Professional Documents
Culture Documents
smt_rcr_633793
smt_rcr_633793
633793 ÷ 633800
SMT RCR
SMT RCR
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions shown in this publication are available in all countries. The availability of single versions
should be checked at the official Piaggio sales network.
"© Copyright 2005 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
www.piaggio.com
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ENGINE ENG
SUSPENSIONS SUSP
CHASSIS CHAS
PRE-DELIVERY PRE DE
CHARACTERISTICS CHAR
Vehicle identification
Chassis prefix
The chassis registration number is stamped on the
right side of the headstock.
RCR: ZAPG11D1A
SMT: ZAPG12D1A
SMT SIZES
Specification Desc./Quantity
Width 805 mm
Length 1972 mm
Max. height 1125 mm
Wheelbase 1,355 mm
CHAR - 7
RCR SIZES
Specification Desc./Quantity
Width 805 mm
Length 2036 mm
Max. height 1222 mm
Wheelbase 1,355 mm
CHAR - 8
Engine
ENGINE
Specification Desc./Quantity
Type single-cylinder, two-stroke
Bore 40 mm
Stroke 39.88 mm
Cubic capacity 49 cm³
Compression ratio 11.5 :1
Carburettor Dell'Orto PHVA-17.5 with manual starter
Engine idle speed 1900 ± 100 rpm
Air filter sponge impregnated with a mixture 50% oil (Selenia Air Filter
Oil) and 50% unleaded petrol.
Start-up With pedal
Transmission Chain
Main ratio: 3.7 (78/21)
RCR final ratio: 4.7 (53/13)
SMT final ratio: 3.78 (53/14)
Gearbox At 6 speeds with selector, fork and distribution drum operated
by external control
Speeds First Speed 11/34
Second Speed 15/30
Third Speed 18/27
Fourth Speed 20/24
Fifth Speed 22/23
Sixth Speed 23/22
Lubrication Separate oiling, mixture oil.
Fuel supply Petrol-oil mixture by carburettor, automatic mixer (variable flow
according to engine speed and throttle valve opening)
Inlet By means of a compression valve on the casing
Cooling system forced coolant circulation system
Capacities
CAPACITY
Specification Desc./Quantity
Fuel Tank Capacity 7 l /
Reserve 1.3 l
Oil mixer tank Capacity 1 l / Reserve 0.25 l
cooling circuit ~ 0.850 l
Transmission oil 0.65 l
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
1 Ignition type Capacitive discharge electronic ignition, with
incorporated HV coil
2 Ignition advance (at TDC) 1.2 mm
3 Spark plug NGK B8 ES
4 Headlight 12 ÷ 35/35 W
5 Rear lights 12V ÷ 21/5W
6 Turn indicators 12V ÷ 10W
7 Battery 12V - 4Ah
8 Fuse 4A
9 Generator Magneto flywheel in alternating current
CHAR - 9
Brakes
BRAKES
Specification Desc./Quantity
Front wheel brake: Hydraulic disc
Ø 240 mm (RCR)
Ø 260 mm (SMT)
Rear wheel brake: Hydraulic Ø 180 mm disc.
