Never operate the engine without the clutch bell

Insufficient braking

BRAKING SYSTEM MALFUNCTION

Possible Cause Operation

Poor braking The rear (drum type) brake is adjusted by regulat-

ing the special adjustment (on the wheel) bearing
in mind that, with the control levers in the rest po-

sition, the wheels must turn freely.

The braking action should begin when the brake

levers are pressed by about a third.

Check the brake pad wear.

If it is not possible to remove any problems by sim-

ply adjusting the transmissions, check the brake

pads and front brake disc, the brake shoes and the

rear drum. If you encounter excessive wear or

scoring, make the necessary replacements.

Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system,

(there must be no flexible movement of the brake

lever).

Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump break-

down, replace

The brake fluid has lost its properties Replace the front brake fluid and top up to the cor-

rect level in the pump

Defective sliding of the cables in their sheathes Lubricate or substitute

Brake noise Check the wear of the brake pads and/or shoes

TROUBL - 5

Troubleshooting NRG Power DD

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective piston sliding Check calliper and replace any damaged part.

Brake disc or drum deformed Using a dial gauge, check the planarity of the disk

with the wheel correctly fitted or the concentricity

of the rear drum.

Electrical system

Battery

BATTERY

Possible Cause Operation

Battery The battery is the electrical device in the system

that requires the most frequent inspections and

thorough maintenance. If the vehicle is not used

for some time (1 month or more) the battery needs

to be recharged periodically. The battery runs
down completely in the course of 5 ÷ 6 months. If
the battery is fitted on a motorcycle, be careful not
to invert the connections, keeping in mind that the
black ground wire is connected to the negative ter­minal while the red wire is connected to the termi­nal marked+. Follow the instructions in the ELEC­TRICAL SYSTEM chapter for the recharging of the

batteries.

Steering and suspensions

Rear wheel

POOR ROAD HOLDING

Possible Cause Operation

Faulty suspension Check that the rear shock absorber and/or the

Tyres deflated or damaged Check the correct pressure of the tyres and the

Loosen the anchorage points of the front and/or

rear suspension unit.

TROUBL - 6

front fork is/are in good working order. Replace or

overhaul the front fork and/or replace the rear

shock absorbers in case of malfunction

condition of the tread. Inflate to the correct pres-

sure or replace.
Check the tightness between the frame, swinging
arm and engine and the fixing of the wheels to the

hub and/or the axle. Check the correct tightening

of the steering ring nut.

NRG Power DD Troubleshooting

Heavy steering

STEERING HARDENING

Possible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring

nuts.

If irregularities continue in turning the steering

even after making the above adjustments, check

the seats in which the ball bearings rotate: replace

if they are recessed.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation

EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring

nuts.

If irregularities continue in turning the steering

even after making the above adjustments, check

the seats in which the ball bearings rotate: replace

if they are recessed.

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

Components of the front suspension damaged. Check the quiet operation in the compression or

release phases of the fork and if necessary over-

haul it. Check that there is no noise or seizing

during the wheel rotation; if there is, change the

wheel bearing.

Components of the rear suspension damaged. Check the absence of noise in the compression or

release of the suspension, if necessary check the

proper tightness to the swinging arm unit and the

absence of rust or replace the entire shock ab-

sorber. Check that there is no noise or seizing

during the wheel rotation; if there is noise or seiz-

ing overhaul the final reduction assembly.

Suspension oil leakage

SUSPENSION LEAKS OIL

Possible Cause Operation

Rear shock absorption malfunctioning Replace the complete shock absorption unit

Hydraulic cartridge in the fork damaged. Replace the hydraulic cartridge

TROUBL - 7

Troubleshooting NRG Power DD

TROUBL - 8

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system NRG Power DD

LEGENDA

Specification Desc./Quantity

1 Voltage regulator
2 Horn button
3 Turn signal switch
4 Light switch
5 Rear brake stop button
6 Front L.H. turn signal light
7 Front headlight
8 Two rear parking light bulbs 12V - 3W
9 Horn
10 Light bulb 12V - 35W for high-beam lamp
11 Light bulb 12V - 35W for low-beam lamp
12 Front R.H. turn signal light
13 Front brake stop light switch
14 Wheel rpm sensor
15 Starter button
16 Ignition key-switch
17 Fuel level sender

ELE SYS - 2

NRG Power DD Electrical system

Specification Desc./Quantity

18 Mixture oil warning light switch
19 Thermistor
20 Magneto flywheel
21 Control device ignition
22 Automatic starter
23 Starter motor
24 Taillight resistor
25 Rear R.H. turn signal light
26 Taillight assembly
27 Choke device continuity check light
28 Battery 12V - 4Ah
29 Rear L.H. turn signal light
30 License plate light pre-wiring
31 Fuse 7,5A
32 Starter remote control

Electrical cables color:
B = White, Bl = Blu, G = Yellow, Mr = Brown, N = Black, Gr = Gray,
Rs = Pink, R = Red, Vi = Purple, V = Green

