VESPA PRIMAVERA 125, PRIMAVERA 150 Service Station Manual

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SERVICE STATION MANUAL

1Q000118 EN

Vespa Primavera125 - 150 i.e. 3Valvole (2013)

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SERVICE STATION

MANUAL

Vespa Primavera125 - 150 i.e. 3Valvole

(2013)

The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the

product or which are required for manufacturing or construction reasons.

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

model should be checked at the official PIAGGIO sales network.

in part is prohibited.

Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy

www.piaggio.com

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SERVICE STATION MANUAL

Vespa Primavera125 - 150 i.e.

3Valvole (2013)

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.

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

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

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

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

injury.

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

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

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INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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This section describes the general specifications of the vehicle.

Rules

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

Safety rules

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

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

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

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

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

Maintenance rules

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

- Use only the appropriate tools designed for this vehicle.

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

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

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

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle.

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

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Vehicle identification

VEHICLE IDENTIFICATION 125

Specification Desc./Quantity

Chassis prefix ZAPM81100

Engine prefix M811M

VEHICLE IDENTIFICATION 150

Specification Desc./Quantity

Chassis prefix ZAPM81200

Engine prefix M812M

VEHICLE IDENTIFICATION USA-CND

Specification Desc./Quantity

Chassis prefix ZAPM818G

Engine prefix M812M

Chassis number

The chassis number «A» is stamped near the fuel tank. To read it, proceed as follows:

- lift the saddle;

- lift the helmet compartment by removing it.

Engine number

The engine number «B» is stamped near the rear left shock absorber lower support.

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Dimensions and mass

WEIGHT AND DIMENSIONS

Specification

Desc./Quantity

Length 1860 mm (73.23 in)

Width 735 mm (28.94 in)

Height 1145 mm (45.08 in)

Wheelbase 1340 mm (52.76 in)

Kerb weight 118 ± 5 kg

Kerb weight versions USA-CND 264 lb.

Maximum weight limit 305 kg

Maximum weight limit versions USA-CND 727 lb.

Engine

125 CM³ ENGINE SPECIFICATIONS

Specification

Desc./Quantity

Type Single-cylinder, 4-stroke

Engine capacity 124 cm³

Bore x stroke 52.0 x 58.6 mm

Max. power 7.9 kW at 7,700 rpm

MAX. torque 10.4 Nm at 6,000 rpm

Idle speed (1,750±100) rpm

Valve clearance (when cold) intake: 0.08 mm exhaust: 0.08 mm

Timing system 3 valves (2 intake, 1 drainage). single overhead camshaft

chain-driven.

Transmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmission

housing with forced-circulation air cooling.

Final reduction with gear reduction unit in oil bath.

Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.

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Specification Desc./Quantity

Cooling Forced-air circulation cooling. Electric Electric starter Ignition Electronic capacitive discharge ignition, with variable advance

and separate H.V. coil.

Ignition advance Three-dimensional map managed by control unit

Spark plug (125 cm³) NGK CR8EB

Electrode gap 0.7 - 0.8 mm

Fuel system Electronic injection with Ø 26 mm throttle body, single injector

Fuel Unleaded petrol (95 RON)

Exhaust silencer Absorption-type exhaust muffler with catalytic converter.

Emissions compliance EURO 3

150 CM³ ENGINE SPECIFICATIONS

Specification Desc./Quantity

Type Single-cylinder, 4-stroke

Engine capacity 155 cm³

Bore x stroke 58.0 x 58.6 mm

MAX. power 9.5 kW at 7,750 rpm MAX. torque 12.8 Nm at 6,500 rpm

Idle speed (1,750±100) rpm

Valve clearance (when cold) intake: 0.08 mm exhaust: 0.08 mm

Timing system 3 valves (2 intake, 1 drainage). single overhead camshaft

chain-driven.

Transmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmission

housing with forced-circulation air cooling.

Final reduction with gear reduction unit in oil bath.

Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper. Cooling Forced-air circulation cooling. Electric Electric starter Ignition Electronic capacitive discharge ignition, with variable advance

and separate H.V. coil.

Ignition advance Three-dimensional map managed by control unit

Spark plug (150 cm³) NGK CR8EB

Electrode gap 0.7 - 0.8 mm

Fuel system Electronic injection with Ø 28 mm throttle body, single injector

Fuel Unleaded petrol (95 RON)

Exhaust silencer Absorption-type exhaust muffler with catalytic converter.

Emissions compliance EURO 3

Transmission

TRANSMISSION

Specification

Desc./Quantity

Transmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmission

housing with forced-circulation air cooling.

Final reduction with gear reduction unit in oil bath.

Capacities

CAPACITY

Specification

Desc./Quantity

Engine oil 1340 (of which 120 cm³ in the filtering cartridge) (45.31 US fl

oz (of which 4.06 US fl oz in the filtering cartridge))

Hub oil 270 cm³ (9.13 US fl oz)

Fuel tank capacity 8 ± 0.1 l (2.11 ± 0.03 UK gal)

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Frame and suspensions

FRAME AND SUSPENSION

Specification Desc./Quantity

Chassis Stamped plate body with welded structural reinforcements.

Front suspension Single arm with helical spring and single double-acting hy-

draulic shock absorber.

Rear suspension Double-acting shock absorber, adjustable to four positions at

preloading.

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 200-mm disc brake with hydraulic control activated by han-

dlebar right-side lever.

Rear brake Ø 140-mm drum brake with mechanical control activated by

handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRES

Specification

Desc./Quantity

Wheel rim type Light alloy.