Tightening Torques
Standard tightening torques
CHAR - 10
ENGINE-VEHICLE
Name Torque in Nm
Shock absorber to chassis upper attachment 30-40
Shock absorber to chassis lower attachment 55-65
Lower arm to shock absorber chassis clamp 55-65
Arm to chassis clamp 55-65
Arm to suspension clamp 55-65
Oscillating fork 70-80
Engine to chassis front attachment 35-40
Engine to chassis lower attachment 25-28
Fork to steering tube clamping 90-130
Fork leg cap 17-19
Muffler to cylinder 9-12
muffler to chassis clamp 17-19
Muffler silencer to chassis 17-19
Steering arm - fork bar clamp 20-24
Handlebar to steering arm 20-24
Front wheel shaft 70-80
Front brake calliper 17-19
Rear wheel axle 70-80
Rear brake calliper 17-19
Rear brake disc 17-19
Front brake disc 11-12
Rear wheel gear 17-19
Head-cylinder stud bolts 10-12
Head-cylinder fixing nuts 19-22
Flywheel to shaft 35-45
Stator to crankcase 8-10
Clutch cover 8-10
Crankshaft pinion 8-10
Crankcase halves fixing screws 8-10
Starter motor to crankcase 32-38
Cylinder head thermistor 32-38
Cylinder head thermostat nut 25-40
Clutch seat 35-45
Crankcase oil drainage cap 10-15
Pinion counterweight 3.5-4.5
Main shaft bearing unit 3.5-4.5
Gearbox sprocket tightening 3.5-4.5
Products
CHAR - 11
CHAR - 12
TOOLING TOOL
TOOLS
Stores code Description
00H0530004.1 Clutch locking tool
00H0530015.1 Engine opening tool
00H0560032.1 Crankshaft gear extractor
001330Y Tool for fitting steering seats
TOOL - 14
020357Y 32 x 35 mm adaptor
020358Y 37x40-mm adaptor
TOOL - 15
020412Y 15 mm guide
020439Y 17 mm guide
020441Y 26 x 28 mm adaptor
TOOL - 16
020456Y Ø 24 mm adaptor
TOOL - 17
MAINTENANCE MAIN
Maintenance chart
AFTER 1000 KM
Action
Coolant- Change
Air filter - cleaning
Odometer gear - greasing
Steering - Check
Brake control levers - greasing
Brake pads - check
Transmission chain - greasing
Tension transmission chain - check
Safety locks - check
Front fork- Check
Electrical system and battery - check
Wheel - Check
Tyres pressure - Check
Fuel and oil hoses - Check
Vehicle and brake test - road test
Engine oil - change
Spark plug / electrode gap - check
Carburettor - Adjustment
Clutch control lever - Adjustment
MAIN - 19
Action
Tyres pressure - Check
Oil filter -Replacement
Fuel and oil hoses - Replacement
Vehicle and brake test - road test
Engine oil - change
Spark plug/electrode gap - replacement
Carburettor - Adjustment
Clutch control lever - Adjustment
EVERY 2 YEARS
Action
Brake fluid - Change
MAIN - 20
Carburettor
KEY:
1. 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. Minimum nozzle
10. Float
11. Starter nozzle
12. Maximum nozzle
13. Float chamber
14. Diffuser
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 condition.
MAIN - 21
- The throttle valve should slide freely in the mixture chamber. Replace it in case of excessive clearance
due to wear.
- If there are wear marks in the mixer chamber causing inadequate tightness or a free valve slide (even
if it is new), replace the carburettor.
- It is advisable to replace the gasket at every refit
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
Specific tooling
020330Y Stroboscopic light to check timing
MAIN - 22
TECHNICAL SPECIFICATIONS
Specification Desc./Quantity
Timing 22º at 3000 rpm
Advance 1.8º at 3000 rpm
Spark plug
Electric characteristic
Spark plug
NGK B8 ES
MAIN - 23
Air filter
Cleaning
- Wash the sponge with water and mild soap.
- Dry it with a clean cloth and short blasts of com-
pressed air.
- Soak the sponge in a solution of 50% petrol and
50% SELENIA AIR FILTER OIL.
- Gently squeeze the filtering element with your
hands without wringing it; let it drip dry and then
refit.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE
PISTON AND CYLINDER.
transmissions
Transmission adjustment
- Adjust the control cables:
- Mix cable: see "Mixer timing" section.
- Throttle cable: adjust it in such a way that the sheath does not have any clearance.
- Splitter control cable: Adjust it in such a way that there is no clearance on the throttle grip.
- Adjust all transmissions in such a way that their sheaths do not have any clearance.