Conceptual diagrams

Ignition

Specification Desc./Quantity

1 Electronic control unit
2 Magneto flywheel
3 Pick - up

IGNITION

ELE SYS - 3

Electrical system NRG Power DD

Specification Desc./Quantity

4 Key switch
5 Spark plug

Headlights and automatic starter section

LIGHTS AND AUTOMATIC CHOKE DEVICE

Specification Desc./Quantity

1 Flywheel magneto
2 Voltage regulator
3 Automatic starter
4 LED taillight
5 Digital instrument unit
6 Headlamp sidelight bulbs
7 Headlamp low-beam light bulb
8 Headlamp high-beam light bulb

ELE SYS - 4

NRG Power DD Electrical system

Battery recharge and starting

BATTERY RECHARGE AND STARTING

Specification Desc./Quantity

1 Flywheel magneto
2 Voltage regulator
3 Fuse 7,5A
4 Battery 12V-14Ah
5 Starter remote control
6 Starter motor
7 LED taillight
8 Ignition key-switch
9 Start up button
10 Stoplight switches
11 Mixture oil level sender

ELE SYS - 5

Electrical system NRG Power DD

Level indicators and enable signals section

SAFETY SWITCHES AND LEVEL GAUGES

Specification Desc./Quantity

1 Voltage regulator
2 Ignition key-switch
3 Fuse 7,5A
4 Battery 12V-14Ah
5 Starter button
6 Starter remote control
7 Starter motor
8 Stoplight switches
9 Fuel level sender
10 Coolant temperature sensor
11 Mixture oil level sender
12 Phonic wheel
13 Digital instrument unit

ELE SYS - 6

NRG Power DD Electrical system

Turn signal lights

TURN SIGNALS AND HORN

Specification Desc./Quantity

1 Voltage regulator
2 Ignition key-switch
3 Fuse 7,5A
4 Battery 12V-14Ah
5 Horn button
6 Horn
7 Turn signal lights
8 Turn signal switch
9 Digital instrument unit

Digital instrument panel

INSTRUMENT UNIT CONNECTOR

Specification Desc./Quantity

1 + Battery

ELE SYS - 7

Electrical system NRG Power DD

Specification Desc./Quantity

2 + permanent power supply
3 Earth
4 Grounding for phonic wheel
5 Power supply to phonic wheel
6 Phonic wheel signal
7 Instrument light and parking light indicator
8 Instrument temperature mass
9 Not connected
10 Rpm indicator signal
11 Instrument temperature signal
12 Fuel level sensor
13 High-beam warning light
14 + Right direction indicator
15 + Left direction indicator
16 Low-oil warning light
17 Low-fuel warning light
18 Not connected
19 Not connected
20 Not connected

Checks and inspections

Checks to be made in the case of ignition ir­regularities and/or no spark on the spark plug

1. Check the condition of the spark plug (clean
it with a metal brush, remove the encrusta­tions, blast it with compressed air and, if
necessary, replace it).

2. Without removing the stator, carry out the
following checks:

CHECK ON THE PICK UP

Specification Desc./Quantity

1 Red and white cable 90±140 ohm
After visually checking the electrical wiring, per­form measurements on the loading reel, the pickup
(see chart) and the continuity using the appropri­ate tester.
If checks on the loading reel, pickup and continuity
show abnormalities, replace the stator; otherwise
replace the central unit. Remember that discon­nections due to replacement of the central unit
must be done with the engine off.

Specific tooling

ELE SYS - 8

NRG Power DD Electrical system

020331Y Digital multimeter

CHECKING THE RECHARGE COIL

Specification Desc./Quantity

1 White/green cable 800±1100 ohm

CHECK CONTINUITY

Specification Desc./Quantity

1 White cable-frame continuity
2 White cable-engine continuity

Ignition circuit

All the control operations of the system that require
the disconnection of cables (checks of the con­nections and the devices making up the ignition
circuit) must be done with the engine off: if this is
not done, the controls might be irreparably dam­aged.

Stator check

- Using a tester, check the resistance between the
brown-earth and black-earth terminal.

N.B.

VALUES ARE STATED AT AMBIENT TEMPER­ATURE. A CHECK WITH THE STATOR AT OP­ERATING TEMPERATURE LEADS TO VALUES
HIGHER THAN THOSE STATED.

Electric characteristic

Stator : Brown-earth

approx. 170 Ω (Pick-Up)

Stator : Black-earth

~ 1 Ω (Stator)

Voltage regulator check

The fault to the voltage regulator may cause, according to the type of fault, the following inconvenients:

1. Bursting of head and taillight bulbs.

2. Head and taillight not operational.

3. Excessive battery recharge (bursting of main fuse).

ELE SYS - 9

Electrical system NRG Power DD

4. Battery not recharging.

5. Turn signals not operational.

6. Dashboard check not operational.

Interventions
FAULT 1

Replace the regulator as definitely faulty.

FAULT 2

a) Check the output from the stator gives the cor­rect voltage: detach the stator connector, inter­pose an AC tester between the grey-blue and
black cables, and check the output voltage is with­in the prescribed limits. If anomalies are found,
replace the stator.
b) If no anomalies are identified, replace the reg­ulator.
c) If the replacement of the regulator does not
solve the fault, check the electric connections.

Specific tooling

020331Y Digital multimeter

Characteristic

Voltage distributed at 3000 rpms

25 to 30V

FAULT 3

After checking that there are no short circuits in the
system towards the earth, replace the regulator
because it is certainly inefficient and replace it with
a protective fuse.
Following the replacement, measure the current
and the recharging voltage on the battery end.