Front wheel rim 11'' x 2.50

Rear wheel rim 11'' x 2.75

Front tyre Tubeless, 110/70 - 11'' 45L

Rear tyre Tubeless, 120/70 - 11'' 56L Front tyre pressure 1.6 bar Rear tyre pressure 1.8 bar

Tightening Torques

FRAME ASSEMBLY

Name

Torque in Nm

Frame-swinging arm bolt 44 to 52 (32.5 to 38.4 lbf*ft)

Engine-swinging arm bolt 40 - 45 (29.5 - 33.2 lb*ft)

Silent block-swinging arm retaining bolts 40 - 45 (29.5 - 33.2 lb*ft)

Centre stand pin 40 - 45 (29.5 - 33.2 lb*ft)

STEERING ASSEMBLY

Name

Torque in Nm

Upper steering ring nut 35 to 40 (25.8 to 29.5 lbf*ft) Lower steering ring nut 12 to 14 (8.9 to 10.3 lbf*ft) Handlebar fixing screw 50 to 55 (36.9 to 40.6 lbf*ft)

FRONT BRAKE

Name

Torque in Nm

Brake fluid pump-hose joint 8 to 12 (5.9 to 8.9 lbf*ft)

Brake fluid pipe-calliper fitting 20 to 25 (14.8 to 18.4 lbf*ft)

Screw tightening calliper to support 20 to 25 (14.8 to 18.4 lbf*ft)

Brake disc screw (°) 5 to 6.5 (3.7 to 4.8 lbf*ft)

Oil bleed valve (on the calliper) 10 to 12 (7.4 to 8.9 lbf*ft)

Handlebar pump 7 to 10 (5.2 to 7.4 lbf*ft)

Brake pump reservoir screw 15 to 20 (11.1 to 14.8 lbf*ft)

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(°) Apply LOCTITE 242 threadlock

SILENCER

Name Torque in Nm

Silencer heat guard fixing screws 4 to 5 (3.6 to 3.7 lbf*ft)

Screws fixing silencer to the crankcase 24 to 27 (17.7 to 19.9 lbf*ft)

Oxygen sensor tightening on exhaust manifold 40 to 50 (29.5 to 36.9 lbf*ft)

FRONT SUSPENSION

Name Torque in Nm

Shock absorber upper nut 20 to 30 (14.8 to 22.8 lb*ft)

Front wheel axle nut 75 to 90 (55.3 to 66.4 lbf*ft)

Shock absorber upper bracket bolts 20 to 25 (14.8 to 18.4 lb*ft)

Wheel screw 20 to 25 (14.8 to 18.4 lbf*ft)

Shock absorber lower bolts (°) 20 to 27 (14.8 to 19.9 lb*ft)

(°) Apply LOCTITE 242 threadlock

REAR SUSPENSION

Name Torque in Nm

Rear wheel axle 104 to 126 (76.7 to 92.9 lbf*ft) Shock absorber - chassis nut 20 to 25 (14.8 to 18.4 lbf*ft) Lower shock absorber clamp 40 - 45 (29.5 - 33.2 lb*ft)

FLYWHEEL

Name

Torque in Nm

Flywheel cover screw 11 - 13 (8.1 - 9.5 lb*ft)

Starter sprocket check fixing screw 5 - 6 (3.7 - 4.4 lb*ft)

Starter motor screws 11 - 13 (8.1 - 9.5 lb*ft)

Flywheel fixing nut 100 - 110 (73.7 - 81 lb*ft)

Freewheel fixing screws 10 - 11 (7.4 - 8.1 lb*ft)

FLYWHEEL COVER

Name

Torque in Nm

Pick-up screws 3 - 4 (2.2 - 2.9 lb*ft)

Stator fixing screws 5 - 6 (3.7 - 4.4 lb*ft) (Loctite 242)

Stator cable plates clamping screws 3 - 4 (2.2 - 2.9 lb*ft)

Fixing clamps of head pump cover by-pass pipe 1.3 - 1.7 (0.9 - 1.2 lb*ft)

Coil fixing screw 11 - 13 (8.1 - 9.5 lb*ft)

CRANKCASE

Name

Torque in Nm

Calibrated fixing dowel 5 - 7 (3.7 - 5.2 lb*ft)

Oil filter cover 24 - 30 (17.7 - 22 lb*ft)

Engine oil level shaft 1.3 - 1.7 (0.9 - 1.2 lb*ft)

Engine crankcase coupling screws 11 - 13 (8.1 - 9.5 lb*ft)

Rear brake screw 15 - 17 (11 - 12.5 lb*ft)

Oil sensor 12 - 14 (8.8 - 10.3 lb*ft)

Oil filter 5 - 6 (3.7 - 4.4 lb*ft)

Oil drain screw 14.7 - 16.7 (10.8 - 12.3 lb*ft)

Oil pump bulkhead screw 4 - 6 (2.9 - 4.4 lb*ft)

Freewheel fixing screws 10 - 11 (7.4 - 8.1 lb*ft)

Oil pump fixing screw 5 - 6 (3.7 - 4.4 lb*ft)

oil pump driving crown gear screw 10 - 14 (7.4 - 10.3 lb*ft)

Rotor cover 1 - 1.50 (0.7 - 1.1 lb*ft)

Rotor clamp 3 - 4 (2.2 - 2.9 lb*ft)

HEAD AND CYLINDER

Name

Torque in Nm

Head cover screws 10.8 - 12.7 (7.9 - 9.4 lb*ft)

Cylinder head nut (PRE-TIGHTENING) 6 - 8 (4.4 - 5.9 lb*ft)

Cylinder head nut (TIGHTENING) 9 - 11 (6.6 - 8.1 lb*ft) (Tighten to the specified torque then rotate

270.0°±5.0°)

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Name Torque in Nm

Cylinder stud bolt fitting See section ENGINE/LUBRICATION/STUD BOLT

Throttle body clamp screws 1.3 - 1.7 (0.9 - 1.2 lb*ft)

Tensioner spring retaining screw 5 - 6 (3.7 - 4.4 lb*ft)

Fastener chain tensioner 11 - 13 (8.1 - 9.5 lb*ft)