Mixer Timing
MAIN - 24
MAIN - 25
Braking system
Rear brake fluid
CAUTION
AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN, AND CLOTHING. IN CASE OF CONTACT,
RINSE WITH WATER. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS
HUMIDITY FROM THE SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS
A CERTAIN VALUE, IT WILL LEAD TO INEFFICIENT BRAKING. NEVER USE BRAKING FLUID
KEPT IN CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR PARTIALLY USED.
WARNING
BRAKE CIRCUIT FLUID IS VERY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH
PAINTED PARTS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID
AND THE BLEEDING OF AIR FROM THE CIRCUITS.
MAIN - 26
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
MAIN - 27
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
Recommended products
AGIP GP 330 Grease for brake levers, throttle
White calcium complex soap-based spray grease
with NLGI 2; ISO-L-XBCIB2
Headlight adjustment
- Position the scooter with rider on a flat ground, 10 m away from a half-lit white screen.
- Make sure that the scooter axle is perpendicular to the screen.
- Measure the height from the centre of the headlight to the ground and then mark a cross on the wall
at the same height measured.
- Start the engine and lock the throttle at 1/3 of its stroke.
- Turn on the low-beam light, the maximum demarcation limit between the dark and the light area must
be at a height not exceeding 8/10 of the height from the ground to the centre of the headlight.
MAIN - 28
Gearbox Oil
Characteristic
Capacity:
0.65 l
MAIN - 29
TROUBLESHOOTING TROUBL
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Fuel nozzles or cock clogged or dirty. Remove, wash with solvent and dry with com-
pressed air.
Excess of deposits on the cylinder ports and in the combustion Descale the thermal group.
chamber.
Muffler obstructed Replace
Air filter clogged or dirty. Clean according to the procedure.
Starter inefficient. (Remains on) Check the mechanical movement of the Starter
control transmission.
Starting difficulties
DIFFICULT STARTING
Possible Cause Operation
Carburettor nozzles clogged or dirty. Remove, wash with solvent and dry with com-
pressed air.
Air filter clogged or dirty. Wash with water and soap and soak again in a
mixture of 50% petrol and 50% oil.
Starter inefficient. Check the mechanical movement.
Engine flooded. Start the vehicle keeping the throttle fully open al-
ternately making the engine run for approx. five
seconds and stopping for other five seconds. If the
engine fails to start, remove the spark plug and
make the engine run with open throttle so as to
expel fuel in excess. Refit a dry spark plug and re-
peat the procedure.
If the fuel tank is empty, refuel and start up.
Spark plug faulty or dirty. Remove the spark plug and make sure it is clean
and in good conditions. Adjust the electrodes at
0.6÷0.7 mm. Replace the spark plug, if required.
Ignition system faulty. Check (see the ELECTRICAL SYSTEM chapter).
LOSS OF BLOWS
Possible Cause Operation
Air filter dirty Clean according to the procedure.
Excess of deposits on the cylinder ports and in the combustion Descale the thermal group.
chamber
Spark plug faulty or dirty Remove the spark plug and make sure it is clean
and in good conditions. Adjust the electrodes at
0.6÷0.7 mm. Replace the spark plug, if required.
Bear in mind that many problems engines have
derive from the use of the wrong spark plug.
TROUBL - 31
Engine overheating
ENGINE OVERHEATING
Possible Cause Operation
No coolant in the cooling circuit Restore the level
Incorrect air bleeding Repeat the operation
Thermostat remains closed Replace
Fluid leak in the radiator Replace the radiator
Coolant leaking from the cooling system Inspect the whole circuit to spot the leak.
Insufficient braking
BRAKE SYSTEM
Possible Cause Operation
Poor braking The braking action should begin as soon as the
brake controls are operated.
TROUBL - 32
Electrical system
Battery
BATTERY
Possible Cause Operation
Battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. Fre-
quently check that the fluid level fully covers the plates; other-
wise, restore the level adding distilled water (never use natural
water, even if it is drinking water) and check fluid density at the
same time. If the vehicle is not used for some time (1 month or
more) the battery needs to be recharged periodically. The bat-
tery tends to discharge completely within three months. If the
battery is fitted on a motorcycle, be careful not to invert the
connections, keeping in mind that the black ground wire is con-
nected to the negative terminal while the red wire is connected
to the terminal marked+.
TROUBL - 33
KEY
1. Electronic ignition device
2. Spark plug
3. Voltage regulator
4. Magneto flywheel
5. Key switch
6. Main fuse
7. Battery
8. Horn
9. Horn button
10. Electric fan pre-installation
11. Rear brake STOP button
12. Front brake STOP button
13. Turn indicator switch
14. Left turn rear indicator bulb
15. Tail lights/stop light bulbs
16. Right turn rear indicator bulb
17. Left turn front indicator bulb
18. High-beam/low-beam bulb
19. Right turn front indicator bulb
ELE SYS - 35
Antitheft
- Remove the headlamp front cowl.
- Operating on the 2 screws shown in the photo-
graph, remove the instrument panel.
ELE SYS - 36
Conceptual diagrams
Ignition
KEY
1. Electronic ignition device
2. Spark plug
4. Magneto flywheel
5. Key switch
ELE SYS - 37
KEY
3. Voltage regulator
4. Magneto flywheel
5. Key switch
15. Tail lights/stop light bulbs
18. High-beam/low-beam bulb
20. Light switch
21. Instrument panel
A. Oil warning light
B. Temperature warning light
C. High-beam warning light
D. Turn indicator warning light
E. Low fuel warning light
F. Instrument panel bulb
26. Automatic starter pre-installation
ELE SYS - 38
KEY
3. Voltage regulator
4. Magneto flywheel
6. Main fuse
7. Battery
ELE SYS - 39
KEY
3. Voltage regulator
5. Key switch
6. Main fuse
7. Battery
21. Instrument panel
A. Oil warning light
B. Temperature warning light
C. High-beam warning light
D. Turn indicator warning light
E. Low fuel warning light
F. Instrument panel bulb
22. Timer
23. Engine temperature warning light control
24. Low oil warning light control
25. Fuel level warning light control
ELE SYS - 40
KEY
3. Voltage regulator
4. Magneto flywheel
5. Key switch
6. Main fuse
7. Battery
8. Horn
9. Horn button
13. Turn indicator switch
14. Left turn rear indicator bulb
16. Right turn rear indicator bulb
17. Left turn front indicator bulb
19. Right turn front indicator bulb
21. Instrument panel
A. Oil warning light
B. Temperature warning light
C. High-beam warning light
D. Turn indicator warning light
ELE SYS - 41
Specific tooling
020331Y Digital multimeter
Ignition circuit
Coil removal
ELE SYS - 42
Electric characteristic
Resistance
5 - 6 kOhm
Tube check
Electric characteristic
Resistance
4 - 6 kOhm
Stator check
WARNING
IF VALUES NON CONFORMING TO THE TABLE ARE DE-
TECTED, CHECK ALL THE ELECTRICAL CONNECTIONS
BEFORE REPLACING THE MAGNETO FLYWHEEL
RESISTANCE VALUES
Specification Desc./Quantity
1 White - Red 100 (Ohm)
2 White - Green 700 (Ohm)
3 White - Yellow 0.5 (Ohm)
4 Earth - Red 100 (Ohm)
5 Earth - Green 820 (Ohm)
6 Earth - Yellow 0.7 (Ohm)
RESISTANCE VALUES
ELE SYS - 43
- Check that the resistance between the terminals and the earth complies with the values indicated in
the table.