ELE SYS - 10

NRG Power DD Electrical system

FAULT 4

a) Interposing the AC tester between the black and
yellow cables on the regulator, check the genera­tor output voltage is within the prescribed values
(this measurement must be carried out with the
battery detached). In the event of anomalies, re­place the stator; otherwise proceed to point b).
b) Insert an ammeter between the stator (blue ca­ble) and the battery and check with the tester that
the current output, at 3,000 rpm and with the bat­tery kept between 12 and 13V, is as shown. If the
values thus obtained are lower than prescribed,
proceed by replacing the regulator.

N.B.

BEFORE CARRYING OUT THE CHECKS ON
THE REGULATOR AND RELATIVE SYSTEM, IT
IS ALWAYS GOOD PRACTICE TO CHECK
THAT THERE IS CONTINUITY BETWEEN THE
BLACK CABLE AND THE GROUND.

N.B.

TO KEEP THE BATTERY BETWEEN 12 AND
13V, CAUSING CURRENT ABSORPTION BY
THE SYSTEM, A 12V - 35W BULB CONNECTED
BETWEEN THE + BATTERY AND GROUND
CAN BE USED.

Specific tooling

020331Y Digital multimeter

Characteristic

Voltage output at 300 rpm

26÷30V

Distributed current

1.5 to 2A

FAULT 5

In the event that the turn signal lights are not op­erational, proceed as follows:

•

Remove the regulator connector and
insert the tester terminals between pin
5 and ground.

•

Turn the ignition switch onto ON and
check for battery voltage. If no voltage

ELE SYS - 11

Electrical system NRG Power DD

is found, check wiring and terminals on
key-switch and battery.

•

Repeat the same procedure with the
ends of the tester inserted between
contact 5 (+) and 6 (-) and check the
presence of the battery voltage with the
key switch at on. If this does not hap­pen, check the regulator's ground ca­ble.

•

If the checks given above are unsuc­cessful, jump pins 5 and 7 on the con­nector, turn the key-switch onto ON
and turn the turn signal switch alter­nately from left to right to visualize the
continuous operation of the lights (as
powered directly by the battery). If the
lights do not go on, check the switch
and its cable, if these are not damaged
or faulty; replace the regulator as defi­nitely faulty.

Specific tooling

020331Y Digital multimeter
FAULT 6

Dashboard check light does not go on. Detach the
connector to the voltage regulator.

•

Apply a tension of 12V to the pin
marked with the number 5, check, us­ing the digital tester; there is an equiv­alent output (12V) from pin 3 for at least
5 seconds.

•

If pins no. 4 and/or no. 3 give no output
voltage, replace the regulator.

•

If pin no. 3 gives output voltage, check
the system and the low-oil or low-fuel
warning lights.

Specific tooling

ELE SYS - 12

NRG Power DD Electrical system

020331Y Digital multimeter

Fuses

The electrical system is protected by a fuse loca­ted on the r.h.s. of the battery bay. To replace it,
lift the seat, remove the battery access door and
then the transparent fuse cover. Ignition system,
headlight, and taillight are not protected by the
fuses.

CAUTION

BEFORE REPLACING THE BLOWN FUSE,
SEARCH AND ELIMINATE THE BREAKDOWN
THAT HAS LED TO THE BLOW OUT.
NEVER TRY TO REPLACE A FUSE USING DIF­FERENT MATERIAL (FOR EXAMPLE A PIECE
OF ELECTRIC WIRE) OR A FUSE FOR A HIGH­ER AMPERAGE THAN THE INDICATED ONE.

Electric characteristic

Fuse

7.5 A

Sealed battery

Putting the sealed battery into service

INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT

1) Voltage check

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

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

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

2) Constant voltage battery charge mode

-Constant voltage equal to 14.40÷14.70V

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

-Duration of the charge: 10 to 12 h recommended
Minimum 6 h
Maximum 24 h

3) Constant current battery charge mode

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

-Duration of the charge: 5 h

WARNING

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF
RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.

ELE SYS - 13

Electrical system NRG Power DD

IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON­TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Dry-charge battery

WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON­TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF
COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP­PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF REACH OF CHILDREN

Use of dry-cell batteries :

1. Having removed the short, closed tube and removed the caps, put into the elements sulphuric
acid of the type for specific weight 1.26 accumulators corresponding to 30° Bé at a temperature
of no less than 15°, until you reach the upper level.

2. Leave to stand for at least 2 hours; afterwards top-up to the level with sulphuric acid.

3. Within twenty four hours, recharge with the special (single or multiple) battery charger that re­charges at an intensity the same as approximately 1/10 the rated capacity of the said battery. At
the end of the charge, make sure that the density of the acid is around 1.27, corresponding to 31°
Bé and that these values are stabilised.

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

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

WARNING

- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE

THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE­SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO
ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

Specific tooling

020333Y Single battery charger
020334Y Multiple battery charger

ELE SYS - 14

NRG Power DD Electrical system

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

Battery maintenance

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

1) Check the level of the electrolyte

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

2)Load status check

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

3) Recharging the battery

Remove the battery from the vehicle removing the negative clamp first.
The normal bench charging must be carried out with the specific (single or multiple) battery charger,
placing the battery charger selector on the type of battery to be recharged. The connections to the power
supply must be made by connecting to the corresponding poles (+ with+ and -with -).