Thermostat cover screws 3 - 4 (2.2 - 2.9 lb*ft)

Pressure reducer counterweight retainer screw 7 - 8.5 (5.2 - 6.2 lb*ft)

Injection manifold fixing screws 11 - 13 (8.1 - 9.5 lb*ft)

Valve clearance adjustment screw 6 - 9 (4.4 - 6.6 lb*ft)

Spark plug tightening 10 - 12 (7.4 - 8.8 lb*ft)

Timing system sprocket fixing screw 4 - 6 (2.9 - 4.4 lb*ft)

Screws fixing cylinder to crankcase 10.8 - 12.7 (7.9 - 9.4 lb*ft)

Head blow by 3 - 4 (2.2 - 2.9 lb*ft)

TRANSMISSION AND FINAL REDUCTION

Name Torque in Nm

Transmission cover screws 11 - 13 (8.1 - 9.5 lb*ft)

Final reduction cover screws 24 - 27 (17.7 - 20 lb*ft)

Driven pulley fixing nut 53 - 59 (40 - 43.5 lb*ft)

Hub oil drain screw 15 - 17 (11 - 12.5 lb*ft)

Freewheel fixing screws 10 - 11 (7.4 - 8.1 lb*ft)

Driving pulley retainer nut 75 - 83 (55 - 61 lb*ft)

LUBRICATION

Name Torque in Nm

Crankcase timing cover screws 11 - 13 (8.1 - 9.5 lb*ft)

Screws fixing oil pump to crankcase 4 - 6 (2.9 - 4.4 lb*ft)

Pump rod screw 13 - 15 (9.5 - 11 lb*ft)

Minimum oil pressure sensor locking 12 - 14 (8.8 - 10.5 lb*ft) (LOCTITE 5091 Edge closure between

metal body and plastic block)

Overhaul data

Assembly clearances

Cylinder - piston assy.

CYLINDER - PISTON (125)

Specification

Desc./Quantity

Piston diameter 51.961 (±0.014) mm

Cylinder diameter 52 (+0.008 -0.020) mm

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CYLINDER - PISTON (150)

Specification Desc./Quantity

Piston diameter 57.947 (± 0.014) mm

Cylinder diameter 58 (+0.008 -0.020) mm

COUPLING CATEGORIES (125)

Name Initials Cylinder Piston Play on fitting

cylinder - piston A 51.980 - 51.987 51.947 - 51.954 0.026 - 0.040 cylinder - piston B 51.987 - 51.994 51.954 - 51.961 0.026 - 0.040 cylinder - piston C 51.994 - 52.001 51.961 - 51.968 0.026 - 0.040 cylinder - piston D 52.001 - 52.008 51.968 - 51.975 0.026 - 0.040

COUPLING CATEGORIES (150)

Name Initials Cylinder Piston Play on fitting

cylinder - piston A 57.980 to 57.987 57.933 to 57.940 0.040 to 0.054 cylinder - piston B 57.987 to 57.994 57.940 to 57.947 0.040 to 0.054 cylinder - piston C 57.994 to 58.001 57.947 to 57.954 0.040 to 0.054 cylinder - piston D 58.001 to 58.008 58.954 to 58.961 0.040 to 0.054

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.

- Check the pin outside diameter

Characteristic

Pin outside diameter

14 (+0 -0.004) mm

- Measure the diameter of the housings on the piston.

Characteristic

Standard diameter

14 (+0.006 +0.001) mm

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- Carefully clean the sealing rings housings.

- Measure the sealing rings - pistons coupling clearance using suitable sensors, as shown in the diagram

- If clearances measured exceed the limits specified in the table below, the piston should be replaced by a new one.

- Check the clearance upon mounting (A) of the bands:

N.B. MEASURE CLEARANCE BY INSERTING THE BLADE OF

THE FEELER GAUGE FROM THE 2nd SEALING RING SIDE.

ASSEMBLY CLEARANCE OF BANDS - SEAL RINGS (125)

DENOMINATION DIMENSIONS ASSEMBLY CLEARANCES (A)

1° compression ring (mm) 52x0.8 0.20 to 0.35 2° compression ring (mm) 52x1.0 0.20 to 0.45 Oil scraper rings (mm) 52x2.0 0.25 to 0.55

ASSEMBLY CLEARANCE OF BANDS - SEAL RINGS (150)

DENOMINATION

DIMENSIONS ASSEMBLY CLEARANCES (A)

1° compression ring (mm) 58x0.8 0.20 to 0.35 2° compression ring (mm) 58x1.0 0.20 to 0.45 Oil scraper rings (mm) 58x2.0 0.25 to 0.55

- Check that the coupling surface with the head is not worn or misshapen.

- Pistons and cylinders are classified according to diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo

Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine

Crankshaft Axial clearance between

crankshaft and connecting rod

Axial clearance between crankshaft and connecting rod

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CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE

Name

Abbreviation Sizes fitting clearance

Half shaft, transmission side A 18.1 (+0; -0.05) mm D = 0.20 - 0.50 Half shaft, flywheel side B 18.1 (+0; -0.05) mm D = 0.20 - 0.50 Connecting rod C 15 (-0.10; -0.15) mm D = 0.20 - 0.50 Spacer tool E 51.4 (+0; +0.05) mm D = 0.20 - 0.50

Crankshaft bearing diameter.

Measure the bearings on both x-y axes.

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CRANKSHAFT

Specification

Desc./Quantity

Camshaft bearings: Standard diameter: Cat. 1 26.998 to 27.004 mm

Crankshaft bearings: Standard diameter: Cat. 2 27.004 to 27.010 mm

- In order to obtain proper bushing lubrication, make sure there are both an outstanding lubrication pressure and a good oil flow rate. To that end, the bushings must be correctly positioned so as not to obstruct the oil supply channels.

