Boulevard 50 2T: Workshop Manual

WORKSHOP MANUAL
BOULEVARD 50 2T
INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME
INDEX OF TOPICS
CHARACTERISTICS CHAR
Characteristics
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 DERBI spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spare parts may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. 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 electric connections have been done properly, particularly the ground and battery connections.
CHAR - 7
Characteristics
Vehicle identification
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Frame prefix ZAPM44100 ÷ 1001
Engine prefix VTHBR1A1 xxxxxxxxx
Dimensions and mass
DIMENSIONS AND MASS

Dry weight 97 Kg
Length 1,880
Maximum height 1150 mm
Seat height 785
Width 735
Wheelbase 1,340
CHAR - 8
Characteristics
Engine
ENGINE
Engine type Two-stroke, single cylinder Piaggio Hi-PER2
Bore x stroke 40 X 39.3 mm
Cubic capacity 49.40 cc
Compression ratio 10,3 :1
Carburettor DELL'ORTO PHVA 17.5
CO adjustment 3.5% ± 0.5
Engine idle speed 1800 to 2000 r.p.m.
Air filter Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and
50% unleaded petrol).
Starting system electric starter/kick-starter
Lubrication With blend and variable oil variable according to the engine
revolutions and the throttle valve opening by means of a pump
controlled by the driving shaft with toothed belt.
Fuel supply Gravity feed, with unleaded petrol (with a minimum octane rat-
ing of 95) with carburettor.
Cooling system forced coolant circulation system
CHAR - 9
Characteristics
Transmission
TRANSMISSION
Transmission With automatic expandable pulley variator, torque server, V-
belt, automatic clutch, gear reduction unit.
Capacities
CAPACITIES
Rear hub oil Quantity: approx. 85 cc
oil mixer tank Plastic, capacity ~ 1.2 l
Fuel tank capacity approx. 7.2 litres (of which 1.5 l is reserve)
Electrical system
ELECTRICAL SYSTEM
Type of ignition Capacitive discharge type electronic ignition, with incorporated
high voltage coil
Ignition advance (before TDC) Fixed 17° ± 1
Recommended spark plug CHAMPION RN2C
Battery 12V-4Ah
Main fuse 7.5 A
Generator In alternate current with three output sections
Frame and suspensions
FRAME AND SUSPENSIONS

Type of chassis Welded tubular steel chassis with stamped sheet reinforce-
ments.
Front suspension Telescopic mechanical fork, 76mm travel.
Rear suspension Single hydraulic shock absorber, 72.5-mm travel
Brakes
FRENI
Front brake Disc brake (Ø 200 mm) with hydraulic control (lever on the right
end of the handlebar) and floating calliper.
Rear brake drum brake (Ø 140 mm) with mechanical linkage.(l.h. brake
lever).
Wheels and tyres
WHEELS AND TYRES

Front wheel rim Die-cast aluminium alloy 3.50 x 12"
Front tyre Tubeless, 120/70-12"
CHAR - 10
Characteristics
Rear wheel rim Die-cast aluminium alloy: 3.00"x12"
Rear tyre Tubeless, 120/70 - 12"
Front tyre pressure 1.8 bar
Rear tyre pressure 2 bar
Rear wheel pressure (rider and passenger): 2.3 bar
Secondary air
Follow these steps to clean the sponge filters of

the secondary air system:
1) Remove the snap-on plastic cover (1) on the
transmission cover using a small screwdriver as a
lever on the retaining tongues in order to insert one
of the three slots found on that cap.
2) Wash the polyurethane sponge with water and
soap, dry all components with compressed air and
refit to place. Refit the intake cap respecting the
angle reference.
3) Undo the two fixing screws (2) on the aluminium
cover of the secondary air housing in order to
reach the polyurethane sponge inside that hous-
ing; clean as indicated in point 2) and refit all
elements after checking the steel tab is not de-
formed and/or does not guarantee correct tight-
ness at its fitting; replace if necessary.
N.B.
UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE
TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMI-
NIUM COVERS.
CAUTION
WHILE CARRYING OUT OPERATION 3), ALWAYS CHECK
THE TWO RUBBER COUPLINGS (3) ON ONE END OF THE
SECONDARY AIR PIPE FOR CORRECT TIGHTNESS AND
CONTINUITY; IF NECESSARY, REPLACE THEM AND USE
NEW CLAMPS TO FIX THEM.
Carburettor
50cc Version
CHAR - 11
Characteristics
Dell'Orto
DELLORTO CARBURETTOR
Type PHVA 17.5 RD
Diffuser diameter Ø 17.5
Regulation reference number 8423
Maximum nozzle: 53
Maximum air nozzle (on the body): Ø 1.5
Tapered pin stamped code: A22
Pin position (notches from above): 1
Diffuser: 209 HA
Minimum nozzle: 32
Minimum air nozzle (on the body): Free
Initial minimum mix screw opening: 1 1/2
Starter jet 50
Starter air nozzle (on the body): Ø 1.5
Stroke of starter pin: 11 mm
Gasoline inlet hole Ø 1.5
Tightening Torques
FRONT BRAKE
Name Torque in Nm
Brake fluid pump - hose fitting 16 ÷20 Nm
Brake fluid pipe-calliper fitting 19 ÷ 24
Calliper tightening screw 24 ÷ 27
Disc tightening screw 8 ÷ 10
Oil bleed screw 7 ÷ 10
FRONT SUSPENSION
Name Torque in Nm
Lower fork fixing screw 15 ÷ 20
Front wheel axle nut 45 - 50
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 35 ÷ 40
Steering lower ring nut 8 ÷ 10
Handlebar fixing screw 50 ÷ 55
ENGINE ASSEMBLY
Name Torque in Nm
Clutch bell nut (**) 40 ÷ 44
Clutch lock ring nut 55 ÷ 60
Nut locking driving pulley on crankshaft (**) 40 ÷ 44 Nm
Start-up lever screw 12 ÷ 13
Flywheel nut (**) 40 ÷ 44
Flywheel fan screws 3÷4
Half-crank case joint bolts 12 ÷ 13
Bolts holding exhaust pipe to the crankcase 22 ÷ 24
Screws holding the filter box to the crank case 4÷5
Head nuts 10 ÷ 11
Starter screws 12 ÷ 13
Ignition spark plug 25 ÷ 30
Hub oil drainage cap 3÷5
Oil hub level dipstick Manual
Rear hub cap screws 12 ÷ 13
Transmission cover screws 12 ÷ 13
Inlet manifold screws 8÷9
CHAR - 12
Characteristics
Name Torque in Nm
Flywheel hood fixing screws 1÷2
Cylinder hood fixing screws 3.5 ÷ 5
Stator clamping screws 3÷4
Pick-Up clamping screw 4÷5
Mixer clamping screws 3÷4
Screw fixing brake lever to the journal on the engine 12 ÷ 13
CHASSIS
Name Torque in Nm
Swinging arm - engine pin* 33 ÷ 41
Frame/swing-arm bolt (*) 64÷72
Shock absorber - chassis nut (*) 20 to 25 Nm
shock absorber - engine pin (*) 33 to 41 N·m
Rear wheel axle (*) 104÷126 N·m
Centre-stand mounting bracket bolt 25÷30 N·m
Centre-stand mounting bracket screw 20÷25 N·m
Side stand fixing screw 12 ÷ 20
Side stand bracket fixing screw 15 ÷ 20
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND CYLINDER

Name Initials Cylinder Piston Play on fitting
Standard coupling M 40.005 - 40.012 39.943 - 39.95 0.055 - 0.069
Standard coupling N 40.012 - 40.019 39.95 - 39.957 0.055 - 0.069
Standard coupling O 40.019 - 40.026 39.957 - 39.964 0.055 - 0.069
Standard coupling P 40.026 - 40.033 39.964 - 39.971 0.055 - 0.069
coupling 1st oversize M1 40.205 - 40.212 40.143 - 40.15 0.055 - 0.069
coupling 1st oversize N1 40.212 - 40.219 40.15 - 40.157 0.055 - 0.069
coupling 1st oversize O1 40.219 - 40.226 40.157 - 40.164 0.055 - 0.069
coupling 1st oversize P1 40.226 - 40.233 40.164 - 40.171 0.055 - 0.069
Coupling 2nd oversize M2 40.405 - 40.412 40.343 - 40.35 0.055 - 0.069
Coupling 2nd oversize N2 40.412 - 40.419 40.35 - 40.357 0.055 - 0.069
Coupling 2nd oversize O2 40.419 - 40.426 40.357 - 40.364 0.055 - 0.069
Coupling 2nd oversize P2 40.426 - 40.433 40.364 - 40.371 0.055 - 0.069
CHAR - 13
Characteristics
Piston rings
SEALING RING
Name Description Dimensions Initials Quantity
Compression ring 40 A 0.10 to 0.25
Compression ring 1st 40.2 A 0.10 to 0.25
oversize
Compression ring 2nd 40.4 A 0.10 to 0.25
Oversize
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity
Connecting rod 11.750-0.05 A clearance E = 0.25 to
0.50
shoulder washer 0.5 ± 0.03 G clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
Half-shaft, transmission 13.75+0.040 C clearance E = 0.25 to
side 0.50 - clearance F =
0.20 to 0.75
Flywheel-side half-shaft 13.75+0.040 D clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
Lining between the 40.64 H clearance E = 0.25 to
shoulders 0.50 - clearance F =
0.20 to 0.75
Cage 11.800-0.35 B clearance F = 0.20 to
0.75
Slot packing system

This type of engines foresees the use of one size of basic gaskets.
CHAR - 14
Characteristics
For 25 km/h engine type versions, use 2 gaskets between cylinder and crankcase.
Products
RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 2-stroke engines: SAE 5W-40, API
(brake, throttle control and mixer, odom- SL, ACEA A3, JASO MA
eter)
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
MONTBLANC MOLYBDENUM Grease for driven pulley shaft adjusting Grease with Molybdenum disulphide
GREASE ring and movable driven pulley housing
AGIP GREASE PV2 Grease for steering bearings, pin seats White anhydrous-calcium based grease
and swinging arm to protect roller bearings; temperature
range between -20 C and +120 C; with
NLGI 2; ISO-L-XBCIB2.
AGIP GREASE SM 2 Grease for odometer transmission gear Lithium grease with NLGI 2 molybdenum
case disulphide; ISO-L-XBCHB2, DIN
KF2K-20
AGIP GP 330 Grease for brake control levers, throttle, White calcium complex soap-based
stand spray grease with NLGI 2; ISO-L-XBCIB2
CHAR - 15
INDEX OF TOPICS
TOOLING TOOL
Tooling
TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54 mm bearing
001467Y009 Driver for OD 42-mm bearings
001467Y013 Pliers to extract ø 15-mm bearings
TOOL - 17
Tooling

001467Y017 Bell for bearings, OD 39 mm
001467Y021 Extraction pliers for ø 11 mm bearings
002465Y Pliers for circlips
006029Y Punch for fitting fifth wheel seat on steer-

ing tube
020004Y Punch for removing fifth wheels from

headstock
020055Y Wrench for steering tube ring nut
020150Y Air heater mounting
TOOL - 18
Tooling

020151Y Air heater
020162Y Flywheel extractor
020163Y Crankcase splitting plate
020164Y Driven pulley assembly sheath
020165Y Start-up crown lock
020166Y Pin lock fitting tool
TOOL - 19
Tooling