4) Battery cleaning

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

WARNING

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

CAUTION

ELE SYS - 15

Electrical system NRG Power DD

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

CAUTION

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

CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST
USED SHORTENS THE LIFE OF THE BATTERY.

Specific tooling

020334Y Multiple battery charger
020333Y Single battery charger

ELE SYS - 16

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle NRG Power DD

Removal of the engine from the vehicle

1. Detach the battery.

2. Remove the exhaust assy.

3. Remove the rear wheel.

4. Remove the rear brake cable.

5. Detach the electrical connection to the fly­wheel.

6. Detach the throttle and mixer cables.

7. Detach the mixture oil, fuel, and vacuum
pump outlet tubing.

8. Detach the H.T. cable from the spark plug.

9. Remove the rear shock-absorber fixing bolt
from the engine.

10.Remove the nut on the l.h.s., and hence re­move the engine - swing-arm fixing bolt.

Locking torques (N*m)

Engine-swinging arm bolt 33 ÷ 41 Shock ab­sorber-engine pin 33 to 41 Nm Rear wheel axle
nut 104 ÷ 126

ENG VE - 2

INDEX OF TOPICS

ENGINE ENG

Engine NRG Power DD

Automatic transmission

Transmission cover

- Loosen the 15 screws and remove the transmis-

sion cover with the aid of a mallet.

N.B.

THE CRANKCASE IS SLIGHTLY BLOCKED BY
THE TIGHT FIT BETWEEN THE SHAFT OF THE
DRIVEN HALF-PULLEY AND THE BEARING
HOUSED ON THE CRANKCASE.

Kickstart

- Remove the seeger ring located on the exterior

of the crankshaft.

- Dismantle the dog gear from its seat, slackening

the tension that the toothed sector applies to it by
means of the spring; to do this, it is necessary to
rotate the toothed sector slightly (see the figure).

CAUTION

WHILE REMOVING THE TOOTHED SECTOR,
BE VERY CAREFUL OF THE SPRING TEN­SION: IT COULD CONSTITUTE A HAZARD FOR
THE OPERATOR.

- Remove the screws shown in the figure and re-

move the engine starting lever.

- For the assembly, work in reverse and tighten the

screws to the prescribed torque..

Locking torques (N*m)

Starter lever replacement 12 to 13 Nm

ENG - 2

NRG Power DD Engine

- Upon refitting, apply the recommended grease to
the bushing, to the spring and along the toothed
sector.

- Use the special tool for the charging of the spring,
as shown in the figure.

- Refit the seeger ring after checking that it is in
good condition.

Specific tooling

020261Y Starter spring fitting

Recommended products

AGIP GREASE MU3 Grease for odometer
transmission gear case

Soap-based lithium grease with NLGI 3; ISO-L­XBCHA3, DIN K3K-20

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side
to avoid damaging the coated surface and use the
driven pulley shaft or a pin of the same diameter
to remove the bearing.

N.B.

IN CASE OF DIFFICULTY A STANDARD 8MM­INSIDE DIAMETER EXTRACTOR CAN BE
USED.

Refitting the driven pulley shaft bearing

-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.

N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.

CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED
SURFACE.

ENG - 3

Engine NRG Power DD

Removing the driven pulley

- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the

whole of the driven pulley assembly.

N.B.

THE UNIT CAN ALSO BE REMOVED WITH THE
DRIVE PULLEY MOUNTED.

Specific tooling

020565Y Flywheel lock calliper spanner

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the inner diameter of the clutch bell.

Characteristic

Clutch bell diameter/standard value

Ø 107+0.2 +0 mm

Clutch bell diameter/max. value allowed after
use

Ø 107.5 mm

Eccentricity measured /max.

0.20 mm

Removing the clutch

- Equip the tool with long pins screwed into position

«A» from the outside, insert the entire driven pulley
in the tool and put the central screw under stress.

CAUTION

THE TOOL WILL BE DEFORMED IF THE CEN­TRAL SCREW IS TIGHTENED UP TOO FAR.

ENG - 4

NRG Power DD Engine

- Using a 34 mm socket wrench remove the clutch
locking nut.

- Loosen the central screw thereby undoing the
driven pulley unit

- Separate the components.

Specific tooling

020444Y Tool for fitting/ removing the driven
pulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction
material.

- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.

N.B.

UPON RUNNING-IN, THE MASSES MUST EX­HIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE AN­OTHER.
VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.

CAUTION

DO NOT OPEN THE MASSES USING TOOLS
TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.

Characteristic

Check minimum thickness

1 mm

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

ENG - 5

Engine NRG Power DD

- Remove the three guide pins and the mobile half

pulley.

Removing the driven half-pulley bearing

- Remove the roller bearing with the special ex-

tractor inserted from the bottom of the fixed half­pulley.

CAUTION

POSITION THE HOLDING EDGE OF THE EX­TRACTION PLIERS BETWEEN THE END OF
THE BEARING AND THE BUILT IN SEALING
RING.

Specific tooling

001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch

housing by means of the special tool.

N.B.

PROPERLY SUPPORT THE HALF-PULLEY SO
AS NOT TO DEFORM THE SLIDING SURFACE
OF THE DRIVING BELT

Specific tooling

020376Y Adaptor handle
020363Y 20 mm guide

ENG - 6

NRG Power DD Engine

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work
surface of the belt. If there are, replace the half­pulley..

- Make sure the bearings do not show signs of un­usual wear.

- Measure the external diameter of the pulley bush­ing.

Characteristic

Stationary driven half-pulley/Standard diame­ter

Ø 33.965 to 33.985 mm

Stationary driven half-pulley / Minimum diam­eter admitted after use

Ø 33.96 mm

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two O­rings.

- Measure the inside diameter of the mobile half­pulley bushing.

Characteristic

Mobile driven half-pulley/ Maximum diameter
allowed

Ø 34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile
half-pulley.

- Fitting the half-pulley on the bushing.

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel
revolving ring

Soap-based lithium grease containing NLGI 2 Mo­lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20

- Make sure the pins and collar are not worn, reassemble the pins and collar.

ENG - 7

Engine NRG Power DD

- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This
operation must be done through one of the holes inside the bushing until grease comes out of the
opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel revolving ring

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible

from the outside.

CAUTION

PROPERLY SUPPORT THE HALF-PULLEY TO
PREVENT DAMAGE TO THE THREADED END
WHILE THE BEARINGS ARE BEING FITTED.

Specific tooling

020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020362Y 12 mm guide
020171Y Punch for Ø 17 mm roller case

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley

does not show signs of deformation

- Measure the free length of the spring

Characteristic

Standard length

118 mm

Minimum length allowed after use

XXXX

ENG - 8

NRG Power DD Engine

Refitting the clutch

- Preassemble the driven pulley group with spring,
sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the
spring being careful not to damage the plastic
sheath and the end of the threaded bar.

- Reassemble the nut securing the clutch and tight­en to the prescribed torque.

CAUTION

SO AS NOT TO DAMAGE THE CLUTCH NUT
USE A SOCKET WRENCH WITH SMALL
CHAMFER.

CAUTION

POSITION THE NON-CHAMFERED SURFACES
OF THE NUT IN CONTACT WITH THE CLUTCH

Locking torques (N*m)

Nut locking clutch unit on pulley 55 ÷ 60 Nm

Refitting the driven pulley

-Refit the driven pulley assembly, the clutch bell
and the nut, using the specific tool.

Specific tooling

020565Y Flywheel lock calliper spanner

Locking torques (N*m)

Driven pulley shaft nut 40 to 44 Nm

ENG - 9

Engine NRG Power DD

Drive-belt

- Make sure the driving belt is not damaged and

does not have cracks in the toothed grooves.

- Check the width of the belt.

Characteristic

Transmission belt/Minimum width

17.5 mm

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer,

then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the
rollers and contrast plate fitted loosely on it do not come off.

Specific tooling

020451Y Start-up crown lock

Mixer gears and belt

- Remove gear and belt.

CAUTION

PAY PARTICULAR ATTENTION TO NOT
TOUCHING OR BENDING THE BELT BE­CAUSE THIS COULD BREAK SUDDENLY DUR­ING OPERATION.

CAUTION

ON REFITTING, MAKE SURE THAT DIRT DOES
NOT GET INTO THE INNER BUSHING OF THE
MIXER CONTROL GEAR AND THAT IT DOES
NOT EXERT ANY STRESS ON THE CRANK­CASE PIN.

N.B.

REPLACE THE BELT EVERY 20000 KM.

ENG - 10

NRG Power DD Engine

Inspecting the rollers case

1) Check that the bushing and the sliding rings of
the mobile pulley do not show signs of scoring or
deformation.

2) Check the roller running tracks on the contact
pulley; there must not be signs of wear and check
the condition of the contact surface of the belt on
the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of
marked facetting on the sliding surface and that
the metallic insert does not come out of the plastic
shell borders.

4) Check the integrity of the sliding blocks of the
contact plate.

- Check that the internal bushing shown in the fig­ure is not abnormally worn and measure inside
diameter «A».

- Measure outside diameter «B» of the pulley slid­ing bushing shown in the figure.

CAUTION

DO NOT LUBRICATE OR CLEAN THE BUSH­ING.

Characteristic

Driving pulley / Maximum diameter:

20.12 mm

Driving pulley/ Standard diameter:

20.021 mm

Driving pulley bushing/ Diameter maximum:

XXX mm

Driving pulley bushing/ Standard diameter:

20 -0.020/-0.041mm

ENG - 11

Engine NRG Power DD

Refitting the driving pulley

- Manually move the mobile driven half-pulley

away pulling it towards the clutch unit and insert
the belt repeating the direction of rotation of the
first fitting.

N.B.

IT IS GOOD PRACTICE ALWAYS TO FIT THE
BELT SO THE WORDING CAN BE READ, IN
THE CASE THAT THIS DOES NOT SHOW A
FITTING SIDE.

- Refit the particular components of the assembly

(roller container assembly with bushing, limiting
washer, stationery half-pulley, cooling fan belt with
drive, washer and nut).

- Tighten the lock nut to torque 20 Nm and then

perform a final 90° lock preventing the rotation of
the drive pulley with the specific tooling.

N.B.

REPLACE THE NUT WITH A NEW ONE AT EV­ERY REFIT

CAUTION

IT IS MOST IMPORTANT WHEN FITTING THE
DRIVING PULLEY UNIT THAT THE BELT IS
FREE INSIDE IN ORDER TO AVOID MAKING A
WRONG TIGHTENING WITH THE POSSIBLE
LATER DAMAGE OF THE CRANKSHAFT
KNURLING.