Characteristic

«A»

AXIS CYLINDER

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- The main bushings have 2 half-bearings, 1 with and 1 without the lubrication channel.

- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason, it is arranged opposed to the cylinder.

- To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be perfectly orthogonal to the cylinder axis, as shown in the photo.

Characteristic

«A»

AXIS CYLINDER

BUSHINGS

TYPE

IDENTIFICATION CRANKSHAFT HALF-BEARINGS

B BLUE 1.971 to 1.976 C YELLOW 1.974 to 1.979 E GREEN 1.977 to 1.982

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- The section of the oil feeding channels is also influenced by the driving depth of the bushings.

- Visually check the wear of the bushings: in the coupling ends shown in the photo the bushing usually keeps the original look, check in the rest of the bushing if there is evident removal of material. If this occurs as stated, proceed to replace the crankcase halves.

N.B. SMALL MARKS AND SCRATCHES OF THE SHAFT ROTA-

TION ARE NORMAL SIGNS OF ENGINE USAGE, AND DO NOT AFFECT THE CORRECT FUNCTIONING.

Measurement of crankcase halves - crankshaft coupling clearance.

- The nominal diameters of the bushings, even if of the same coupling category, may differ by hundredths due to the plastic slackening of the material of the crankcase due to the driving load.

- Measure along the axis of the « A» cylinder, using a bore meter at two depths indicated in the figure, the diameter of the bushings.

- After measuring the two diameters, take the average.

Characteristic

«A»

AXIS CYLINDER

- The bushings housing hole in the crankcase half is divided into two categories depending on the size, Category 1 and Category 2.

CRANKCASE DIAMETER WITHOUT BUSHING

Specification

Desc./Quantity

CAT 1 30.959 to 30.965 mm CAT 2 30.953 to 30.959 mm

- Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat.

2). Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The spare crankshaft has half-shafts of the same category.

- According to the classification of the shaft CAT.1 - CAT.2 combine a complete crankcase pre-fitted with suitable bushings according to the starting shaft.

Recommended products

AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions.

API GL-4

Characteristic

Hub oil

270 cm³

Locking torques (N*m)

Hub oil drain screw 15 to 17

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Air filter

- Remove the helmet compartment.

- Disconnect the air intake pipe from the filter box.

- Undo the six screws and remove the air-box cover.

- To clean the filtering element proceed as follows: remove the paper filtering element, blast with compressed air and then refit it.

- Make sure the filtering element is in the correct position.

- Check that the air passage sections are not damaged or deformed.

- Check the correct sealing of the coupling between the filter housing and the cover.

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.

Engine oil

In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine.

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In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Change oil and replace filter as indicated in the scheduled maintenance table. The engine must be emptied by draining off the oil through the drainage plug of the mesh pre-filter, flywheel side; furthermore to facilitate oil drainage, loosen or remove the cap/dipstick. Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter and remove it. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from oil dipstick/cover. Then start up the vehicle, leave it running for a few minutes and switch it off: After about five minutes, check the level and, if necessary, top-up but never exceeding the MAX level reference mark. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

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

Recommended products

eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines.

JASO MA, MA2 - API SL - ACEA A3

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Check

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

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

- Undo cap/dipstick, dry it off with a clean cloth and reinsert it, screwing down completely.

- Remove the cap/dipstick again and check that the level is between the MIN and MAX reference marks; top up if necessary. The MAX level mark indicates a quantity of around 1220 cm³ of engine oil. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level.

Oil top-up

The oil should be topped up after having checked the level and in any case by adding oil without

ever exceeding the MAX. level.

Engine oil filter

Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended products

eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines.

JASO MA, MA2 - API SL - ACEA A3

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Oil pressure warning light

The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been started.

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

Checking the ignition timing

Position the engine at top dead centre (TDC) in compression. To do this, use the appropriate tools. Use the holes on the engine crankcase to secure the tool. Position the specific tool in the window between the flywheel pick-up references as illustrated in the figure. The arrows stamped respectively on the valve frame and sprocket must coincide.

N.B. IF THE TIMING UNIT IS NOT IN PHASE CHECK THE COR-

RECT FITTING OF COMPONENTS.

- As a further verification of the correct distribution timing, insert a pin into the hole on the gear of the camshaft and check that it coincides with the special blind hole on the frame of the head.

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Checking the valve clearance

To remove the head cover:

- Remove the rear shock absorber.

- Remove the helmet compartment.

- Lift the body.

- Remove the clamp of the H.V. wire To check valve clearance, centre the reference marks of the timing system. Use a feeler gauge to check that the clearance between the valve and the set screw corresponds with the indicated values. When the valve clearance values, intake and exhaust respectively, are different from the ones indicated below, adjust them by loosening the lock nut and operating on the corresponding set screw, as shown in the figure.

Characteristic

Valve clearance (when cold)

intake: 0.08 mm exhaust: 0.08 mm

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 brake pads.

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Top-up

Proceed as follows:

- Remove the upper handlebar cover.

- Remove the reservoir cap by loosening the two screws, remove the gasket and top-up using only the fluid 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; DO NOT

LET IT COME INTO CONTACT WITH THE PAINTED PARTS. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS

MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLUID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE.

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.

SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 CUNA NC 956 DOT 4 synthetic fluid

Locking torques (N*m)

Brake pump reservoir screws 15 to 20

Headlight adjustment

Proceed as follows:

1. Position the vehicle in running order and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit white screen; ensure that the longitudinal axis of the vehicle is perpendicular to the screen;

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2. Turn on the headlight and check that the boundary of the light beam projected onto the screen is not higher than 9/10 or lower than 7/10 of the distance between the centre of the headlight and the ground;

3. Otherwise, adjust the right headlight with screw «A».

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

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

Anti-evaporation system

Canister inspection

The canister is essential to treat the hydrocarbons present in the volume of gas that escapes from the tank when there is an increase in internal pressure (tank heating induced by the cooling radiator, by the motor or by the external environment). The volume of air is limited by the operation of the ventilation valve (Roll-over). Although the amount of hydrocarbons coming from the tank is small enough to avoid the saturation of the canister, it is necessary to regenerate the activated carbon by means of a reversed flow of ambient air sucked by the engine. These vacuums of pollution and carbon regeneration take place at each cycle of use of the vehicle.