Lights list
BULBS
Specification Desc./Quantity
1 Front headlamp bulbs 12V. 35/35 W.
Type: Twin filament
2 light/stop bulb: 12 V, 21/5 W
Type: Twin filament
3 Turn indicators bulb: 12 V, 10 W
Fuses
The electrical system is protected by a 4 ampere
fuse «B» located on the fuse box «A» on the bat-
tery positive cable. Before replacing a blown fuse,
find and solve the problem that caused it to blow.
Do not substitute the fuse with any alternative form
of conductor
Sealed battery
Sealed battery start-up operations
ELE SYS - 44
Dry-charge battery
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-
TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF
COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP-
PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF REACH OF CHILDREN
Use of dry-cell batteries :
1. Having removed the short, closed tube and removed the caps, put into the elements sulphuric
acid of the type for specific weight 1.26 accumulators corresponding to 30° Bé at a temperature
of no less than 15°, until you reach the upper level.
2. Leave to stand for at least 2 hours; afterwards top-up to the level with sulphuric acid.
3. Within twenty four hours, recharge with the special (single or multiple) battery charger that re-
charges at an intensity the same as approximately 1/10 the rated capacity of the said battery. At
the end of the charge, make sure that the density of the acid is around 1.27, corresponding to 31°
Bé and that these values are stabilised.
4. Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.
5. Once the above operations have been performed, install the battery in the vehicle ensuring that
it is wired up properly..
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE
THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE 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
020333Y Single battery charger
020334Y Multiple battery charger
ELE SYS - 45
Battery maintenance
The battery is an electrical device which requires careful monitoring and diligent maintenance. The
maintenance rules are:
1) Check the level of the electrolyte
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical
system: the battery works overcharged and is subject to quick wear.
2)Load status check
After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure).
When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific
weight of 1.26 to 1.28 at a temperature of no lower than 15° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
The battery runs down completely in the course of three months. If it is necessary to refit the battery in
the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked
(-) must be connected to the -negative clamp while the other two red wires marked (+) must be con-
nected to the clamp marked with the +positive sign.
3) Recharging the battery
Remove the battery from the vehicle removing the negative clamp first.
The normal bench charging must be carried out with the specific (single or multiple) battery charger,
placing the battery charger selector on the type of battery to be recharged. The connections to the power
supply must be made by connecting to the corresponding poles (+ with+ and -with -).
4) Battery cleaning
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS
AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
CAUTION
ELE SYS - 46
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST
USED SHORTENS THE LIFE OF THE BATTERY.
Specific tooling
020334Y Multiple battery charger
020333Y Single battery charger
Battery installation
Battery
For battery access, it is necessary to insert the key
on the tank cover lock, turn the key rightwards and
lift the cover. Dismantle the two fixing wing nuts of
the saddle and extract them, the battery compart-
ment is under the saddle. The battery is the elec-
trical device that requires the most frequent
inspections and diligent maintenance. The main
points of maintenance to be observed are as fol-
lows: Check the electrolyte level, this must be
checked frequently and it must reach the maxi-
mum level. To maintain such level, use distilled
water only. If necessary add water frequently,
check the vehicle electric system: the battery is
working in overcharge and is easily impaired.
Battery maintenance
- Keep the tank caps perfectly closed. It is impor-
tant.
- Keep the upper part perfectly clean, dry and away
from corrosive materials. The battery terminals
must be cleaned and greased to avoid corrosion.
- Check the battery disposal capacity with a den-
sitometer. 1.265 or most, it is considered a good
capacity: if less, the battery must be charged. The
ELE SYS - 47
ELE SYS - 48
ENG VE - 50
ENG VE - 51
ENG VE - 52
ENG VE - 53
ENG VE - 54
ENGINE ENG
Specific tooling
020565Y Flywheel lock calliper spanner
Specific tooling
020581Y Flywheel extractor
ENG - 56
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 57
Head fitting
- To refit it, carry out the removal operations but in reverse order
- Fit a new gasket between the head and the cylinder
- Make sure the coupling surfaces are perfectly clean
- Place the head on the cylinder and tighten the four stud bolts in two or three stages, tightening one
stud bolt and afterwards the one that is diametrically opposite
- Refit the thermoswitch and fit an adhesive gasket on the thread
- Fit the thermostat and its fixing nut
- Connect the thermoswitch connector and the spark plug tube - Connect the radiator coupling to the
cylinder head
- Connect the coupling from the radiator to the hydraulic pump
- Fill the cooling system reservoir with coolant
- Purge the system by operating on the coolant pump cap
ENG - 58
ENG - 59
Characteristic
Serviceability limit:
0.05 mm
Characteristic
Maximum piston ring gap allowed:
0.5 mm
Characteristic
Serviceability limit:
0.35 mm
ENG - 60
Recommended products
AGIP CITY TEC 2T Mixer oil
synthetic oil for 2-stroke engines: JASO FC, ISO-
L-EGD
Crankcase - crankshaft
Crankshaft removal
ENG - 61
Specific tooling
00H0530015.1 Engine opening tool
ENG - 62
Specific tooling
00H0530015.1 Engine opening tool
Characteristic
Serviceability limit:
0.8 mm
ENG - 63
Characteristic
Serviceability limit:
0.35 mm
Characteristic
Serviceability limit:
0.05 mm
ENG - 64
Crankcase fitting
Specific tooling
020376Y Adaptor handle
020441Y 26 x 28 mm adaptor
020455Y 10-mm guide
- Fit the hydraulic pump shaft
- It is crucial to make sure that the washer is cor-
rectly fitted
- Fit the pump rotor and fix it with its nut
- Fit a new gasket on the pump cover and then fit
the pump cover
ENG - 65
- Place the crankcase right cover and, with the aid of a screwdriver, rotate the clutch shaft until it is
aligned with the tappet
- Using a screwdriver, rotate the oil pump shaft and the crankshaft so as to engage the oil pump pinions
and those of the hydraulic pump
- Tighten the screws on the crankcase cover in two or three stages, tighten one screw first and then the
one that is diametrically opposite
ENG - 66
Specific tooling
020376Y Adaptor handle
020441Y 26 x 28 mm adaptor
020412Y 15 mm guide
ENG - 67
ENG - 68
ENG - 69
Recommended products
AGIP CITY HI TEC 4T oil to lubricate flexible
transmissions (throttle control)
Oil for 4-stroke engines
ENG - 70
ENG - 71
Characteristic
Spring serviceability limit:
31 mm
Characteristic
Serviceability limit:
3.8 mm
Characteristic
Serviceability limit:
0.15 mm
ENG - 72
Pinion fitting
Specific tooling
ENG - 73
Right cover
ENG - 74
- Unscrew the fixing nut (2) first and then the rotor
(3). Push the driving gear, remove the hydraulic
pump and the gaskets
ENG - 75
Specific tooling
020565Y Flywheel lock calliper spanner
Specific tooling
0.0H.056.0.032.1 Crankshaft gear extractor
Clutch fitting
ENG - 76
Lubrication
Oil pump
ENG - 77
Removal
Oil pump removal
ENG - 78
Refitting
Pipe purging
- Fill up the fuel tank with a mixture of oil and petrol
at 2.5% using the oil recommended for this type of
engine
- Start the engine and let it run for about 10 minutes
with the oil pump control lever (2) fully open in or-
der to send out all the air in the pipe together with
the oil
- DO NOT fully rev up the engine while purging
- Carry out this operation in a well-ventilated area
Fuel supply
WARNING
IF THE SCOOTER IS NOT USED FOR OVER 1 MONTH, DRAIN ALL THE FUEL OF THE CARBU-
RETTOR FLOAT CHAMBER. OTHERWISE, THE NOZZLES CAN GET PARTIALLY OR FULLY
CLOGGED
WARNING
THE CARBURETTOR CAN BE REMOVED OR REPLACED WITH THE ENGINE FITTED ON THE
SCOOTER
ENG - 79
Reed valve
ENG - 80
ENG - 81
ENG - 82
ENG - 83
ENG - 84
ENG - 85
SUSPENSIONS SUSP
Front
Front suspension removal
- Remove the stem and the fork leg from the fork
plate.