Specific tooling

020451Y Start-up crown lock

Locking torques (N*m)

Crankshaft pulley nut 18 to 20 + 90° N.m

End gear

ENG - 12

NRG Power DD Engine

Removing the hub cover

• Remove the transmission cover

• Remove the clutch assembly

• Discharge the rear hub oil.

• Remove the 5 screws indicated in the figure.

• Remove the hub cover with driven pulley shaft.

See also

Refitting the clutch

Removing the wheel axle

- Remove the intermediate gear and the complete
gear wheel axle.

- When removing the intermediate gear pay atten­tion to the various shim adjustments.

Removing the wheel axle bearings

- Remove the oil seal and the seeger ring.

- Remove the bearing by pushing from the outside
towards the inside of the gear compartment, using
the appropriate punch.

Specific tooling

020363Y 20 mm guide
020376Y Adaptor handle
020358Y 37x40-mm adaptor

ENG - 13

Engine NRG Power DD

Removing the driven pulley shaft bearing

- Remove the seeger ring inside the cover.

- Remove the oil seal from the outside.

- Remove the centring dowels and position the

cover on a plane.

- Position the special tool on the internal track of

the bearing and remove said bearing with the aid
of a press.

Specific tooling

020452Y Tube for removing and refitting the
driven pulley shaft

- Position the special tube on the internal raceway

of the bearing and from the shaft toothed side as
indicated in the figure. Expel the driven pulley shaft
with the aid of a press.

Specific tooling

020452Y Tube for removing and refitting the
driven pulley shaft

Inspecting the hub shaft

- Check that the three shafts exhibit no wear or

deformation on the toothed surfaces, at the bear­ing housings and at the oil guards.

- In case of anomalies, replace the damaged com-

ponents.

- Check that the fitting surface is not dented or dis-

torted.

- If faults are found, replace the hub cover.

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.

ENG - 14

NRG Power DD Engine

Refitting the driven pulley shaft bearing

- Support the inner track of the bearing from the
outside of the hub cover with the specific tool posi­tioned under the press and insert the driven pulley
axle.

- Refit the oil seal flush with the cover.

Specific tooling

020452Y Tube for removing and refitting the
driven pulley shaft

• Heat the hub cover and insert the bearing with
the specific punch.

• Fit the snap ring with the concave or radial part
on the bearing side.

N.B.

FIT THE BALL BEARING WITH THE SHIELD
FACING THE OIL SEAL.

Specific tooling

020151Y Air heater
020376Y Adaptor handle
020439Y 17 mm guide
020358Y 37x40-mm adaptor

Refitting the wheel axle bearing

- Heat the half crankcase on the transmission side
using a thermal gun.

- After lubricating its outer strip, insert the bearing
with the special adapter with the aid of a hammer.

- Refit the seeger ring and the oil seal using the 42
x 47 mm adapter and the handle.

Specific tooling

020151Y Air heater
020376Y Adaptor handle
020363Y 20 mm guide
020359Y 42x47-mm adaptor

ENG - 15

Engine NRG Power DD

Refitting the ub cover

- Refit the whole wheel axle.

- Refit the intermediate gear paying attention to the

two shim thicknesses.

- Apply LOCTITE 510 for surfaces to the hub cov-

ers and refit the same with driven pulley shaft.

- Refit the 5 screws and tighten them to the speci-

fied torque.

N.B.

CLEAN THE CONTACT SURFACES OF THE
HUB COVER AND THE HALF CRANKCASE OF
RESIDUE FROM PREVIOUS GASKETS BE­FORE APPLYING A NEW ONE.

Locking torques (N*m)

Locking torque: 11 to 13 Nm

Flywheel cover

Removing the stator

- Remove the three stator fixings shown in the

photo

- Remove the two pick-up fixings shown in the

photo

- Remove the stator with the wiring

ENG - 16

NRG Power DD Engine

Refitting the stator

- Refit the stator and flywheel proceeding in the
inverse direction, tightening the studs to the pre­scribed torque.

THREAD THE CABLE OF THE STATOR INTO
THE SPECIFIC HOUSING OF THE CRANK­CASE AND MAKE SURE THAT IT IS LOCKED
BY THE TAB OF THE RETURN LINE OF THE
COOLING SYSTEM.

Locking torques (N*m)

Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4

Refitting the flywheel cover

•

Fit the rubber seal on the flywheel con­nector and around the inlet coolant
hose.

•

Keeping the flywheel connector rubber
clamp on the coolant inlet hose, refit
the flywheel cover paying attention in
inserting the strap in the groove.

•

Tighten the 4 studs, noting that the two
longer golden screws are inserted in
the 2 top holes and are also responsi­ble for restraining the secondary air­box.

Flywheel and starting

ENG - 17

Engine NRG Power DD

Removing the starter motor

•

Remove the center stand by unscrew­ing the four clamping screws (two per
side) of the engine block

•

R

emove the two clamps shown in the figure

Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper

spanner.

- Remove the nut.

CAUTION

THE USE OF A CALLIPER SPANNER OTHER
THAN THE ONE SUPPLIED COULD DAMAGE
THE STATOR COILS

- Extract the flywheel with the extractor.

Specific tooling

020565Y Flywheel lock calliper spanner
020162Y Flywheel extractor

ENG - 18

NRG Power DD Engine

Inspecting the flywheel components

- Check the condition of the flywheel and any dis­tortions that might cause rubbing on the stator and
on the Pick-Up.

Refitting the flywheel magneto

- Fit the flywheel being careful to insert the key
properly.

- Lock the flywheel nut at the prescribed torque

- Check the Pick-Up air gap.

- The air gap may not be modified in the fitting of
the Pick-Up.

- Other values derive from deformations visible on
the Pick-Up support.

N.B.

A VARIATION OF THE AIR GAP DISTANCE
CAN LEAD TO A VARIATION IN THE IGNITION
ADVANCE SUCH AS TO CAUSE PINGING,
KNOCKING ETC.

Locking torques (N*m)

Flywheel nut 40 to 44 N.m

Refitting the starter motor

- Fit a new O-ring on the starter and lubricate it.

- Fit the starter on the crankcase, locking the two
screws to the prescribed torque.

N.B.

REFIT THE REMAINING PARTS AS DESCRI­BED IN THE CYLINDER HEAD, TIMING, LUBRI­CATION, FLYWHEEL AND TRANSMISSION
CHAPTERS.

Locking torques (N*m)

Starter motor screws 11 ÷ 13

ENG - 19

Engine NRG Power DD

Cylinder assy. and timing system

Removing the intake manifold

Use an anti-tampering TORX spanner to remove
the two clamping screws of the intake manifold

Removing the cylinder head

Remove the 4 screws shown in the figure

Removing the cylinder - piston assy.

Remove the cylinder very carefully

ENG - 20

NRG Power DD Engine

Remove the snap rings and remove the pin

CAUTION

AFTER EACH REMOVAL OPERATION RE­PLACE THE PIN RETENTION SNAP RINGS

Inspecting the small end

- Measure the internal diameter of the small end
using an internal micrometer.

N.B.

IF THE DIAMETER OF THE ROD SMALL END
EXCEEDS THE MAXIMUM DIAMETER AL­LOWED, SHOWS SIGNS OF WEAR OR OVER­HEATING REPLACE THE CRANKSHAFT AS
DESCRIBED IN THE "CRANKCASE AND
CRANKSHAFT" CHAPTER".

Characteristic

Rod small end: standard diameter

17 +0.011-0.001

Rod small end: maximum allowable diameter

17,060 mm

Inspecting the wrist pin

- Check the wrist pin external diameter using a mi­crometer

Characteristic

Wrist pin: standard diameter

12 +0.005 +0.001 mm

ENG - 21

Engine NRG Power DD

Inspecting the piston

- Measure the bearings on the piston using a bore

meter

- Calculate the piston-pin coupling clearance.

Characteristic

Wrist pin housing: standard diameter

12 +0.007 +0.012

Wrist pin housing: standard clearance

0.002 ÷ 0.011 mm

- Measure the outer diameter of the piston, per-

pendicular to the pin axis.

- Take the measurement in the position shown in

the figure
To classify the cylinder-piston fitting, check the ap­propriate table

See also

Cylinder - piston assy.

Inspecting the cylinder

- Check that the cylinder does not show seizures.

Otherwise, replace it or adjust it respecting the al­lowable increases

- Measure the internal diameter of the cylinder with

a bore meter, according to the directions given in
the figure

- Check that the fitting surface with the head is not

dented or distorted.
To classify the cylinder-piston fitting, check the ap­propriate table

See also

Cylinder - piston assy.

ENG - 22

NRG Power DD Engine

Inspecting the piston rings

- Alternatively insert the two sealing rings in the
cylinder
Using the piston, insert the seals perpendicularly
to the cylinder axis.

- Measure the opening of the sealing rings using a
thickness gauge as shown in the photograph

- If the values are higher than the values prescri­bed in the chart, substitute the rings

Removing the piston

- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.

-Push detail 2 into detail 1 until the stop and extract detail 2.

- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3
all the way in.

N.B.

REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM
THE REMOVAL OPERATIONS

Specific tooling

020166Y Pin lock fitting tool

Locking torques (N*m)

Locking head nuts: 10 to 11 N·m

- Use new wrist pin snap rings.

- Use new cylinder base gasket.

- Before refitting carefully clean all the surfaces.

- Use oil to be mixed during the fitting of the piston
and the cylinder.

CAUTION

POSITION THE ARROW PRINTED ON THE PIS­TON CROWN TOWARDS THE EXHAUST
OPENING.
THE WRIST PIN SNAP RINGS MUST BE POSI­TIONED ON THE PISTON WITH THE SPECIFIC
TOOL

Recommended products

AGIP CITY TEC 2T Oil

Recommended oil

ENG - 23

Engine NRG Power DD

Inspecting the timing system components

CAUTION

CHECK THE CORRECT REED UNIT SEAL; NO
LIGHT MUST PASS BETWEEN THE SUPPORT
AND LAMELLA.

Crankcase - crankshaft

ENG - 24

NRG Power DD Engine

Splitting the crankcase halves

Remove the eight crankcase union fasteners.

Install the special strip on the half crankcase on
the flywheel side and separate the half crankcase
on the flywheel side from the transmission side

Specific tooling

020163Y Crankcase splitting plate

Removing the crankshaft

- Install the specific tool on the half crankcase on
the transmission side using four M6 screws of an
adequate length.