To control the canister, it is necessary to proceed with its removal while keeping the 2 pipes connected.

•

Shake the Canister and make sure there is no noise.

•

Using a compressed air gun, blow alternately in 3 ducts and make sure that pressure does not build inside the canister.

•

Check that the air flow is kept free and that no carbon residues escape out of any pipe.

If you detect noise, clogging or loss of carbon, replace the canister.

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Safety valve check

The cleaning of the canister is achieved via a controlled flow of air from the vacuum socket in the intake manifold. To ensure that the engine works properly, it is necessary that the flow of air is not too intense, this is achieved by means of a restricted section 0.0354in (0.9 mm) formed in the socket on the intake manifold. The relative connecting pipe with the canister, includes the installation of the safety valve. This is a one-way valve which ensures the passage of air in the direction of the manifold when the control vacuum is greater than 2.9PSI (20kPa) (200mbar). The vacuum of the engine at idle, causes a slight flow of air easily compensated by the idle speed adjustment parameters. When the vehicle is stopped, the safety valve will be closed due to the lack of control vacuum therefore, any expansion of the fuel tank, will not cause pollution of the intake manifold, and then cause flooding of the engine.

To control the valve, it is preferable to it, alternatively just access the manifold side pipe.

•

Connect the MITY-VAC pump on the engine side duct.

•

Select the pump command on the "vacuum" position, then slowly apply vacuum up to the valve threshold check opening.

If you detect different pressures, replace the valve. N.B. An opening vacuum that is too high, causes a lack of regeneration of the activated carbon; vice versa, an opening vacuum that is too low, increases the flow of air to the engine causing the thinning of idle.

Characteristic

Standard opening vacuum

(2.90-3.77)PSI (20-26)kPa (200-260)mbar

Roll-over valve check

The valve must enable the following results:

•

Aeration of the tank while riding (the ambient air enters the tank in relation to the volume of fuel used).

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•

Pressurisation of the tank (while riding or during a break, you may experience increases in the temperature inside the tank. The valve must pressurize the tank to limit the escape of fuel vapour to the canister).

•

Prevent pollution of the canister with the liquid fuel (in case of fall of the vehicle, the valve must block the connection with the canister).

To control the valve, it is necessary to remove it from the vehicle. For the check, it is planned to use a MITY-VAC pump and a piece of tube, then proceed as follows:

•

Connect the MITY-VAC pump to the lower joint of the safety valve (white).

•

Select the "vacuum" control position and keeping the valve in the vertical axis, check that it is possible to intake air without movements of the gauge needle.

•

Switch the control of the pump to "pressure" and, keeping the valve in the vertical axis, check that it is possible to pressurise the valve up to values slightly below 1.45PSI(~0.87PSI) 10kPa(~6kPa) 100mbar(~60mbar).

N.B. The setting pressure is easily recognisable in that, when it is reached, the valve discharges the air emitting a little noise.

•

Position the valve in the horizontal axis and check that you can pressurise it to values well above the setting pressure (eg. 7.25PSI (50 kPa) (0.5bar) without guaranteeing the maintenance).

If you detect abnormal behaviour, replace the valve. N.B. Any malfunction of the valve can cause deformation of the fuel tank or aggravate the working conditions of the canister.

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

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Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

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

with specific oil for foam filter treatment. Press with your hand

without squeezing, allow it to drip dry and refit.

Excessive drive belt wear Check it and replace, if necessary

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

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

Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Silencer obstructed Replace

Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-

aged parts and lubricate the movable guide of the driven pulley

with grease.

Wrong valve adjustment Adjust the valve clearance properly

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

Valve seat distorted Replace the head unit

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

Starting difficulties

START-UP PROBLEMS

Possible Cause

Operation

Flat battery Check the state of the battery. If it shows signs of sulphation,

replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1/10 of the capacity

of the battery itself.

Faulty spark plug Replace the spark plug

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

Starter motor and start-up system fault Check starter motor.

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

Air filter obstructed or dirty. Remove the sponge, wash with water and car shampoo, soak

with specific oil for foam filter treatment. Press with your hand

without squeezing, allow it to drip dry and refit.

Fuel pump fault Check the pump.

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause

Operation

Wrong valve adjustment Adjust the valve clearance properly

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

Misshapen/worn valve seats Replace the head unit

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

Worn or broken piston rings or piston rings that have not been

fitted properly

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn valve oil seal Replace the valve oil seal

Worn valve guides Check and replace the head unit if required

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Insufficient lubrication pressure

LOW LUBRICATION PRESSURE

Possible Cause Operation

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

By-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump components

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

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

Check that the faying surface between the clutch masses and

the clutch housing is mainly in the middle and with equivalent

specifications on the three masses.

Check that the clutch housing is not scored or worn abnormally.

Insufficient braking

INEFFICIENT OR NOISY BRAKING

Possible Cause

Operation

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

drum wear conditions.

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

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

the disc.

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

no flexible movement of the brake lever).

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

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

the back part of the crankcase.

Brakes overheating

BRAKE OVERHEAT

Possible Cause

Operation

Rubber gaskets swollen or stuck. Replace gaskets.

Compensation holes on the pump clogged. Clean carefully and blast with compressed air.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and

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

the disc.

Defective piston sliding. Check calliper and replace any damaged part.

Electrical system

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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 to 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keep-

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

chapter for the recharging of the batteries.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

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

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

tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause

Operation

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

in turning the steering even after making the above adjust-

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

place if they are recessed.