020261Y Starter spring fitting
020265Y Bearing fitting base
020325Y Pliers for brake-shoe springs
020329Y Mity-Vac vacuum-operated pump
020330Y Stroboscopic light to check timing
TOOL - 20
Tooling

020331Y Digital multimeter
020332Y Digital rpm indicator
020333Y Single battery charger
020334Y Multiple battery charger
TOOL - 21
Tooling

020335Y Magnetic mounting for dial gauge
020350Y Electrical system check instrument
020357Y 32x35-mm Adaptor

020376Y Adaptor handle
020412Y 15-mm guide
TOOL - 22
Tooling

020456Y Ø 24 mm adaptor
020483Y 30-mm guide
020565Y Flywheel lock calliper spanner
494929Y Exhaust fumes analyser
TOOL - 23
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance
Maintenance chart
EVERY 2 YEARS
Action
Brake fluid - change
AFTER 1000 KM
50'
Action
Hub oil - change
Oil mixer/throttle linkage - adjustment
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
AFTER 5000 KM, 25000 KM, 35000 KM AND 55000 KM

40'
Action
Hub oil level - check
Spark plug/electrode gap - replacement
Air filter - clean
Brake pads - check condition and wear
AFTER 10000 KM, 50000 KM

95'
Action
Hub oil - change
Air filter - clean
Idling speed (*) - adjustment
Variable speed rollers - replacement
Driving belt - checking
Transmission elements - lubrication
Suspensions - check
Headlight - adjustment
(*) See regulations in the «Adjusting the idle speed» section
AFTER 15000 KM AND 45000 KM

65'
MAIN - 25
Maintenance
Action
Hub oil level - check
Air filter - cleaning
Driving belt - replacement
SAS box (sponge) (**) - cleaning
(**) See regulations in the «Secondary air system» section
AFTER 20000 KM AND 40000 KM

110'
Action
Hub oil - change
Air filter - clean
Cylinder cooling system - check/cleaning
Driving belt - checking
Mixer belt - replacement
Suspensions - check
(*) See section «Adjusting the idle speed»
AFTER 30000 KM
130'
Action
Hub oil - change
Air filter - clean
Flexible brake tubes - replacement
Suspensions - check
MAIN - 26
Maintenance

AFTER 60000 KM
150'
Action
Hub oil - change
Air filter - clean
Cylinder cooling system - check/cleaning
Mixer belt - replacement
Flexible brake tubes - replacement
Suspensions - check
Carburettor
- Disassemble the carburettor in its parts, wash all

of them with solvent, dry all body grooves with
compressed air to ensure adequate cleaning.
- Check carefully that the parts are in good condi-
tion.
-The throttle valve should move freely in the
chamber. Replace valve in case of wear due to
excessive clearance.
- If there are wear marks in the chamber causing
inadequate tightness or a free valve slide (even if
it is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit.
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE
GASKETS TO AVOID PETROL LEAKS
MAIN - 27
Maintenance
1. Automatic starter - 2. Idle air set screw - 3. Idle speed set screw - 4. Throttle valve spring - 5. Throttle
valve tapered pin - 6. Throttle valve - 7. Carburettor body - 8. Pin - 9. Min. jet - 10. Float - 11. Max. jet
- 12. Float chamber
Checking the spark advance
-Check to be made at over 4000 rpm with strobo-

scopic gun. The advanced ignition measured must
be 17° before the TDC.
- This value is correct when the reference mark on
the flywheel hood is aligned with the reference
mark on the cooling fan and the phase shifter on
the stroboscopic gun is set on 17°.
N.B.
IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS
PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK
THE CORRECT KEYING OF THE FLYWHEEL ON THE
CRANKSHAFT.
Specific tooling
020330Y Stroboscopic light to check timing
Spark plug
Place the vehicle on its central stand

- Remove the central cover, indicated in the figure,
by undoing the 2 fixing screws;
- Disconnect spark plug HV wire hood;
-Undo the spark plug using the socket wrench;
-Examine the condition of the spark plug, check
that the insulating material is whole and measure
the distance between the electrodes using a thick-
ness gauge.
-Adjust the distance if necessary by bending the
side electrode very carefully.
In the case of defects, replace the spark plug with
one of the specified type;
MAIN - 28
Maintenance
- Engage the spark plug with the due inclination

and screw it right down by hand, then do it up with
the wrench at the prescribed torque;
-Put the hood on the sparking plug as far as it will
go;
- Refit the central flap.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MO-
TOR IS COLD. THE SPARK PLUG MUST BE REPLACED
EVERY 5000 KM. USE OF STARTERS NOT CONFORMING
OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERI-
OUSLY DAMAGE THE ENGINE.
Characteristic
Recommended spark plug
CHAMPION RN2C
Electric characteristic
Electrode gap
0.6 to 0.7 mm.
Locking torques (N*m)

Spark plug 25 - 30 Nm
Hub oil
Check
Do the following to check the correct level:

1) Stand the vehicle on the centre-stand on flat
ground;
2) Remove the dipstick «A», and dry it with a clean
cloth. Reinsert it, screwing it in all the way;
3) Remove the stick and check that the oil level is
slightly over the second notch starting from the
lower end;
4) Screw the dipstick back in, checking that it is
locked in place.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
MAIN - 29
Maintenance
Replacement
- Remove the oil filler cap «A».

- Loosen the oil draining cap «B» and let the oil
completely drain the tank.
- Tighten the draining cap and refill the hub with oil
(approx. 75 cc).
Air filter
-Remove the cap of the purifier, unscrewing the six

clamping screws and removing the filter.
Cleaning:
-Wash with water and neutral soap.
- Dry with a clean cloth and short blasts of com-
pressed air.
-Saturate with a 50% mixture of gasoline and oil.
-Drip dry the filter and then squeeze it between the
hands without wringing.
-Let it dry and refit it again.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE
PISTON AND CYLINDER.
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased ad-
hesiveness
MAIN - 30
Maintenance
Checking the ignition timing
- Adjust the control cables:

Mix cable: see procedure indicated in "Mixer tim-
ing".
Throttle cable: adjust the set screw on the carbu-
rettor in such a way that the sheath has no back-
lash.
Splitter control cable: adjust set screw on the throt-
tle control to the handlebar in such a way that there
is no backlash on the throttle control.
Adjust all transmissions in such a way that their
sheathings show no sign of backlash.
Mixer Timing
- Using the transmission set screw on the crank-
case, with throttle control untwisted, adjust the
reference mark on the rotating plate so that it is
lined up with the reference mark on the mixer
body, as shown in the figure.
While doing this, the engine must be fuelled with a
2 % oil mixture (0.5 litre minimum if the reservoir
is empty).
CAUTION
IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN
THE RESERVOIR BLEED THE MIXER AS FOLLOWS: RE-
FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED
TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE
MIXER PIPE FROM THE CARBURETTOR AND LOOSEN
THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE)
UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE
SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO
FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY
PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH
THE RELEVANT METAL CLIP.
AGIP CITY TEC 2T Mixer oil
synthetic oil for 2-stroke engines: JASO FC, ISO-
L-EGD
Braking system
MAIN - 31
Maintenance
Level check
Proceed as follows:
- Rest the vehicle on its centre stand with the han-
dlebars perfectly horizontal;
- Check the level of liquid with the related warning
light «A».
A certain lowering of the level is caused by wear
on the pads.
Top-up
Proceed as follows:
- Remove the tank cap by loosening the two
screws, remove the gasket and top up using only
the liquid specified without exceeding the maxi-
mum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR

EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
CAUTION
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE
SURE THAT IT DOES NOT COME INTO CONTACT WITH
THE PAINTWORK.
CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS,
IT ABSORBS MOISTURE FROM THE SURROUNDING AIR.
IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID
EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEF-
FICIENT.
NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY
USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID
MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EV-
ERY TWO YEARS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO
THE CHANGING OF BRAKE FLUID AND THE BLEEDING
OF AIR FROM THE CIRCUITS.
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
MAIN - 32
Maintenance
Headlight adjustment
Proceed as follows:
1. Place the vehicle, in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10-m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the scooter is perpendicular to the screen;
2. Turn on the headlight and check that the bor-
derline of the projected light beam on the screen
is not higher than 9/10 or lower than 7/10 of the
distance from the ground to the centre of vehicle
headlamp;
3. If otherwise, adjust the right headlight with screw
«A».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
CO check
In the event that the exhaust on the vehicle being

tested does not have an exhaust gases collection
port, proceed as follows:
- Remove the R.H. side fairing
- Remove the secondary air box cover with the
aluminium cap by acting upon the clamp shown in
the figure.
Attach the exhaust gas collection tube to the sec-

ondary air rubber manifold. Such joint must be
sealed in order to guarantee accurate CO read-
ings.
- Start the engine, adjust the idle speed to 1,700 ± 100 rpm and check the CO value is equal 3.5 ± 1%
MAIN - 33
Maintenance
- If the parameters found do not agree with the above figures, act upon the idle adjusting screw. Oth-
erwise, check the automatic choke device
Specific tooling
020320Y Exhaust gases analyser
The check must be carried out after having care-

fully cleaned all carburettor components, with the
air filter clean, and the spark plug in good condi-
tions.
- Remove the R.H. side fairing
- Warn-up the engine by riding the vehicle on the
road for at least 10 minutes
- Shut down the engine
- Remove the 2 secondary air box screws shown
in the figure
− Place a plastic sheet between the one-way valve

and the aluminium outlet as shown in the figure
− Ensure the one-way valve packing properly

seals the aluminium outlet fitting.
− Refit the aluminium outlet onto the SAS box as
shown in the picture.
MAIN - 34
Maintenance
- Attach the special tool and move the joints as

shown in the figure.
- Start the engine, adjust the idle speed to 1,700 ±
100 rpm and check the CO value is equal 3.5 ± 1%
- If the parameters found do not agree with the
above figures, act upon the idle adjusting screw.
Otherwise, check the automatic choke device.
Specific tooling
020320Y Exhaust gases analyser
020625Y Kit for sampling gas from the exhaust
manifold
SAS filters inspection and cleaning
After removing the spark plug cap, remove the

RHS fairing, by loosening the three fixing screws
«B» shown in the figure.
Remove the SAS aluminium cover fixing screws
«A». Detach the metal hose from its rubber hous-
ing on the cover, without detaching it from the
cover/bellow. Hence remove plate and plastic cov-
er, extract the sponge and wash it with soap. Dry
with compressed air before refitting, ensuring to
correctly positioning the plate in the housing ma-
chined on the plastic and aluminium covers.
Whenever removing the part, always replace the
O-ring located on the special housing on the cover.
MAIN - 35
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Troubleshooting
This section makes it possible to find the solutions to use in troubleshooting.

