This manual has been produced by Nacional Motor, S.A.U. for use by DERBI dealer and sub-agency workshops. It is assumed that those using this publication for training purposes and for repairing DERBI machines have a basic knowledge of mechanics and of the methods inherent in the technique of vehicle repair. Significant variations in the characteristics of the machines or in the specific repair operations will be communicated by means of updates to this manual.
GENERAL INFORMATION MAINTENANCE REGULATIONS GENERAL TECHNICAL DATA MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS SPECIFICATIONS ELECTRICAL SYSTEM SPECIFICATIONS GENERAL TIGHTENING TORQUE SPECIFICATIONS PERIODICAL INSPECTIONS AND ADJUSTMENTS SEAT, FAIRING AND FUEL TANK ENGINE CHASSIS ELECTRICAL SYSTEM ENGINE INSPECTION DISMANTLING THE ENGINE INSPECTION AND REPAIR REASSEMBLING THE ENGINE AND MAKING ADJUSTMENTS CHASSIS – FRONT WHEEL AND BRAKES REAR WHEEL AND BRAKES TRANSMISSION FORKS HANDLEBARS SHOCK A
REGULATIONS This section describes the machine’s general safety and maintenance work rules. SAFETY REGULATIONS In the event of having to carry out work on the engine while this is running, ensure that the area is well ventilated, where possible using extractor fans. Never leave engines running in closed spaces. Exhaust gases are poisonous. Petrol is extremely inflammable and in certain conditions may explode. Smoking must not be allowed in the work area, nor should there be naked flames or sparks.
Use genuine DERBI spare parts and lubricants recommended by the Manufacturer. Non-genuine or unauthorised parts may damage the machine. Only use the specific tools intended for this machine. During re-assembly, always use new seals, gaskets, piston rings and grommets. After dismantling, clean the components with solvents that are non-inflammable or that have a high flammability point. Grease all working surfaces before assembling, excluding tapered joints.
RACING 125 GENERAL TECHNICAL DATA 6 Engine Single cylinder 2-stroke EURO 2 Diameter x stroke 56,0 x 50,7 mm Cylinder capacity 124,9 cm3 Carburettor Mikuni TM 28-92 Cooling Liquid Starting Electric Compression ratio 12,5 : 1 Maximum power 11 kW (14.9 HP) / 8.000 Fuel Lead-free petrol Greasing system Wet crankcase Ignition Ignition Spark plug NGK BR8ES Primary transmission Gears Clutch Multi-disk Gears 6 speed Front suspension 40 mm Ø hydraulic fork.
PREPARATION FOR REMOVAL AND DISMANTLING 1. Remove all the dirt, grime, dust and other foreign material before removing and dismantling. 2. Use proper cleaning tools and equipment. See “SPECIAL TOOLS”. 3. On dismantling the motorcycle, always keep paired parts together. This includes gears, cylinders, pistons and other parts submitted to natural wear in pairs. Paired parts must always be reassembled or replaced together. 4.
SPARE PARTS S 1. Use only genuine DERBI spare parts. For all lubrication tasks use oils and greases recommended by DERBI. Other makes may seem similar in their function and appearance, but are inferior in quality. SEALS, RETAINING RINGS AND O-RINGS 1. Replace all seals, retaining rings and O-rings when servicing the engine. All surfaces receiving seals, retaining ring edges and O-rings must be cleaned. 2. Apply oil to all paired parts and bearings during reassembly.
LOCKING RINGS 1. Examine all the locking rings carefully before fitting. Always replace the gudgeon pin circlips after every use. Replace distorted locking rings. On fitting a locking ring (1), ensure that the sharp edge (2) is on the opposite side to the force (3) to be applied to it. See the figure on the side, (4) Axle. SPECIAL TOOLS The following special tools are needed for assembly and for complete and exact adjustments.
3. 00M12501260 Clutch holder. This tool is used to hold the clutch assembly when fitting or dismantling its axle nut. 4. 00M12501261 Crankcase separator. This tool is used to separate the crankshaft from the case. 4. 00H05100181 40 mm fork seal inserting tool This tool is used for inserting the seals into the forks, as described in the corresponding section.
GENERAL SPECIFICATIONS MODEL GPR 125 Racing BASIC WEIGHT With oil and full fuel tank 131 kg TYPE OF FLUID Engine oil AGIP CITY 2-stroke API SJ « DONUT» + JASO MA - PART SYNTHETIC oil, SAE Viscosity: SAE 10W30 or higher OIL CAPACITY Engine oil. Regular oil change. Total capacity 0,75 L. 0,8 L. AIR FILTER Wet-type element FUEL Type Fuel tank capacity Reserve volume Lead free petrol (95 octane or higher) 12 L. 2 L.
MODEL NEUMÀTICOSTYRES Size Front Rear TYRE PRESSURES (COLD) Rider only Front Rear Rider and passenger Front Rear FRENO Front brake Type Operation Front brake Type Operation GPR 125 Racing Tubeless 110/80 – 17 “ 140/70 – 17” 170 kPa (1,7 kg/cm2) 190 kPa (1,9 kg/cm2) 190 kPa (1,9 kg/cm2) 210 kPa (2,1 kg/cm2) 300 mm Ø disk. VENTILATED With the right hand 180 mm Ø disk.
ENGINE SPECIFICATIONS MODEL GPR 125 Racing CYLINDER HEAD <0,03 mm> * The lines indicate measurement at a right angle CYLINDER Diameter 56,00 ~ 56,02 mm Conicity limit 0,05 mm Ovality limit 0,01 mm PISTON Cylinder-piston play Diameter of piston “D” 0.045 ÷ 0.050 mm <0.10 mm> 55.950 ÷ 55.
MODEL GPR 125 Racing CLUTCH Thickness of friction disks Quantity Thickness of the separators Quantity Free length of clutch spring Quantity Minimum length Clutch freeing method Actioning rod warp limit 2.9 ÷ 3.1 mm 7 parts 2.7 mm 1.05 ÷ 1.35 mm 6 parts 0.05 mm 34.5 mm 5 parts 32 mm Internal by lever system <0.
ENGINE TIGHTENING TORQUES PARTS TO BE TIGHTENED Spark plug AMNT. THREAD SIZE 1 TIGHTENING TORQUE Nm m.Kg M14 x 1.25 20 2.0 Cylinder head Cap nuts 5 M8 x 1.25 22 2.2 Cylinder Stud bolt 9 M8 x 1.25 13 1.3 Nut 4 M8 x 1.25 28 2.8 6 M5 x 0.8 7 0.7 M6 x 1.0 10 1.0 Exhaust valve support, valve cover LOCTITE bolt securing adhesive Seal Stud Exhaust valve pulley Stud Thermostat valve cover Bolt 3 M6 x 1.0 8 0.8 Water pump cover Bolt 2 M6 x 1.0 8 0.
PARTS TO BE TIGHTENED AMNT. THREAD SIZE TIGHTENING TORQUE Nm m.Kg Drive sprocket Nut 1 M6 x 1.0 60 6 Tachometer cog housing Stud 1 M6 x 1.0 5 0.5 Stop lever Stud 1 M6 x 1.0 14 1.4 Change pedal Stud 1 M6 x 1.0 15 1.5 15 1.5 80 8 Starter motor Rotor 1 Nut 16 1 M12 x 1.
MODEL GPR Racing 125 c.c. STEERING SYSTEM Type of steering bearing Rigid ball bearing FRONT SUSPENSION Free length of forks spring 851 mm 845 mm Spring strength 20 N/mm Travel 110 mm Oil/bar capacity 340 cm3 Type of oil FSAE 7.
MODEL GPR Racing 125 c.c. FRONT DISK BRAKES Type Disk width Brake pad thickness VENTILATED hydraulic disk 4.0 mm 3.5 mm 4.5 mm 1.5 mm REAR DISK BRAKES Type Inner diameter of brake drum Brake shoe thickness VENTILATED hydraulic disk 4.0 mm 3.5 mm 4.5 mm 1.
MODEL GPR 125 Racing VOLTAGE Ignition system: Ignition point (B.T.D.C) Advance type 12V 17 º a 1.500 rpm Digital DIU Model of magneto/manufacturer Detector coil resistance Generator coil resistance Generator coil resistance Model of DIU/manufacturer F4FU/YAMAHA 310 Ω ± 20% W/R-W/L 730 Ω ± 20% B/R-G/W 600 Ω ± 20% G/L-G/W 1D0/YAMAHA IGNITION COIL Model Primary winding resistance Secondary winding resistance 3RW/YAMAHA 0.23 Ω ± 20% 7.
MODEL GPR 125 Racing HORN Type Quantity Maximum current Flat 1 1,5 A (12V) TURN INDICATOR RELAY Frequency Power 65 ~ 100 cycles/mínute 10W x 2 SAFETY CIRCUIT Type Individual circuit current x quant. Main Reserve Fuse 15A x 1 7,5A x 1 STARTER RELAY Type Model Nominal voltage Minimum functioning voltage Coil resistance Electromagnetic 12 V 180 A 12 V 8V 4.2 ~ 4.6 Ω a 20 ºC STARTER MOTOR Output power Length of the brushes Spring pressure Commutator diameter Depth of the mica 0.
The following table specifies torques for standard ISO fixing devices. The torque specifications for special components or assemblies are indicated in the respective chapters of this manual. To prevent distortions, tighten assemblies with various fixing devices progressively and in a crossed or alternating manner until the specified torque is reached. Unless stated otherwise, the specified torques require threads to be clean and dry. Components should be at room temperature.
CHASSIS TIGHTENING TORQUES DESCRIPTION OF SECURING DEVICE TIGHTENING TORQUE (m-Kg) MAX. TORQUE (m-Kg) M6x100 INSTRUM.-CHASSIS SUPPORT SECURING DEV. 0,8-1 1 M10xl.5 10.9 TOP SEC. SHOCK-CHASSIS SEC.DEV. 4,5-5,5 5,5 MI0x1.5 10.9 SHOCK-SWING.ARM BOTTOM SEC.DEV. 4,5-5,5 5,5 M8x1.25 12.9 ENGINE-CHASSIS CRADLE SEC. DEV 2,5-2,9 2,9 M8x1.25 8.8 REAR SUBCHASSIS – CHASSIS SEC.DEV. 1,7-1,9 1,9 M8X125 12.9 CYL.HEAD BRACE-CHASSIS SEC.DEV. 2,5-2,9 2,9 M8x125 12.9 REAR ENGINE-CHASSIS SEC.DEV.
TIGHTENING TORQUE (m-Kg) MAX. TORQUE (m-Kg) 1-1,2 Sealed 1,2 M10x150 10.9 BRAKE BRACE SEC. DEV. 3,5-4 4 M6x18.8 REAR BRAKE CYLINDER SEC. DEV. 0,8-1 1 4.8 AUTHOR. FAIRING SUPPORTS SEC. DEV. 0,1-0,2 0,2 4.8 AUTHOR. FAIRING COVER SEC. DEV. 0,1-0,2 0,2 M5x80 VARIOUS METAL PARTS TO CHASSIS SEC. DEV. 0,35-0,45 0,45 M6x100 VARIOUS METAL PARTS TO CHASSIS SEC. DEV. 0,8-1 1 M8xl25 VARIOUS METAL PARTS TO CHASSIS SEC. DEV. 1,5-1,9 1,9 M5x80 VARIOUS PLASTIC PARTS TO CHASSIS SEC. DEV.
INTRODUCTION This chapter contains all the necessary information for carrying out recommended inspections and adjustments. If followed correctly, these preventative maintenance procedures will ensure a reliable operation of the machine and a longer operating life. The need for costly servicing will be significantly reduced. This information applies not only to machines already in service but also new machines in preparation for being sold.
Nº SERVICE ELEMENT 1000 5000 10000 15000 20000 25000 km/2m km/12m km/24m km/36m km/36m km/60m 23 Front forks Change the oil 24 Rear shock absorber Check 25 Electrical wiring Check 26 Front headlight Height adjustment 27 Tyres Check wear 28 Tyres Pressure X 29 Wheels Check X 30 Inlet reeds 31 Cylinder head, cylinder and piston 32 Piston segments Check 33 Piston segments Replacement 34 Cylinder head bolts/nuts Check tightness X X X X 35 Fuel and oil pipes Check X
DISMANTLING 1. Extract: - Seat. N.B. INSERT THE IGNITION KEY, TURN IT CLOCKWISE A QUARTER TURN AND THEN REMOVE THE SEAT. 2. Extract: Passenger seat. - The nut under the seat must be unscrewed. - Pull the seat forwards. 3. Extract: - Cowling. The black cover (1) in the figure must be be removed by unscrewing the bolts (2) on both sides. The studs (4) on both sides then need to be unscrewed, and the clamp securing the exhaust pipe. The cowling (3) can then be removed by pulling out backwards. 4.
5. Dismantle: Bottom fairing Remove the screws located at the bottom (keel joint) and another located at the front. 6. Dismantle: Fuel tank. Remove the 3 screws in the picture. N.B. THE FUELTAP WORKS BY PRESSURE. IF THIS IS WORKING PROPERLY, THE TANK DISMANTLING PROCESS IS VERY STRAIGHTFORWARD AND IS OUTLINED BELOW: - DISCONNECT THE FUEL LEVEL SENSOR (1). - REMOVE THE ENGINE BREATHER PIPE (2). - REMOVE THE FUEL OUTLET PIPE (3).
CO MEASUREMENT AND VACUUM RUNNING ADJUSTMENT 1. Start the engine and leave to warm up for a few minutes. 2. Connect: -An inductive tachometer to the spark plug lead. N.B. THE IDLING REGULATOR IS ACCESSED FROM THE LEFT HAND SIDE OF THE MACHINE. SEE THE COVER DISMANTLING METHOD IN THE PREVIOUS SECTION. 3. Check: - Idle speed (standard). Outside that specified => Adjust. Turn the no load running screw (1) inwards or outwards until the specified no load running is obtained. No load running: 1.250 ~ 1.
5. Adjust: - CO concentration. Adjustment steps: - Turn the mixture screw inwards or outwards until the specified CO concentration is obtained. Adjustment band: Rub probe point~ up to 6 turns outwards. N.B. TURN THE NO LOAD RUNNING SCREW (2) TO ADJUST THE ENGINE’S NO LOAD RUNNING, SINCE THE CO CONCENTRATION ADJUSTMENT MAY AFFECT THE NO LOAD RUNNING. - After adjusting, check the CO concentration and remove the CO probe. Ensure that there are no variations in the idle speed.
- Loosen the throttle cable locknut (2). - Turn the adjuster (1) inwards or outwards until the specified play is obtained. Turning inwards (a) = Increasing the play. Turning outwards (b) = Reducing the play. - Tighten the locknut. N.B. IF THE PLAY IS STILL INCORRECT, ADJUST IT USING THE ADJUSTER BELOW THE TWIST GRIP. WARNING AFTER ADJUSTMENT, TURN THE HANDLE IN BOTH DIRECTIONS TO ENSURE THAT THERE IS NO NO-LOAD VARIATION . INSPECTING THE SPARK PLUG 1. Extract: - Spark plug connector. - Spark plug.
4.Clean: - Spark plug (Clean the spark plug with a spark plug cleaner or wire brush) 5. Measurement: - Gap between the electrodes (a), (using a feeler guage). Outside that specified => Adjust the gap. Gap between electrodes: 0,7 mm 6. Fit: - Spark plug Spark plug: 20 N.m ( 2 kgf.m) N.B. - BEFORE REFITTING THE SPARK PLUG, CLEAN ITS SEATING SURFACE AND GASKET.
INSPECTING THE ENGINE OIL LEVEL 1. Place the motorcycle on a flat surface. N.B. MAKE SURE THE MOTORCYCLE IS VERTICAL WHEN CHECKING THE OIL LEVEL. 2. Start the engine and leave to warm up for a few minutes. 3. Stop the engine. 4. Check the oil level in the inspection window (1) (located in the right hand crankcase cover). N.B.: THE OIL LEVEL MUST BE BETWEEN THE MAXIMUM (2) AND THE MINIMUM (3). 5. If the oil is below the minimum level, add oil up to the correct level.
5. Replenish: - Oil in the crankcase. Quantity of oil: 0,8 L 6. Check: - The engine oil level. See “INSPECT THE ENGINE OIL LEVEL” section INSPECTING THE EXHAUST SYSTEM 1. Inspect: - Bolts (1) (exhaust pipe) Loose/damaged => Tighten/replace. - Gasket (exhaust pipe). Leaking exhaust fumes => Tighten/replace. Bolt: 8 N.m (0,8 kgf.m) 2. Inspect: Bolts securing the exhaust pipe to the chassis. Loose/damaged => Tighten/replace. Bolt: 17-19 N.m (1,7-1,9 kgf.m) RENEWING AIR FILTER N.B.
- To remove the top cover, remove the clips securing the filter body (see picture). - Extract the foam air filter, wash it in soapy water, then wring it out and dry it completely. Next, soak it in special oil for filters and refit it. Fitting: - Fit in reverse order to dismantling. - Then refit the top filter cover. - Seal the box cover with silicon. Recommended oil: AGIP FILTER OIL WARNING NEVER USE PETROL TO CLEAN THE AIR FILTER ELEMENT. A SOLVENT OF THIS TYPE MAY CAUSE FIRE OR EXPLOSION.
ADJUSTING THE FRONT BRAKES This machine is fitted with hydraulically activated disk brakes. This type of brakes comes with adjustment factory set. You must check that the brake fluid level is between the maximum and minimum. N.B. REMEMBER THAT THE LEVEL WILL BE AFFECTED BY THE DEGREE OF BRAKE PAD WEAR. ADJUSTING THE REAR BRAKES 1. Check: - Brake pedal clearance (a). Outside that specified => Adjust. Clearance: 5 - 10 mm 2. Adjust: - Brake pedal clearance.