Noisy suspension

NOISY SUSPENSION

Possible Cause

Operation

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

sorber works properly and the ball bearings are good condition.

Finally, check the locking torque of the wheel axle nut, the brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber

work properly.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause

Operation

Faulty or broken seals Replace the shock absorber Check the condition of wear of the

steering covers and the adjustments.

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 57

KEY

1. Battery

2. Starter relay contacts

3. Starter motor

4. Main fuse

5. Ignition switch

6. Secondary fuses

7. Voltage regulator

8. Magneto flywheel

9. Speed sensor

10. Instrument panel

11. MODE button

12. Turn indicator control

13. Pre-installation for anti-theft device

14. Turn indicator switch

15. Left turn indicator bulbs

16. Turn indicators warning lights

17. Right turn indicator bulbs

18. Stop light

19. Stop buttons

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20. Starter button

21. Starter relay coil

22. High beam warning light

23. Light switch

24. Headlight relay

25. Headlight

26. Saddle opening actuator

27. Horn button

28. Horn

29. Engine oil pressure warning light

30. Engine oil pressure sensor

31. Fuel level transmitter

32. Fuel gauge

33. Low fuel warning light

34. Roll-over sensor

35. engine stop switch

36. Immobilizer LED

37. Left front daylight running light

38. Right front daylight running light

39. Rear daylight running light

40. License plate light

41. Injector

42. Idle valve

43. Engine speed sensor

44. Engine temperature sensor

45. Lambda probe

46. Fuel pump

47. H.V. coil

48. Injection warning light

49. Throttle body position

50. Diagnostics socket

51. Immobilizer antenna

52. Injection ECU Cable colour:

Az = Sky blue Bi = White Ar = Orange Gi = Yellow

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BL = Blue Ma = Brown Ne = Black Rs = Red Ro = Pink Ve = Green Vi = Violet Gr = Grey

Components arrangement

1. RIGHT HAND STOP SWITCH

- Remove the upper handlebar cover to reach it.

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2. HEADLIGHT

- Remove the upper handlebar cover to reach it.

3. SECONDARY FUSES

- Open the front case to reach it.

4. TURN INDICATORS INTERMITTENCE

5. HORN

6. VOLTAGE REGULATOR

- Remove the leg shield back plate to reach it.

7. INJECTION ECU

8. HEADLIGHT SOLENOID

- Remove the leg shield back plate to reach it.

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9. LAMBDA PROBE

10. LAMBDA PROBE CONNECTOR

11. FLYWHEEL CONNECTOR

- To reach it, remove the helmet compartment.

12. FRONT RIGHT TURN INDICATOR

- Remove the leg shield back plate to reach it.

13. LEFT HAND STOP SWITCH

- Remove the upper handlebar cover to reach it.

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14. FRONT LEFT TURN INDICATOR

- Remove the leg shield back plate to reach it.

15. INJECTOR

- To reach it, remove the helmet compartment.

16. ENGINE TEMPERATURE SENSOR

- To reach it, remove the helmet compartment.

17. IDLE SPEED ADJUSTMENT DEVICE

- To reach it, remove the helmet compartment.

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18. THROTTLE POSITION SENSOR

- To reach it, remove the helmet compartment.

19. H.V. COIL

- To reach it, remove the helmet compartment.

20. HORN SWITCH

21. TURN INDICATOR SWITCH

22. HIGH/LOW BEAM LIGHTS SWITCH

- Remove the upper handlebar cover to reach it.

23. INSTRUMENT PANEL

- Remove the upper handlebar cover to reach it.

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24. STARTER BUTTON

- Remove the upper handlebar cover to reach it.

25. IGNITION SWITCH

26. IMMOBILIZER AERIAL

- Remove the leg shield back plate to reach it.

27. STARTER RELAY

- Remove the footrests to reach it.

28. BATTERY

29. MAIN FUSE

- Remove the battery cover to reach it.

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30. REAR LIGHT

- Remove the rear headlight assembly to reach it.

31. REAR LEFT TURN INDICATOR

32. LICENSE PLATE LIGHT

- Remove the license plate cover to reach it.

33. REAR RIGHT TURN INDICATOR

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34. STARTER MOTOR

- To reach it, remove the helmet compartment.

35. DIAGNOSTICS SOCKET

- Remove the battery cover to reach it.

36. PRE-INSTALLATION FOR ANTI-THEFT DEVICE

- Remove the footrests to reach it.

Ground points

On the vehicle there is a ground point on the chassis marked with the letter "A", remove the footrest to access it.

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There is another ground point "B" on the starter motor.

On the left side of the chassis, under the footrest, there is the chassis-engine ground lead "C".

Electrical system installation

Front side

1. Left stop button

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2. Left control lock

3. Headlight connector

4. Instrument panel connector

5. Right control lock

6. Right stop button

7. Left electrical controls connector

8. Ignition switch

9. Voltage regulator

10. Turn indicator control device

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11. Voltage regulator connector

12. Front left turn indicator connector

13. Horn connections

14. Saddle opening switch connector

15. To speed sensor on wheel

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16. Headlight relay base

17. Front right turn indicator connector

18. Secondary fuses

19. Speed sensor connector

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20. Right electrical controls connector

21. Injection ECU

22. Immobilizer aerial

23. Headlight relay

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24. Ground point on chassis

25. Negative battery pole

26. Diagnostics socket

27. Positive battery pole

28. Main fuse

29. To rear cable harness

30. Pre-installation for anti-theft device

31. Saddle opening actuator connector

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32. Starter relay

33. Roll-over sensor connector

34. Roll-over sensor

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Back side

1. Engine temperature sensor connector

2. Injector connector

3. Oxygen sensor connector

4. Magneto flywheel connector

5. Starter motor positive

6. Starter motor negative

7. Throttle body position sensor connector

8. Idle valve connector

9. H.V. coil connections

Conceptual diagrams

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Ignition

KEY

1. Battery

4. Main fuse

5. Ignition switch

6. Secondary fuses

41. Injector

43. Engine speed sensor

44. Engine temperature sensor

45. Lambda probe

47. H.V. coil

49. Throttle body position

52. Injection ECU

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Battery recharge and starting