- Secure the stem adequately in the vice with alu-
minium clamps to avoid scratching the stem.
- Loosen the upper screw.
SUSP - 87
SUSP - 88
SUSP - 89
Refitting
Carry out removal operations in reverse order being careful to observe the following tightening torques:
REFITTING
Name Torque in Nm
Fork stem cap 17 ÷ 19 Nm
Fork plate upper clamp 8 ÷ 10 Nm
SUSP - 90
Name Torque in Nm
Fork plate lower clamp 8 ÷ 10 Nm
Front wheel shaft 70-80
Front brake calliper clamps 17 ÷ 19 Nm *
Rear
SUSP - 91
BRAK SYS - 93
Disc Inspection
BRAK SYS - 94
BRAK SYS - 95
BRAK SYS - 96
Fill
Rear - combined
BRAK SYS - 97
CAUTION
WHILE CARRYING OUT THESE OPERATIONS, THE SCOOTER MUST BE UPRIGHT.
WARNING
- BRAKING CIRCUIT FLUID IS HYGROSCOPIC.
IT ABSORBS HUMIDITY FROM THE SUR-
ROUNDING AIR.
IF THE LEVEL OF HUMIDITY IN THE BRAKING
FLUID EXCEEDS A GIVEN VALUE, BRAKING
EFFICIENCY WILL BE REDUCED.
THEREFORE, ALWAYS USE FLUID FROM
SEALED CONTAINERS.
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 FREQUENTLY.
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 DE-
GREASE THE DISC SHOULD THERE BE OIL ON IT. WHEN THE OPERATION IS OVER, TIGHTEN
THE OIL BLEED SCREW TO THE PRESCRIBED TORQUE.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE
OF ACCIDENTAL CONTACT, WASH WITH WATER.
WARNING
BRAKE CIRCUIT FLUID IS VERY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH
PAINTED PARTS.
CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SUR-
ROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKE FLUID EXCEEDS A GIVEN VALUE,
BRAKING EFFICIENCY WILL BE REDUCED.
Specific tooling
020329Y MityVac vacuum-operated pump
Front
- Once the bleed valve is closed, fill the system with brake liquid to the maximum level.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
BRAK SYS - 98
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE
OF ACCIDENTAL CONTACT, WASH WITH WATER.
WARNING
BRAKE CIRCUIT FLUID IS VERY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH
PAINTED PARTS.
CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SUR-
ROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKE FLUID EXCEEDS A GIVEN VALUE,
BRAKING EFFICIENCY WILL BE REDUCED.
BRAK SYS - 99
Specific tooling
020329Y MityVac vacuum-operated pump
Coolant replacement
System bleed
- Insert the gasket on the pump cover, the cover and the two sleeves
- Pour recommended oil in the transmission
- Fill up the cooling system
- Fit the other parts following the removal procedures but in reverse order
Thermostat
Removal
Check
Thermoswitch check
- Immerse the thermoswitch in hot water to check
its resistance
- The thermoswitch should not get into contact with
the container walls or bottom; otherwise, the read-
ing will not be accurate.
1 - Thermometer
2 - Thermoswitch
- Replace the thermoswitch if the results do not fall
within the specification values
Characteristic
Activation
124 ± 3°C
Deactivation
114 ± 3°C
Thermostat check
Measuring the valve opening temperature:
- Immerse the thermostat and the thermometer in
hot water.
Neither of them should get into contact with the
container walls or bottom; otherwise, the reading
will not be accurate.
1 - Thermometer
2 - Thermostat (the thermostat must be totally im-
mersed into the water)
- Replace the thermostat if the results do not fall
within the specification values.