ADJUSTING JUS G THE TIMING G CHAÍN C TENSION SO 1. Put the motorcycle on the centre stand. 2. Check: - Drive chaIn tension (a). Outside that specified => Adjust. (distance between the chain guide and the furthest point vertically) Drive chain tension: 11 mm 3. Loosen: - Axle nut (1) (both sides). 4. Loosen: - Axle (2). 5. Adjust: - Drive chain tension. - Move the axle inwards or outwards using the bolt (3) until the specified tension is obtained. 6. Tighten the axle nuts to the nominal torque.
INSPECTING THE TYRES 1.Measurement: - Tyre pressure Outside that specified => Adjust. WARNING TYRE PRESSURE SHOULD ONLY BE CHECKED OR ADJUSTED WHEN THEIR TEMPERATURE IS THE SAME AS AMBIENT TEMPERATURE. THE TYRES AND SUSPENSION SHOULD BE ADJUSTED IN ACCORDANCE WITH THE TOTAL LOAD – RIDER, PILLION PASSENGER AND ACCESSORIES (COVERS, SIDEBAGS, ETC. IF THESE ARE APPROVED FOR THIS MODEL) AND IN ACCORDANCE WITH THE RIDING SPEED OF THE MOTORCYCLE. NEVER OVERLOAD THE MOTORCYCLE.
WARNING RIDING WITH WORN TYRES IS DANGEROUS. WHEN THE TYRE TREAD BEGINS TO SHOW SIGNS OF WEAR, THE TYRES SHOULD BE REPLACED IMMEDIATELY. MENDING A PUNCTURED INNER TUBE IS NOT RECOMMENDED. IF IT IS ABSOLUTELY NECESSARY TO DO SO, TAKE GREAT CARE, AND REPLACE THE INNER TUBE WITH A GOOD QUALITY ONE AS SOON AS POSSIBLE. NEVER USE TUBELESS TYRES ON A WHEEL DESIGNED FOR TYRES WITH INNER TUBES. THE TYRE MAY FAIL, AND THE RESULTING BLOW-OUT MAY CAUSE AN ACCIDENT. Wheels for tubed tyres => use only tubed tyres.
INSPECTING AND TIGHTENING THE SPOKES 1. Inspect: - Spokes (1). Warps/damage => Replace. INSPECTING THE WHEELS 1. Inspect: - Wheels Damaged/distorted => Replace. N.B. ALWAYS CARRY OUT WHEEL BALANCING WHEN A TYRE OR A WHEEL IS FITTED OR REPLACED. WARNING NEVER ATTEMPT TO REPAIR A WHEEL. INSPECTING THE BATTERY 1. Extract: - Fuel tank. See “SEATS, FAIRING AND FUEL TANK” section. 2. Inspect: - Battery terminals. Dirtiness => Clean with wire brush. Poor connection => Put right.
N.B. AFTER CLEANING THE TERMINALS, APPLY A THIN LAYER OF GREASE TO THEM. Replace the battery if: - The voltage falls below a specific value. ATTENTION BEFORE USING THE NEW BATTERY, IT MUST BE CHARGED TO ENSURE MAXIMUM PERFORMANCE. 3. Fit: - Battery. 4. Connect: - Battery cables. ATTENTION CONNECT THE POSITIVE CABLE (1) TO THE BATTERY FIRST AND THEN THE NEGATIVE CABLE (2). 5. Fit: Fuel tank See “SEATS, FAIRING AND FUEL TANK” section.
2. Inspect: - Fuse. Steps for the inspection: - Connect the multi-meter to the fuse to check if there is a circuit. N.B. ADJUST THE MULTI-METER SELECTOR TO Ω X. If the meter indicates , replace the fuse. 3. Replacing: - Blown fuse. Replacement steps: - Disconnect the main switch. - Fit a new fuse with the correct amperage. - Turn on the switches to check the functioning of the corresponding electrical devices. - If the fuse blows again immediately, inspect the electrical circuit.
ADJUSTING THE HEADLIGHT BEAM 1. Adjustment - Headlight beam height To adjust the height, turn the screw (2) in one of two directions: SCREWING IN => Lower UNSCREWING => Raise 2. Adjust: - Headlight dispersion. To adjust the headlight width, turn the screw (1) in one of two directions: SCREWING IN => Increase UNSCREWING => Decrease REPLACING THE HEADLIGHT BULBS 1. Extraiga: - Headlight bulb holder. Disconnect the bulb holder, turn it a quarter turn (see photo) and pull it out.
WARNING KEEP INFLAMMABLE PRODUCTS AND HANDS AWAY FROM THE BULB WHILE IT IS LIT, BECAUSE IT WILL BE HOT. DO NOT TOUCH IT UNTIL IT COOLS DOWN. ATTENTION AVOID TOUCHING THE BULB GLASS. KEEP IT FREE OF OIL. IF NOT, THE TRANSPARENCY OF THE GLASS, THE DURABILITY OF THE BULB AND THE AMOUNT OF LIGHT EMITTED WILL BE AFFECTED. IF THE BULB BECOMES SOILED WITH OIL, CLEAN IT CAREFULLY WITH A DAMP CLOTH OR WITH ALCOHOL OR THINNER. CHANGING TURN INDICATOR BULBS 1. Extract: - Glass screw (1). 2.
4. Should the headlight need to be completely dismantled, the two screws (1) securing the unit to the cowling need to be removed, and the unit removed by pushing carefully through the rear of the cowling. DISMANTLING THE ENGINE N.B.: THERE IS NO NEED TO REMOVE THE ENGINE TO DISMANTLE THE FOLLOWING COMPONENTS: - CYLINDER HEAD - CYLINDER - PISTON - MAGNETO FLYWHEEL DISMANTLING S G THE SIDE S COVERS CO S AND FUEL U TANK 4. Extract: - FRONT covers - Rider’s seat.
REMOVING THE ENGINE FROM THE CHASSIS 1. Dismantle side covers. 2. Remove the petrol tank. 3. Remove the exhaust pipe. 4. Remove the gear change lever. - Remove bolt (1). - Remove change backlash bush (2). 5.Remove chain. Remove chain coupling link clip. 6. Extract the radiator. Drain the cooling system. 7. Dismantling the carburettor. - Remove filter box-carburettor pipe (secured with a jubilee clip). - Loosen jubilee clip on carburettor pipe to cylinder. - Remove carburettor.
Remove system inlet (1) and outlet (2) hoses and tank hose (3). Remove radiator. 8. Extract oil pump cable. Remove cover.
Remove the retaining circlip with pulley and torsion recovery spring. - Extract cables and remove them from the engine. 9. Extract the oil tank to engine hose. - Remove the tank hose and plug it. - Plug the oil tank outlet. 10. Remove the clutch operating cable. - Free the clutch cable from the handlebars. - Remove the the tensioning cable from the crankcase. - Remove the clutch operating cable. 11. Free exhaust valve operating cable. - Remove cover (1).
12. Remove electrical connections. - Remove spark plug connector. - Remove the temperature meter cable. - Remove the magneto cable. - Remove earth cable from right hand side of the crankcase. - Remove neutral earth cable. - Remove starter motor power supply cable. - Remove cables from the coil. 13. Removing the engine cradle. - Remove the UNEX clamps. - Remove the 6 bolts securing the cradle to the engine and to the chassis. - Withdraw the engine cradle from below the machine. 14. Extracting the engine.
3. Extract: - Gudgeon pin circlip. - Gudgeon pin. - Piston. - Connecting rod big end needle bearing assembly. N.B. BEFORE REMOVING THE CIRCLIP FROM THE GUDGEON PIN, COVER THE BASE OF THE CYLINDER WITH A CLEAN CLOTH TO PREVENT ANYTHING FROM FALLING INTO THE ENGINE. BEFORE REMOVING THE GUDGEON PIN, ELIMINATE THE ROUGH EDGES OF THE CICLIP GROOVE AND THE HOLE. ONCE THE ROUGH EDGING HAS BEEN ELMINATED, AND IF THERE IS STILL DIFFICULTY IN REMOVING THE GUDGEON PIN, USE THE GUDGEON PIN EXTRACTOR.
2. Extract: - Magneto flywheel (1). - Pin. N.B. EXTRACT THE MAGNETO FLYWHEEL USING THE ROTOR EXTRACTOR (2). CENTRE THE ROTOR EXTRACTOR ON THE MAGNETO FLYWHEEL. ENSURE THAT THE GAP BETWEEN THE EXTRACTOR AND THE FLYWHEEL IS THE SAME AT ALL POINTS AFTER FITTING THE SECURING BOLTS. IF NECESSARY, LOOSEN ONE OF THE BOLTS TO ADJUST THE EXTRACTOR POSITION. ATTENTION COVER THE END OF THE CRANKSHAFT WITH THE SPANNER TO PREVENT DAMAGE. Magneto flywheel extractor: 00M12501259 3. Extract: - Plate (1).
2. Extract: - Gasket. - Guide pins. 3. Extract: - Pressure plate bolts (1). - Clutch springs (2). - Pressure plate (3). - Friction disks (4). - Separators (5). - Spring (6). N.B. LOOSEN THE PRESSURE PLATE BOLTS DIAGONALLY. 4. Extract: - Push rod 1 - Ball - Locknut N.B. FLATTEN OUT THE TAB OF THE TAB WASHER. LOOSEN THE CLUTCH HOUSING NUT WHILE HOLDING THE HOUSING WITH THE UNIVERSAL CLUTCH HOLDER .