KEY

1. Battery

2. Starter relay contacts

3. Starter motor

4. Main fuse

5. Ignition switch

6. Secondary fuses

7. Voltage regulator

8. Magneto flywheel

18. Stop light

19. Stop buttons

20. Starter button

21. Starter relay coil

35. engine stop switch

52. Injection ECU

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Level indicators and enable signals section

KEY

1. Battery

4. Main fuse

5. Ignition switch

6. Secondary fuses

9. Speed sensor

10. Instrument panel

29. Engine oil pressure warning light

30. Engine oil pressure sensor

31. Fuel level transmitter

32. Fuel gauge

33. Low fuel warning light

34. Roll-over sensor

35. engine stop switch

36. Immobilizer LED

51. Immobilizer antenna

52. Injection ECU

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Devices and accessories

KEY

1. Battery

4. Main fuse

5. Ignition switch

6. Secondary fuses

10. Instrument panel

11. MODE button

13. Pre-installation for anti-theft device

26. Saddle opening actuator

27. Horn button

28. Horn

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Lights and turn indicators

Versions for market USA-CND

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KEY

1. Battery

4. Main fuse

5. Ignition switch

6. Secondary fuses

10. Instrument panel

12. Turn indicator control

14. Turn indicator switch

15. Left turn indicator bulbs

16. Turn indicators warning lights

17. Right turn indicator bulbs

18. Stop light

19. Stop buttons

22. High beam warning light

23. Light switch

24. Headlight relay

25. Headlight

37. Left front daylight running light

38. Right front daylight running light

39. Rear daylight running light

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40. License plate light

52. Injection ECU INJECTION

KEY

1. Battery

4. Main fuse

5. Ignition switch

6. Secondary fuses

21. Starter relay coil

34. Roll-over sensor

35. engine stop switch

36. Immobilizer LED

41. Injector

42. Idle valve

43. Engine speed sensor

44. Engine temperature sensor

45. Lambda probe

46. Fuel pump

47. HV coil

48. Injection warning light

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49. Throttle body position

50. Diagnostics socket

51. Immobilizer aerial

52. Injection ECU

Checks and inspections

Immobiliser

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by means of the coded keys that the control unit recognises. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobilizer system consists of the following components:

- Control unit

- Immobilizer antenna

- master and service keys with built-in transponder

- HV coil

- diagnosis LED The diagnosis led also works as a blinking light to deter theft. This function is activated every time the ignition switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process. When the ignition switch is turned to "ON", it interrupts the function of the immobiliser lamp and a start enable lamp comes "ON". The duration of the flash depends on the programming of the electronic control unit. If the LED is off regardless of the position of the ignition switch and/or the instrument panel is not initiated, check if:

- there is battery voltage

- there is power to the control unit.

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Virgin circuit

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

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

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

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

- Insert the MASTER key again and turn it to «ON» for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, the Master key transponder is strictly matched with the control unit. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be

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

Diagnostic codes

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

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

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

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

permanently. In this condition no operations are possible including the start up of the vehicle.

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

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

4. Programmed control unit - Master key in: a

0.7-sec flash is displayed followed by the LED remaining off for 2 secs.

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

•

1-flash code

•

2-flash code

•

3-flash code

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Diagnostic code - 1 flash

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

Diagnostic code - 2 flashes

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

Diagnostic code - 3 flashes

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

Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel. The generator is directly connected to the voltage regulator.

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

Recharge system voltage check

Look for any leakage

1) Access the battery by removing the specific cover.

2) Check that the battery does not show signs of losing fluid before checking the output voltage.

3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole (-) of the battery and the black cable and only then disconnect the black cable from the negative pole (-) of the battery.

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

Charging current check

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the multimeter leads between the battery terminals..

3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm. Maximum current output check.

- With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter. With an efficient battery a value must be detected: > 20A

VOLTAGE REGULATOR/RECTIFIER

Specification

Desc./Quantity

Type Non-adjustable three-phase transistor

Voltage 14 to 15V at 5000 rpm with lights off

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Starter motor

1. Battery

2. Fuse No. 1

3. Starter relay

4. Starter motor

5. Ignition switch

6. Fuse no. 2

7. Stop buttons

8. Starter button

9. CDI control unit

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Horn control

1. Battery

2. Fuse No. 1

3. Ignition switch

4. Fuse no. 2

5. Horn button

6. Horn

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Turn signals system check

1. Battery

2. Fuse No. 1

3. Ignition switch

4. Fuse no. 2

5. Turn indicator device

6. Turn indicator switch

7. Turn indicators

level indicators

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

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If faults are detected:

1) With a multimeter, check resistance values between the White-Green cable and the Black cable of the fuel level transmitter under different conditions.

2) If the transmitter operates correctly but the indication on the instrument panel is not exact, check that the cable harnesses between them are not interrupted.