Characteristic
Valve opening at 67±3 °C :
0.1 mm
Valve opening at 75°C :
3 mm
Refitting
CHASSIS CHAS
Seat
Headlight assy.
CHAS - 107
CHAS - 108
Footrest
Side fairings
Rear fairings
- Remove the saddle
- Remove the two fixing screws indicated in the
photograph
Air deflector
- Undo the two screws indicated in the photograph
to remove the air deflector
CHAS - 109
Rear mudguard
CHAS - 110
Fuel tank
- Remove the saddle
- Remove the front fairing halves
- Remove the mixer oil reservoir
- Remove the metal clamp fixing the reservoir by
operating on the two screws indicated in the pho-
tograph
- Remove the electrical cable harness of the low
fuel sensor
- Remove the fuel pipe and the low-fuel intake pipe
from the cock
- Slide off the fuel tank from its seat
Front mudguard
- Remove the 4 screws shown in the figure, the
transmission clamps and the mudguard
Radiator fan
Radiator removal
- Remove the front fairing
- Remove the radiator clamp indicated in the pho-
tograph
- Using the specific pliers, disconnect the coolant
pipes
WARNING
CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS
COLD. SCALDING COOLANT OR ITS VAPOURS CAN
CAUSE SERIOUS BURNS. COLLECT THE COOLANT IN A
CONTAINER. COOLANT IS HARMFUL. AVOID CONTACT
WITH THE SKIN AND EYES.
Specific tooling
020544y Pliers for clamps
Radiator fitting
CHAS - 111
Radiator fitting
- Fit the radiator following the removal procedures but in reverse order
- Fill the reservoir with the recommended coolant and make sure there are no leaks in the system
Expansion tank
Battery
Battery compartment
- Remove the rear mudguard
- Remove the side fairings
- Remove the two screws indicted in the photo-
graph and then remove the battery compartment
CHAS - 112
CHAS - 113
PRE-DELIVERY PRE DE
Aesthetic inspection
Vehicle check
- Paintwork
- Plastic parts fitting
- Damage
- Dirt
Locking Check
- All the tightening torques
- External screw of covers
Electrical system
Electrical system
- Fill up the battery with acid for batteries, charge it using a suitable battery charger.
- Key switch
- Low-beam light, high-beam light, warning lights, tail light
- Headlight adjustment
- Rear light
- Stop light (front and rear brake, if necessary)
- Turn indicators and their warning lights
- Speedometer and instrument panel lighting
- Horn
- Starter button
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 BATTERY LIFE.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
FIRST DETACH THE NEGATIVE LEAD BEFORE REMOVING THE BATTERY FROM THE VEHICLE.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE LEAD.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-
TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF
COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP-
PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
PRE DE - 115
Levels check
Level check
- Brake oil level
- Gearbox oil level
- Mixer oil level
Road test
Test drive
- Cold start
- Speedometer operation check
- Throttle control operation
- Riding stability
- Rear and front brake efficiency
- Front and rear wheel shock absorber
- Abnormal noise
- Restarting when warmed up
- Fluid leakage (after the road test)
Static test
Static check
- Tyre pressure
- Correct operation of all locks
- Mirrors and accessories fitting
- Tools supplied, user manual, warranty certificate and customer services document
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
WARNING
PRE DE - 116
Functional inspection
Functional check
- Brake lever travel
- Throttle control adjustment and free travel
- Uniform turning of the steering
PRE DE - 117
B
Battery: 33, 39, 44, 45, 47, 112
Brake: 93–96, 100
C
Carburettor: 21, 80, 82
Coolant: 102
F
Fuel: 32, 79, 111
Fuses: 44
H
Headlight: 28, 107
I
Identification: 7
M
Maintenance: 19
S
Spark plug: 23
T
Tank: 111, 112
Transmission: 32
Tyres: 10