5. Extract: - Clutch housing nut (1). - Tab washer (2). - Clutch housing (3). - Pressure washer (4). - Clutch bell casing (5). - Spacer (6). - Washer (7). N.B. HOLD THE MAGNETO FLYWHEEL USING THE ROTOR HOLDER. THEN LOOSEN THE ENGINE PINION NUT. 6. Extract: - Nut. - Special washer. - Crankshaft output gear - Pin. - Crankshaft housing cover 7. Extract: - Nut - Tab washer - Balancing (anti-vibration) gear. - Pin.
GEAR CHANGE C G SHAFT S N.B. THE GEAR CHANGE SHAFT CANNOT BE DISMANTLED WITH THE ENGINE MOUNTED IN THE FRAME. SEE “REMOVING THE ENGINE FROM THE CHASSIS”. 1. Extract: - Gear change shaft (1). - Bolt (2). - Positioning cam (3) - Torsion spring (4). CRANKCASE 1. Extract: - Bolts (crankcase). - Battery cable bracket. N.B. UNDO THE BOLTS DIAGONALLY. LOOSEN EACH BOLT A QUARTER TURN IN TURN, AND REMOVE THEM WHEN THEY ARE COMPLETELY LOOSE. 2.
3. Extract: - Right crankcase N.B. PLACE THE ENGINE WITH THE LEFT HAND CRANKCASE FACING DOWN AND THEN INSERT A SCREWDRIVER IN THE CRANKSHAFT SEPARATING SLOTS (A). 4. Extract: Guide pins. BALANCER C , TRANSMISSION S SS O AND GEAR G S SELECTOR C O 1. Extract: - Gear fork 1 guide lever (short). - Gear fork 2 guide lever (long). - Gear selector (3). - Gear fork 1 (4). - Gear fork 2 (5). - Gear fork 3 (6). - Drive shaft assembly (7). - Driven shaft assembly (8). 2. Extract: - Balancing counterweight (9).
3. Extract: - Neutral switch. CRANKSHAFT 1. Extract: - Crankshaft with the rocker shaft. N.B. DETACH THE CRANKSHAFT USING THE CRANKCASE SEPARATOR TOOL (2). TIGHTEN THE CRANKCASE SEPARATOR BOLTS RIGHT DOWN, BUT ENSURE THAT THE BODY OF THE TOOL IS PARALLEL WITH THE CASING. IF NECESSARY, LOOSEN ONE OF THE BOLTS A LITTLE TO ADJUST THE POSITION OF THE CRANKCASE SEPARATOR. Crankcase separator: 00M12501261 CYLINDER HEAD 1. Eliminate: - Carbon deposits sediments (and gasket remains). N.B.
3. Measurement: - Distortion Outside that specified => Rectify. Cylinder head distortion: less than 0.03mm Steps for measuring the distortion and rectification: - Place a ruler (1) and a thickness calliper (2) on the head cylinder surface, as in the figure to the side. - Measure the distortion. - If the distortion is outside that specified, rectify the cylinder head. - The lines in the picture correspond to the different directions that need to be checked with the ruler.
DIAMETER OF THE CYLINDER “C” 56.00 – 56.02 mm TAPER LIMIT “T” 0.05 mm OVALNESS “R” 0,01 mm “C” = D MAXIMUM “T” = (D1 O D2 MAXIMUM) - (D5 O D6 MAXIMUM) “R” = (D1, D3 O D5 MAXIMUM) - (D2,D4 O D6 MINIMUM) - If it is outside that specified , rectify or replace the cylinder and replace the piston and the rings together. Step 2: - Measure the base of the piston “P” with a micrometer. (a) 10 mm from the piston base. DIAMETER OF THE PISTON P. STANDARD 55.950 – 59.955 mm 0.25 mm OVER-MEASUREMENT 0.
INSPECTING THE PISTON RINGS 1. Measure: - Lateral clearance. Outside that specified => Replace the piston and its rings all together. N.B. ELIMINATE THE CARBON DEPOSITS FROM THE PISTON RING GROOVES, BEFORE MEASURING THE LATERAL PLAY. Lateral play (piston rings): Top ring : 0.02 – 0.06 mm Secondary (scraper) ring: : 0.035 – 0.070 mm 2. Position: - The piston rings (in the cylinder). N.B.
CRANKSHAFT S 1. Measure: - Crankshaft lack of alignment Outside that specified => Replace the crankshaft and/or bearings. N.B. MEASURE CRANKSHAFT POOR ALIGNMENT BY SLOWLY TURNING THE CRANKSHAFT ASSEMBLY. Poor alignment limit: 0,03 mm 2. Measure: - Connecting rod side clearance Outside that specified => Replace the connecting rod big end bearing, crankshaft elbow and/or the connecting rod. Connecting rod side clearance: 0.20 – 0.70 mm 3.
INSPECTING S C G THE C CLUTCH U C BELL HOUSING OUS G 1. Inspect: - Primary sprocket teeth (1). - Bell housing sprocket teeth (2). Wear/damage => Replace both sprockets. Excessive noise when running => Replace both sprockets. INSPECTING S C G THE C CLUTCH U C 1. Inspect: - Friction disks Wear/damage => Replace the friction disk assembly. 2. Measure: - Thickness of the friction disks Outside that specified => Replace the friction disk assembly. Measure at 4 different positions.
4. Measure: - Separator distortion Outside that specified => Replace the separator assembly. Take the measurement on a flat table with the aid of a thickness calliper (1). Distortion limit (separators): less than 0,05mm. 5. Inspections: - Clutch springs. Damage => Replace the spring assembly. 6. Measure: - Free length (springs) (a). Outside that specified => Replace the spring assembly. Free length (springs): 34.5 mm 7. Inspect: - Claws (of the bell housing) (1).
INSPECTING THE ACTIONING ROD 1. Inspect: - Ball (1). - Activating rod (2). Wear/cracks/damage => Replace. INSPECTION OF THE FORKS AND GEAR SELECTOR 1. Inspect: - Fork follower (1). - Ends of the gear change forks (2). Scratches/warping/wear/damage => Replace. 2. Inspect: - Gear selector slots. Wear/damage/scratches => Replace. - Gear change selector follower. Wear/damage => Replace. 3. Inspect: - Gear change fork 1 centre right (1). - Gear change fork 2 top left (2).
4. Check: - Movement of the gear change forks (in the guide bar) Irregular movement => Replace the fork and the bar. N.B. IF THE GEAR CHANGE FORK AND THE TRANSMISSION SPROCKETS ARE FOUND TO BE DAMAGED, REPLACE THE SPROCKETS THAT ARE SIDE BY SIDE ALL TOGETHER. 5. Measure: - Warping of the shafts (drive and driven) Use a support between points and a dial gauge for linear measurement (1). Outside that specified => Replace the warped shaft. 6. Inspect: - Sprocket teeth Blue colouring/grooves/wear => Replace.
CRANKCASES 1. Wash the casings well with petrol. 2. Clean well the seal-bearing surfaces and the casing contact surfaces. 3. Inspect: - Crankcases Cracks/damage => Replace - Oil passages Obstructions => Blow through the passages with compressed air. BEARINGS AND RETAINING RINGS 1. Inspect: - Bearings Clean and lubricate, then turn the inner ring by hand. Roughness => Replace 2. Inspect: - Retaining rings Damage/wear => Replace. LOCKING RINGS AND WASHERS 1.
VALVES, ROCKERS AND CAMSHAFT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 65 Complete crankshaft Washer Nut Connecting rod Pin Washer Roller bearing Piston Set of rings Roller bearing Gudgeon pin Circlip Bearing Oil seal Oil seal Collar Key Straight key Traction gear Balancer (Counterweight) Bearing Bearing Straight key Balancer gear
CRANKSHAFT AND BALANCER SHAFT 1. Fit: - Crankcase separator Crankcase separator: 00M12501261 2. Fit: - Crankshaft N.B. HOLD THE CONNECTING ROD WITH ONE HAND WHILE TURNIING THE NUT ON THE SPECIAL TOOL WITH THE OTHER HAND. USE THE TOOL UNTIL YOU FEEL THE CRANKSHAFT FIT INTO THE BEARING. ATTENTION TO PREVENT SCRATCHING TO THE CRANKSHAFT AND TO HELP ITS FITTING, APPLY GREASE TO OIL SEAL EDGES AND ENGINE OIL TO THE BEARINGS. 3. Fit: - Rocker shaft. Always use new rubber rings. 4.
TRANSMISSION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 67 Primary shaft 2nd gear pinion 3rd gear pinion 5th gear pinion 6th gear pinion Washer Circlip Bearing Roller bearing Secondary shaft 1st gear cogwheel 2nd gear cogwheel 3rd gear cogwheel 4th gear cogwheel 5th gear cogwheel 6th gear cogwheel Flat washer Round spring clip Washer Circlip Washer Bearing Bearing Oil seal 25 26 27 28 29 30 Collar Ring gear Washer Nut Plate Bolt
GEAR 1 2 3 4 5 6 7 8 9 10 68 SELECTOR Selector drum Stop lever Spring Stud Gear change fork 1 Gear change fork 2 Gear change fork 3 Gear change fork 1 guide lever Gear change fork 2 guide lever Round spring clip
1. Fit: - Primary and secondary transmission shafts (driving and driven). - Bottom left gear change fork (1). - Centre right gear change fork (2). - Top left gear change fork (3). - Guide bar (1) (short) (4). - Guide bar (2) (long) (5). N.B. FIT THE GEAR CHANGE FORKS WITH THE ENGRAVED MARK UPWARDS AND IN ORDER (1,2,3,) 6. Check: - Gear selector operation Irregular operation => Adjust. N.B. CHECK THAT TRANSMISSION AND FORK OPERATION IS NORMAL BY TURNING THE GEAR CHANGE SELECTOR BY HAND.
4. Tighten: - Bolts (crankcase cover) Bolts (casing): 1,0 Kgf.m (10 N.m) 5. Apply: - 2-stroke engine oil. (to the crankshaft elbow joints, bearings, oil feed holes). 6. Check: - Operation of the crankshaft and transmission. Irregular operation => Repair.
GEAR 1 2 3 4 71 CHANGE C G SHAFT S Complete selector shaft Bolt Stop cam Torsion spring
1. Fit: - Torsion spring (1). - Positioning cam (2) - Bolt N.B. SECURE THE SPRING TO THE STOP CAM AND ENSURE THE LATTER IS IN THE CORRECT POSITION, THEN TIGHTEN THE SECURING BOLT TO THE SPECIFIED TORQUE. Bolt (limiter rod): 14 N.m (1.4 kgf.m) 2. Fit: - Gear change shaft assembly (3). N.B. APPLY GREASE TO THE RETAINING RING PINS FIT THE ENDS OF THE SPRING INTO THE LIMITER (4).
CLUTCH U C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 73 AND CLUTCH C U C BELL HOUSING OUS G Clutch bell housing Clutch housing Clutch plate Washer Pressure plate Spring Bolt with washer Friction disk Friction disk Spring Primary traction gear Washer Nut Washer Flat washer Washer Nut Separator Push rod 1 Washer Nut Sphere Push rod 2 Complete push cam 25 26 27 28 Spring Flat washer Oil seal Roller bearing
INSTALLING THE CLUTCH BELL HOUSING 1. Fit: - Balancing gear - Primary gear - Clutch bell housing N.B. TAKE CARE TO FIT THE BALANCING GEAR AND THE PRIMARY GEAR WITH THE CENTRING MARKS LINED UP. FITTING THE CLUTCH 1. Fit: - Clutch bell casing (1). - Pressure washer (2). - Clutch housing (3). - Tab washer (4). - Clutch housing nut (5). 2. Tighten: - Clutch housing nut. N.B. TIGHTEN THE CLUTCH HOUSING NUT WHILE HOLDING THE HOUSING WITH THE UNIVERSAL CLUTCH HOLDER .
4. Fit: - Friction disks (1). - Separators (2). N.B. - FIT THE DISKS AND SEPARATORS ALTERNATELY INTO THE CLUTCH ASSEMBLY, STARTING WITH A FRICTION DISK AND ENDING WITH A FRICTION DISK AS WELL. - LUBRICATE ALL THE DISKS AND SEPARATORS WITH ENGINE OIL BEFORE FITTING. - BE SURE TO FIT EACH SEPARATOR WITH ITS PROJECTIONS TURNED AT 90º TO THE PREVIOUS ONE. CONTINUE WITH THIS PROCEDURE IN A CLOCKWISE DIRECTION UNTIL ALL THE SEPARATORS HAVE BEEN INSTALLED. 5. Fit: - Activating rod. - Ball. 6.
9. Adjust: - Position of the activating plate. Adjustment steps: - Loosen lock nut (1). - Turn the adjuster (2) clockwise or anticlockwise to line up the marks. - Hold the adjuster to stop it from moving and tighten the locknut. ATTENTION BE CAREFUL NOT TO OVERTIGHTEN THE ADJUSTER (2) AND ELIMINATE THE CLEARANCE BETWEEN THE TWO ACTIVATING RODS. - Tighten the lock nut (1). Lock nut: 10 N.m (1kgf.m) 10. Fit: - Guide pins. - Crankcase gasket - Right hand crankcase cover Crankcase cover bolts: 8 N.m (8kgf.
MAGNETO G O 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 77 AND STARTER S SYSTEMS S S S Magneto flywheel support Bolt Starter wheel Roller bearing Intermediate starter gear shaft Flat washer Intermediate starter gear Intermediate starter gear plate Bolt Starter clutch Starter clutch spring cover Pin Spring Bolt Magneto Stator Nut Flat washer Bolt
INSPECTING THE STARTER GEAR 1. Inspect: - Starter system gear teeth (a) (b) (c). Rough edges/swarfing/roughness/wear => Replace. 2. Check: - Operation of the starter clutch. Push the guide pins in the direction of the arrow. Non-smooth functioning => Replace. Checking steps: - Hold the starter clutch. - On turning the (big) starter gear clockwise (A), the starter clutch and the starter gear should be coupled. - If not, the starter clutch is damaged. Replace.
N.B. FIT THE ROTOR PROVISIONALLY, ALIGNING THE KEYWAY WITH THE KEY. TURN THE STARTER GEAR CLOCKWISE AND FIT THE ROTOR ONTO THE STARTER GEAR. 5. Tighten: - Nut (magneto flywheel). Magneto flywheel nut: 80 N.m (8kgf.m) N.B. TIGHTEN THE NUT (1) WHILE HOLDING THE FLYWHEEL (2) WITH THE ROTOR HOLDER (3). TAKE CARE NOT TO ALLOW THE ROTOR HOLDER TO TOUCH THE ROTOR PROTRUSIONS. 6. Fit: - Guide pins. - Crankcase cover gasket. - Left hand crankcase cover Crankcase cover bolts: 5 N.m (5kgf.
CYLINDER, 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 80 PISTON S O , C CYLINDER HEAD AND EXHAUST US VALVE Cylinder head Stud Nut Flat washer Spark plug Head gasket Cylinder Cylinder gasket Clutch cable securing plate Stud Stud Pin Nut Exhaust valve Right hand exhaust valve cover Bolt Exhaust valve gasket Oil seal SEEGER Ring Clutch valve activation support Bolt Left hand exhaust valve cover.
FITTING PISTON RINGS, PISTON AND CYLINDER 1. Fit according to the following sequence: - Secondary ring (scraper) (1). - Top ring (compression) (2). N.B. - LUBRICATE THE PISTON AND THE RINGS WELL WITH ENGINE OIL. 2. Fit: - Piston - Connecting rod big end needle bearings - Gudgeon pin - Circlip N.B. - APPLY ENGINE OIL TO THE GUDGEON PIN. - THE ARROW ON THE PISTON SHOULD BE TOWARDS THE EXHAUST SIDE. - BEFORE FITTING THE CIRCLIP, COVER THE CRANKCASE OPENING WITH A CLEAN CLOTH. 3. Fit: • Guide pins (1).
4. Lubricate: - External surface of the piston - Rings - Inner surface of the cylinder 5. Fit: - Cylinder (1). N.B. - FIT THE CYLINDER WITH ONE HAND WHILE COMPRESSING THE RINGS WITH THE OTHER. FITTING THE CYLINDER HEAD 1. Fit: - Cylinder head gasket 2. Fit: - Cylinder head - Nut with washer Cylinder head nuts tightening torque: 22 N.m (2,2 kgf.m) N.B. - APPLY ENGINE OIL TO THE BOLT THREADS.
FITTING THE REED VALVE N.B. BEFORE FITTING, CHECK THAT THERE ARE NO CRACKS, DISTORTIONS OR BREAKAGES ON THE REED PETALS. IF THERE ARE, THEY MUST BE REPLACED IN THE FOLLOWING WAY: - REMOVE THE SECURING SCREWS FROM THE HEIGHT LIMITER AND FROM THE INLET VALVE PETALS. - CHECK THAT THERE ARE NO CRACKS IN THE PETALS’ SECURING BASE. IF THERE ARE, RENEW THE REEDS.
3. Fit: - Spark plug Spark plug: 20 N.m (2.0 kgf.m) 14. Fit: - Oil drain plug - Fill with 800 c.c. of SAE 10W30 oil through the plug hole located on the right hand crankcase cover. Oil drain plug: 15 N.m (1.5 kgf.m) REFITTING G THE ENGINE G INTO O THE FRAME 1. Dismantle side covers. 2. Remove the petrol tank. 3. Remove the exhaust pipe. 4. Dismantling the carburettor. - Remove filter box-carburettor pipe (secured with a jubilee clip). - Loosen jubilee clip on carburettor pipe to cylinder.
7. Extracting the radiator. - Drain the cooling system. Remove system inlet (1) and outlet (2) hoses and tank hose (3). Remove radiator.
8. Extracting the oil pump cable. - Remove cover. Remove the retaining circlip with pulley and torsion recovery spring Extract cables and remove them from the engine. 9. Extracting the oil tank to engine hose. - Remove the tank hose and plug it. - Plug the oil tank outlet. 10. Removing the clutch operating cable. - Free the clutch cable from the handlebars. - Remove the the tensioning cable from the crankcase. - Remove the clutch operating cable. 11. Freeing the exhaust valve operating cable.
12. Removing electrical connections. - Remove spark plug connector. - Remove the temperature meter cable. - Remove the magneto cable. - Remove earth cable from right hand side of the crankcase. - Remove neutral earth cable. - Remove starter motor power supply cable. - Remove cables from the coil. 13. Removing the engine cradle. - Remove the UNEX clamps. - Remove the 6 bolts securing the cradle to the engine and to the chassis. - Withdraw the engine cradle from below the machine. 14. Extracting the engine.
CARBURETTOR U O 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 88 Air screw assembly Idler jet Main jet Washer Spray Spray needle Pin Bolt Needle valve Idler screw assembly Spring Seal Bolt Washer Throttle valve Pipe Tube clip Breather tube Drain screw Breather tube Float Ring Sheath Cable adjusting nut 25 26 27 28 29 Washer Filter Cover Clip Drain pipe
DISMANTLING 1. Extract: - Rider’s seat. - Fairing. - Fuel tank. - Air filter canister. See “SEAT, SIDE COVERS AND FUEL TANK” section in CHAPTER 3. 2. Drain: - Fuel (carburettor bowl). N.B. PLACE A CLOTH UNDER THE FUEL DRAIN PIPE TO ABSORB SPILT FUEL. WARNING PETROL IS HIGHLY INFLAMMABLE. AVOID SPILLING PETROL ON TO A HOT ENGINE. 3. Disconnect: - Breather pipe. - Fuel pipe. - Drain hose. 4. Loosen: - Pipe clamp screws. - Bolt (air filter canister). N.B.
DISMANTLING S G N.B. THE PARTS BELOW CAN BE CLEANED AND INSPECTED WITHOUT DISMANTLING THE CARBURETTOR. (ALL THE INTERNAL PARTS, EXCEPT THE CHOKE, CAN BE CLEANED AND INSPECTED WITHOUT DISMANTLING THE CARBURETTOR). - CLOSING VALVE - CLOSING VALVE NEEDLE 1. Extract: - Complete carburettor. 2. Extract: - Throttle cable N.B. COMPRESS THE GAS VALVE RETURN SPRING AGAINST THE COVER AND EXTRACT THE THROTTLE CABLE TERMINAL THROUGH THE GAS VALVE CHANNEL. 3. Extract: - Cold start (choke) valve puller bracket.
4. Extract: - Low speed circuit air quantity regulator (“compensator”) screw. - Spring - Washer - O-ring 5. Extract: - Carburettor bolts and bowl. N.B. THIS ENABLES ACCESS TO THE MAXIMUM, MINIMUM AND COLD START BORES, AS WELL AS THE FLOAT AND ITS NEEDLE VALVE. Compensator screw: ¼ de vuelta. INSPECTION S C O 1. Clean: - All the components of the carburettor with solvent (take care not to damage the carburettor bowl gasket or the cold start valve O-ring). 2.
I – The condition of the cold start system piston valve. => In the event of the vulcanised closing seat or the metal body of the piston being damaged (scratches and/or corrosion that exceed 25% of its total area). - Size of the bores based on the numbers etched onto them. => If they are not in agreement with that specified, replace them with suitable ones. Failure to do so may result in the performance of the engine being affected. - The position of the tapered dosing needle.
- The absence of scratches on the minimum circuit air regulator screw cone. These would affect its performance. - The absence of scratches on the sliding valve. => In the event of these exceeding 25% of its total area, renew it. N.B. BE SURE TO FIT A VALVE WITH THE SAME CHARACTERISITCS (SEE MARKINGS ON ITS BASE). REFITTING G This is a reversal of the “REMOVAL” procedure. Take care with the following points: 1. Fit: - Spring (closing valve).
5. Adjust: - Idle speed See the “MEASURING AND ADJUSTING IDLE SPEED” section in CHAPTER 3. 6. Adjust: - Throttle cable play. See the “ADJUSTING THE THROTTLE CABLE” section in CHAPTER 3. ADJUSTING JUS G THE FUEL U LEVEL 1.Measure: - Fuel level (a). Outside that specified => Adjust. Fuel level: 1.5 – 2.5 mm below the bowl line Adjustment steps: - Place the motorcycle on a flat surface. - Place a jack or a support under the engine to ensure that the carburettor is positioned vertically.
FRONT O 17 18 Front 110/80 tyre Front wheel assy.
DISMANTLING WARNING - ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING. - PLACE THE MOTORCYCLE ON A FLAT SURFACE. 1. Extract: - Front brake calliper (Bolts 1 and 2). 2. Extract: - Nut protecting cover. - Nut (left side). 3. Raise: - Front wheel (Put a suitable support under the engine). 4. Extract: - Front wheel axle. - Front brake disk assembly. - Dustguard/spacer. - Front wheel. INSPECTING THE FRONT WHEEL 1. Inspect: - Front wheel axle.
See the “INSPECTING THE TYRES” section in CHAPTER 3. - Front wheel See the “INSPECTING THE WHEELS” section in CHAPTER 3. 3. Check: - Spokes. Warps/damage => Replace. 5. Measure: - Distortion of the front wheel Above that specified => Replace. Distortion limits for the front wheel: Radial (a): 0,5 mm Lateral (b): 0,8 mm 6. Check: - Front wheel bearings. Bearings allow play in the wheel hub or the wheel does not turn freely => Replace. - Retaining rings. Damage/wear => Replace. 7. Inspect: - Spacer.
INSPECTING THE SPEEDOMETER This speedometer is fitted with a Hall Effect sensor. As this is a precision magnetic device, it should not be dismantled. In the event of it becoming faulty, the unit must be renewed. DISMANTLING THE FRONT DISK CALLIPER - Loosen the banjo bolt (1) from the bottom end of the brake pipe and tighten it slightly. - Unscrew the calliper mounting bolts (2) and separate the calliper (3) backwards from the disk. PRECAUTION CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIATELY.
Extracting the front brake pads. - Remove the front brake calliper (see “Dismantling the front brake calliper” in this chapter). Extract: - Pad springs (1). - Pin. - Brake pads (2). Fitting the front brake pads - Press the calliper pistons in manually. - Fit the pads inside the calliper. - Adjust the pad springs. WARNING DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE LEVER IS OPERATING FULLY. THIS IS ACHIEVED BY PUMPING THE LEVER UNTIL THE PADS ARE AGAINST THE DISK.
N.B. THE MASTER CYLINDER (1) IS INCORPORATED INTO THE FRONT BRAKE LEVER ASSEMBLY. - EXTRACT THE SCREWS (2) AND THE FRONT BRAKE LEVER ASSEMBLY. PRECAUTION CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIATELY. Extract: - Brake lever mounting bolt and nut. - Brake lever. Fitting the front master cylinder: - Fit the brake lever assembly and tighten the securing screw. - Tighten the flexible brake pipe bolt. - Bleed the brake system pipe (consult “Bleeding the brake system pipe” in this chapter).
Checking the brake calliper main cylinder: - Check that the anti-dust boots are not damaged. If they are, change them. - Check that the piston return is not damaged. If it is, renew it. - Check that the relief port and feed port are not blocked. if the relief port is blocked, the brake pads will bind on the disk. Inject compressed air to clean the ports. Extracting the brake disk: - Remove the front wheel. - Unscrew the mounting bolts and extract the disk.
Brake disk distortion: - Raise the motorcycle on the jack so that the tyre is clear of the ground. - To check the front disk, turn the handlebars completely to one side. - Place a dial calibrator against the disk (A) as shown, and measure the disk’s deviation from centre as the tyre is turned by hand (B). - If the deviation from centre exceeds the service limit, renew the disk. Disk deviation from centre: Standard: less than 0.
Purge the air completely from the master cylinder using this procedure. - Remove the transparent plastic cap from the bleed nipple and place the other end of the pipe in a container. - Repeat the following procedure until there is no air left emerging from the plastic pipe: - Pump the brake lever until it becomes hard and holds the brakes down. - Open and close the purge valve quickly while keeping the brake on. - Release the brake. N.B.
3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR USE IN THE BRAKE. THIS LOWERS THE BRAKE FLUID EVAPORATION POINT AND MAY RESULT IN THE BRAKES NOT WORKING EFFICIENTLY. IN ADDITION, IT MAY CAUSE DETERIORATION OF THE BRAKE PARTS. 4) DO NOT LEAVE THE RESERVOIR CAP OFF AT ANY TIME, TO PREVENT CONTAMINATION OF THE FLUID. 5) DO NOT CHANGE THE FLUID IN RAINY OR VERY WINDY CONDITIONS. 6) EXCEPT ON THE BRAKE LININGS AND THE DISK, USE ONLY BRAKE FLUID, ISOPROPILIC ALCOHOL OR ETHYL ALCOHOL FOR CLEANING BRAKE PARTS.
ASSEMBLING THE FRONT WHEEL Reverse the “DISMANTLING” procedures. Take care with the following points: 1. Lubricate: - Front wheel axle. - Bearing. - Retaining rings. Recommended lubricant: Lithium soap based grease 2. Fit: - Front wheel 3. Tighten: - Front wheel axle. - Axle nut (front wheel). ATTENTION BEFORE TIGHTENING THE WHEEL AXLE, PUSH THE FRONT FORKS DOWN SEVERAL TIMES, HOLDING THE HANDLEBARS, TO CHECK THEIR OPERATION. Axle nut: 70-80 N.m (7-8 kgf.
WHEEL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 106 DIAGRAM G Rear wheel assembly 140/70 17” rear tyre Rear wheel axle assembly Drag plate securing bolt. M16 hexagonal nut Bearing Bearing separator Rear brake disk Brake disk securing bolt GPR plate separator bush Z-50 drag plate Self locking nut Wheel tensioner Tensioner cap Chain tensioner bolt 130P secondary chain Coupling link.
BRAKE DIAGRAM G Rear brake calliper Rear brake calliper bleed nipple Rear brake pad Rear brake pad fixing spring Rear brake cylinder assembly. Reservoir to cylinder to pipe Clamp Brake cylinder protector Securing screw Washer Self locking nut Brake pedal assembly Rear brake cylinder bar assy.
DISMANTLING WARNING - ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING. - PLACE THE MOTORCYCLE ON A FLAT SURFACE. 1. Extract: - Wheel axle (1). - Spacer. N.B. ON WITHDRAWING THE WHEEL AXLE, THE SPACER WILL DROP DOWN. TAKE CARE NOT TO LOSE IT. 2. Extract: - Rear wheel. N.B. ON EXTRACTING THE WHEEL, PUSH THE WHEEL FORWARDS TO REMOVE THE DRIVE CHAIN, THEN EXTRACT THE WHEEL BACKWARDS TO AVOID THE BRAKE CALLIPER.
Fitting the rear calliper - Fit the bottom end of the flexible brake pipe and the calliper. Fit the wheel axle, the brake puller and the flexible hose securing clips. Nominal torque (wheel axle): 110-130 N.m (11-13 kgf.m) Tighten to nominal torque (brake puller): 35-40 N.m (3,5 – 4 kgf.m) - Tighten the brake banjo bolt. - Check brake fluid level. - Bleed the braking system pipe (consult “Bleeding the brake system pipe”, in the chapter corresponding to the front brakes).
WARNING DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE PEDAL IS OPERATING FULLY. PUMP THE LEVER UNTIL THE PADS ARE AGAINST THE DISK. IF NOT, THE BRAKE WILL NOT WORK THE FIRST TIME THE PEDAL IS USED. Inspecting the pads for wear - Removing the rear brake pads. - Examine both brake pads. If the wear has caused the wear indicating groove (1) to disappear, both pads must be renewed. Extracting the rear main cylinder - Remove the cover protecting the main cylinder.
Checking the rear main cylinder (visual check) - Extract the main cylinder (consult “Extracting the rear main cylinder” in this section). - Dismantle the rear main cylinder. - Check that there are no scratches, corrosion or holes in the inner walls of the main cylinder and on the outer part of each piston. If any damage is discovered on the master cylinder or on the pistons, change them. - Examine the primary and secondary seals.
Brake disk wear - Measure the thickness of the disks (A) at the point where they are most worn. - If the disk is more worn than specified in the service limit, renew it. Measurement area (B). Standard brake disk thickness: 3,80 – 4,10 mm Service limit: 3,50 mm Brake disk distortion - Raise the motorcycle on the jack so that the tyre is clear of the ground. - Place a dial calibrator against the disk (A) as shown, and measure the disk’s deviation from centre as the tyre is turned (B) by hand.
Extract: Reservoir cap (threaded) - Fill the reservoir with brake fluid up to the top reservoir line. - With the cap removed, pump the brake pedal slowly several times until no bubbles can be seen rising through the liquid. Purge the air completely from the main cylinder using the following procedure: - Remove the transparent plastic cap from the bleed valve and place the other end of the pipe in a container.
WARNING WHEN WORKING WITH THE DISK BRAKE, TAKE THE FOLLOWING PRECAUTIONS: 1) NEVER RE-USE BRAKE FLUID. 2) DO NOT USE FLUID FROM A CONTAINER THAT HAS BEEN LEFT OPEN OR HAS BEEN LEFT UNUSED FOR A PROLONGED PERIOD OF TIME. 3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR USE IN THE BRAKE. THIS REDUCES THE BRAKE FLUID EVAPORATING POINT AND MAY RESULT IN THE BRAKES NOT WORKING EFFICIENTLY. IN ADDITION, IT MAY CAUSE DETERIORATION OF THE BRAKE PARTS.
INSPECTING THE REAR WHEEL 1. Inspect: - Rear wheel axle - Rear wheel - Rear wheel bearings - Retaining rings See the “REAR WHEEL” section 2. Measure: - Distortion of the rear wheel See the “REAR WHEEL” section FITTING G THE REAR WHEEL Reverse the “DISMANTLING” procedures. Take care with the following points: 1. Fit: - Rear wheel. 2. Adjust: - Drive chain tension See the “ADJUSTING THE DRIVE CHAIN” section in “CHAPTER 3. 3. Tighten: - Rear wheel axle. - Axle nut (rear wheel) (1).
DISMANTLING 1. Place the motorcycle on a flat surface. WARNING ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING. 2. Extract: - Gear change pedal - Left hand crankcase cover - Pinion See the “DISMANTLING THE ENGINE” section in CHAPTER 4. 3. Extract: - Rear wheel See the “REAR WHEEL” section. 4. Extract: - Coupling circlip(1). - Coupling plate (2). - Coupling link. - Drive chain 5. Extract: - Chain sprocket, by removing the bolts.
INSPECTING THE DRIVE CHAIN 1. Inspect: - Chain stiffness Stiffness => Clean and lubricate, or replace. 2. Inspect: - Drive chain (1). - Chain sprocket (2). More than ½ tooth of wear => Replace the whole chain. 3. Clean: - Drive chain Place the chain in a container with petrol and brush it to remove as much of the dirt as possible. Then remove the chain from the petrol, dry and lubricate it. Lubricant for the drive chain: Engine oil CHAIN SPROCKET 1. Fit: - Chain sprocket. - Nut.
FITTING THE CHAIN SPROCKET AND THE DRIVE CHAIN 1. Fit: - Chain sprocket assembly 2. Fit: - Drive chain (1). - Coupling link (2). - Coupling plate (3). 3. Fit: - Circlip (1). ATTENTION FIT THE CHAIN COUPLING CIRCLIP FACING IN THE DIRECTION INDICATED IN THE FIGURE 4. Fit: - Pinion - Gear change pedal See the “DISMANTLING THE ENGINE” section in CHAPTER 4. 5. Adjust: - Drive chain tension See the “ADJUSTING THE DRIVE CHAIN TENSION” section in CHAPTER 3. 6. Tighten: - Wheel axle.
FORK O 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 119 Forks 2 (with the numbers ...
DISMANTLING FRONT SUSPENSION ATTENTION TO CARRY OUT THE PROCESS OF DISMANTLING THE FORKS WITHOUT REMOVING THEM FROM THE BOTTOM PLATE. TO DO SO, HOLD THE FORKS IN A BENCH VICE BY THE STEERING COLUMN, THEREBY PREVENTING THEM FROM BEING SCRATCHED. - Extract the top closing bolt. - Remove the top bolt. ATENCIÓN THE BOTTOM BAR OF THE FORKS WILL COME FREE. HOLD IT TO PREVENT IT FROM FALLING.
Extract the spring and the preload spacer. - Extract the oil seal dust guard together with its security circlip. - Firmly separate the bar from the fork stem. Extract the elements: - Dust guard (1). - Oil seal (2). - Washer (3). - Scraper (4).
- Proceed with cleaning and degreasing all the front suspension components, so that they can be subsequently checked. INSPECTING THE FRONT FORKS - Check the degree of wear on the suspension bar guide bush. Replace it in the event of it being damaged on over 30% of its total surface. - With the aid of some X-shaped chocks and a comparison meter fitted on a fixed support, determine the degree of non-alignment of the bar. Service limit: 0,4 mm.
Reassemble the assembly, paying special attention to the tightening of the fork stem, as well as the fitting of the oil seal, putting a little oil on its edges and inserting it with the aid of the special tool. Refill the hydraulic fluid and do not forget to insert the preload bush between the spring and the closing plug. N.B. TO FIT THE OIL SEAL, USE THE SPECIAL TOOL DESIGNED SPECIALLY FOR THIS OPERATION (AS IN THE PHOTO).
N.B. TIGHTEN ALL BOLTS TO THEIR NOMINAL TORQUE. - Top forks to the chassis: 30-35 N.m (3 – 3.5 kgf.m) - Top plate to the forks: 17-19 N.m (1.7-1.9 kgf.m) 2. Dismantle: Front fairing - Disconnect lighting connections. - Disconnect dashboard connections. - Remove the front fairing securing bolts with the frame (1). 3. Dismantle: Top plate – Top plate bolts-forks (1) and plate-chassis (2). 4. Separate: Forks wheel assembly (downwards). 5. Check: - Functioning (top and bottom bearings).
HANDLEBARSS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 125 Right hand semi-handlebar sub-assembly Left hand semi-handlebar sub-assembly M8 bolt Handlebar counterweight Silentblock bush M5 Allen screw Throttle twist-grip assembly Electric starter switch assembly Handlebar securing clamp Throttle cable sub-assembly M5 bolt Front brake cylinder assembly.
DISMANTLING WARNING - ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING. - PLACE THE MOTORCYCLE ON A FLAT SURFACE. RIGHT HAND HALF HANDLEBAR 1. Extract: - Right hand light switch assembly. - Front brake lever assembly. - Handlebar counterweight - Throttle twist-grip. 2. Extract: - Half handlebar securing bolts. LEFT HAND HALF HANDLEBAR 1. Extract: - Left hand switch assembly. - Clutch lever assembly. - Handlebar counterweight - Left-hand grip. N.B.
INSPECTING THE HALF HANDLEBARS 1. Inspect: - Half handlebars Warping/cracks/damage => Replace. WARNING DO NOT ATTEMPT TO STRAIGHTEN A WARPED HANDLEBAR. THIS MAY SERIOUSLY WEAKEN THE HANDLEBARS. DISMANTLING THE STEERING COLUMN 1. Extract: - Top plate closing plug. - Top plate (with half handlebars fitted to it). 2. Lift up the front of the motorcycle. The front wheel will descend. N.B. SUPPORT THE STEERING SHAFT FIRMLY TO PREVENT ANY RISK OF THE MACHINE FALLING.
2. Place the front wheel in its correct position. 3. Fit: - Top plate, with half handlebars fitted to it. - Top plate nut. Top plate nut: 30-35N.m(3-3.5kgf.m) FITTING THE HALF HANDLEBARS 1. Fit: - Components corresponding to the side to be fitted. 2. Fit: - The half handlebars onto the top plate. Fitting torques: - Plate to half handlebar nut: 17 - 19 N.m with sealer (1.7 – 1.9 kgf.m) - Handlebar counterweight: 3.5 - 4.5 N.m (0.35 -0.45 kgf.m) N.B.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 129 Swinging arm assembly Swinging arm shaft assembly M14 hexagonal nut Needle bearing Swinging arm adhesive Swinging arm stop bush Shock absorber separator bottom bush Shock absorber assembly M10 hexagonal head bolt D10 washer M10 hexagonal nut M10 hexagonal head bolt Chain cover Countersunk head bolt Chain rubbing plate Self-locking bolt Flat washer Shock absorber separator top bush
DISMANTLING 1. Place the motorcycle on a flat surface. WARNING ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING. 2. Extract: - Rear wheel. - Wheel sprocket. - Brake disk. - Rear calliper. See the “GEAR RATIO” section. 3. Extract: - Nut (top and bottom). - Shock absorber. 4. Extract: - Swinging arm shaft nut. - Wheel axle nut. - Washers (swinging arm). - Shafts. - Swnging arm. INSPECTION 1.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 131 Front electrical wiring system Rear electrical wiring system Front right hand headlight assembly Front left hand headlight assembly Bolt Flat washer Front headlight bulb Front pilot light assembly Pilot light fitting Pilot light brake bulb Pilot light sidelight bulb Sidelight cluster sub-assembly Screw Clutch spring stop washer Rear right hand turn indicator assembly. Rear leftt hand turn indicator assembly.
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 132 Securing nut 15A fuse M6 self-locking nut M6 Crosshead screw Coil separator bush Neutral switch Seal Coil Spark plug cap Escape valve motor.
O - Orange GR - Green B - Black BR - Brown W - White G - Grey Y - Yellow BL - Blue R - Red P- Pink VI - Violet 1 1A 1B 1C 2 2A 2B 2C 2D 2E 3 4 5 6 7 8 8A 8B 9 10 11 12 13 14 133 Front headlight 12v 35W R/H front headlight dipped beam 12v 35W L/H front headlight main beam 12v 2.
CHECKING CONNECTORS Check for corrosion, damp etc. in the connectors. 1. Disconnect: - Connectors 2. Dry each of the terminals with compressed air. 3. Connect and disconnect two or three times. 4. Pull the conductor to check if it is loose. 5. If the terminal comes loose, bend the pin (1) and refit the terminal in the connector. 6. Connect: - Connector N.B. THE TWO PARTS OF THE CONNECTOR MAKE A SOUND WHEN THEY FIT TOGETHER. 7. Check the circuit with a Multimeter. N.B.
INSPECTION STEPS Using a multimeter, check the circuit between the terminals to make sure that they are correctly connected. Replace the component if any of the combinations gives an incorrect reading. N.B. - SWITCH THE “ON” AND “OFF” SWITCH ON AND OFF SEVERAL TIMES. - ADJUST THE METER SELECTOR TO THE “X1” POSITION. - ADJUST THE GAUGE TO “ZERO”.
IF THE IGNITION SYSTE FAILS (NO SPARK OR INTERMITTENT SPARK) PROCEDURES Check: 1. 2. 3. 4. 5. 6. 7. 8. Spark plug. Gap between electrodes Resistance of the connector Ignition coil. Main switch. Resistance of the impulse coil. Resistance of the field coil. Ignition system connections. N.B. - REMOVE THE FOLLOWING PARTS BEFORE DIAGNOSIS: 1) FAIRING AND SEATS 1. Spark plug Standard spark plug NGK BR8ES - Check the spark plug condition. - Check the type of spark plug. - Check the gap between the electrodes.
3. Resistance of the spark plug connector Terminal (+) Terminal (-) Spark plug side(1). Spark plug lead side (2). - Remove the connector. - Connect the Multimeter (Ω x 1) to the spark plug connector. N.B. - ON REMOVING THE SPARK PLUG CONNECTOR, DO NOT PULL IT WITH THE SPARK PLUG LEAD. REMOVAL =>TURN IN AN ANTI-CLOCKWISE DIRECTION. FITTING => TURN IN A CLOCKWISE DIRECTION. - CHECK THE SPARK PLUG LEAD WHEN CONNECTING THE CONNECTOR.
Terminal (+) Terminal (-) Orange / Green (1) Spark plug lead (2) - Connect the Multimeter (Ω x 1) to the ignition coil. - Check the resistance of the coil secondary winding. Secondary winding resistance: 7.9 ± 20 % a 20°C OUTSIDE THAT SPECIFIED BOTH CONFORM TO SPECIFICATIONS 5. Main switch (ignition key) Renew the ignition coil. NO CIRCUIT See the “INSPECTING THE SWITCHES” section. CIRCUIT Renew the main switch (ignition key) 6.
7. Charging coil resistance - Disconnect the field coil connector from the electrical system. - Connect the Multimeter (x 100) to the field coil connector Terminal (+) Terminal (-) Black/Red Terminal Green/White Terminal - Check the resistance of the field coil. Resistance of the field coil. 730 ± 20 % a 20°C OUTSIDE CONFORMS THAT SPECIFIED TO SPECIFICATIONS Outside that specified. Renew generating coil. 8.
STARTER MOTOR NOT WORKING PROCEDURES Check: 1. 2. 3. 4. 5. 6. 7. Main fuse. Battery. Starter motor. Starter relay. Ignition key. Starter switch. Connections. NO 1. Main fuse CIRCUIT - Remove the fuse. - Connect the Multimeter (Ω x 1) to the fuse. - Check that there is a circuit in the fuse. Fuse defective, replace. CIRCUIT 2. Battery - Check the condition of the battery. See the “INSPECTING THE BATTERY” section in CHAPTER 3. Minimum voltage: 12 V Recharge or renew the battery.
3. Starter motor - Connect the positive terminal of the battery (1) and the starter motor cable (2), using a bridging conductor (3) on the relay (4) as shown in the figure. WARNING THE CONDUCTOR USED FOR BRIDGING MUST HAVE A CAPACITY COMPATIBLE WITH THAT OF THE STARTER MOTOR. IF NOT, THE MOTOR MAY BURN OUT. *as in the figure. DOES - Check starter motor functioning. NOT TURN OVER Defective starter motor – repair or replace. TURNS OVER 4.
TURNS OVER 5. Main switch - Disconnect the main switch connection from the electrical system. - Check the circuit between the Red and Red/Black conductors. See the “INSPECTING THE SWITCHES” section. O GR BL R/W LOCK OFF INCORRECT ON TURNS OVER 6. Neutral switch. - Disconnect the neutral switch conductor from the electrical system. - Check the circuit between the “Blue” (1) and the “Earth”. See the “INSPECTING THE SWITCHES” section. 142 Defective main switch - replace.
BL NEUTRAL IN GEAR INCORRECT 80 1 Defective neutral switch – replace. CORRECT 7. Starter switch - Disconnect the starter switch conductor from the electrical system. - Check the starter switch circuit between the “Red/Black” (1) and “Black” (2) conductors. See the “INSPECTING THE SWITCHES” section. STOP ENGINE Y/GR GR/B ENGINE R/B W/B OFF INCORRECT ON Defective starter switch – replace. CORRECT 8. Connections Check the ignition system connections. See the “INSPECTING THE SWITCHES” section.