For each breakdown, a list of the possible causes and respective interventions is given.
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed air
Excess of encrustations in the combustion chamber Remove the encrustations
Lack of compression wear of the piston rings or cylinder Check the worn parts and replace them
Exhaust pipe clogged due to excessive encrustations Replace the exhaust pipe and check the carburation and mixer
timer
Air filter blocked or dirty Clean according to the procedure
Starter inefficient (stays on) Check the mechanical sliding, continuity of the circuit, the pres-
ence of power and electrical wiring
Clutch slipping Check the centrifugal brake shoe assembly and /or clutch bell
and replace if necessary
Defective mobile pulley sliding Check the parts, change the faulty parts and lubricate the driv-
en pulley using only Montblanc-Molibdenum Grease (dis.
498345) grease
Driving belt worn Replace
Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air
Fuel filter on vacuum operated cock blocked Clean the cock filter
Roller wear; Presence of oil; Dirt Check the cap with filter is fitted to the transmission cover;
clean the speed variator, replace the rollers if worn out
Rear wheel spins at idle
REAR WHEEL
Idling rpm too high Check the idling speed and, if necessary, adjust the C.O.
Clutch fault Check the spring/friction mass and the clutch bell
Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged
Starting difficulties
DIFFICULTY STARTING
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Faulty fuel cock Check that, at ignition and with throttle untwisted, no petrol
flows out the delivery pipe; otherwise, replace the vacuum-op-
erated cock
Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Defective spark plug or with incorrect electrode gap Check and if necessary replace the spark plug and the elec-
trode gap
Battery flat Check the state of the battery. If it shows signs of sulphation
replace it and bring the new battery into service charging it for
eight hours at a current of 1/10 of the capacity of the battery
itself
- Engine flooded. Start the vehicle keeping the throttle fully open alternately mak-
ing the engine run for approx. five seconds and stopping for
other five seconds. If however it does not start, remove the
spark plug, the engine over with the throttle open being careful
TROUBL - 37
Troubleshooting

to keep the cap in contact with the spark plug and the spark
plug grounded but away from its hole. Refit a dry spark plug
and start the vehicle.
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Faulty spark plug Remove the encrustation, restore the plug gap or replace being
sure to use the types of spark plug recommended at all times.
Bear in mind that many problems engines have, derive from
the use of the wrong spark plug
Intake joint cracked or with a bad seal Replace intake joint and check for correct sealing on the head
Purifier-carburettor fitting damaged Replace
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Excess of encrustations in the combustion chamber Remove the encrustations
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air
Dirty carburettor Wash the carburettor with solvent and dry with compressed air
Water in the carburettor Empty the tank through the appropriate bleed nipple.
Air filter dirty Clean or replace
Defective floating valve Check the proper sliding of the float and the functioning of the
valve
Tank breather hole obstructed Restore the proper reservoir aeration
Engine tends to cut-off at idle
ENGINE STOP IDLING

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air
Starter that stays open Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Reed valve does not close Check / replace the reed pack
Wrong idling adjustment Correctly adjust the engine idling and check the level of the
C.O.
Spark plug defective or faulty Replace the spark plug with one with the specified degree and
check the plug gap
Excessive exhaust noise
INCREASED NOISINESS
Secondary metal air pipe deteriorated Check there are no leaks on the hoses on the crankcase and
the housing, check that there is a cap with filter and it is correctly
fitted to the transmission cover
Good condition of the missing secondary air circuit components Check the individual components and the piping, check the
precision of the fitting. Replace the damaged components
TROUBL - 38
Troubleshooting
High fuel consumption
HIGH FUEL CONSUMPTION

Air filter blocked or dirty. Clean according to the procedure
Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and
power supply
SAS malfunctions
SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-
FLER
Secondary air reed blocking Replace
Secondary air filter clogging Clean the filter and the housing
Blockage of the secondary air fitting on the muffler Remove the encrustations from the joint being careful not to let
the debris fall into the muffler
Transmission and brakes
Clutch grabbing or performing inadequately
CLUTCH BRAKES
Slippage or irregular functioning Check that the masses open and return normally
Check that there is no grease on the masses
Check that the clutch masses' contact surface with the clutch
bell is mainly in the middle with characteristics equivalent on
the three masses
Check that the clutch bell is not scored or worn abnormally
Never operate the engine without the clutch bell
Check the cap with filter is fitted to the transmission cover
Insufficient braking
BRAKING SYSTEM MALFUNCTION

Poor braking The rear (drum type) brake is adjusted by regulating the special
adjustment (on the wheel) bearing in mind that, with the control
levers in the rest position, the wheels must turn freely.
The braking action should begin when the brake levers are
pressed by about a third.
Check the brake pad wear.
If it is not possible to remove any problems by simply adjusting
the transmissions, check the brake pads and front brake disc,
the brake shoes and the rear drum. If you encounter excessive
wear or scoring, make the necessary replacements.
Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be
no flexible movement of the brake lever).
Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump breakdown, replace
The brake fluid has lost its properties Replace the front brake fluid and top up to the correct level in
the pump
Defective sliding of the cables in their sheathes Lubricate or substitute
Brake noise Check the wear of the brake pads and/or shoes
TROUBL - 39
Troubleshooting
Brakes overheating
BRAKES OVERHEATING
Defective piston sliding Check calliper and replace any damaged part.
Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the
wheel correctly fitted or the concentricity of the rear drum.
Electrical system
Battery
BATTERY
Battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. If the
vehicle is not used for some time (1 month or more) the battery
needs to be recharged periodically. The battery runs down
completely in the course of 5 ÷ 6 months. If the battery is fitted
on a motorcycle, be careful not to invert the connections, 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
Rear wheel
REAR WHEEL
Idle speed set too high Adjust idle speed. Adjust C.O. if necessary
Faulty clutch Check springs / frictional weights and clutch housing.
Heavy steering
STEERING HARDENING
Torque not conforming Check the tightening of the top and bottom ring nuts.
If irregularities continue in turning the steering even after mak-
ing the above adjustments, check the seats in which the ball
bearings rotate: replace if they are recessed.
Excessive steering play
EXCESSIVE STEERING CLEARANCE

EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring nuts.
If irregularities continue in turning the steering even after mak-
ing the above adjustments, check the seats in which the ball
bearings rotate: replace if they are recessed.
TROUBL - 40
Troubleshooting
Noisy suspension
NOISY SUSPENSION
NOISY SUSPENSION If the front suspension is noisy, check: the efficiency of the front
shock absorbers; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers and the movement
bushings.
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION

Oil leakage from suspension Service the pumping members and check the sleeves and
sealing rings are in good conditions. Replace the damaged
parts
TROUBL - 41
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system
ELECTRICAL SYSTEM DIAGRAM

1 Stop button on rear brake
2 Light switch
3 Turn indicator switch
4 Horn button
5 Horn
6 Front turn indicator bulbs Front turn indicator bulbs 12V-10W x 2
7 Front left turn indicator
8 Heater control device
9 Magneto flywheel
10 Electronic ignition device
11 Starter motor
ELE SYS - 43
Electrical system
12 Fuse box
13 Battery 12V - 4Ah
14 rear left turn indicator
15 Rear turn indicator bulbs Two, 12V-10W, spherical
16 Stop and tail light bulb Type: Spherical
Power: 12V 21/5W
Quantity: 1
17 Rear light assembly
18 rear right turn indicator
19 Voltage regulator
20 Mixer oil warning light control
21 Start-up remote control switch
22 Ground lead (-)
23 starter motor wire unit
24 Automatic starter
25 Carburettor heater
26 Chassis wire unit
27 Fuel level transmitter
28 front right turn indicator
29 Key switch
30 Starter button
31 Front brake stop button
32 Headlight
33 Headlight bulb 12V-35/35W
34 Front tail light bulb Type: All glass
Power: 12V 5W
Quantity: 1
35 Left turn indicator warning light 12V - 2W
36 Headlight warning light 12V 1.2W
37 High-beam warning light 12V - 1.2W
38 Instrument panel light bulbs Type: All glass
Power: 12V 1.2W
Quantity: 3
39 Low fuel warning light
40 Right turn indicator warning light 12V - 2W
41 Low oil warning light 12V - 1.2W
42 Odometer with warning lights and level indicator
Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black,

Ro = Pink, Rs = Red, Ve = Green, Vi = Purple
Conceptual diagrams
ELE SYS - 44
Electrical system
Ignition
IGNITION
1 Electronic control unit
2 Magneto flywheel
3 Pick - up
4 Key switch
5 Spark plug
ELE SYS - 45
Electrical system
Headlights and automatic starter section
LIGHTS
1 Voltage regulator
2 Magneto flywheel
3 Light switch
4 Rear light bulb 12V - 5W
5 Headlight bulb 12V-35/35W
6 High-beam warning light 12V - 1.2W
7 N°3 instrument lighting bulbs 12V - 1.2W
8 Taillight bulb 12V - 5W
9 Headlight warning light 12V - 1.2W
10 Heater control device
11 Key switch contacts
12 Fuse 7,5A
13 Carburettor heater
14 Automatic starter
ELE SYS - 46
Electrical system
Battery recharge and starting
BATTERY RECHARGE AND STARTING

1 Magneto flywheel
2 Voltage regulator
3 Main fuse 7,5A
4 Brake light filament 12V - 21W
5 Front and rear brake light button
6 Start up button
7 Starter motor
8 Remote starter switch
9 Battery 12V - 4Ah
ELE SYS - 47
Electrical system
Level indicators and enable signals section
START PERMISSIVE BUTTONS AND LEVEL INDICATORS

1 Magneto flywheel
2 Voltage regulator
3 Key switch
4 Main fuse 7,5A
5 Brake light filament 12V - 21W
6 Front and rear brake light button
7 Start up button
8 Starter motor
9 Remote starter switch
11 Low oil warning light 12V - 1.2W
12 Oil level sender
13 Low fuel warning light 12V - 1.2W
14 Fuel gauge
15 Fuel level sender
ELE SYS - 48
Electrical system
Turn signal lights
TURN INDICATORS AND HORN

1 Battery 12V - 4Ah
2 Main fuse 7,5A
3 Key switch
4 Magneto flywheel
5 Voltage regulator
6 Horn button
7 Horn
8 Indicators switch
9 Two (2) turn signal warning light bulbs 12V - 2W
10 4 Turn indicator bulbs 12V-10W
Checks and inspections
1) No-load test: the starter motor, when unloaded,

must absorb no more than 10A with a supply volt-
age ≥ 12V and must rotate at ≥ 15,000 rpm.
2) Load test: when the starter motor is so braked
that it absorbs 47A with supply voltage ≥ 10V, tor-
que of ≥ 0.2 N•m must be obtained at 10,000 rpm.
3) Static torque test: when the rotor is locked and
the supply voltage is <7V, the absorbed current
must not exceed 130A and the torque must be at
least 0.55 N•m
Specifications
ELE SYS - 49
Electrical system
- Rated voltage 12V.

- Rated power 0.25 kW.
- Left-hand rotation view from pinion side.
- Connected to the engine by pinion and crown wheel on crankshaft, transmission side.
- Push-button control.
- Battery used for the test:12V-3,6Ah.
N.B.
THESE VALUES MUST BE MEASURED WITH A CHARGED BATTERY AND AFTER THE STARTER
HAS BEEN ROTATING FOR 30" UNDER CONDITIONS OF POINT 1
In case the cause of ignition failure or malfunction

cannot be easily identified at sight, first of all re-
place the control unit by another one in operating
conditions.
Remember that the engine must be off to discon-
nect and replace the control unit.
If after replacement the vehicle starts properly, the
control unit is failing and must be replaced.
If the failure persists, check the generator and the

stator components as follows:
After visually checking the electrical connections,
use a specific tester to measurement the stator
winding and the pickup (see table).
If any failure is found after checking the loading coil
and the pick-up, replace the stator and the dam-
aged parts.
Disconnect the connector on the flywheel cover
and measure the resistance between either con-
tact and the earthing.
Specific tooling
PICK-UP CHECK
1 1) Brown cable and earth ~ 170 Ω
STATOR WINDING CHECK

1 1) Black cable and earth ~1Ω
ELE SYS - 50
Electrical system
Ignition circuit
1) Check the state of the spark plug (clean it with

a metallic brush, remove all incrustations, blow it
with compressed air, and replace it if necessary).
2) Without removing the stator, perform the checks
described below:
After a visual inspection of the electrical connec-
tions, carry out the measurements on the charging
coil and pick-up (see table), and check for con-
tinuity using the special tester, 020331Y.
If the continuity checks or the inspections on the
coil and pick-up are incorrect, proceed by replac-
ing the stator, otherwise replace the ECU.
Remember to detach the ECU wirings when the
engine is not running.
Specific tooling
PICK - UP CHECK (FIGURE A)

1 Red cable (1) and White cable (2) 90 ÷ 140 Ohm
RECHARGING COIL CHECK (FIGURE B)

1 Red cable (3) and Green cable (4) 800 ÷ 1100 Ohm
CONTINUITY CHECK
1 White cable - Engine Continuity
2 White cable - Frame Continuity
ELE SYS - 51
Electrical system
Stator check
- Using a tester, check the resistance between the

stator wiring.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERA-
TURE LEADS TO VALUES HIGHER THAN THOSE STATED.
Electric characteristic
Stator : Grey ÷ Ground
~ 1 ohm
Stator : White ÷ Ground
~ 1 ohm
Stator : Green - Ground
~ 1Kohm
Stator : Blue ÷ Yellow
~ 1 ohm
Pick-Up: Red - ground
~ 170 Ω (Pick-Up)
Voltage regulator check
Voltage regulator
A fault in the voltage regulator can cause the fol-
lowing problems depending on the type of fault:
1) Blow out of the lighting system bulbs.
2) Failure of the lighting system.
3) Excessive battery charging (blowing of main
fuse).
4) Battery recharging failure.
5) Failure of the turn indicators.
6) Failure of the oil and petrol check lamp.
Operations
FAULT 1:
Make sure that at 5000 rpm with the lights on that
the regulation voltage is between 13V and 14.5V.
Make sure that at 5000 rpm with the lights off the
regulation voltage is ï£ 16V.
If the regulation voltage is greater than >16V re-
place the regulator.
ELE SYS - 52
Electrical system
FAULT 2:
a) Make sure the stator is supplying voltage cor-
rectly: disconnect the regulator connector and
place tester 020331 y between the grey-blue wire
(2) and the black wire (6) to measure the alternat-
ing voltage and make sure that the voltage sup-
plied at 3000 rpm, is between 25 and 30V (FIG>
A). If there are any anomalies, replace the stator.
b) If the tests do not reveal any anomalies, replace
the regulator.
c) If replacement of the regulator does not restore
correct operation, check the connections of the
electrical system.
FAULT 3
After checking that there are no short circuits in the
system towards earthing with the engine off and
the regulator connector detached, replace the reg-
ulator because it is certainly inefficient, and re-
place the protection fuse.
Following the replacement, measure the current
and the recharging voltage on the battery ends
(FIG. B). The values detected must be 1.5 ÷ 2 A
and 13 V at 3000 rpm.
FAULT 4
a) By positioning tester 020331Y between the yel-
low wire terminal (8) on the regulator and the black
wire (6) (FIG. D), check the generator output volt-
age is within 26 and 30 V at 3,000 rpm (this meas-
urement must be carried out with the battery
detached). In the event of anomalies, replace the
stator; otherwise proceed to point b).
b) Yellow wire (1) attached to the regulator. Insert
an ammeter between the stator's blue wire (2) and
the battery, and check, using tester 020331Y, that
the current output, at 3,000 rpm and with the bat-
tery kept between 12 and 13V, is approx. 1.5 - 2 A
(FIG. C).
ELE SYS - 53
Electrical system
If the values thus obtained are lower than prescri-

bed, proceed by replacing the regulator. Before
carrying out inspections on the regulator and its
electrical system, it is always advisable to check
for continuity between the black wire and earth.
FAULT 5
(FIG. E) If the turn indicators do not work, proceed
as follows:
- Remove the regulator connector, and insert the
tester probes between the contact 5 (yellow-red)
and the ground lead.
- Turn the key switch to ON and check that the
battery is getting voltage. If no voltage is detected,
check the wiring and the contacts on the key
switch and on the battery.
(FIG. F) Repeat the procedure now placing the

tester probes between contacts 5 (yellow/ red) and
6 (black), and check the presence of the battery
voltage with the key switch set to ON. If there is no
voltage, check the regulator ground wiring.
(FIG. G) If the above tests have positive results,

jump the contacts 5 (yellow/red) and 7 (blue/black)
on the connector, set the key switch to ON and
shift the turn indicator switch to the right and left to
see when the lights are steadily on (as they are
powered directly from the battery). If even after this
operation the turn indicators fail to turn on, check
that the wiring is not damaged and the switch
works properly. If these last two tests have a pos-
itive result, replace the regulator because it is cer-
tainly not functioning properly.
ELE SYS - 54
Electrical system
FAULT 6
Oil reserve check warning light not working
(FIG H) - Disconnect the voltage regulator con-
nector.
- Supply 12V to the terminal marked with number
5; with a digital tester check that the terminal num-
ber 4 has a similar output (12V) for about 5 sec-
onds.
- If no voltage is detected for terminal number 4,
replace the regulator.
- If there is voltage for terminal number 4, check
both the installation and the bulb of the oil warning
light.
Specific tooling
Sealed battery
INSTRUCTIONS FOR REFRESHING THE

STOCK CHARGE OF AN OPEN CIRCUIT
1) Voltage check
Before installing the battery on the vehicle, check
the open circuit voltage with a normal tester.
- If the voltage exceeds 12.60 V, the battery may
be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge
is required as explained in 2).
2) Constant voltage battery charge mode
-Constant voltage equal to 14.40÷14.70V
-Initial charge voltage equal to 0.3÷0.5 for nominal
capacity
-Duration of the charge: 10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal ca-
pacity of the battery
-Duration of the charge: 5 h
ELE SYS - 55
Electrical system
WARNING
-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW
12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE
NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT
TO EXCEED EIGHT HOURS OF CONTINUOUS RECHARG-
ING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
1 Hold the vertical tube

2 Look at the level
3 The float must be freed
Dry-charge battery
The battery is an electrical device which requires careful monitoring and diligent maintenance. The
maintenance rules are:
1) Check the level of the electrolyte
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level.
If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works
overcharged and is subject to quick wear.
2)Load status check
After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure).
When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific
weight of 1.26 to 1.28 at a temperature of no lower than 15° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
After charging the battery, check each element electrolyte level and density. If the scooter is not used
for a given time (1 month or more) it will be necessary to periodically recharge the battery.
The battery runs down completely in the course of three months.
If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering
that the earth wire (black) marked (-) must be connected to the - negative terminal while the other two
red wires marked (+) must be connected to the terminal marked with the + positive sign.
Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),
setting the battery charger selector to the type of battery to be recharged. Connections to the power
supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).
4) Cleaning the battery
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
WARNING
- Before recharging the battery, remove the plugs of each cell. Keep the battery away from naked flames
or sparks when charging.
Remove the battery from the vehicle removing the negative clamp first.
CAUTION
ELE SYS - 56
Electrical system
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED.

USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN
CAUSE A FIRE.
CAUTION
DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BAT-
TERY: USE DISTILLED WATER ONLY.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT
IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Specific tooling
WARNING
- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact
with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about
15 minutes and seek immediate medical attention.
In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg or vegetable oil. Seek immediate medical attention
Batteries produce explosive gases; keep clear of free flames, sparks or cigarettes; ventilate the area
when recharging the battery indoors.
Always protect your eyes when working close to batteries.
Keep out of the reach of children.
1)- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type
specified for batteries, with a specific gravity of 1.26, corresponding to 30° Bé, at a minimum temperature
of 15°C until the upper level is reached.
2) - Leave to rest for at least 2 hours; then, restore the level with sulphuric acid.
3)- Within the following 24 hours, recharge with the specific battery charger (single) or (multiple) at a
density of about 1/10 of the battery nominal capacity and until the acid density is about 1.27, corre-
sponding to 31º Bé, and these values are stabilised.
4) - Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.
5)- Once the above operations have been performed, install the battery in the vehicle ensuring the
connections between the wiring and the battery terminals are correct.
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE
THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE-
SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO
ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.
Specific tooling
ELE SYS - 57
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle
Removal of the engine from the vehicle

Remove the engine from the frame
-Disconnect the battery.

-Remove the muffler assembly.
- Remove the rear wheel.
- Remove the mechanical transmission of the rear brake.
-Disconnect the electric terminals.
- Remove the throttle grip and mixer transmissions.
- Disconnect the hoses (petrol-oil-vacuum-operated cock control).
WARNING
Be very careful when handling fuel.
CAUTION
When installing the battery, first attach the positive cable and then the negative cable.
WARNING
Wear safety goggles when using hitting tools.
ENG VE - 59
INDEX OF TOPICS
ENGINE ENG
Engine
Automatic transmission
Transmission cover
- Loosen the 15 screws and remove the transmis-

sion cover with the aid of a mallet.
N.B.
THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT
FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY
AND THE BEARING HOUSED ON THE CRANKCASE.
Kickstart
- Remove the seeger ring located on the exterior

of the crankshaft.
- Dismantle the dog gear from its seat, slackening
the tension that the toothed sector applies to it by
means of the spring; to do this, it is necessary to
rotate the toothed sector slightly (see the figure).
CAUTION
WHILE REMOVING THE TOOTHED SECTOR, BE VERY
CAREFUL OF THE SPRING TENSION: IT COULD CONSTI-
TUTE A HAZARD FOR THE OPERATOR.
- Upon refitting, apply the recommended grease to

the bushing, to the spring and along the toothed
sector.
- Use the special tool for the charging of the spring,
as shown in the figure.
- Refit the seeger ring after checking that it is in
good condition.
Specific tooling
020261Y Starter spring fitting
AGIP GREASE MU3 Grease for odometer
transmission gear case
ENG - 61
Engine
Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20
- Remove the screws shown in the figure and re-

move the engine starting lever.
- For the assembly, work in reverse and tighten the
screws to the prescribed torque..

Starter lever replacement 12 to 13 Nm
Removing the driven pulley shaft bearing
- Slightly heat the crankshaft from the inside side

to avoid damaging the coated surface and use the
driven pulley shaft or a pin of the same diameter
to remove the bearing.
N.B.
IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-
AMETER EXTRACTOR CAN BE USED.
Refitting the driven pulley shaft bearing
-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.
N.B.
WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.
CAUTION
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED
SURFACE.
ENG - 62
Engine
Removing the driven pulley
- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the
whole of the driven pulley assembly.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Specific tooling
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.

- Measure the inner diameter of the clutch bell.
Characteristic
Clutch bell diameter/standard value
Ø 107+0.2 +0 mm
Clutch bell diameter/max. value allowed after
use
Ø 107.5 mm
Eccentricity measured /max.
0.20 mm
Removing the clutch
- Equip the tool with long pins screwed into position

«A» from the outside, insert the entire driven pulley
in the tool and put the central screw under stress.
CAUTION
THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW
IS TIGHTENED UP TOO FAR.
ENG - 63
Engine
- Using a 34 mm socket wrench remove the clutch

locking nut.
- Loosen the central screw thereby undoing the
driven pulley unit
- Separate the components.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
Inspecting the clutch
- Check the thickness of the clutch mass friction

material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
ENG - 64
Engine
- Remove the three guide pins and the mobile half

pulley.
Removing the driven half-pulley bearing
- Remove the roller bearing with the special ex-

tractor inserted from the bottom of the fixed half-
pulley.
CAUTION
POSITION THE HOLDING EDGE OF THE EXTRACTION PLI-
ERS BETWEEN THE END OF THE BEARING AND THE
BUILT IN SEALING RING.
Specific tooling
001467Y029 Bell for bearings, O.D. 38 mm
- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch
housing by means of the special tool.
N.B.
PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO
DEFORM THE SLIDING SURFACE OF THE DRIVING BELT
Specific tooling
020363Y 20-mm guide
Inspecting the driven fixed half-pulley
- Check that there are no signs of wear on the work

surface of the belt. If there are, replace the half-
pulley..
- Make sure the bearings do not show signs of un-
usual wear.
- Measure the external diameter of the pulley bush-
ing.
Characteristic
ENG - 65
Engine
Stationary driven half-pulley/Standard diame-

ter
Ø 33.965 to 33.985 mm
Stationary driven half-pulley / Minimum diam-
eter admitted after use
Ø 33.96 mm
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two O-

rings.
- Measure the inside diameter of the mobile half-
pulley bushing.
Characteristic
Mobile driven half-pulley/ Maximum diameter
allowed
Ø 34.08 mm
- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile
half-pulley.
- Fitting the half-pulley on the bushing.
AGIP GREASE SM 2 Grease for the C-ring of
the tone wheel
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This
operation must be done through one of the holes inside the bushing until grease comes out of the
opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.
AGIP GREASE SM 2 Grease for the C-ring of the tone wheel
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
ENG - 66
Engine
Refitting the driven half-pulley bearing
- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.
- Fit the new roller bearing with the wording visible
from the outside.
CAUTION
PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT
DAMAGE TO THE THREADED END WHILE THE BEARINGS
ARE BEING FITTED.
Specific tooling
020362Y 12 mm guide
020171Y Punch for Ø 17 mm roller case
Inspecting the clutch spring
- Check that the contrast spring of the driven pulley

does not show signs of deformation
- Measure the free length of the spring
Characteristic
Standard length
118 mm
Minimum length allowed after use
XXXX
Refitting the clutch
- Preassemble the driven pulley group with spring,

sheath and clutch.
- Position the spring with the sheath
- Insert the components in the tool and preload the
spring being careful not to damage the plastic
sheath and the end of the threaded bar.
ENG - 67
Engine
- Reassemble the nut securing the clutch and tight-

en to the prescribed torque.
CAUTION
SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK-
ET WRENCH WITH SMALL CHAMFER.
CAUTION
POSITION THE NON-CHAMFERED SURFACES OF THE
NUT IN CONTACT WITH THE CLUTCH

Nut locking clutch unit on pulley 55 ÷ 60 Nm
Refitting the driven pulley
-Refit the driven pulley assembly, the clutch bell

and the nut, using the specific tool.
Specific tooling

Driven pulley shaft nut 40 to 44 Nm
Drive-belt
- Make sure the driving belt is not damaged and

does not have cracks in the toothed grooves.
- Check the width of the belt.
Characteristic
Transmission belt/Minimum width
17.5 mm
ENG - 68
Engine
Removing the driving pulley
- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer,
then remove the drive and the plastic fan.
- Remove the stationary half-pulley.
- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the
rollers and contrast plate fitted loosely on it do not come off.
Specific tooling
020451Y Starting ring gear lock
Mixer gears and belt
- Remove gear and belt.

CAUTION
PAY PARTICULAR ATTENTION TO NOT TOUCHING OR
BENDING THE BELT BECAUSE THIS COULD BREAK SUD-
DENLY DURING OPERATION.
CAUTION
ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET
INTO THE INNER BUSHING OF THE MIXER CONTROL
GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON
THE CRANKCASE PIN.
N.B.
REPLACE THE BELT EVERY 20000 KM.
Inspecting the rollers case
1) Check that the bushing and the sliding rings of

the mobile pulley do not show signs of scoring or
deformation.
2) Check the roller running tracks on the contact
pulley; there must not be signs of wear and check
the condition of the contact surface of the belt on
the half-pulleys (mobile and stationary).
3) Check that the rollers do not show signs of
marked facetting on the sliding surface and that
the metallic insert does not come out of the plastic
shell borders.
ENG - 69
Engine
4) Check the integrity of the sliding blocks of the

contact plate.
- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inside
diameter «A».
- Measure outside diameter «B» of the pulley slid-
ing bushing shown in the figure.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHING.
Characteristic
Driving pulley / Maximum diameter:
20.12 mm
Driving pulley/ Standard diameter:
20.021 mm
Driving pulley bushing/ Diameter maximum:
XXX mm
Driving pulley bushing/ Standard diameter:
20 -0.020/-0.041mm
Refitting the driving pulley
- Manually move the movable driven half-pulley

away by pulling it towards the clutch unit and insert
the belt observing the direction of rotation of the
first fitting.
N.B.
IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO
THAT THE WORDS CAN BE READ IN CASE IT DOES NOT
SHOW A FITTING SIDE.
- Refit the components of the assembly (roller con-

tainer assembly with bushing, limiting washer, sta-
tionary half-pulley, cooling fan belt with drive,
washer and nut).
- With the specific tool, tighten the lock nut to 20
Nm and then perform a final 90° locking in order to
prevent the rotation of the driving pulley.
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
CAUTION
UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-
MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN
ENG - 70
Engine
ORDER TO AVOID WRONG TIGHTENING AND CONSE-

QUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling
020451Y Starting ring gear lock

Crankshaft pulley nut 18 to 20 + 90° Nm
For 25 km/h engine type versions, the limit washer is 5.5 mm thick
End gear
Removing the hub cover
- Drain the rear hub oil

- Remove driven pulley
- Remove the rear brake shoes
- Remove the 5 screws fixing the cover to the
crankcase
- Remove the cover with the wheel axle and pull it
out
- Remove the intermediate gear with the appropri-
ate shim washers
Removing the wheel axle bearings
- Remove the oil seal and the seeger ring.

- Fix the hub cover properly to avoid damaging the
sealing surface with the housing
- Remove the wheel axle bearing using the specific
tool
Specific tooling
020363Y 20-mm guide
ENG - 71
Engine
020477Y 37 mm adaptor
Removing the driven pulley shaft bearing
- Remove the seeger ring

- Heat the engine crankcase but do not direct the
hot air towards the bearing
- Extract the driven pulley shaft together with the
bearing with a few mallet blows
ENG - 72
Engine
- Remove the bearing off the driven pulley shaft

using the specific tool and a press
N.B.
USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALL-
ER INTERNAL DIAMETER
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
Inspecting the hub shaft
- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of anomalies, replace the damaged com-
ponents.
- Check capacity ( A ) of the transmission gear
(wear, deformations, etc.)
- Check the pulley shaft seating: Superficial wear
( B ) may indicate irregularities in the crankcase
seatings or in the pulley shaft capacities
Inspecting the hub cover
- Check that the fitting surface is not dented or dis-

torted.
- If faults are found, replace the hub cover.
ENG - 73
Engine
Refitting the driven pulley shaft bearing
- Support the inner track of the bearing from the

outside of the hub cover with the specific tool posi-
tioned under the press and insert the driven pulley
axle.
- Refit the oil seal flush with the cover.
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
- Slightly heat the hub cover and then fit the bear-
ing with the specific drift.
- Fit the circlip with the concave or radial part facing
the bearing.
N.B.
FIT THE BALL BEARING WITH THE SHIELD FACING THE
OIL SEAL.
Specific tooling
020151Y Air heater
020439Y 17-mm guide
Refitting the wheel axle bearing
- Support the hub cover on a wooden surface

- Heat up the hub cover using the thermal gun.
- Preassemble the bearing on the specific punch
using grease and then insert the bearing in its
seating
- Refit the seeger ring and the oil seal using the 42
x 47 mm adaptor
N.B.
POSITION THE OIL SEAL WITH THE SEALING LIP FACING
THE HUB INTERNAL SIDE
Specific tooling
020150Y Air heater mounting
020151Y Air heater
ENG - 74
Engine
020363Y 20-mm guide

Refitting the hub bearings
- Remove the wheel axle on the cover and pay at-

tention not to damage the sealing lip of the oil seal
- Apply a thin layer of grease on the two shim
washers of the intermediate gear and fit one on the
cap so that it does not interfere with the wheel axle
gear when placing the transmission shaft
Refitting the ub cover
- Apply product recommended for surfaces on the

hub cap and refit cap on the crankcase
- Fit the 5 screws and tighten them to the specified
torque.
N.B.
CLEAN THE CONTACT SURFACES OF THE HUB COVER
AND THE HALF CRANKCASE OF RESIDUE FROM PREVI-
OUS GASKETS BEFORE APPLYING A NEW ONE.
Loctite 510 Liquid sealant
ENG - 75
Engine
Gasket

hub cap screws 24 - 26
Flywheel cover
Cooling hood
- Remove the four fixings shown in the figure.

- Remove the fan cover
- Remove the oil piping retention band from the

hood
- Remove the 2 screws shown in the figure
Cooling fan
- Remove the cooling fan by acting on the three

fixings indicated in the figure.
ENG - 76
Engine
Removing the stator
- Remove the three stator fixings shown in the

photo
- Remove the two pick-up fixings shown in the
photo
- Remove the stator with the wiring
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to
the specified torque.
N.B.
THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE
CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM-
BLY.
Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4
Flywheel and starting
Removing the starter motor
Remove the two clamps shown in the figure
ENG - 77
Engine
Removing the flywheel magneto
- Lock the rotation of the flywheel using the calliper

spanner.
- Remove the nut.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
- Extract the flywheel with the extractor.
Specific tooling
020162Y Flywheel extractor
Inspecting the flywheel components
- Check the condition of the flywheel and any dis-

tortions that might cause rubbing on the stator and
on the Pick-Up.
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key

properly.
- Lock the flywheel nut at the prescribed torque
- Check the Pick-Up air gap.
- The air gap may not be modified in the fitting of
the Pick-Up.
- Other values derive from deformations visible on
the Pick-Up support.
ENG - 78
Engine
N.B.
A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO
A VARIATION IN THE IGNITION ADVANCE SUCH AS TO
CAUSE PINGING, KNOCKING ETC.

Flywheel nut 40 to 44 N.m
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.

- Fit the starter on the crankcase, locking the two
screws to the prescribed torque.
N.B.
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.

Starter screws 11 ÷ 13
Cylinder assy. and timing system
Removing the intake manifold
Use an anti-tampering TORX spanner to remove

the two clamping screws of the intake manifold
Removing the cylinder head
Remove the 4 screws shown in the figure
ENG - 79
Engine
Removing the cylinder - piston assy.
Remove the cylinder very carefully
Remove the snap rings and remove the pin

CAUTION
AFTER EACH REMOVAL OPERATION REPLACE THE PIN
RETENTION SNAP RINGS
Inspecting the small end
- Measure the internal diameter of the small end

using an internal micrometer.
N.B.
IF THE DIAMETER OF THE ROD SMALL END EXCEEDS
THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF
WEAR OR OVERHEATING REPLACE THE CRANKSHAFT
AS DESCRIBED IN THE "CRANKCASE AND CRANK-
SHAFT" CHAPTER".
Characteristic
Rod small end: standard diameter
17 +0.011-0.001
Rod small end: maximum allowable diameter
17,060 mm
ENG - 80
Engine
Inspecting the wrist pin
- Check the wrist pin external diameter using a mi-

crometer
Characteristic
Wrist pin: standard diameter
12 +0.005 +0.001 mm
Inspecting the piston
- Measure the bearings on the piston using a bore

meter
- Calculate the piston-pin coupling clearance.
Characteristic
Wrist pin housing: standard diameter
12 +0.007 +0.012
Wrist pin housing: standard clearance
0.002 ÷ 0.011 mm
- Measure the outer diameter of the piston, per-

pendicular to the pin axis.
- Take the measurement in the position shown in
the figure
To classify the cylinder-piston fitting, check the ap-
propriate table
See also
ENG - 81
Engine
Inspecting the cylinder
- Check that the cylinder does not show seizures.

Otherwise, replace it or adjust it respecting the al-
lowable increases
- Measure the internal diameter of the cylinder with
a bore meter, according to the directions given in
the figure
- Check that the fitting surface with the head is not
dented or distorted.
To classify the cylinder-piston fitting, check the ap-
propriate table
See also
Inspecting the piston rings
- Alternatively insert the two sealing rings in the

cylinder
Using the piston, insert the seals perpendicularly
to the cylinder axis.
- Measure the opening of the sealing rings using a
thickness gauge as shown in the photograph
- If the values are higher than the values prescri-
bed in the chart, substitute the rings
Removing the piston
- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.
-Push detail 2 into detail 1 until the stop and extract detail 2.
- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3
all the way in.
N.B.
REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM
THE REMOVAL OPERATIONS
Specific tooling
020166Y Pin lock fitting tool

Locking head nuts: 10 to 11 N·m
ENG - 82
Engine
- Use new wrist pin snap rings.

- Use new cylinder base gasket.
- Before refitting carefully clean all the surfaces.
- Use oil to be mixed during the fitting of the piston
and the cylinder.
CAUTION
POSITION THE ARROW PRINTED ON THE PISTON
CROWN TOWARDS THE EXHAUST OPENING.
THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON
THE PISTON WITH THE SPECIFIC TOOL
AGIP CITY TEC 2T Oil
Recommended oil
ENG - 83
Engine
Inspecting the timing system components

CAUTION
CHECK THE CORRECT REED UNIT SEAL; NO LIGHT
MUST PASS BETWEEN THE SUPPORT AND LAMELLA.
Crankcase - crankshaft
Splitting the crankcase halves
Remove the eight crankcase union fasteners.
Install the special strip on the half crankcase on

the flywheel side and separate the half crankcase
on the flywheel side from the transmission side
Specific tooling
ENG - 84
Engine
Removing the crankshaft
- Install the specific tool on the half crankcase on

the transmission side using four M6 screws of an
adequate length.
- Remove the crankshaft from the transmission
side half crankcase
Specific tooling
Removing the crankshaft bearings
The bearings can stay on either the half crankcase

or the crankshaft indifferently
- Using the special tool, remove any bearings that
have been left on the crankshaft
N.B.
The half rings must be inserted on the bearings with a few mal-
let blows.
Specific tooling
004499Y001 Bearing extractor bell
004499Y006 Bearing extractor ring
004499Y002 Bearing extractor screw
004499Y007 Half rings
- Using the specific tool remove any bearings left
on the half crankcase
Specific tooling
001467Y007 Driver for OD 54 mm bearing
001467Y006 Pliers to extract 20 mm bearings
ENG - 85
Engine
Refitting the crankshaft bearings
Heat the bearings in an oil bath at around 150°C

and fit them on the crankshaft, if necessary using
a section of tube that acts on the bearing's inner
track
Specific tooling
020265Y Bearing fitting base
Inspecting the crankshaft alignment
With the specific tool shown check that the eccen-

tricity of the surfaces of diam. «A»-«B»-« C» are
within 0.03 mm. (reading limit on the dial gauge);
in addition, check the eccentricity of diam. «D», for
which a maximum reading of 0.02 mm is permitted.
In the case where eccentricity is not much above
prescribed levels, straighten the shaft by acting
on the counterweights with a shim or tighten them
in a clamp (with an aluminium bushing) as re-
quired..
Specific tooling
020074Y Mounting base for checking crank-
shaft alignment
Refitting the crankshaft
- Position the transmission side half crankcase on

two wooden supports
- Using a thermal gun, heat the bearing seat to
about 120°
ENG - 86
Engine
- Firmly insert the crankshaft until the bearing rea-

ches the end-of-stroke stop
- Let the temperature of the half crankcase settle

at the temperature of the crankshaft.
- Again install the special crankcase separation
plate NOT installing the crankshaft protection
- During the assembly phase keep the central
thrust screw loose.
- Take the four clamping screws to the end of the
stroke and loosen them again with the same angle
(e.g. 90°)
- When the temperature has settled, preload the
thrust screw of the tool manually until the ball bear-
ing clearance is cancelled out.
Specific tooling
Refitting the crankcase halves
- Prepare the coupling surface with LOCTITE 510

applying a thin layer of it after degreasing the sur-
face using a suitable solvent (e.g. trichloroethy-
lene)
- Heat the flywheel-side half crankcase with a ther-
mal gun.
Loctite 510 Liquid sealant
Gasket
ENG - 87
Engine
- Keeping the half crankcase on the transmission

side, insert the flywheel side half crankcase with a
clean precise movement
- Insert at least three clamping screws and tighten
up rapidly
- Insert the other 5 screws and tighten them to the
specified torque.

crankcase coupling screws 11 - 13
- Move the crankcase separation plate in a position
back from the one indicated in the figure
- Install the special magnetic support with dial
gauge at the end of the crankshaft
- Check the axial clearance of the crankcase
If this is not within the maximum limit allowed, re-
peat the crankcase coupling procedure
Specific tooling
Characteristic
Axial clearance with warm crankcase
0.10 ÷ 0.12 mm
Axial clearance with cold crankcase
0.06 to 0.08 mm
Limit value with cold crankcase
0.02 ÷ 0.03 mm
Lubrication
Crankshaft oil seals
ENG - 88
Engine
Refitting
- Install a new flywheel-side oil seal only with the

special tool's punch
The flywheel-side oil seal is recognised by its
smaller diameter
N.B.
THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE
WITH THE FITTED WRENCH
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
- Install a new transmission side oil seal using the
special tool with adapter ring.
The transmission-side oil seal is recognised by the
larger diameter
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
Oil pump
Removal
- Remove the 2 screws shown in the figure
ENG - 89
Engine
Remove the tube passage seal from the crank-

case shown in the figure
Refitting
To refit, perform the steps in the reverse direction

to disassembly
Remember to drain after refitting using the screw
shown in the figure
Fuel supply
- Completely empty the fuel tank.

- Remove the petrol delivery pipe and the low-
pressure pipe.
- Loosen the clip and remove the cock.
- Clean the tank and the filter of the cock with a
specific solvent.
- Refit the cock making sure that there is an O-
Ring.
- Turn the cock to the direction it had before it was
removed and block the clip.
N.B.
THE FILTER CAN BE UNSCREWED FROM THE COCK TO
FACILITATE CLEANING.
ENG - 90
Engine
- Disconnect the fuel supply and the suction taking

pipe from the carburettor.
- Check that there are no fuel leaks between the
two tubes.
- Close the fuel outlet pipe.
- By means of the MITYVAC pump apply 0.1 bar
of suction to the tap.
- Make sure that the suction is kept stable and that
and that there are no fuel leaks.
- Reconnect the suction pipe to the manifold.
- Position the fuel pipe with the outlet at the point
of the tap.
- Turn the engine by using the starter for five sec-
onds with the carburettor at minimum.
- Take up the fuel by means of a graded burette.
N.B.
THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-
RECT NUMBER OF REVS OR BY THE WRONG POSITION
OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB-
TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-
LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY
REDUCED FOR THE PURPOSE OF ENHANCING THE SUC-
TION PULSATION AND THEREBY GUARANTEE A CON-
STANT TAP FLOW RATE.
Specific tooling
Characteristic
Minimum flow rate
20 cc
ENG - 91
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions
This section is devoted to operations that can be carried out on the suspensions.
Front
Removing the front wheel
- Remove the wheel axle lock nut.

- Remove the wheel axle and the wheel.
- Upon removal take care not to damage the sen-
sor that detects movement in the odometer.
Front wheel hub overhaul

Ball bearings on wheel hub
- Remove the front wheel

- Keep the wheel level by means of two wooden
wedges
- With the appropriate pliers and tool remove the
wheel bearing on the side the rpm indicator detects
movement, as shown in the photograph
- Remove the internal spacer

- Use appropriate handle, adaptor and guide and
hit with a mallet to extract the bearing and the
spacer bushing on the brake disc side; insert han-
dle on the side the rpm indicator detects move-
ment, as shown in the photo
SUSP - 93
Suspensions
- Check that the bearings do not show flaws or

jamming. Otherwise, replace them.
- Check that the internal spacer does not show ab-
normal wear. Otherwise, replace it.
- With a hot air gun heat the seat of the bearing on
the brake calliper side
- With an appropriate tool remove the bearing on
the brake disc side
- Insert the spacer bushing on the brake disc side
- With a hot air gun heat the seat of the bearing on

the side the rpm indicator detects movement
- Insert the internal spacer with the centring ring
facing to the brake disc side, as shown in the photo
- Use an appropriate tool to insert the bearing on
the side the rpm indicator detects movement
Specific tooling
001467Y009 Driver for OD 42-mm bearings
020412Y 15-mm guide
Refitting the front wheel
- Follow the same procedure as per removal but in reverse order, tighten to the specified torque, re-
member to offset the odometer movement sensor by 90° compared with its own seating on the wheel
so as to avoid damages.

Front wheel axle nut 45 - 50
SUSP - 94
Suspensions
Handlebar
Removal
Handlebars removal
Remove the handlebar cover before carrying out

this operation,.
- After removing the transmissions and discon-
necting the electrical terminals, remove the termi-
nal fixing the handlebar to the steering.
- Check all components and replace faulty parts.
N.B.
IF THE HANDLEBAR IS BEING REMOVED TO REMOVE
THE STEERING, TILT THE HANDLEBAR FORWARD TO
AVOIDING DAMAGING THE TRANSMISSIONS.
Refitting
Carry out the removal operations but in the reverse

order, observing the prescribed tightening torque.

Handlebar fixing screw 50 ÷ 55
Front fork
Overhaul
Seal replacement and stanchion removal
- Remove the wheel axle.

- Remove the lower screw (1).
- Discharge the oil in the suspension.
- Remove the stem.
- Replace the sealing rings (3-4) with new ones.
- Insert the new sealing rings only after lubricating
their seatings.
- Refit the stem and the lower screw (1).
SUSP - 95
Suspensions
- Remove the upper screw (2).

- Add 30 cc ±1 "Fork PG" oil (SAE 20W oil for
forks).
- Refit all components.

Upper screw tightening torque 20 to 25 Nm Lower
screw tightening torque: 20 to 25 Nm
Steering column
Refitting
Lower and upper bearing races to frame
Lower and upper seating on the chassis
LOWER AND UPPER SEATING ON THE CHASSIS

Titolo Durata/ Testo Breve Indirizzo
Valore (< 4000 car.) Immagine
Lower and
upper seating
on the chas-
sis
Steering bearing
Steering locking ring nut
Steering lock ring nut
Top washer and upper bearing housing
- Lubricate race and balls with Z2 grease.

- Tighten to the specified torque and then rotate
the tool through 80° - 90° in an anticlockwise di-
rection.
Removal
Lower and upper races from frame
SUSP - 96
Suspensions
To remove the bearing seats from the chassis, use

the appropriate tool as shown in the figure.
N.B.
To remove the lower seating of the lower bearing just use a
screwdriver as a lever between the seating and the shell.
LOWER AND UPPER SEATING FROM THE CHASSIS

Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Lower and upper seating from
the chassis
Top washer and upper bearing housing
After removing the upper seating, tilt the vehicle to

a side and take out the steering tube making sure
mudflaps have been removed and the calliper dis-
connected.
Rear
Removing the rear wheel
- Use a screwdriver as a lever between the drum

and the cover.
-Straighten the split pin and remove the cap.
-Remove the wheel acting on the central fixing
point.
WARNING
-ALWAYS USE NEW SPLIT PINS FOR REFITTING.
SUSP - 97
Suspensions
Refitting the rear wheel
-Refit the parts in the reverse order as for removal,

lock the wheel nut to the specified torque.
WARNING
- FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN OR-
DER TO AVOID BACKSLASH BETWEEN THE CAP AND
THE WHEEL AXLE.

Rear wheel axle 104 ÷ 126
Shock absorbers
Removal
- To replace the shock absorber remove the rear

cover and battery access flap to get and remove
the shock absorber/ chassis anchoring nut. Then
remove the shock absorber/engine anchorage
nut.
- When refitting, tighten the shock absorber/chas-
sis anchoring nut and the shock absorber/engine
pin to the prescribed torque.

Shock absorber/engine pin torque 33 to 41 N·m
Shock absorber/frame nut torque 20 to 25 Nm
Centre-stand
Centre-stand bolt refitting and caulking to mounting bracket
- Caulk the end of the pin «P» between the two

punches shown in the figure.
- After caulking it must be possible for the stand to
turn freely.
N.B.
UPON REFITTING USE NEW O-RING AND PIN, GREASE
THE SPRING ATTACHMENTS AND THE PIN.
Centre-stand assy. removal
SUSP - 98
Suspensions
- Work on the screws shown in the figure.

- When refitting, secure to the prescribed torque.

Stand screw torque 18.5 to 19 Nm
Centre-stand bolt removal from mounting bracket
- Remove the stand support bracket from the en-

gine.
- Drill a 5 mm hole in the bracket so that the pin
«P» can come out.
SUSP - 99
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Braking system
Once the muffler and the wheel have been re-

moved, follow these steps:
1.Remove the shoe spring using the specific span-
ner.
2. Remove the shoe with the aid of a lever.
3. Refit the new shoes giving a few taps with the
mallet.
4. Attach the spring using the specific pliers.
Specific tooling
020325Y Pliers for brake-shoe springs
Front brake calliper
Overhaul
- Remove the calliper assembling bolts and take out the internal bodies and components. If necessary,
in order to make it easier to take out the plungers, inject (shorts blasts of) compressed air through the
brake fluid pipe.
- Check that the cylinders of the internal and external body of the calliper do not show scratches or signs
of erosion; otherwise, replace the entire calliper.
CAUTION
ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS
SERVICED.
Front brake disc
Disc Inspection
- Remove the wheel and check for unevenness of

the disc.
Maximum permissible out of true is 0.1 mm. If the
value measured is greater, fit a new disc and re-
peat the check.
- If the problem persists, check and replace the
wheel rim if necessary.
Specific tooling
BRAK SYS - 101

Braking system
Front brake pads
Removal
- To facilitate this operation remove the two calliper

fixings. With the calliper detached from its support
but still connected to the brake fluid line, remove
the plastic cover by prising it with a screwdriver.
- Remove the outside circlip from the brake pad
pin, the leaf spring and the pads.
- Renew the pads when friction facing thickness is
less than 1.5 mm.
Fill
Front
-Once the bleed valve is closed, fill the system with

brake liquid to the maximum level.
-Undo the bleed screw.
-Apply the tube of the special tool to the bleed
screws.
When bleeding it is necessary to fill the oil tank in
continuation while working with a MITYVAC pump
on the bleed screws until no more air comes out of
the system.
The operation is finished when just oil comes out
of the bleed screws.
-Do up the bleed screw.
-When the operation is over, tighten up the oil
bleed screw to the prescribed torque.
N.B.
IF AIR CONTINUES TO COME OUT DURING PURGING, EX-
AMINE ALL THE FITTINGS:
IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAUL-
TY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS
SEALS ON THE PUMP AND CALLIPER PISTONS.
CAUTION
- DURING THE OPERATIONS, THE VEHICLE MUST BE ON
THE STAND AND LEVEL.
N.B.
BRAK SYS - 102

Braking system
DURING PURGING FREQUENTLY CHECK THE LEVEL TO

PREVENT AIR GETTING INTO THE SYSTEM THROUGH
THE PUMP.
WARNING
- BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT AB-
SORBS HUMIDITY FROM THE SURROUNDING AIR.
IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX-
CEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE
REDUCED.
THEREFORE, ALWAYS USE FLUID FROM SEALED CON-
TAINERS.
UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS
YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS.
IF THE BRAKES ARE USED INTENSELY AND/OR IN
HARSH CONDITIONS, CHANGE THE FLUID MORE FRE-
QUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID
MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS
SEAT ON THE CALLIPER.
CAREFULLY DRY THE CALLIPER AND DEGREASE THE
DISC SHOULD THERE BE OIL ON IT.
Specific tooling
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid

Oil bleed screw 8 ÷ 12
Front brake pump
-After removing the front and rear handlebar covers, act on the two stand fixing points (see the figure).
- Disconnect the tube, collecting the brake oil in a container.
- On refitting, perform the operation in reverse.

- Tighten the hydraulic line to the prescribed torque
and bleed the system.

Brake fluid pump - hose fitting 20 ÷ 25 Nm
BRAK SYS - 103

Braking system
Removal
- Bleed the circuit and drain the brake fluid through

the bleeding screw located on the calliper and ac-
tuate the brake lever until no more fluid flows out.
-Remove the oil pump from the handlebar; remove
the brake lever and then remove the wheel cylin-
der.
1 - Tank cap screw.
2. Tank cover.
3. Diaphragm.
4. Bellows.
5. Sealing ring.
6. Piston.
7. Gasket.
8 - Spring
CAUTION
- THE PRESENCE OF BRAKE FLUID ON THE DISC OR
BRAKE PADS REDUCES THE BRAKING EFFICIENCY.
IN THIS CASE, REPLACE THE PADS AND CLEAN THE
DISC WITH A HIGH-QUALITY SOLVENT.
CONTACT WITH BRAKE FLUID WILL DAMAGE PAINTED
SURFACES.
RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL
FOR LONGER THAN 20 SECONDS.
AFTER WASHING, THE PIECES MUST BE DRIED WITH A
BLAST OF COMPRESSED AIR AND A CLEAN CLOTH.
THE SEALING RINGS MUST BE IMMERSED IN THE OPER-
ATING LIQUID.
Refitting
Before fitting, the parts must be perfectly clean and

free of traces of oil, diesel fuel, grease, etc.. They
should be washed thoroughly in denatured alcohol
before proceeding.
- Reinstall the individual parts in the reverse order
to the removal, paying attention to the correct po-
sitioning of the rubber parts in order to ensure leak
tightness.
1 - Tank cap screw.
2. Tank cover.
3. Diaphragm.
4. Bellows.
BRAK SYS - 104

Braking system
5. Sealing ring.
6. Piston.
7. Gasket.
8. Spring.
BRAK SYS - 105

INDEX OF TOPICS
CHASSIS CHAS
Chassis
Carrozzeria
Removing the ignition key-switch when on *off*
• Remove the shield back plate

• Push the lock body until the stop spring does not
show grooves.
• Keep the lock body blocked with a screwdriver
and remove the spring with a pair of pliers.
• Take out the lock block.
Removing the ignition key-switch when on *lock*
Remove the shield.

- Remove the switch of the key switch.
- Make a hole on the block using a drill as shown
in the figure.
- Insert the wheel cylinder with the key and with the
anchoring tab facing down halfway on the lock
body taking care that the insertion phase of the key
is oriented matching "ON" (the only position that
enables the cylinder to get into the lock body); now
turn the key leftwards to "OFF" and at the same
time press until the cylinder is completely in.
Footrest
- Remove the side fairings

- Remove the shield back plate
- Remove the 6 screws shown in the photograph
CHAS - 107
Chassis
Rear mudguard

- Remove the 4 screws shown in the photograph
Helmet bay

- Remove the helmet compartment by undoing the
4 screws indicated in the figure
CHAS - 108
Chassis
Fuel tank

- Remove the rear mudguard
- Remove the crews shown in the photograph
- Remove the shock absorber upper clamping in
order to create the necessary space to take out the
tank.
CHAS - 109
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection

Lock check
- Safety locks
- clamping screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
Electrical system:
- Main switch
- Headlamps: high-beam lights, low-beam lights, tail and parking lights and their warning lights
- Adjusting the headlights according to the regulations currently in force
- Rear light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel gauge
- Instrument panel warning lights
- Horn
- Starter
PRE DE - 111
Pre-delivery
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE
OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Levels check
Level check:
- Hydraulic braking system fluid level.
- Rear hub oil level
- Engine coolant level.
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
Static test
Static control after the test ride:
PRE DE - 112
Pre-delivery
- Starting when warm

- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional check up:

Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 113
INDEX OF TOPICS
TIME TIME
Time
This section is devoted to the time necessary to

carry out repairs.
The description and code for each operation is in-
dicated.
Engine
ENGINE
Code Action Duration
1 001001 engine from frame - removal and re-
fitting
TIME - 115
Time
Crankcase
CRANKCASE
1 001133 Engine crankcase - Replacement
TIME - 116
Time
Crankshaft
CRANKSHAFT
1 001118 Main bearings - Replacement
2 001100 Clutch-side oil seal - Replacement
3 001099 Oil seal, flywheel side - Replacement
4 001117 Crankshaft - Replacement
TIME - 117
Time
Cylinder assy.
CYLINDER- PISTON
1 001002 Cylinder-Piston - Replacement
2 001107 Cylinder / piston - Inspection / clean-
ing
TIME - 118
Time
Cylinder head assy.
HEAD
1 001097 Cooling hood - Replacement
2 001093 Spark plug - Replacement
3 001126 Head - Replacement
4 001013 Intake manifold - Replacement
5 001178 Disc pack - Replacement
TIME - 119
Time
Driven pulley
DRIVEN PULLEY - CLUTCH

1 001012 Driven pulley - overhaul
2 001110 Driven pulley- Replacement
3 001022 Clutch - Replacement
4 001155 Clutch bell housing - Replacement
TIME - 120
Time
Oil pump
OIL PUMP
1 001028 Mix movement gear socket - Re-
placement
2 001019 Mixer belt - replacement
3 001018 Mixer - Replacement
TIME - 121
Time
Driving pulley
DRIVING PULLEY
1 001066 Driving pulley - Removal and refitting
2 001086 Driving half-pulley - replace
3 001011 Driving belt - Replacement
4 001177 Variator rollers / shoes - Replace-
ment
TIME - 122
Time
Transmission cover
TRANSMISSION COVER
1 001087 Flywheel cover - Replacement
2 001135 Transmission cover bearing - Re-
placement
3 001096 Transmission crankcase cover - Re-
placement
TIME - 123
Time
Flywheel magneto
FLYWHEEL - FAN
1 001109 Cooling fan - Replacement
2 001173 Rotor - Replacement
3 001067 Stator - Fitting and Refitting
4 001058 Flywheel - Replacement
TIME - 124
Time
Carburettor
CARBURATOR
1 001008 Carburettor - Inspection
2 001063 Carburettor - Replacement
3 007020 Carburettor heating tubing - replace-
ment
4 001081 Automatic choke - Replacement
TIME - 125
Time
Exhaust pipe
MUFFLER
1 001009 Muffler - Replacement
2 001095 Muffler guard - Replacement
3 001136 Exhaust emissions - Adjustment
TIME - 126
Time
Air cleaner
AIR CLEANER
1 004122 Air cleaner carburettor fitting - Re-
placement
2 001014 Air filter - Replacement / cleaning
3 001015 Air filter box - Replacement
TIME - 127
Time
Frame
STAND
1 004001 Frame - replace
2 004004 Stand - Replacement
3 001053 Stand bolt - Replacement
TIME - 128
Time
Legshield spoiler
FRONT SHIELD SPOILER

1 004159 Plates / Stickers - Replacement
2 004149 Shield central cover - Replacement
3 004064 Front shield, front part - Removal and
refitting
4 004015 Footrest - Removal and Refitting
5 004053 Spoiler - Replacement
TIME - 129
Time
Rear cover
REAR SHIELD
1 004174 Trunk levers - Replacement
2 004065 Legshield, rear part - Removal and
refitting
3 004081 Top box lid - Replacement
TIME - 130
Time
Central cover
CENTRAL COVER
1 004059 Spark plug inspection flap - Replace-
ment
2 004106 Under-saddle band - Replacement
3 004085 Fairing (1) - Replacement
4 004105 Right side clamp - Replacement
5 004131 Luggage rack support - Replacement
TIME - 131
Time
Mudguard
MUDGUARDS
1 004002 Front mudguard - Replacement
2 004009 Rear mudguard - Replacement
TIME - 132
Time
Fuel tank
FUEL TANK
1 004168 Fuel tank cap - Replacement
2 005010 Tank float - Replacement
3 004112 Cock-carburettor hose - Replace-
ment
4 004005 Fuel tank - Replacement
5 004007 Fuel valve - Replacement
6 004109 Fuel tank breather - change
TIME - 133
Time
Tank oil
OIL RESERVOIR
1 005018 Oil reservoir float - Replacement
2 004017 Oil reservoir - Replacement
3 004095 Oil reservoir cock - Replacement
4 004091 Oil reservoir hose - Replacement
Rear shock-absorber
TIME - 134
Time
REAR SHOCK ABSORBER

1 003007 Rear shock absorber - Removal and
Refitting
Steering column bearings
STEERING FIFTH WHEELS

1 003051 Complete fork - Replacement
2 003002 Steering fifth wheels - Replacement
3 003073 Steering clearance - Adjustment
TIME - 135
Time
Handlebar covers
HANDLEBAR COVERS
1 004019 Handlebar rear section - Replace-
ment
2 004018 Handlebar front section - Replace-
ment
3 005078 Odometer glass - Replacement
4 005076 Clock / Cell - Replacement
5 005014 Odometer - Replacement
6 005038 Instrument panel warning light bulbs
- Replacement
TIME - 136
Time
Handlebar components
HANDLEBAR COMPONENTS
1 004066 Driving mirror - Replacement
2 002037 Brake or clutch lever - Replacement
3 002071 Left hand grip - Replacement
4 003001 Handlebar - Replacement
5 005017 Stop switch - Replacement
6 002024 Front brake pump - Removal and Re-
fitting
7 002054 Throttle or splitter transmission com-
plete - Replacement
8 002060 Complete throttle control - Replace-
ment
9 004162 Mirror support and/or brake pump fit-
ting U-bolt - Replacement
10 002059 Right hand grip - Replacement
TIME - 137
Time
Swing-arm
SWINGING ARM
1 001072 Engine-frame connection swinging
arm - Replacement
TIME - 138
Time
Seat
SADDLE
1 004003 Saddle - Replacement
2 004068 Passenger handgrip - Replacement
TIME - 139
Time
Turn signal lights
TURN INDICATOR LIGHTS

1 005002 Front headlamp - Replacement
2 005012 Front turn indicator - Replacement
3 005067 Front turn indicator bulb - Replace-
ment
4 005008 Headlight bulbs - Replacement
5 005005 Taillight - change
6 005066 Rear light bulbs - Replacement
7 005022 Rear turning indicators - Replace-
ment
8 005068 Rear turning indicator bulb - Re-
placement
TIME - 140
Time
Front wheel
FRONT WHEEL
1 003038 Front wheel axle - Remov. and refitt.
2 002011 Odometer movement sensor - Re-
placement
3 003040 Front wheel bearings - Replacement
4 003047 Front tyre - Replacement
5 003037 Front wheel rim - Removal and Re-
fitting
6 004123 Front wheel - Replacement
7 002041 Front brake disc - Replacement
Grease tone wheel or drive

Please take note that the code has been intro-
duced:
900001 - Tone wheel / drive greasing - 15'.
Never mistake the codes 002011 (movement sen-
sor replacement) and 005089 (tone wheel replace-
ment) in the event of noise of the indicated
components. The grease recommended is TUTE-
LA MRM 2 (soap-based lithium grease with Mo-
lybdenum disulphide).
In the following points we indicate with an arrow
the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 141
Time
Rear wheel
REAR WHEEL
1 004126 Rear wheel tyre - Replacement
2 001071 Rear wheel rim - Removal and Refit-
ting
3 001016 Rear wheel - Replacement
4 002002 Rear brake pads/shoes - Repl.
TIME - 142
Time
Electric start
ELECTRICAL START-UP
1 001020 Starter motor - Replacement
2 005045 Starter motor cable harness - Re-
placement
3 001017 Starter sprocket wheel - Replace-
ment
4 001021 Kick starter - Inspection
5 008008 Starter spring pack - Replacement
6 001084 Starter lever - Replacement
TIME - 143
Time
Electric devices
ELECTRICAL DEVICES
1 005007 Battery - change
2 005011 Start-up contactor - Replacement
3 005052 Fuse (1) - Replacement
4 005054 Fuse block (1) - Replacement
TIME - 144
Time
ELECTRICAL DEVICES
1 005001 Electrical system - Replacement
2 005009 Voltage regulator - Replacement
3 001094 Spark plug cap - Replacement
4 001023 Control unit - Replacement
5 005114 Electrical system - Service
TIME - 145
Time
Electronic controls
ELECTRIC CONTROLS
1 005039 Lights switch - Replacement
2 005006 Light or turning indicator switch - Re-
placement
3 005040 Horn button - Replacement
4 005003 Horn - Replacement
5 005041 Starter button - Replacement
6 005016 Key switch - Replacement
7 004096 Lock series - Replacement
TIME - 146
Time
Transmissions
TRANSMISSION
1 002051 Odometer transmission assembly -
Replacement
2 002012 Splitter - Replacement
3 002057 Carburettor / splitter transmission
complete - Replacement
4 002058 Mix / splitter transmission complete -
Replacement
5 002053 Rear brake transmission complete -
Replacement
6 002049 Odometer cable - Replacement
7 003061 Accelerator transmission - adjust
TIME - 147
Time
Brake callipers
CALLIPER
1 002021 Front brake hose - Remov. and Re-
fitt.
2 002007 Front brake shoes/pads - Remov.
and Refitt
3 002039 Front brake calliper - Removal and
Refitting
4 002047 Front brake fluid and air bleed sys-
tem - Replacement
TIME - 148
Time
Steering column
STEERING
1 003048 Fork oil seal - Replacement
2 003076 Fork sheath - Replacement
3 003079 Fork stem - Replacement
4 003010 Front suspension - Service
TIME - 149
Time
Helmet bay
HELMET COMPARTMENT
1 004016 Helmet compartment - Removal and
Refitting
2 005046 Battery cover - change
TIME - 150
Time
Rear wheel axle
REAR WHEEL AXLE

1 001156 Gear reduction unit cover - Replace-
ment
2 004125 Rear wheel axle - Replacement
3 001010 Geared reduction unit - Service
4 003065 Gear box oil - Replacement
TIME - 151
Time
Secondary air box
SECONDARY AIR HOUSING

1 001164 Crankcase secondary air connection
- Replacement
2 001161 Secondary air filter - Replacement /
Cleaning
3 001162 Secondary air housing - Replace-
ment
4 001163 Muffler secondary air connection -
Replacement
5 001165 Secondary air reed - Replacement
TIME - 152
A
Air filter: 30
B
Battery: 40, 47, 55, 56
Brake: 101–103, 148
C
Carburettor: 11, 27, 125
E
Engine stop:
F
Fuel: 39, 90, 109, 133
H
Headlight: 33
Horn:
Hub oil: 29
I
Identification: 8
M
Maintenance: 7, 25
S
Saddle:
Shock absorbers: 98
Spark plug: 28
Stand:
Start-up:
T
Tank: 109, 133, 134
Transmission: 10, 39, 61, 123
Turn indicators:
Tyres: 10

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WORKSHOP MANUAL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

Dimensions and mass

DIMENSIONS AND MASS

Frame and suspensions

FRAME AND SUSPENSIONS

Wheels and tyres

WHEELS AND TYRES

Follow these steps to clean the sponge filters of

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDER

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Slot packing system

RECOMMENDED PRODUCTS TABLE

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Driver for OD 54 mm bearing

001467Y009 Driver for OD 42-mm bearings

001467Y013 Pliers to extract ø 15-mm bearings

001467Y014 Pliers to extract ø 15-mm bearings

Stores code Description

001467Y021 Extraction pliers for ø 11 mm bearings

002465Y Pliers for circlips

006029Y Punch for fitting fifth wheel seat on steer-

020004Y Punch for removing fifth wheels from

020055Y Wrench for steering tube ring nut

020150Y Air heater mounting

Stores code Description

020162Y Flywheel extractor

020163Y Crankcase splitting plate

020164Y Driven pulley assembly sheath

020165Y Start-up crown lock

020166Y Pin lock fitting tool

Stores code Description

020262Y Crankcase splitting plate

020265Y Bearing fitting base

020325Y Pliers for brake-shoe springs

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

Stores code Description

020332Y Digital rpm indicator

020333Y Single battery charger

020334Y Multiple battery charger

Stores code Description

020350Y Electrical system check instrument

020357Y 32x35-mm Adaptor

020376Y Adaptor handle

020412Y 15-mm guide

Stores code Description

020483Y 30-mm guide

020565Y Flywheel lock calliper spanner

494929Y Exhaust fumes analyser

AFTER 5000 KM, 25000 KM, 35000 KM AND 55000 KM

AFTER 10000 KM, 50000 KM

AFTER 15000 KM AND 45000 KM

AFTER 20000 KM AND 40000 KM