- Remove the crankshaft from the transmission
side half crankcase

Specific tooling

020163Y Crankcase splitting plate

ENG - 25

Engine NRG Power DD

Removing the crankshaft bearings

The bearings can stay on either the half crankcase
or the crankshaft indifferently

- Using the special tool, remove any bearings that

have been left on the crankshaft

N.B.

The half rings must be inserted on the bearings
with a few mallet blows.

Specific tooling

004499Y001 Bearing extractor bell
004499Y006 Bearing extractor ring
004499Y002 Bearing extractor screw
004499Y007 Half rings

- Using the specific tool remove any bearings left

on the half crankcase

Specific tooling

001467Y007 Driver for OD 54 mm bearing
001467Y006 Pliers to extract 20 mm bearings

Refitting the crankshaft bearings

Heat the bearings in an oil bath at around 150°C
and fit them on the crankshaft, if necessary using
a section of tube that acts on the bearing's inner
track

Specific tooling

020265Y Bearing fitting base

ENG - 26

NRG Power DD Engine

Inspecting the crankshaft alignment

With the specific tool shown check that the eccen­tricity of the surfaces of diam. «A»-«B»-« C» are
within 0.03 mm. (reading limit on the dial gauge);
in addition, check the eccentricity of diam. «D», for
which a maximum reading of 0.02 mm is permitted.
In the case where eccentricity is not much above
prescribed levels, straighten the shaft by acting
on the counterweights with a shim or tighten them
in a clamp (with an aluminium bushing) as re­quired..

Specific tooling

020335Y Magnetic support for dial gauge
020074Y Support base for checking crankshaft

alignment

Refitting the crankshaft

- Position the transmission side half crankcase on
two wooden supports

- Using a thermal gun, heat the bearing seat to
about 120°

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Engine NRG Power DD

- Firmly insert the crankshaft until the bearing rea­ches the end-of-stroke stop

- Let the temperature of the half crankcase settle
at the temperature of the crankshaft.

- Again install the special crankcase separation
plate NOT installing the crankshaft protection

- During the assembly phase keep the central
thrust screw loose.

- Take the four clamping screws to the end of the

stroke and loosen them again with the same angle

(e.g. 90°)

- When the temperature has settled, preload the

thrust screw of the tool manually until the ball bear-

ing clearance is cancelled out.

Specific tooling

020163Y Crankcase splitting plate

Refitting the crankcase halves

- Prepare the coupling surface with LOCTITE 510
applying a thin layer of it after degreasing the sur­face using a suitable solvent (e.g. trichloroethy­lene)

- Heat the flywheel-side half crankcase with a ther­mal gun.

Recommended products

Loctite 510 Liquid sealant

Gasket

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NRG Power DD Engine

- Keeping the half crankcase on the transmission
side, insert the flywheel side half crankcase with a
clean precise movement

- Insert at least three clamping screws and tighten
up rapidly

- Insert the other 5 screws and tighten them to the
specified torque.

Locking torques (N*m)

crankcase coupling screws 11 - 13

- Move the crankcase separation plate in a position
back from the one indicated in the figure

- Install the special magnetic support with dial
gauge at the end of the crankshaft

- Check the axial clearance of the crankcase
If this is not within the maximum limit allowed, re­peat the crankcase coupling procedure

Specific tooling

020335Y Magnetic support for dial gauge

Characteristic

Axial clearance with warm crankcase

0.10 ÷ 0.12 mm

Axial clearance with cold crankcase

0.06 to 0.08 mm

Limit value with cold crankcase

0.02 ÷ 0.03 mm

Lubrication

Crankshaft oil seals

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Engine NRG Power DD

Refitting

- Install a new flywheel-side oil seal only with the
special tool's punch
The flywheel-side oil seal is recognised by its
smaller diameter

N.B.

THE USE OF THE SPECIFIC TOOL IS NOT
COMPATIBLE WITH THE FITTED WRENCH

Specific tooling

020340Y Flywheel and transmission oil seals
fitting punch

- Install a new transmission side oil seal using the
special tool with adapter ring.
The transmission-side oil seal is recognised by the
larger diameter

Specific tooling

020340Y Flywheel and transmission oil seals
fitting punch

Oil pump

Removal

- Remove the 2 screws shown in the figure

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NRG Power DD Engine

Remove the tube passage seal from the crank­case shown in the figure

Refitting

To refit, perform the steps in the reverse direction
to disassembly
Remember to drain after refitting using the screw
shown in the figure

Fuel supply

The vehicle comes with a membrane pump con­trolled by the depression that is generated in the
intake manifold. Therefore, the tank has an intake
in the lowest point that sends the fuel to the pump
and from here to the carburettor.
To determine the correct functioning of the pump,
the following measurements can be made on the
amounts distributed:

1) Start up the engine, bring it to normal operating
temperature and then shut it off.

2) Disconnect the fuel adduction line on the car­burettor and insert it into a graduated tube.

3) Start up the engine without the accelerator and
keep it idle.

4) After the engine is started, count to 10 and then
turn it off.

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Engine NRG Power DD

5) Check that the quantity of fuel is not less than
the prescribed value.

Characteristic

Fuel distributed

~100cc X 10"

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