Electric characteristic

Resistance value with full tank

<= 7 Ω

Resistance value with empty tank

90 +13/-3 Ω

Lights list

1. Battery

2. Fuse No. 1

3. Fuse no. 2

4. Ignition switch

5. Fuse No. 5

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6. Light solenoid

7. CDI control unit

8. Light switch

9. High beam warning light

10. Headlight

11. Front daylight running light

12. License plate light

13. Rear daylight running light

14. Instrument panel lighting

BULBS

Specification Desc./Quantity

1 High/low beam light bulb Type: Halogen (HS1)

Power: 12V - 35/35W

Quantity: 1

2 Front side light bulb Type: LED

Quantity: 2

3 Stop light bulb Type: LED

Quantity: 1

4 Rear tail light bulb Type: Incandescent

Power: 12V - 10W

Quantity: 1

5 License plate light bulb Type: Incandescent

Power: 12V - 5W

Quantity: 1

6 Front turn indicator light bulb Type: Halogen, BAZ9s base, Amber

Power: 12V - 6W

Quantity: 1 RHS + 1 LHS

7 Rear turn indicator light bulb Type: Halogen, BAZ9s base, Amber

Power: 12V - 6W

Quantity: 1 RHS + 1 LHS

Versions for market USA-CND

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1. Battery

2. Fuse No. 1

3. Fuse no. 2

4. Ignition switch

5. Fuse No. 5

6. Light solenoid

7. CDI control unit

8. Light switch

9. High beam warning light

10. Headlight

11. Front daylight running light

12. License plate light

13. Rear daylight running light

14. Instrument panel lighting

BULBS

Specification

Desc./Quantity

1 High/low beam light bulb Type: Halogen (HS1)

Power: 12V - 60/55W

Quantity: 1

2 Front daylight running light bulbs Type: LED

Quantity: 2

3 Turn indicator light bulbs Type: Incandescent, amber

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Specification Desc./Quantity

Power: 12V - 10W

Quantity: 2 RHS + 2 LHS

4 Rear daylight bulbs Type: Halogen (HY6W)

Power: 12V - 6W

Quantity: 1 RHS + 1 LHS

5 Stop light bulb Type: Incandescent

Power:12V - 21W

Quantity: 1

6 License plate light bulb Type: Incandescent

Power: 12V - 5W

Quantity: 1

Fuses

The electrical system is protected by a main fuse and four secondary fuses, positioned as:

MAIN FUSE HOLDER «A»: battery compartment. Access to main fuse «A»:

- Remove the battery compartment cover as described in «Battery» paragraph.

- Open the fuse holder.

SECONDARY FUSES «B»: inside the front case. Access to the secondary fuses «B»:

- Open the front case.

- Open the fuse holders.

CAUTION

BEFORE REPLACING THE FUSE IT IS NECESSARY TO FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. DO NOT REPLACE THE FUSE WITH ANY ALTERNATIVE FORM OF CONDUCTOR.

CAUTION

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IN ORDER TO AVOID DAMAGING THE ELECTRIC SYSTEM, NEVER DISCONNECT THE WIRING WHILE THE ENGINE IS RUNNING. DO NOT TIP THE VEHICLE TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF THE BATTERY ELECTROLYTE.

CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK OF FIRE.

CAUTION

PROCEED WITH CAUTION. DO NOT DAMAGE THE TONGUES OR THEIR SEATS. HANDLE THE PAINTED AND PLASTIC COMPONENTS CAREFULLY. DO NOT SCRATCH OR DAMAGE THEM.

FUSE CHART

Specification Desc./Quantity

Fuse No. 1 Capacity: 20 A

Protected circuits: battery recharge circuit, fuses No. 2 and 3

(live), fuses No. 4 and 5.

Fuse No. 2 Capacity: 5 A

Protected circuits: ignition switched live instrument panel, in-

dicators, antitheft device pre-installation, stop lights, starter

circuit, headlight relay, horn, daylight running lights.

Fuse No. 3 Capacity: 5 A

Protected circuits: ignition switched live tilting sensor, control

unit.

Fuse No. 4 Capacity: 7.5 A

Protected circuits: battery-powered control unit.

Fuse No. 5 Capacity: 10 A

Protected circuits: battery-powered instrument panel, antitheft device pre-installation, headlight; ignition switched live sad-

dle opener actuator.

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Dashboard

A = Speedometer B = Immobilizer LED C = Engine control warning light D = Turn indicator warning light E = Low fuel warning light F= Digital display G = Low engine oil pressure warning light H = High-beam headlight warning light

I = Fuel gauge with petrol symbol L = Total or partial odometer M = Clock

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Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and afterwards every six months.

INSTRUCTIONS FOR BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE

1) Voltage check

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

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

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

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 to 14.70V

- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity

- Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h

3) Constant current battery charge mode

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

- Charge time: Maximum 5 h

Battery installation

VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)

WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK FOLLOWED BY MAGNESIUM MILK, BEATEN EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; 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 THE REACH OF CHILDREN

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1) Battery preparation

Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.

2) Electrolyte preparation.

Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulphuric acid.

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times. Do not remove the container from the battery.

5) Take out the container.

Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point.

6) Battery closing.

Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery.

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Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery. The filling process is now complete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. Place the battery down for 1 to 2 hours prior to the charging from the battery.

7) Recharging the new battery

With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged.

If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle.

The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between

12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).

d - Press the red button, as shown in figure.

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e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.

f - Check the ignition of the green LED indicated with a red arrow in figure.

g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place

h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

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Connectors

DIAGNOSTICS CONNECTOR

1. Not connected

2. Ground lead (Black)

3. Electronic control unit (Orange-Black)

FLYWHEEL

a1. Gi - Voltage regulator b1. GrVe - Pickup c1. Gi - Voltage regulator a2. RoBi - Engine oil pressure sensor b2. Gi - Voltage regulator c2. Rs - Pickup +

FUEL PUMP CONNECTOR

1. Power from relay (Black - Green)

2. Not connected

3. Not connected

4. Negative from control unit (Green)

5. Not connected

INJECTION ECU

1. Ve - fuel pump

2. MaBi - injection warning light

3. AzRs -lambda probe heater

4. Gi - immobilizer LED

5. RsBi - + battery

6. RsGi - injector ground

7. GrVe - Sensor ground

8. RoNe - + H.V. coil

9. NeVe - + loads

10. ArNe - K Line

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VESPA PRIMAVERA 125, PRIMAVERA 150 Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual