Piaggio Liberty 125 - 150 MY 2009 (en))

SERVICE STATION MANUAL*******

Liberty 125 - 150 (2009)

SERVICE STATIONMANUAL

Liberty 125 - 150 (2009)

The descriptions and illustrations given in this publication are not binding. While the basic specificationsas 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 tocomponents, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.Not all versions/models shown in this publication are available in all countries. The availability of each

model should be checked at the official Piaggio sales network."© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."PIAGGIO & C. S.p.A. - After-Sales

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

SERVICE STATION MANUALLiberty 125 - 150 (2009)

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

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

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

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

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

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

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

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

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

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water

and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working

area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that

you do not breathe in the dust produced by the wear of the friction material. Even though the latter

contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

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

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all

the work surfaces, except tapered couplings, before refitting these parts.

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

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,

nuts and screws are not interchangeable with coupling members using English measurements. Using

unsuitable coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make

sure the electrical connections have been made properly, particularly the ground and battery connec-

tions.

Characteristics Liberty 125 - 150 (2009)

CHAR - 6

Vehicle identification

The chassis prefix «A» is stamped on the right

strut.

The engine prefix «B» is stamped near the rear left

shock absorber lower support.

VEHICLE IDENTIFICATION (125)Specification Desc./QuantityChassis prefix M67100Engine prefix M671M

VEHICLE IDENTIFICATION (150)Specification Desc./QuantityChassis prefix M67200Engine prefix M672M

Liberty 125 - 150 (2009) Characteristics

CHAR - 7

Dimensions and mass

WEIGHTS AND DIMENSIONSSpecification Desc./QuantityKerb weight 114±5 kgWheelbase 1325 mm

Length 1935 mmWidth 760 mmHeight 1120 mm

Engine

SPECIFICATIONS - 125 ENGINESSpecification Desc./Quantity

Type Single-cylinder, 4-strokeEngine capacity 124 cm³

Bore x stroke 57.0 x 48.6 mmCompression ratio 10.6 ± 0.5: 1Engine idle speed 1650 ± 100 rpm

Timing system 2 valves, single overhead camshaft, chain-driven.Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm

Max. power 7.7 kW at 8,250 rpmMAX. torque 9.6 Nm at 7,250 rpmTransmission Automatic expandable pulley variator with torque server, V-

belt, self-ventilating dry automatic centrifugal clutch and trans-mission housing with forced-circulation air cooling.

Final reduction gear Gear reduction unit in oil bath.


CHAR - 8

Specification Desc./QuantityLubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.Cooling Forced-air circulation cooling.Starter starterIgnition Capacitive discharge ignition, with variable advance and sep-

arate HV coil.Ignition advance Three-dimensional map managed by control unit

Spark plug CHAMPION RG 6 YCAlternative spark plug NGK CR7EB

Fuel system KEIHIN CVK 27 carburettor and vacuum-operated fuel pump.Fuel Unleaded petrol (95 RON)

Exhaust silencer Absorption-type exhaust muffler with catalytic converter.Emissions compliance EURO 3

SPECIFICATIONS - 150 ENGINESSpecification Desc./Quantity

Type Single-cylinder, 4-strokeEngine capacity 151 cm³

Bore x stroke 62.8 x 48.6 mmCompression ratio 10.6 ± 0.5 : 1Engine idle speed 1,650±100 rpm

Timing system 2 valves, single overhead camshaft, chain-driven.Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm

Max. power 8.9 kW at 7,750 rpmMAX. torque 11.8 Nm at 6,500 rpmTransmission Automatic expandable pulley variator with torque server, V-

belt, self-ventilating dry automatic centrifugal clutch and trans-mission housing with forced-circulation air cooling.

Final reduction gear Gear reduction unit in oil bath.Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.Cooling Forced-air circulation cooling.Starter starterIgnition Capacitive discharge ignition, with variable advance and sep-



Fuel system KEIHIN CVK 27 carburettor and vacuum-operated fuel pump.Fuel Unleaded petrol (95 RON)

Exhaust silencer Absorption-type exhaust muffler with catalytic converter.Emissions compliance EURO 3

Transmission

TRANSMISSIONSpecification Desc./Quantity

Main drive Automatic expandable pulley variator with torque server, V-belt, automatic self-ventilating centrifugal dry clutch

Final reduction gear Gear reduction unit in oil bath.

Capacities

CAPACITIESSpecification Desc./Quantity

Engine oil 1.10 lTransmission oil 200 cm3

Fuel tank capacity about 7 litres (1.5 l of which is reserve)


CHAR - 9

Electrical system

ELECTRICAL SYSTEMSpecification Desc./Quantity

Starter starterIgnition Capacitive discharge ignition, with variable advance and sep-



Battery Sealed, 12 V / 10 AhAlternator alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONSSpecification Desc./Quantity

Chassis Tubular steel frameFRONT SUSPENSION Ø 32 Hydraulic telescopic fork - travel: 76 mm

Rear suspension Hydraulic single shock absorber and spring adjustable to 4 po-sitions at preloading; travel: 85.5 mm.

Brakes

BRAKESSpecification Desc./QuantityFront brake Ø 240mm drum brake with twin-plunger floating calliper.Rear brake Ø 140-mm drum brake with mechanical control activated by the

handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRESSpecification Desc./QuantityWheel rim type Light alloy wheel rims.Front wheel rim 16'' x 2.15Rear wheel rim 14'' x 2.75

Front tyre Tubeless, 90/80 - 16" 51JRear tyre Tubeless, 110/80 - 14" 59J

Front tyre pressure (with passenger) 2 bar (- bar)Rear tyre pressure (with passenger) 2.2 bar (2.5 bar)

Secondary air

In order to reduce polluting emissions, the vehicle

is furnished with a catalytic converter in the muf-

fler.

To favour the catalytic process, an extra amount

of oxygen is added to the exhaust through a sec-

ondary air system (SAS).


CHAR - 10

This system allows more oxygen to be added to

the unburned gases before they reach the con-

verter, thus improving the action of the catalytic

converter.

The air enters the exhaust duct from the head, and

is purified by a black filter.

The system is fitted with a control valve that disa-

bles operation while decelerating to avoid unwan-

ted noise.

To ensure the best functioning of the SAS system

clean the filter as indicated in the scheduled main-

tenance table.

The filter sponge should be cleaned with water and

mild soap, then it should be dried with a cloth and

slight blows of compressed air.

Carburettor

125cc Version

Kehin

CARBURETTOR SETTINGSpecification Desc./Quantity

Type CVEK27Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4Setting stamping 2701A

Maximum jet 82Maximum air jet (on the body) 85

Tapered pin stamping NJHAThrottle valve spring 130 ÷ 180 gr.

Minimum jet 42Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 2 ½Starter nozzle 42

Starter air jet (on the body) Ø 1.5Starter pin travel 10 mm (at 24°)Starter resistance 20 Ohm (at 24°)

150cc Version


CHAR - 11

Kehin

CARBURETTOR SETTINGSpecification Desc./Quantity

Type CVEK27Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4Setting stamping 2702B

Maximum jet 80Maximum air jet (on the body) 130

Maximum air jet (on the body) MAJ2 80Tapered pin stamping NELAThrottle valve spring 130 ÷ 180 gr.

Minimum jet 35Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 2Starter nozzle 42

Starter air jet (on the body) Ø 1.5Starter pin travel 10 mm (at 24°)Starter resistance 20 Ohm (at 24°)

Tightening Torques

MOTOREName Torque in Nm

Ignition spark plug 10 to 15 NmHead cover screws 8 ÷ 10

Head-cylinder stud bolt nuts 6 to 7 + 90° + 90° *Screws fixing head and cylinder to crankcase 8 to 10

Chain tensioner pad screw 5 to 7 NmTiming chain tensioner screws 8 ÷ 10 Nm

Timing chain tensioner central screw 5 to 6Camshaft pulley screw 12 to 14

Rocking lever axle and camshaft bearing screw 3 to 4 NmValve clearance adjustment lock nuts 7 ÷ 9 Nm

Engine oil pre-filter cover: 25 to 28 NmEngine oil drainage cap 25 to 28Alternator flywheel nut 40 ÷ 44 Nm

Stator screws 3 to 4Pick-up screws 3 to 4

Oil pump bulkhead screw 4 to 5Timing chain/oil pump compartment cover screws 4 to 5 Nm

Oil decantation labyrinth sheet screws 7 to 8Oil pump crown screw 8 to 10

Screws fixing oil pump to the crankcase 5 to 6Oil pump coupling screws 7 ÷ 9 Nm

Oil sump screws 8 to 10 NmInlet manifold screw 7 - 9

Carburettor/manifold clamp screw 1.2 ÷ 1.5 NmScrews fixing cables to starter motor 1.5 to 2.5

Starter screws 11 to 13Transmission cover screws 11 ÷ 13 Nm

Crankcase cooling cover screw 2 to 2.5Nut locking clutch unit on pulley 55 to 60 Nm

Crankshaft pulley nut 18 to 20 + 90° NmDriven pulley shaft nut 40 ÷ 44 NmHub oil drainage screw 3 to 5 NmRear hub cap screws 24 ÷ 26 Nm

Wheel axle nut 115 ÷ 125Crankcase half union screw 8 to 10

Per assicurare una corretta coppia di bloccaggio lubrificare i dadi prima del montaggio.


CHAR - 12

* Montando dei nuovi prigionieri, l'operazione di serraggio dei dadi comprende l'effettuazione di 3 rotazioni di 90° dopo il primobloccaggio a 6÷7 Nm, pertanto: 6÷7 Nm + 90° + 90° + 90° a passaggi incrociati.

STEERING ASSEMBLYName Torque in Nm

Upper steering ring nut 35 ÷ 40Lower steering ring nut 12 ÷ 14handlebar fixing screw 45 ÷ 55

FRAME ASSEMBLYName Torque in Nm

Engine-swinging arm pin 33 to 41Frame-swinging arm bolt 64 - 72

Shock absorber - chassis nut 20 to 25Shock absorber/engine pin 33 - 41 N.m

Rear wheel axle 104 ÷ 126Stand bolt 20 ÷ 25

Front mudguard fixing screw 4 ÷ 6

FRONT SUSPENSIONName Torque in Nm

Fork bottom screw 20 ÷ 25Front wheel axle 45 to 50

Odometer drive screw 6 ÷ 7

FRONT BRAKEName Torque in Nm

Brake fluid pump-hose fitting 20 ÷ 25Brake fluid pipe-calliper fitting 20 ÷ 22

Calliper tightening screw 20 ÷ 25Disc tightening screw (Apply LOCTITE 243 medium-strength

threadlocker)8 ÷ 12 Nm

Oil bleeding valve 8 ÷ 12

Overhaul data

Assembly clearances

Cylinder - piston assy.

PISTON TO CAST IRON CYLINDER COUPLING (125)Name Initials Cylinder Piston Play on fitting

Coupling M 56.997 to 57.004 56.944 to 56.951 0.046 to 0.060Coupling N 57.004 to 57.011 56.951 to 56.958 0.046 to 0.060Coupling O 57.011 to 57.018 56.958 to 56.965 0.046 to 0.060Coupling P 57.018 to 57.025 56.965 to 56.972 0.046 to 0.060

Coupling 1st oversize M1 57.197 to 57.204 57.144 to 57.151 0.046 to 0.060Coupling 1st oversize N1 57.204 to 57.211 57.151 to 57.158 0.046 to 0.060Coupling 1st oversize O1 57.211 to 57.218 57.158 to 57.165 0.046 to 0.060Coupling 1st oversize P1 57.218 to 57.225 57.165 to 57.172 0.046 to 0.060Coupling 2nd oversize M2 57.397 to 57.404 57.344 to 57.351 0.046 to 0.060Coupling 2nd oversize N2 57.404 to 57.411 57.351 to 57.358 0.046 to 0.060Coupling 2nd oversize O2 57.411 to 57.418 57.358 to 57.365 0.046 to 0.060Coupling 2nd oversize P2 57.418 to 57.425 57.365 to 57.372 0.046 to 0.060Coupling 3rd oversize M3 57.597 to 57.604 57.544 to 57.551 0.046 to 0.060Coupling 3rd oversize N3 57.604 to 57.611 57.551 to 57.558 0.046 to 0.060Coupling 3rd oversize O3 57.611 to 57.618 57.558 to 57.565 0.046 to 0.060Coupling 3rd oversize P3 57.618 to 57.625 57.565 to 57.572 0.046 to 0.060


CHAR - 13

COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER(125)

Name Initials Cylinder Piston Play on fittingCoupling A 56.980 ÷ 56.987 56.933 ÷ 56.940 0.040 ÷ 0.054Coupling B 56.987 ÷ 56.994 56.940 ÷ 56.947 0.040 ÷ 0.054Coupling D 57.001 ÷ 57.008 56.954 ÷ 56.961 0.040 ÷ 0.054Coupling C 56.994 ÷ 57.001 56.947 ÷ 56.954 0.040 ÷ 0.054

Coupling 1st oversize A1 57.180 ÷ 57.187 57.133 ÷57.140 0.040 ÷ 0.054Coupling 1st oversize B1 57.187 ÷ 57.194 57.140 ÷ 57.147 0.040 ÷ 0.054Coupling 1st oversize D1 57.201 ÷ 57.208 57.154 ÷ 57.161 0.040 ÷ 0.054Coupling 1st oversize C1 57.194 ÷ 57.201 57.147 ÷ 57.154 0.040 ÷ 0.054Coupling 2nd oversize A2 57.380 ÷ 57.387 57.333 ÷ 57.340 0.040 ÷ 0.054Coupling 2nd oversize B2 57.387 ÷ 57.394 57.340 ÷ 57.347 0.040 ÷ 0.054Coupling 2nd oversize C2 57.394 ÷ 57.401 57.347 ÷ 57.354 0.040 ÷ 0.054Coupling 2nd oversize D2 57.401 ÷ 57.408 57.354 ÷ 57.361 0.040 ÷ 0.054Coupling 3rd oversize A3 57.580 ÷ 57.587 57.533 ÷ 57.540 0.040 ÷ 0.054Coupling 3rd oversize B3 57.587 ÷ 57.594 57.540 ÷ 57.547 0.040 ÷ 0.054Coupling 3rd oversize C3 57.594 ÷ 57.601 57.547 ÷ 57.554 0.040 ÷ 0.054Coupling 3rd oversize D3 57.601 ÷ 57.608 57.554 ÷ 57.561 0.040 ÷ 0.054

COUPLING BETWEEN (ASSO-WERKE) PISTON AND CYLINDER (150)Name Initials Cylinder Piston Play on fitting

Coupling A 62.580 to 62.587 62.533 to 62.540 0.040 to 0.054Coupling B 62.587 to 62.594 62.540 to 62.547 0.040 to 0.054Coupling C 62.594 to 62.601 62.547 to 62.554 0.040 to 0.054Coupling D 62.601 to 62.608 62.554 to 62.561 0.040 to 0.054

Coupling 1st oversize A1 62.780 to 62.787 62.733 to 62.740 0.040 to 0.054Coupling 1st oversize B1 62.787 to 62.794 62.740 to 62.747 0.040 to 0.054Coupling 1st oversize C1 62.794 to 62.801 62.747 to 62.754 0.040 to 0.054Coupling 1st oversize D1 62.801 to 62.808 62.754 to 62.761 0.040 to 0.054Coupling 2nd oversize A2 62.980 to 62.987 62.933 to 62.940 0.040 to 0.054Coupling 2nd oversize B2 62.987 to 62.994 62.940 to 62.947 0.040 to 0.054Coupling 2nd oversize C2 62.994 to 63.001 62.947 to 62.954 0.040 to 0.054Coupling 2nd oversize D2 63.001 to 63.008 62.954 to 62.961 0.040 to 0.054Coupling 3rd oversize A3 63.180 to 63.187 63.133 to 63.140 0.040 to 0.054Coupling 3rd oversize B3 63.187 to 63.194 63.140 to 63.147 0.040 to 0.054Coupling 3rd oversize C3 63.194 to 63.201 63.147 to 63.154 0.040 to 0.054Coupling 3rd oversize D3 63.201 to 63.208 63.154 to 63.161 0.040 to 0.054

COUPLING BETWEEN (RIGHT WAY) PISTON AND CYLINDER (150)Name Initials Cylinder Piston Play on fitting

Coupling A 62.580 to 62.587 62.541 to 62.548 0.032 to 0.046Coupling B 62.587 to 62.594 62.548 to 62.555 0.032 to 0.046Coupling C 62.594 to 62.601 62.555 to 62.562 0.032 to 0.046Coupling D 62.601 to 62.608 62.562 to 62.569 0.032 to 0.046

Piston rings


CHAR - 14

SEALING RINGS (125)Name Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 to 0.30Oil scraper ring 57x1 A 0.10 to 0.30Oil scraper ring 57x2.5 A 0.10 to 0.35

Compression ring 1stoversize

57.2 x 1 A 0.15 to 0.30

Oil scraper ring 1stoversize

57.2x1 A 0.10 to 0.30


57.2x2.5 A 0.10 to 0.35

Compression ring 2ndoversize

57.4x1 A 0.15 to 0.30

Oil scraper ring 2ndoversize

57.4x1 A 0.10 to 0.30


57.4x2.5 A 0.10 to 0.35

Compression ring 3rdoversize

57.6x1 A 0.15 to 0.30

Oil scraper ring 3rdoversize

57.6x1 A 0.10 to 0.30


57.6x2.5 A 0.10 to 0.35

Maximum clearance after use: 1 mm

SEALING RINGS (150)Name Description Dimensions Initials Quantity

Compression ring 62.6x1 A 0.15 to 0.30Oil scraper ring 62.6x1 A 0.20 to 0.40Oil scraper ring 62.6x2.5 A 0.20 to 0.40

Compression ring 1stoversize

62.8x1 A 0.15 to 0.30


62.8x1 A 0.20 to 0.40


62.8x2.5 A 0.20 to 0.40

Compression ring 2ndoversize

63.0 x 1 A 0.15 to 0.30


63.0 x 1 A 0.20 to 0.40


63.0 x 2.5 A 0.20 to 0.40

Compression ring 3rdoversize

63.2 x 1 A 0.15 to 0.30


63.2 x 1 A 0.20 to 0.40


63.2 x 2.5 A 0.20 to 0.40

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (125)Name Description Dimensions Initials Quantity

Transmissionside half-shaft

16.6 +0-0.05 A D = 0.20 to 0.50

Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 to 0.50Connecting rod with PP 18 -0.10 -0.15 C 0.20 to 0.50

Crank pin width 51.400 E


CHAR - 15

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS(125)

Name Description Dimensions Initials QuantityCrankshaft Category 1 28.998 to 29.004Crankshaft Category 2 29.004 to 29.010Crankcase Category 1 32.953 to 32.959Crankcase Category 2 32.959 to 32.965

Crankshaft half-bearing Category B - blue 1.973 to 1.976Crankshaft half-bearing Category C - yellow 1.976 to 1.979Crankshaft half-bearing Category E - green 1.979 to 1.982Crankshaft category 1 -Crankcase category 1

E - E

Crankshaft category 1 -Crankcase category 2

C - C


C - C


B - B

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (150)Name Description Dimensions Initials Quantity

Transmissionside half-shaft

16.6 +0-0.05 A D = 0.20 to 0.50

Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 to 0.50Connecting rod with PP 18 -0.10 -0.15 C 0.20 to 0.50

Crank pin width E 51.4 +0.050

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS(150)

Name Description Dimensions Initials QuantityCrankshaft Category 1 28.998 to 29.004Crankshaft Category 2 29.004 to 29.010Crankcase Category 1 32.959 ÷ 32.965Crankcase Category 2 32.953 ÷ 32.959

Crankshaft half-bearing Category B - blue 1.973 to 1.976Crankshaft half-bearing Category C - yellow 1.976 to 1.979Crankshaft half-bearing Category E - green 1.979 to 1.982Crankshaft category 1 -Crankcase category 1

E - E


C - C


C - C


B - B


CHAR - 16

CharacteristicCrankshaft/crankcase axial clearance «A»:

0.15 ÷ 0.40

Slot packing system

SHIMMING SYSTEMValue measured Gasket thickness

0 ÷ 0.1 0.8 ± 0.050.1 ÷ 0.3 0.6 ± 0.050.3 - 0.4 0.4 ± 0.05

CharacteristicCompression ratio

10.6 ± 0.5: 1


CHAR - 17

Products

RECOMMENDED PRODUCTS TABLEProduct 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(brakes, throttle control and odometer)

Oil for 4-stroke engines

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-creased adhesiveness

AGIP GP 330 Grease for brake levers, throttle, stand White calcium complex soap-basedspray grease with NLGI 2; ISO-L-XBCIB2

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MASynthetic oil

AGIP GREASE MU3 Grease for odometer transmission gearcase

Soap-based lithium grease with NLGI 3;ISO-L-XBCHA3, DIN K3K-20

UNIT OF MEASURE - CONVERSION - ENGLISH SYSTEM TO INTERNATIONAL SYSTEM (IS).Specification Desc./Quantity

1 Inch (in) 25.4 Millimetres (mm)1 Foot (ft) 0.305 Meter (m)1 Mile (mi) 1.609 Kilometre (km)

1 US Gallon (USgal) 3.785 Litre (l)1 Pound (lb) 0.454 Kilogram (kg)

1 Cubic inch (in³) 16.4 Cubic centimetres (cm³)1 Foot pound (ft lb) 1,356 Newton meter (Nm)

1 Mile per hour (mi/h) 1,602 Kilometres per hour (km/h)1 Pound per square inch (PSI) 0.069 (bar)

1 Fahrenheit (°F) 32+(9/5) Celsius (°C)


CHAR - 18

INDEX OF TOPICS

TOOLING TOOL

APPROPRIATE TOOLSStores code Description

001330Y Tool for fitting steering seats

001467Y009 Driver for OD 42-mm bearings

001467Y013 Calliper to extract ø 15-mm bearings

002465Y Calliper for circlips

005095Y Engine support

008564Y Flywheel extractor

Tooling Liberty 125 - 150 (2009)

TOOL - 20

Stores code Description020004Y Punch for removing steering bearings

from headstock

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crankshaftalignment

020150Y Air heater mounting

020151Y Air heater

020193Y Oil pressure check gauge

Liberty 125 - 150 (2009) Tooling

TOOL - 21

Stores code Description020262Y Crankcase splitting plate

020263Y Driven pulley assembly sheath

020287Y Clamp to fit piston on cylinder

020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing


TOOL - 22

Stores code Description020331Y Digital multimeter

020332Y Digital rpm indicator

020648Y Single battery charger

020335Y Magnetic mounting for dial gauge

020357Y 32x35-mm Adaptor020359Y 42x47-mm Adaptor


TOOL - 23

Stores code Description020360Y 52x55-mm Adaptor

020363Y 20-mm guide

020364Y 25-mm guide

020368Y driving pulley lock wrench

020375Y 28 x 30 mm adaptor

020376Y Adaptor handle


TOOL - 24

Stores code Description020382Y011 adapter for valve removal tool

020409Y Multimeter adaptor - Peak voltage detec-tion

020412Y 15-mm guide

020414Y 28-mm guide

020423Y Driven pulley lock wrench


TOOL - 25

Stores code Description020424Y Driven pulley roller casing fitting punch

020425Y Punch for flywheel-side oil seal

020426Y Piston fitting fork

020427Y Piston assembly band

020428Y Piston position check mounting

020430Y Pin lock fitting tool


TOOL - 26

Stores code Description020431Y Valve oil seal extractor

020434Y Oil pressure check fitting

020444Y Tool for fitting/ removing the driven pulleyclutch

020565Y Flywheel lock calliper spanner

020622Y Transmission-side oil seal punch

494929Y Exhaust fumes analyser


TOOL - 27

Stores code Description020625Y Kit for sampling gas from the exhaust

manifold

020481Y005 EFI Technology interface wiring

020680Y Diagnosis Tool

020469Y Reprogramming kit for vehicle diagnostictester

020641Y EFI Technology software upgrade


TOOL - 28

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

MAINTENANCE TABLEReplacement Check* Check level every 3,000 km** Replace every 2 yearsClean the external filter of the Secondary Air System (SAS) every 2 years

Km x 1,000 1 6 12 18 24 30 36 42 48 54 60 66 72Safety locks Ignition spark plug Centre stand (lubrication) Driving belt Throttle control (adjustment) Air filter SAS filter Oil net filter (cleaning) Oil filter Valve clearance Electrical system and battery Cylinder ventilation system Brake control lever (greasing) Brake fluid level ** Engine oil * Hub oil Headlight aiming adjustment Brake pads Sliding blocks / variable speed rollers Tyre pressure and wear Vehicle test ride Idle speed Odometer gear (greasing) Suspension Steering Transmission Operation time 80' 150' 160' 150' 175' 95' 270' 95' 175' 150' 160' 95' 270'

Hub oil

Check

Maintenance Liberty 125 - 150 (2009)

MAIN - 30

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Engine

Poor performance

POOR PERFORMANCEPossible Cause Operation

Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, thensoak it in a mixture of 50% petrol and 50% specific oil. Presswith your hand without squeezing, allow it to drip dry and refit.

Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed airDirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol and wash the

tank, if necessary. Replace the cock as a last resource.Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace

if necessary.Excessive drive belt wear Check it and replace, if necessary

Lack of compression: parts, cylinder and valves worn Replace the worn partsOil level exceeds maximum Check for causes and fill to reach the correct level

Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valvesIncorrect timing or worn timing system elements Time the system again or replace the worn parts

Silencer obstructed ReplaceInefficient automatic transmission Check the rollers and the pulley movement, replace the dam-

aged parts and lubricate the movable guide of the driven pulleywith grease.

Wrong valve adjustment Adjust the valve clearance properlyOverheated valves Remove the head and the valves, grind or replace the valvesValve seat distorted Replace the head unit

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

Rear wheel spins at idle

REAR WHEEL ROTATES WITH ENGINE AT IDLEPossible Cause Operation

Idling rpm too high Adjust the engine idle speed.Clutch fault Check the springs / clutch masses

Starting difficulties

START-UP PROBLEMSPossible Cause Operation

Flat battery Check the state of the battery. If it shows signs of sulphationreplace it and bring the new battery into service charging it foreight hours at a current of 1/10 of the capacity of the battery

itselfFaulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components

Engine flooded Try starting-up with the throttle fully open. If the engine fails tostart, remove the spark plug, dry it and before refitting, makethe motor turn so as to expel the fuel excess taking care to

connect the cap to the spark plug, and this in turn to the ground.If the fuel tank is empty, refuel and start up.

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearanceRpm too low at start-up or engine and start-up system dam-

agedCheck the starter motor and the kick-starter unit

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refillVacuum operated cock failure Check that fuel is adequately supplied through the pipe by ap-

plying a vacuum to the vacuum pipeFailing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace

if necessary.

Troubleshooting Liberty 125 - 150 (2009)

TROUBL - 32

Possible Cause OperationStart-up enabling buttons failure Check continuity using an Ohm meter, with the switch pressed;

replace if necessaryCarburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air

Air filter obstructed or dirty. Remove the sponge, wash with water and car shampoo, thensoak it in a mixture of 50% petrol and 50% specific oil. Presswith your hand without squeezing, allow it to drip dry and refit.

Fuel pump fault Check the pump control device

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUSTPossible Cause Operation

Worn valve guides Check and replace the head unit if requiredWorn valve oil seal Replace the valve oil seal

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling sealWorn or broken piston rings or piston rings that have not been

fitted properlyReplace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure

LOW LUBRICATION PRESSUREPossible Cause Operation

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

Oil pump with excessive clearance Perform the dimensional checks on the oil pump componentsOil filter too dirty Replace the cartridge filterOil level too low Restore the level adding the recommended oil type

Engine tends to cut-off at full throttle

THE ENGINE TENDS TO STOP AT MAXIMUM THROTTLEPossible Cause Operation

Maximum jet clogged Remove the carburettor, wash with solvent and dry with com-pressed air

Water or condensation in the carburettor chamber Remove the tank, wash with solvent and dry with compressedair

Level in chamber too low Restore the level in the chamber by bending on the float thethrusting reed of the petrol intake rod so as to have the floatparallel to the chamber level with the carburettor inverted.

Engine tends to cut-off at idle

THE ENGINE TENDS TO STOP AT IDLE SPEEDPossible Cause Operation

Incorrect idle adjustment Adjust using the rpm indicatorIncorrect timing Time the system and check the timing system components

The starter remains on Check: electric wiring, circuit not interrupted, mechanicalmovement and power supply; replace if necessary

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit componentsPressure too low at the end of compression Check the thermal group seals and replace worn components

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air

Liberty 125 - 150 (2009) Troubleshooting

TROUBL - 33

High fuel consumption

EXCESSIVE FUEL CONSUMPTIONPossible Cause Operation

Air filter blocked or dirty. Clean according to the procedureInefficient Starter Check: electric wiring, circuit continuity, mechanical sliding and

power supplyLoose nozzles Check the maximum and minimum nozzles are adequately

fixed in their fittingsIncorrect float level Restore the level in the chamber by bending on the float the

thrusting reed of the petrol intake rod so as to have the floatparallel to the chamber level with the carburettor inverted.

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible Cause Operation

Slippage or irregular functioning Check that there is no grease on the masses.Check that the faying surface between the clutch masses andthe clutch housing is mainly in the middle and with equivalent

specifications on the three masses.Check that the clutch housing is not scored or worn abnormally

Never run the engine without the clutch housing

Insufficient braking

INEFFICIENT OR NOISY BRAKINGPossible Cause Operation

Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk ordrum wear conditions.

Front brake disk loose or deformed Check the brake disc screws are locked; use a dial gauge anda wheel mounted on the vehicle to measure the axial shift of

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

no flexible movement of the brake lever).Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Excessive clearance in the rear brake control cable Adjust the clearance with the appropriate adjuster located onthe back part of the crankcase.

Brakes overheating

BRAKE OVERHEATPossible Cause Operation

Rubber gaskets swollen or stuck Replace gaskets.Compensation holes on the pump clogged Clean carefully and blast with compressed air

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge anda wheel mounted on the vehicle to measure the axial shift of

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


TROUBL - 34

Electrical system

Battery

BATTERYPossible Cause Operation

Battery The battery is the electrical device in the system that requiresthe most frequent inspections and thorough maintenance. If thevehicle is not used for some time (1 month or more) the battery

needs to be recharged periodically. The battery runs downcompletely in the course of 5 to 6 months. If the battery is fittedon a motorcycle, be careful not to invert the connections, keep-

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

chapter for the recharging of the batteries.

Turn signal lights malfunction

TURN INDICATOR NOT WORKINGPossible Cause Operation

Electronic ignition device failure With the key switch set to "ON" jump the contacts 2 (Blue-Black) and 9 (Orange) on the electronic control unit connector.If by operating the turn indicator control the lights are not stead-

ily on, replace the control unit; otherwise, check the cableharness and the switch.

Steering and suspensions

Heavy steering

STEERING HARDENINGPossible Cause Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-larities continue in turning the steering even after making theabove adjustments, check the seats in which the ball bearingsrotate: replace them if they are recessed or if the balls are flat-

tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCEPossible Cause Operation

Excessive steering clearance Check the tightening of the top ring nut. If irregularities continuein turning the steering even after making the above adjust-ments, check the seats in which the ball bearings rotate: re-

place if they are recessed.

Liberty 125 - 150 (2009) Troubleshooting

TROUBL - 35

Noisy suspension

NOISY SUSPENSIONPossible Cause Operation

NOISY SUSPENSION If the front suspension is noisy, check: that the front shock ab-sorber works properly and the ball bearings are good condition.

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

work properly.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSIONPossible Cause Operation

Oil leakage from suspension Replace the rear shock absorber or the front fork cartridge.


TROUBL - 36

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Ignition

LEGENDA

29. Dispositivo accensione elettronica con commutatore lampeggiatori e starter

31. Contatti del commutatore a chiave

33. Fusibile 15A

34. regolatore di tensione

35. Bobina A.T.

41. Pick-up

Electrical system Liberty 125 - 150 (2009)

ELE SYS - 38

Battery recharge and starting

LEGENDA

33. Fusibile 15A


39. Volano magnete

40. Regolatore di tensione

Liberty 125 - 150 (2009) Electrical system

ELE SYS - 39

LEGENDA

19. Pulsante avviamento

20. Motorino avviamento

21. Teleruttore avviamento

22. Stop freno anteriore e posteriore

23. Filamento per luce stop


32. Fusibile 7,5A

33. Fusibile 15A


Devices and accessories

SCHEMA SERVIZI


ELE SYS - 40

LEGENDA

1. Relè

2. Deviatore luci

3. Lampada luce di città

4. Lampade per illuminazione strumento e spia luci

5. Spia luci abbaglianti

6. Filamento per luce di posizione posteriore

7. Filamento anabbagliante del proiettore

8. Filamento abbagliante del proiettore

9. Lampada illuminazione targa

10. Fusibile 7,5A

11. Fusibili 7,5A

12. Pulsante claxon

13. Claxon in c.c.

14. Spia pressione olio motore

15. Sensore pressione olio motore

16. Spia riserva carburante

17. Indicatore livello carburante

18. Trasmettitore livello carburante



ELE SYS - 41

30. Diagnostica


32. Fusibile 7,5A

33. Fusibile 15A


36. Commutatore lampeggiatori

37. Lampade lampeggiatori

38. Lampade spie lampeggiatori

SCHEMA SERVIZI

LEGENDA

24. Potenziometro T.P.S

25. Sensore temperatura esterna

26. Riscaldatore carburatore

27. Starter automatico

28. Valvola MA J2 (solo versione 150cc)


30. Diagnostica


33. Fusibile 15A


ELE SYS - 42


LEGENDA

1. Relè

2. Deviatore luci

3. Lampada luce di città

4. Lampade per illuminazione strumento e spia luci

5. Spia luci abbaglianti

6. Filamento 5W per luce di posizione posteriore

7. Filamento anabbagliante del proiettore

8. Filamento abbagliante del proiettore

9. Lampada illuminazione targa

10. Fusibile 7,5A

11. Fusibili 7,5A

12. Pulsante claxon

13. Claxon in c.c.

14. Spia pressione olio motore

15. Sensore pressione olio motore

16. Spia riserva carburante

17. Indicatore livello carburante


ELE SYS - 43

18. Trasmettitore livello carburante

19. Pulsante avviamento

20. Motorino avviamento

21. Teleruttore avviamento

22. Stop freno anteriore e posteriore

23. Filamento per luce stop

24. Potenziometro T.P.S

25. Sensore temperatura esterna

26. Riscaldatore carburatore

27. Starter automatico

28. Valvola MA J2 (solo versione 150cc)


30. Diagnostica


32. Fusibile 7,5A

33. Fusibile 15A


35. Bobina A.T.

36. Commutatore lampeggiatori

37. Lampade lampeggiatori

38. Lampade spie lampeggiatori

39. Volano magnete

40. Regolatore di tensione

41. Pick-up

Checks and inspections

Ignition circuit

All the control operations of the system that entail disconnecting cables (to check connections and the

devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls

might be irretrievably damaged.

The battery provides the basic power supply. The system is adjusted so that the start-up system im-

mediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition

system.

The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected

to the Pick-Up by the chassis and the engine ground lead.


ELE SYS - 44

To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis

ground connection bonding is efficient.

No spark plug

Once the lack of power to the spark plug has been

detected and the LED indicates it can be ignited,

follow this procedure:

- Check the Pick-Up.

Disconnect the control unit connector and check

that the cable between terminal No. 3 (Green) and

terminal No. 12 (Black) is not interrupted.

The check includes the Pick-Up and its power line.

If a break in the circuit is found, check again the

flywheel and the engine earth connectors. If non-

conforming values are measured, replace the

Pick-Up; otherwise, repair the cable harness.

Electric characteristicPick-up resistance valuePick-up resistance value: 105 ÷ 124 Ohm

- HV primary coil check

Disconnect the control unit connector and check

that the cable between terminal No. 4 (violet) and

terminal No. 12 (black) is not interrupted (see fig-

ure).

If non-conforming values are measured, check

again the HV coil primary directly on the positive

and negative terminals.

If the values are correct, repair the cable harness

or reset the connections; otherwise, replace the

HV coil

Electric characteristicHigh voltage coil primary resistance valueHigh voltage coil primary resistance value: 0.4 ÷

0.5 Ohm

- HV coil secondary check

Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable

terminal and the HV coil negative terminal (see figure).


ELE SYS - 45

If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis,

check the peak voltage with the multimeter adaptor.

Specific tooling020409Y Multimeter adaptor - Peak voltage detection

Electric characteristicHigh voltage coil secondary resistance value

High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm

- Pick-Up

Disconnect the control unit connector and connect

the positive terminal to connector No. 3 and the

negative terminal to connector No. 12 (see figure).

Use the start-up system to run the engine and

measure the voltage produced by the Pick-Up.

Replace Pick-Up if non-conforming values are

measured.N.B.THE MULTIMETER MUST BE SELECTED TO DETECTCONTINUOUS VOLTAGE.

Electric characteristicPick-Up voltage valuePick-Up voltage value: > 2 Volt

- H.V. coil

With the control unit and HV coil connected to the

circuit, measure the voltage of the coil primary dur-

ing the start-up test with the voltage peak adaptor

and connect the positive terminal to the ground

one and the negative to the coil positive connector.

If non-conforming values are measured, replace

the control unit.THE POSITIVE TERMINAL OF THE HV COIL PRIMARY ISBLACK.

Electric characteristic


ELE SYS - 46

High voltage coil voltage valueHigh voltage coil voltage value: > 100 Volt

Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel.

The generator is directly connected to the voltage regulator.

In turn, the latter is directly connected to ground and to the battery positive passing through the 15A

safety fuse.

This system therefore requires no connection to the ignition key.

The three-phase alternator provides good recharge power and at low revs a good compromise is ach-

ieved between generated power and idle stability.

For this reason, it is very important that the idle speed is adjusted as prescribed.

Specific tooling020333Y Single battery charger

020334Y Multiple battery charger

Remote controls check

To check the operation of a solenoid:

1) Check that, given regular conditions, there is no

continuity between terminals 87 and 30.

2) Apply a 12V voltage to power terminals 86 and

85 of the solenoid.

3) With the solenoid fed, check that there is con-

tinuity between terminals 87 and 30.

4) If these conditions are not met, the solenoid is

surely damaged and, therefore, it should be re-

placed.

Switches check

To check buttons and switches, check that, according to their position, the continuity of contacts is

correct as indicated in the following charts.

KEY

Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red

Gre: Green Pr: Purple


ELE SYS - 47

STARTER BUTTON

LIGHT SWITCH

TURN INDICATOR SWITCH

HORN BUTTON


ELE SYS - 48

Stator check

Disconnect the connector from the voltage regu-

lator and check there is continuity between any

yellow cable and the other two cables.

Electric characteristicOhm value:0.7 ÷ 0.9 Ohm

Also check that all yellow cables are insulated from

the ground connection.

If non-conforming values are detected, repeat the

checks directly to the stator. In case of further rep-

etitions of incorrect values replace the stator or

repair the wiring.

Voltage regulator check

With a perfectly charged battery and lights off,

measure voltage at the battery poles with a high

running engine.

The voltage should not exceed 15.2 Volt.

In case higher voltages are detected, replace the

regulator.

In case of voltage values lower than 14 Volt, check

the stator and the corresponding cable harness.


ELE SYS - 49

Recharge system voltage checkConnect an ammeter induction clamp to the volt-

age regulator positive terminal, measure the bat-

tery voltage and turning on the vehicles lights with

engine off, wait for the voltage to set at about 12

V. Start the engine and measure the current gen-

erated by the system with lights on and a high

running engine.

In case the generated current value is lower than

8A, repeat the test using a new regulator and/sta-

tor alternatively.

Starter motor

KEY

1. Battery

2. Fuse «A ».

3. Starter remote control

4. Starter motor


ELE SYS - 50

5. Key switch contacts

6. Fuse No. 2

7. Stop buttons

8. Stop light bulb

9. Starter buttonWARNINGALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.If it does not work:

1) Check that the Red cable between the battery and the start-up remote control switch, and the latter

and the starter motor are not interrupted.

2) Check the start-up remote control switch.

3) Check the contacts of the key switch, the starter button and the stop buttons.

4) Check that fuses No. 2 and fuse «A» are in good conditions.

5) If none of these components is damaged, check wiring for continuity.

Horn control

KEY

1. Battery

2. Fuse «A ».


4. Fuse No. 2

5. Horn button


ELE SYS - 51

6. HornWARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.

If the horn does not work:

1) Check that fuses operate properly.

2) Check the key switch and horn button contacts.

3) If the components are not damaged, check wiring for continuity.

Choke Inspection

Refer to the engine section to check the resistance

and operating conditions of the component. As re-

gards voltage supply, keep the connector connec-

ted to the system and check that the two terminals

receive battery voltage when the engine is on

(see figure).

If no voltage is detected, connect the multimeter

negative terminal to the ground lead and the pos-

itive terminal to the automatic starter orange cable;

with the key switch set to "ON" check whether

there is battery voltage; if there is no voltage,

check the wiring connections to the key switch.

If there is voltage, check again the ignition control

unit connector.

After disconnecting the starter, start up the engine

and keep it at idle speed; then check if there is

voltage by connecting the multimeter positive

probe to terminal 9 (Orange), and the negative one

to terminal 11 (White/Black) (see figure).

Replace the control unit if there is no voltage; oth-

erwise, check the wiring connections between the

starter and the control unit.


ELE SYS - 52

Turn signals system check

KEY

1. Battery

2. Fuse «A ».


4. Control unit.

5. Turn indicator switch.

6. Right turn indicator bulbs

7. Left turn indicator bulbsWARNING


- If the turn indicators do not work, proceed as fol-

lows:

- Disconnect the electronic control unit connector

and check that there is voltage between terminal

9 (Orange) and the earth connection with the key

switch set to "ON".

- Check that the same happens between terminal

9 (Orange) and terminal 12 (Black).


ELE SYS - 53

If no voltage is detected, check the cable harness

and the connections; otherwise, proceed as fol-

lows:

- Jump terminals 2 (Black/Blue) and 9 (Orange),

see figure. Turn the turn indicator switch alternate-

ly to the left and to the right with the key switch in

"ON" and check if the lights turn on.

If they do, replace the control unit because it is

faulty.

If they do not turn on, check the control unit-turn

indicator switch connection cable harness; then,

repeat the test.

level indicatorsWARNING


If faults are detected:

1) With a multimeter, check resistance values be-

tween the White-Green cable and the Black cable

of the fuel level transmitter by moving the arm with

the float.

2) If the transmitter operates correctly but the in-

dication on the instrument panel is not exact,

check that the cable harnesses between them are

not interrupted.

Electric characteristicResistance value when the tank is full<= 7 Ω

Resistance value when the tank is empty90 +13/-3 Ω

Lights list

BULBSSpecification Desc./Quantity

1 High/low beam light bulb Type: Halogen (H4)Power: 12V - 55/60W

Quantity: 12 Front side light bulb Type: All glass

Power: 12V 5W


ELE SYS - 54

Specification Desc./QuantityQuantity: 1

3 Front turn indicator light bulb Type: SphericalPower: 12V - 10W

Quantity: 1 RHS + 1 LHS4 Rear turn indicator light bulb Type: SPHERICAL

Power: 12V - 10WQuantity: 1 RHS + 1 LHS

5 Stop and tail light bulb Type: SphericalPower: 12V 21/5W

Quantity: 16 12V - 2W warning light bulbs Type: All glass

Function: Turn indicatorsQuantity: 2

7 12V - 1.2W warning light bulb Type: All glassFunction: engine oil, high-beam lights, fuel reserve

Quantity: 38 Instrument panel lighting bulbs Type: All glass

Power: 12V 1.2WQuantity: 4

9 License plate bulb Type: ALL GLASSPower: 12V - 5W

Quantity: 1

Fuses

The electrical system is protected by:

1. One 15A fuse «A» located next to the battery

2. Four 7.5A fuses located below the front grille.

Undo the screw underneath the PIAGGIO clip-on

badge and remove the front grille to reach fuses.CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS-TEM, PERFORMED INCORRECTLY OR WITHOUT STRICTATTENTION TO THE TECHNICAL SPECIFICATIONS OFTHE SYSTEM CAN CAUSE MALFUNCTIONING AND RISKOF FIRE.CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVETHE FAILURE THAT CAUSED IT TO BLOW. NEVER TRYTO REPLACE THE FUSE WITH ANY OTHER MATERIAL(E.G., A PIECE OF ELECTRIC WIRE).


ELE SYS - 55

FUSE CHARTSpecification Desc./Quantity

1 FUSE A Threshold of operation: 15ALocation: Battery compartment

Protected circuits: Battery-powered, ECU, rechargecircuit, live power supply to carburettor heater, automatic

starter, circuits protected by fuses No. 1-2-3-4.2 Fuse No. 1 Threshold of operation: 7.5

Location: front partProtected circuits: Instrument panel bulbs, license

plate light bulb, rear tail light, front light bulb3 Fuse No. 2 Threshold of operation: 7.5

Location: front partProtected circuits: horn, oil pressure warning light, lowfuel indicator and warning light, stop light, starter button.

4 Fuse No. 3 Threshold of operation: 7.5Location: front part

Protected circuits: Low-beam light bulb5 Fuse No. 4 Threshold of operation: 7.5

Location: front partProtected circuits: high-beam light bulb, high-beam

warning light

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge

and recharging, if necessary.

These operations should be carried out before delivering the vehicle, and on a six-month basis while

the vehicle is stored in open circuit.

Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-

quired, before storing the vehicle and afterwards every six months.

INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1) Voltage check up

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

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

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

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 to 14.70V

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

- Charge time:

10 to 12 h recommended

Minimum 6 h


ELE SYS - 56

Maximum 24 h

3) Constant current battery charge mode

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

- Charge time: Maximum 5 h

Battery installation

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

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

1) Battery preparation

Position the battery on a flat surface. Remove the

adhesive sheet closing cells and proceed as quick-

ly as possible to run the subsequent activation

phases.

2) Electrolyte preparation.

Remove the container of the electrolyte from the

pack. Remove and preserve cover strips from the

container, in fact, the strip will later be used as a

closing cover.

Note: Do not pierce the sealing of the container or

the container itself because inside there is sulfuric

acid.


ELE SYS - 57

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with

the six areas sealed in line with the six battery filler

holes. Push the container down with enough force

to break the seals. The electrolyte should start to

flow inside the battery.

Note: Do not tilt the container to prevent the flow

of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20

minutes or more.

Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container

two or three times. Do not remove the container from the battery.

5) Take out the container.

Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte

remains in the container. Now, gently pull the container out from the battery, only do this when the

container is completely empty, and proceed immediately to the next point.

6) Battery closing.

Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure

that the strip is levelled with the top part of the battery.

Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect

your hands and do not bring your face close to the battery.

The filling process is now complete.

Do not remove the strip of caps under any circumstances, do not add water or electrolyte.

Place the battery down for 1 to 2 hours prior to the charging from the battery.

7) Recharging the new battery

With the above-mentioned procedure, the battery

will have gained around 70% - 75% of its total

electrical capacity. Before installing the battery on

the vehicle, it must be fully charged and then must

be recharged.

If the battery is to be installed on the vehicle

prior to this pre-charged one, the battery will

not be able to exceed 75% charge without jeop-

ardising its useful life on vehicle.

The dry charge battery MF like the completely loa-

ded YTX, must have a no-load voltage between


ELE SYS - 58

12.8 - 13.15 V Bring the battery to full charge, us-

ing the 020648Y battery charger:

a - select the type of battery with the red switch on

the left of the panel battery charger panel

b - select NEW on the yellow timer

c - connect the clamps of the battery charger to the

battery poles (black clamp to negative pole (-) and

red clamp to positive pole (+)).

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

e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-

ure.

f - Check the ignition of the green LED indicated

with a red arrow in figure.


ELE SYS - 59

g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED

has taken place

h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less

than 12.8 V, proceed with a new recharge of the

battery starting from point c of the recharge pro-

cedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,

disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.


ELE SYS - 60

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the

head

- Undo the 2 screws fixing the silencer to the hous-

ing; then remove the whole muffler paying atten-

tion to the interference between its supporting

bracket and the cooling cover.

Removal of the engine from the vehicle

• Remove the spark plug access cover.

• Remove the helmet compartment.

• Remove the entire muffler assembly.

• Disconnect the spark plug cap.

• Remove the 3 screws on the transmis-

sion cover fixing the rear brake trans-

mission.

• Cut the fixing clamp and disconnect the

transmission air pipe. Disconnect the

engine ground lead after having un-

screwed the specific screw on the cov-

er.

Engine from vehicle Liberty 125 - 150 (2009)

ENG VE - 62

• Disconnect the electrical connections

of the starter motor, automatic starter,

carburettor heater and magneto fly-

wheel.

• On the carburettor, disconnect the

throttle control transmission, the fuel

pipes and the TPS (For 200 cm³ mod-

els only: disconnect the MAJ2 control

solenoid valve connector).

• Disconnect the fuel valve low-pressure

pipe from the manifold

• Remove the rear shock absorber un-

screwing the top and bottom clamps.

• Unscrew the engine-swinging arm pin

nut on the right-hand side of the vehicle

and slide off the pin from the left-hand

side.WARNINGHANDLE FUEL WITH CARE.CAUTIONWHEN INSTALLING THE BATTERY, ATTACH THE POSI-TIVE LEAD FIRST AND THEN THE NEGATIVE ONE.

See alsoHelmet bayExhaust assy. Removal

Liberty 125 - 150 (2009) Engine from vehicle

ENG VE - 63

INDEX OF TOPICS

ENGINE ENG

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- To remove the transmission cover it is necessary

to remove the rear plastic cover first by inserting a

screwdriver in the corresponding slotted holes.

Using the clutch bell lock wrench, remove the driv-

en pulley axle locking nut and recover the washer.

- Remove the cap/dipstick from the engine oil filling

hole.

- Remove the 10 screws and the ground cable fas-

tened under one of them.

- Remove the transmission cover. If this operation

is performed directly on the vehicle, it is necessary

to remove the cooling air sleeve and the three air

filter housing retainers.

Specific tooling020423Y Driven pulley lock wrench

Air duct

- Unscrew the Torx screws fixing the air duct bulk-

head and remove the bulkhead.

- Remove the 3 screws, then take out the duct as

well as the filter.

Liberty 125 - 150 (2009) Engine

ENG - 65

Air duct filter

- Unscrew the 2 fixing screws and slide off the filter.

- Clean with water and milid soap.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Use the specific tools to remove the bearing from

the crankcase.CAUTIONUSE AN APPROPRIATE REST SURFACE TO AVOID DAM-AGING THE COVER PAINT.

Specific tooling020376Y Adaptor handle


Engine Liberty 125 - 150 (2009)

ENG - 66

Refitting the driven pulley shaft bearing

- Heat up the crankcase inside with the hot air gun.

- Insert the bearing in its housing, refit the Seeger

ring.N.B.ALWAYS REPLACE THE BEARING WITH A NEW ONEUPON REFITTING.

Specific tooling020151Y Air heater


020357Y 32x35-mm Adaptor

020412Y 15-mm guide

Removing the driven pulley

- Remove the spacer, the clutch housing and the

whole driven pulley unit.N.B.THE UNIT CAN ALSO BE REMOVED WITH THE DRIVINGPULLEY MOUNTED.

Inspecting the clutch drum

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

- Measure the clutch bell inside diameter.

CharacteristicMax. value clutch bellMax. value: Ø 134.5 mm

Clutch bell standard valueStandard value: Ø 134 - 134.2 mm


ENG - 67

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2

bearings (inside diameter: 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft unit on the support to check

the crankshaft alignment.

- Using a feeler dial gauge and the magnetic base,

measure the bell eccentricity.

- Repeat the measurement in 3 positions (Central,

internal, external).

- If faults are found, replace the bell.

Specific tooling020074Y Support base for checking crankshaftalignment


Characteristicclutch bell inspection: Limit eccentricity.Admissible limit eccentricity: 0.15 mm

Removing the clutch

- By means of a calliper spanner, block the clutch

assembly rotation. - With a 46 mm spanner re-

move the clutch lock nut. - Remove the clutch and

the spring.CAUTIONUPON REMOVING THE CLUTCH ASSEMBLY LOCK NUT,PAY ATTENTION TO KEEP THE ASSEMBLY IN ITS SEATSO THAT IT DOES NOT COME OUT DUE TO THE SPRINGTHRUST

Specific tooling020565Y Flywheel lock calliper spanner


ENG - 68

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 DIFFERENTFROM ONE ANOTHER.VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TOTEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLS TO PREVENTA VARIATION IN THE RETURN SPRING LOAD.

CharacteristicCheck minimum thickness1 mm

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

- Remove the 3 guide pins and the movable half-

pulley.

Removing the driven half-pulley bearing

- Remove the retainer ring using two flat blade

screwdrivers.

- Using a hammer and pin, knock the ball bearing

out as shown in the figure.

- Remove the roller bearing using the specific ex-

tractor.N.B.REST THE HALF-PULLEY ON A WOOD SURFACE TOAVOID DAMAGING THE THREADED RINGLET OF THEDRIVEN PULLEY UPON REMOVING IT.

Specific tooling020375Y 28 x 30 mm adaptor


ENG - 69


020439Y 17-mm guide

Inspecting the driven fixed half-pulley

- Measure the external diameter of the pulley bush-

ing.

CharacteristicMinimum diameter permittedØ 40.96 mm

Standard diameterØ 40.965 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.

CharacteristicMinimum admissible diameter:Ø 41.08 mm

Standard diameterØ 41.035 mm


ENG - 70

Refitting the driven half-pulley bearing

- Assemble a new roller bearing using the specific

punch, fit the bearing with the label facing outward

and insert it completely up to the punch on the half-

pulley.N.B.REST THE HALF-PULLEY ON A WOOD SURFACE TOAVOID DAMAGING THE THREADED RINGLET OF THEDRIVEN PULLEY UPON REMOVING IT.

Specific tooling020424Y Driven pulley roller casing fittingpunch

- To assemble the new ball bearing insert it com-

pletely down in its housing with the specific punch

and finally assemble the Seeger ring.

Specific tooling020375Y 28 x 30 mm adaptor


020439Y 17-mm guide

Refitting the driven pulley

- Check that the faying surfaces between the 2

half-pulleys and the belt do not show any signs of

wear, scoring and grease.

- Insert the new oil seals and O-rings on the mov-

able half-pulley.

- Assemble the half-pulley on the ringlet with the

appropriate protection sheath.

- Make sure the pins and collar are not worn, re-

assemble 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 operation is necessary to avoid

the presence of grease beyond the O-rings.

Specific tooling


ENG - 71

020263Y Driven pulley assembly sheath

Recommended productsAGIP GREASE SM 2 Grease for the C-ring ofthe tone wheelSoap-based lithium grease containing NLGI 2 Mo-

lybdenum disulphide; ISO-L-XBCHB2, DIN

KF2K-20

Inspecting the clutch spring

- Measure the length of the spring when it is re-

laxed.

CharacteristicStandard length:106 mm

Refitting the clutchVersione 125

- Refit the clutch assembly following the fitting op-

eration but in reverse order and using the calliper

spanner. Lock the nut to the specified torque.CAUTIONUSE A BOX-SPANNER WITH SMALL CHAMFER SO ASNOT TO DAMAGE THE CLUTCH NUT.UPON FITTING THECLUTCH ASSEMBLY LOCK NUT, PAY ATTENTION TOKEEP THE ASSEMBLY IN ITS SEAT UNTIL SOME NUTTHREADS HOLD IT IN PLACE

Locking torques (N*m)Locking torque 55 ÷ 60 Nm


ENG - 72

Refitting the driven pulley

- Reassemble the clutch housing and spacer.

Drive-belt

During the wear checks foreseen in the scheduled

maintenance, check that the rim bottom of the

toothing does not show signs of incisions or cracks

(see figure): the rim bottom of the tooth must not

have incisions or cracks; if it does, change the belt.

- Check that the drive belt is not damaged.

- Check the width of the belt.

BELT SIZESpecification Desc./QuantityMinimum width 21.5 mmStandard width 22.5 ± 0.2 mm


ENG - 73

Removing the driving pulley

- Lock the driving pulley with the specific tool as

shown in the figure. - Disassemble the central nut

and the cup washer, remove the drive and the 2

washers. - Remove the stationary half pulley and

the steel washer.

Specific tooling020368Y driving pulley lock wrench

- Remove the belt and slide the movable half-pul-

ley with the relevant bush, taking care of the falling

free assembled rollers.

- Remove the return rollers plate with the relative

guide sliders.

Inspecting the rollers case

- Check that the internal bushing is not abnormally worn and measure inner diameter.N.B.

DO NOT LUBRICATE OR CLEAN THE BUSHING.

BUSHING ROLLER HOUSINGSpecification Desc./Quantity

Maximum allowable diameter Ø 26.121 mmStandard diameter Ø 26+0 +0.021 mm

BUSH SLIDE PULLEYSpecification Desc./Quantity

Minimum diameter permitted Ø 25.950 mmStandard diameter Ø 26-0.020 -0.041 mm

CVT ROLLERSSpecification Desc./Quantity

Minimum diameter permitted Ø 18.5 mmStandard diameter Ø 26±0.1 mm


ENG - 74

- Check the guide shoes for the variator back-plate

are not worn.

- Check there is no wear in the roller housing, and

the surfaces in contact with the belt on either of the

pulley halves.

- Pre-assemble the movable half-pulley with the

roller contrast plate by placing the rollers as shown

in the figure, that is, during insertion, the closed

side should be on the left side of the pulley thrust.

- Mount the complete bushing unit on the driving

shaft.


ENG - 75

- Open the rear pulley and insert the belt observing

the correct direction of rotation.WARNINGIT IS MOST IMPORTANT THAT WHEN FITTING THE FRONTPULLEY UNIT, THE BELT IS FREE INSIDE SO AS TO AVOIDA WRONG TIGHTENING OF THE DRIVING HALF-PULLEY.

Refitting the driving pulley

- Reassemble the parts of the unit (internal lining,

fixed half-pulley, external lining, drive and nut),

spread threadlock on the thread and screw the nut

to the prescribed torque.

-Avoid the half-pulley rotation using a calliper

spannerN.B.REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT

Specific tooling020368Y driving pulley lock wrench

Recommended productsLoctite 243 Medium strength threadlockMedium Loctite 243 threadlock

Locking torques (N*m)Locking torque 75 to 83

Refitting the transmission cover

- Check that there are 2 alignment dowels and that

the sealing gasket for the oil sump on the trans-

mission cover is adequately fitted.

- Replace the cover and tighten the 10 screws to

the specified torque.

- Refit the oil loading cap/bar.

- Refit the steel washer and the driven pulley nut.

- Tighten the nut to the prescribed torque using the

lock wrench and the torque wrench tools.

- Refit the plastic cover.


ENG - 76

Specific tooling020423Y Driven pulley lock wrench

Locking torques (N*m)Transmission cover screws 11 to 13 Driven pul-ley shaft nut 54 to 60

End gear

Removing the hub cover

- Empty the rear hub through the oil drainage tap

located inside the hub cover

- Remove the brake shoe and relevant spring

- Remove the 7 flanged screws as shown in the

figure.

- Remove the rubber cover and the brake shoes

lever sliding unscrewing the relevant retaining

screw to reach the rear of the cover

- Take off the hub cover and relevant gaskets

Removing the wheel axle

Remove the intermediate gear and the complete

hub cover.


ENG - 77

Removing the hub bearings

- Check the state of the bearings being examined

(wear, clearance and noisiness). If faults are de-

tected, do the following.

- Use the specific bearing extractor to remove the

three 15 mm bearings (2 in the crankcase and 1 in

the hub cover).

Specific tooling001467Y009 Driver for OD 42-mm bearings

001467Y013 Calliper to extract ø 15-mm bear-ings

Removing the wheel axle bearings

- Take out the clip on the outside of the hub cover.

- Remove the bearing with the adequate tools ad-

equately supporting the hub cover, as shown in the

figure.


020364Y 25-mm guide

With the appropriate tools, remove the oil seal as

shown in the figure.



Removing the driven pulley shaft bearing

If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven

pulley.

- Extract the driven pulley shaft from its bearing.

- Remove the oil seal using a screwdriver, working from inside the bearing and being careful not to

damage the housing, make it come out of the belt transmission side.

- Remove the Seeger ring shown in the figure


ENG - 78

With the sectional punch, remove the driven pulley

shaft bearing.



020363Y 20-mm guide

See alsoRemoving the driven pulley

Inspecting the hub shaft

- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and

the oil seal housings.

- If faults are found, replace the damaged compo-

nents.

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted. - Check the load capacity of the bearings and

the brake camshaft. - If faults are found, replace the hub cover.

Refitting the driven pulley shaft bearing

- Heat up the parts using the specific heat gun

Specific tooling020150Y Air heater mounting

020151Y Air heater

- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of

the hub cover using the adequate tools



ENG - 79

- Refit the Seeger ring with the opening facing the

bearing as shown in the figure and fit a new oil seal

flush with the crankcase.

Refitting the wheel axle bearing

- Heat up the parts using the specific heat gun

Specific tooling020151Y Air heater

020150Y Air heater mounting

-The wheel axle bearing on the cover, should be assembled with the specific tools

Specific tooling020364Y 25-mm guide



• Assemble the Seeger ring.

• Assemble the oil seal flush with the in-

ternal surface as shown in the figure to

the hub using the adequate tools and

with the seal lip towards the inside of

the hub.



Refitting the hub cover bearings

- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the

specific heat gun.

Specific tooling020150Y Air heater mounting

020151Y Air heater


ENG - 80

- The three 15 mm bearings must be fitted using

the appropriate tools.

Refitting the hub bearings

- Insert the cover prepared in the crankcase taking

care of inserting the gear of the pulley shaft on the

intermediary gear.

Refitting the ub cover

- Fit a new gasket together with the centring dow-

els.

- Fit the gearbox cover, making sure the breather

pipe is in the correct position.

- Screw the 7 screws to the specified torque, po-

sitioning the support plate of the pipe in the posi-

tion shown in the figure.

- Remove the control pin of the shoe taking care

so as the long tooth coincides with the groove on

the control lever.


Flywheel cover


ENG - 81

Cooling hood

-Remove the housing acting on the 4 retaining

screws.CAUTIONDURING REMOVAL SLIDE THE HOUSING CONNECTORON THE HOUSING.

- Loosen the clamp and remove the carburettor

from the manifold.

-Remove the complete manifold acting on the 2

retainers as shown in the figure.

- Remove the 2 self-tapping screws, left and right

and the lateral base retaining screw on the crank-

case base.

- Take off the housings.

- Remove the gasket seal of the housing on the

head.N.B.IF THE FLYWHEEL HOUSING IS NOT REMOVED, IT IS AL-SO NECESSARY TO REMOVE THE TWO KNOB SCREWS.

On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggest

to intervene on the vacuum socket inserting on the intake manifold widening the hole from 0.4 mm to

1.5 mm. Remember that such operation must have performed on a disassembled manifold which must

be cleaned afterwards.

Cooling fan

- Remove the cooling fan by acting on the three

fixings indicated in the figure.


ENG - 82

- Refit the parts in reverse order of the removal

operation.

- Make sure that there are spacers with the two

rear retainers of the housing.

- The long spacers should be in a high position.CAUTIONTAKE CARE TO CORRECTLY POSITION THE FLYWHEELCONNECTOR.

Removing the stator

- Remove the electric terminal of the minimum oil

pressure switch.

- Remove the two Pick-Up screws and the one for

the wiring harness bracket as well as the two stator

fixing screws shown in the figure.

- Remove the stator and its wiring.

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-

ers to the specified torque.

- Place the cable harness as shown in the figure.N.B.THE PICK-UP WIRE SHOULD BE POSITIONED BETWEENTHE UPPER SCREW AND THE REFERENCE DOWEL ASSHOWN IN THE DETAIL DRAWING.

Locking torques (N*m)Stator screw 3 to 4


ENG - 83

Flywheel and starting

Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper

spanner.

- Remove the nut.CAUTIONTHE USE OF A CALLIPER SPANNER OTHER THAN THEONE SUPPLIED COULD DAMAGE THE STATOR COILS

Specific tooling020565Y Flywheel lock calliper spanner

- Extract the flywheel with the extractor.

Specific tooling008564Y Flywheel extractor

Inspecting the flywheel components

- Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate.

Refitting the flywheel magneto

- Fit the flywheel being careful to insert the key

properly.

- Lock the flywheel nut to the prescribed torque

- Check that the Pick-Up air gap is between 0.34

to 0.76 mm.

The air gap cannot be modified when assembling

the Pick-Up.

Different values result from deformations visible

on the Pick-Up mounting.N.B.A VARIATION IN THE AIR GAP DISTANCE MODIFIES THEIGNITION SYSTEM IDLE SPEED

Locking torques (N*m)


ENG - 84

Flywheel nut 52 to 58

Refitting the starter motor

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

- Fit the starter motor on the crankcase and lock

the 2 screws to the prescribed torque.N.B.REFIT THE REMAINING PARTS AS DESCRIBED IN THECYLINDER HEAD, TIMING, LUBRICATION, FLYWHEELAND TRANSMISSION CHAPTERS.

Locking torques (N*m)Starter screws 11 to 13

Cylinder assy. and timing system

Removing the timing system drive

- Remove the parts listed below first: transmission

cover, belt driving pulley, oil pump pulley cover and

pinion separator washer.

- Remove the tappet cover.

- Remove the central screw fastener and the au-

tomatic valve lifter retaining cover, as shown in the

figure.

- Remove the return spring of the automatic valve

lifter unit and the automatic valve lifter unit and its

end of stroke washer.

- Loosen the central screw on the tensioner first.

- Remove the two fixings shown in the figure.

- Remove the tensioner with its gasket.


ENG - 85

- Remove the internal hex screw and the counter-

weight shown in the figure.

- Remove the camshaft command pulley and its

washer.

- Remove the command sprocket wheel and the

timing chain.

- Remove the screws indicated in the figure, the

spacer bar and the tensioner slider.

The chain tensioner slider must be removed from

the transmission side. As regards the lower chain

guide slider, it may only be removed after the head

has been removed.N.B.IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-SURE THAT THE INITIAL DIRECTION OF ROTATION ISMAINTAINED.

See alsoRemoving the driving pulley

Transmission coverRemoval

Removing the cam shaft

- Remove the 2 screws and the camshaft retainer

shown in the diagram.

- Remove the cam shaft.


ENG - 86

- Remove the pin of the rocking levers from the

flywheel side holes.

- Remove the rocking levers and the elastic wash-

er.N.B.MARK THE ROCKERS ASSEMBLE POSITION, SO AS TOAVOID THE INVERSION OF INTAKE WITH THE EXHAUST.

Removing the cylinder head

- Remove the spark plug.

- Remove the 2 side fixings shown in the figure.

- Loosen the 4 head-cylinder fastening nuts in two

or three stages and in criss-cross fashion.

- Remove the head, the two alignment dowels and

the gasket.N.B.IF NEEDED, THE HEAD MAY BE REMOVED WITH THECAMSHAFT, ROCKER PINS AND FIXING BRACKET. THEHEAD CAN ALSO BE REMOVED WITHOUT REMOVINGTHE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

Removing the valves

- Using the specific tool fitted with the element

shown in the figure, remove the cotters, the caps

and the spring between the valves.

Specific tooling020382Y Valve cotters equipped with part 012removal tool

020382Y011 adapter for valve removal tool


ENG - 87

- Remove the oil seals with the appropriate tool.

- Remove the lower spring supports.

Specific tooling020431Y Valve oil seal extractor

Removing the cylinder - piston assy.

- Remove the chain guide slider.

- Remove the cylinder base gasket.CAUTIONTO AVOID DAMAGING THE PISTON, SUPPORT IT WHILEREMOVING THE CYLINDER.

- Remove the two retainer rings, the wrist pin and

the piston.

- Remove the 3 piston rings from the piston.N.B.BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR-ING REMOVAL.

Inspecting the small end

- Measure the internal diameter of the connecting

rod small end using an internal micrometer.N.B.IF THE DIAMETER OF THE CONNECTING ROD SMALLEND EXCEEDS THE MAXIMUM DIAMETER ALLOWED,SHOWS SIGNS OF WEAR OR OVERHEATING REPLACETHE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASEAND CRANKSHAFT" CHAPTER".

CharacteristicConnecting rod small end check-up: Maximumdiameter


ENG - 88

15.030 mm

Connecting rod small end check-up: Standarddiameter15+0.015+0.025 mm

Inspecting the wrist pin

- Check the outer diameter of the gudgeon pin.

CharacteristicStandard pin diameter14.996 to 15 mm

Minimum diameter permittedØ 14.994 mm

- Calculate the piston pin coupling clearance.N.B.THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.FOR THIS REASON MEASUREMENT OF THE DIAMETERMUST BE CARRIED OUT ACCORDING TO THE AXIS OFTHE PISTON.

CharacteristicPiston pin bore - standard diameterØ 15+0.001 +0.006

- Measure the outside diameter of the piston, per-

pendicular to the gudgeon pin axis.

- Measure 36.5 mm from the piston crown's shown

in the figure.N.B.THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.FOR THIS REASON MEASUREMENT OF THE DIAMETERMUST BE CARRIED OUT ACCORDING TO THE AXIS OFTHE PISTON.


ENG - 89

- Using a bore meter, measure the inner cylinder

diameter at three different points according to the

directions shown in the figure.

- Check that the coupling surface with the head is

not worn or misshapen.

- Pistons and cylinders are classified into catego-

ries based on their diameter. The coupling is car-

ried out in pairs (A-A, B-B, C-C, D-D).

CharacteristicMaximum allowable run-out:0.05 mm

- The cylinder rectifying operation should be car-

ried out with a surfacing that respects the original

angle.

- The cylinder surface roughness should be 0.9

micron.

- This is indispensable for a good seating of the

sealing rings, which in turn minimises oil consump-

tion and guarantees optimum performance.

- The pistons are oversized due to cylinder rectifi-

cation and are subdivided into three categories

1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They

are also classified into 4 categories A-A, B-B, C-

C, D-D.

Inspecting the piston

- Carefully clean the sealing ring housings.

- Measure the coupling clearance between the sealing rings and the piston grooves using suitable

sensors, as shown in the diagram.

- If the clearance is greater than that indicated in the table, replace the piston.

STANDARD COUPLING CLEARANCEName Description Dimensions Initials Quantity

Top piston ring 0.025 to 0.070Middle piston ring 0.015 to 0.060

oil scraper 0.015 to 0.060

MAXIMUM ADMITTED CLEARANCE AFTER USEName Description Dimensions Initials Quantity

Top piston ring 0.080 mmMiddle piston ring 0.070 mm


ENG - 90

Name Description Dimensions Initials Quantityoil scraper 0.070 mm

Inspecting the piston ringsN.B.

TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-TER.

See alsoPiston rings

Removing the piston

- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-

wards the exhaust.

- Fit the pin retainer ring onto the appropriate tool.

Specific tooling020430Y Pin lock fitting tool

- With the opening in position indicated on the tool,

take retainer ring in the closed position using the

punch.

- Fit the wrist pin retainer ring using the plug as

shown in the figureN.B.THE TOOL FOR INSTALLING THE RETAINER RINGS MUSTBE USED MANUALLY.CAUTIONUSING A HAMMER TO POSITION THE RINGS CAN DAM-AGE THE LOCKING HOUSING.


ENG - 91

Choosing the gasket

- Provisionally fit the piston into the cylinder, with-

out any base gasket.

- Assemble a dial gauge on the specific tool.

- Set the dial gauge to zero at a contrast plane with

an average preload, for example 5 mm. Keeping

the zero setting position, fit the tool on the cylinder

and lock it with 2 nuts, as shown in the figure.

- Rotate the crankshaft up to the TDC (the inver-

sion point of the dial gauge rotation)

- Calculate the difference between the two meas-

urements.

- By means of the table, see the SPECIFICA-

TIONS chapter, identify the cylinder base gasket

thickness to be used upon refitting. Correctly iden-

tify the cylinder base gasket thickness to keep the

correct compression ratio.

- Remove the special tool and the cylinder.

Specific tooling020428Y Piston position check mounting


ENG - 92

Refitting the piston rings

- Place the oil scraper spring on the piston.

- Refit the oil scraper ring with the join of spring

ends on the opposite side from the ring gap and

the word 'TOP' towards the piston crown. The ta-

pered side of the middle piston ring should always

be facing away from the piston crown.

- Fit the middle piston ring with the identification

letter facing the piston crown. In any case, the step

must be facing opposite the piston crown.

- Fit the top piston ring with the word 'top' or the

reference mark facing the crown of the piston.

- Offset the piston ring gaps on the three rings by

120° to each other as shown in the figure.

- Lubricate the components with engine oil.N.B.SO AS TO OBTAIN THE BEST CONFIGURATION THE 2SEALING RINGS ARE MADE WITH A CONTACT CONICALCYLINDER SECTION.

Refitting the cylinder

- Insert the cylinder base gasket with the thickness

determined above.

- Using the fork support and the piston ring retain-

ing band, refit the cylinder as shown in the figure.N.B.BEFORE FITTING THE CYLINDER, CAREFULLY BLOWOUT THE LUBRICATION DUCT AND OIL THE CYLINDERBARREL.

Specific tooling020426Y Piston fitting fork


ENG - 93

020427Y Piston assembly band

Inspecting the cylinder head

- Using a trued bar check that the cylinder head

surface is not worn or distorted.

- Check that the camshaft and rocking lever pin

bearings show no signs of wear.

- Check that the cylinder head cover surface, the

intake manifold and the exhaust manifold are not

worn.

CharacteristicMaximum admitted unevenness: Cylinderhead check0.05 mm

STANDARD DIAMETERSpecification Desc./Quantity

Standard diameter A Ø 32.5 to 32.525Standard diameter B Ø 20 to 20.021Standard diameter C Ø 12 to 12.018

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.

- Ensure that the camshaft drive pulley, the chain

assembly and the sprocket wheel are not worn.

- If sings of wear are found, replace the parts. if the

chain, pinion or pulley are worn, replace the whole

assembly.


ENG - 94

- Remove the central screw and the tensioner

spring. Check that the one-way mechanism is not

worn.

- Check the condition of the tensioner spring.

- If examples of wear are found, replace the whole

unit.

Inspecting the valve sealings

- Measure the width of the sealing surface on the valve seats.

VALVE SEAL SURFACESpecification Desc./Quantity

Intake valve - seal surface 2.4 to 2.8 mmExhaust valve - seal surface 2.2 to 2.6 mm

Inspecting the valve housings

- Remove any carbon formation from the valve guides.

- Measure the inside diameter of each valve guide.

- Take the measurement at three different heights in the rocker arm push direction.

CharacteristicStandard drainage guide diameter

5.012 mm

Standard intake guide diameter

5.012 mm


ENG - 95

- If the width of the impression on the valve seat or

the diameter of the valve guide exceed the speci-

fied limits, replace the cylinder head.

- Check width of the impression on the valve seat

«V»

CharacteristicWear limits:Max. 1.6 mm.

Inspecting the valves

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

- Calculate the clearance between valve and valve

guide.

CharacteristicMinimum diameter admitted - Intake:4.96 mm

Minimum diameter admitted - Exhaust:4.95 mm

Standard clearance - Intake:0.013 to 0.040 mm

Standard clearance - Exhaust:0.025 to 0.052 mm

Maximum clearance admitted- Intake:0.062 mm

Maximum clearance admitted - Exhaust:0.072 mm

- Check that there are no signs of wear on the

contact surface with the articulated register termi-

nal.

- If the sealing surface on the valves is wider than

the specified limit, damaged in one or more points

or curved, replace the valve with a new one.

CharacteristicStandard valve length - Intake:80.6 mm

Valve standard length: Exhaust


ENG - 96

79.6 mm

- If no faults are found during the above checks,

you can use the same valves. For best sealing re-

sults, it is advisable to grind the valves. Grind the

valves gently with a fine-grained lapping com-

pound. During grinding, keep the cylinder head in

a horizontal position. This will prevent the lapping

compound residues from penetrating between the

valve stem/guide coupling.CAUTIONTO AVOID SCORING THE FAYING SURFACE, DO NOTKEEP ROTATING THE VALVE WHEN NO LAPPING COM-POUND IS LEFT. CAREFULLY WASH THE CYLINDERHEAD AND THE VALVES WITH A SUITABLE PRODUCTFOR THE TYPE OF LAPPING COMPOUND BEING USED.

- Insert the valves into the cylinder head.

- Test the 2 valves alternatively.

- The test is carried out by filling the manifold with

petrol and checking that the head does not ooze

through the valves when these are just pressed

with the fingers.

Inspecting the springs and half-cones

- Check that the upper spring caps and the cotter

halves show no signs of abnormal wear.

- Check the unloaded springs length.

CharacteristicValve spring length33.9 to 34.4 mm


ENG - 97

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the lower caps of the valve spring on the

head.

- Use the punch to fit the 2 sealing rings one at a

time.

Specific tooling020306Y Punch for assembling valve sealrings

- Fit the valves, the springs and the spring retaining

caps. Using the appropriate tool with adapter 11,

compress the springs and insert the cotters in their

seats.

Specific tooling020382Y Valve cotters equipped with part 012removal tool

020382Y011 adapter for valve removal tool

Inspecting the cam shaft

- Inspect the cam shaft for signs of abnormal wear

on the cams.

CharacteristicStandard diameter Bearing AØ: 32.5 mm -0.025 -0.050 mm

Standard diameter Bearing B20 -0.020 -0.041 mm

Minimum admitted diameter bearing AØ: 32.440 mm

Minimum admitted diameter bearing BØ: 19.950 mm

Intake cam height27.512 mm

Exhaust cam height27.212 mm


ENG - 98

- Check there is no wear on the cam shaft retaining

plate and its associated groove on the cam shaft.

- If any of the above dimensions are outside the

specified limits, or there are signs of excessive

wear, replace the defective components with new

ones.

CharacteristicMaximum axial clearance admitted0.42 mm

- Check there are no signs of wear on the auto-

matic valve lifter cam, or the end-of stroke roller,

or the rubber buffer on the automatic valve-lifter

retaining cover.

- Check that the valve lifter spring has not yielded.

- Replace any defective or worn components.

- Check there are no signs of scoring or wear on

the rocking lever bolt.

Check there are no signs of wear on the pad from

contact with the cam and on the jointed adjustment

plate.

- Measure the internal diameter of each rocking

lever.

-Check that the elastic washer dedicated to the

axle clearance of the rocking levers is not worn. -

In case of failure, replace the damaged compo-

nents.

CharacteristicMinimum diameter permittedØ 11.970 mm

Maximum diameter allowedØ 12.030 mm

Refitting the head and timing system components

- Fit the timing chain guide slider.

- Insert the head and cylinder alignment dowels, fit the head gasket and the head on the cylinder.


ENG - 99

-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.


- Fit the two screws on the outside of the timing

chain side and tighten them to the specified torque.N.B.BEFORE INSTALLING THE HEAD, MAKE SURE THAT THELUBRICATION CHANNEL IS CLEAN USING A COM-PRESSED AIR JET.


- Fit the timing chain sprocket wheel on the crank-

shaft, with the chamfer facing the insertion side.

- Loop the timing chain around the sprocket on the

crankshaft.

- Fit the tensioner pad by the cylinder head.

- Fit the spacer and the screw fastener.

- Fit the pin, the exhaust rocking lever, the spring

washer and the intake rocking lever.

- Lubricate the 2 rocking levers through the holes

at the top.

- Lubricate the 2 bearings and insert the camshaft

in the cylinder head with the cams opposing the

rocking levers.

- Insert the retention plate and tighten the two

screws shown in the figure to the prescribed tor-

que.



ENG - 100

- Refit the spacer on the cam shaft.

- Rotate the engine so that the piston is at top dead

centre, using the reference marks on the flywheel

and the crankcase.

- While doing so, fit the chain onto the control cam-

shaft pulley and keep the reference 2V in corre-

spondence with the reference mark on the head.

- Fit the pulley onto the camshaft.

- Assemble the counterweight with the corre-

sponding fixing screw and tighten to the specified

torque.

Locking torques (N*m)Locking torque 7 to 8.5

-Fit the end-stop ring on the automatic valve lifter

cam and fit the automatic valve lifter cam to the

cam shaft.

- Fit the automatic valve lifter return spring.

- During this operation the spring must be loaded

approximately 180°.N.B.GREASE THE END STOP RING TO PREVENT IT COMINGOUT AND FALLING INTO THE ENGINE.

- Fit the automatic valve-lifter retaining dish, using

the counterweight screw fastener as a reference.

- Tighten the clamping screw to the prescribed tor-

que.


- Set the tensioner cursor in the rest position.

- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed

torque.


ENG - 101


- Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed

torque.


- Adjust the valve clearance.

- Fit the spark plug

CharacteristicSpark plugChampion RG6YC

Electric characteristicElectrode gap0.8 mm


- Assemble the casing sealing gasket on the head.

On the fitting direction, use the supplements on the

timing side as reference.

- Assemble the screw fixing the housing to the

crankcase to the specified torque and the 2 self-

tapping screws joining the half-shells.

- Take care that the gasket is well inserted in its

housing during the assembly stage.

- Place the spark plug access cap.


- Fit the intake manifold and lock the 2 screws to

the specified torque.

- Fit the carburettor onto the intake manifold and

lock the clampN.B.FIT THE CARBURETTOR THROUGH THE SUPPLEMENTON THE MANIFOLD.



ENG - 102

- Refit the cylinder head cover, tightening the 4

clamping screws to the prescribed torque.

- Refit the fan and the housing.

- Reassemble the oil pump control, the chain com-

partment cover, the by-pass and the oil sump as

described in the lubrication chapter.

- Reassemble the driving pulley, the belt and the

transmission cover as described in the transmis-

sion chapter.


Crankcase - crankshaft

- Precautionary remove the following units:

transmission cover, driving pulley, driven pulley

and belt, rear hub cover, gears, bearings and oil

seals as described in the transmission chapter.

- Remove the oil sump, the by-pass, the chain

compartment cover and the oil pump as in the lu-

brication chapter.

- Remove the flywheel cover, the fan, the flywheel

and the stator as described in the magneto fly-

wheel chapter.

- Remove the oil filter and the oil pressure bulb.

- Remove the cylinder-piston-head unit as descri-

bed in the cylinder head timing system chapter.

- Remove the 2 retainers indicated in the figure

and the starter motor.

- Before opening the crankcase, it is advisable to

check the axial clearance of the crankshaft. To do

this, use a plate and a support with specific tool

dial gauge.

Specific tooling020262Y Crankcase splitting plate


CharacteristicStandard clearance


ENG - 103

0.15 to 0.40 mm

Splitting the crankcase halves

Remove the 11 coupling screws to the crankcase.

- Separate the crankcase while keeping the crank-

shaft in one of the two halves of the crankcase.

Remove the crankshaft.CAUTIONIF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC-CIDENTALLY FALL.

- Remove the coupling gasket of the crankcase

halves.

- Remove the two screws and the internal shield

shown in the diagram.CAUTIONWHILE OPENING THE CRANKCASES AND REMOVINGTHE CRANKSHAFT, CHECK THAT THE THREADEDSHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-INGS. FAILURE TO OBSERVE THIS PRECAUTION CANDAMAGE THE MAIN BUSHINGS.

- Remove the oil seal on the flywheel side.

- Remove the oil filter fitting shown in the diagram

- Check the axial clearance on the connecting rod.

CharacteristicStandard clearance0.20 to 0.50 mm


ENG - 104

- Check the radial clearance on the connecting rod.

-Check the surfaces that limit the axial clearance

are not scored and measure the width of the crank-

shaft between these surfaces, as shown in the

diagram.CAUTIONBE CAREFUL NOT TO LET THE MEASUREMENT BE AF-FECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.

CharacteristicStandard clearance0.036 to 0.054 mm

- If the axial clearance between crankshaft and

crankcase is exceeding and the crankshaft does

not have any defect, the problem must be due to

either excessive wear or wrong machining on the

crankcase.CAUTIONTHE CRANKSHAFT CAN BE REUSED WHEN THE WIDTHIS WITHIN THE STANDARD VALUES AND THE SURFACESSHOW NO SIGNS OF SCORING.

CharacteristicDistance between the shoulders55.67 to 55.85 mm

- Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces

shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart

below.

STANDARD DIAMETERSpecification Desc./Quantity

Category 1 28.998 to 29.004Category 2 28.004 to 29.010


ENG - 105

Inspecting the crankshaft alignment

To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated

in figure.

- Check that the crankshaft cone, the tab seat, the

oil seal capacity, the toothed gear and the threa-

ded tangs are in good working order.

- In case of failures, replace the crankshaft.

The big end bushings cannot be replaced. For the

same reason, the connecting rod may not be re-

placed and, when cleaning the crankshaft, be very

careful that no impurities get in through the shaft's

lubrication holes.

In order to prevent damaging the connecting rod

bushings, do not attempt cleaning the lubrication

duct with compressed air.

- Make sure that the 2 caps on the crankpin are

properly fitted.

- A wrong installation of a cap can seriously affect

the bushing lubrication pressure.N.B.THE MAIN BEARINGS ARE NOT GRINDABLE

Specific tooling020074Y Support base for checking crankshaftalignment

CharacteristicOff-line maximum admittedA = 0.15 mmB = 0.01 mmC = 0.01 mmD = 0.10 mm


ENG - 106

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.

- On the transmission side crankcase half, take

particular care cleaning the housing and oil ducts

for the following components: the oil pump, the oil

by-pass valve, the main bushings and the cooling

jet on the transmission side (see diagram).

- Take particular care, also, that there are no signs

wear in the oil by-pass valve housing (see Chapter

Lubrication), as this could prevent a good seal in

the piston, which regulates the oil pressure.N.B.THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-ER OPERATION OF THIS COMPONENT IMPROVES PIS-TON CROWN COOLING. CLOGGING HAS EFFECTS THATARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-ERABLE DROP IN THE LUBRICATION PRESSURE FORMAIN BUSHINGS AND CONNECTING ROD.

- On the flywheel side crankcase half, take partic-

ular care cleaning the oil ducts for the main bush-

ings, the oil duct for the jet that lubricates the

cylinder head and the oil drainage duct at the fly-

wheel side oil seal.N.B.THE HEAD LUBRICATION CHANNEL IS PROVIDED WITHA SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEADLUBRICATION; THIS CHOICE WAS MADE TO REDUCETHE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-ING MECHANISMS. A JET FAILURE CAUSES A DE-CREASE OF THE MAIN BUSHING AND CONNECTING RODLUBRICATION PRESSURE.

- Inspect the mating surfaces on the crankcase

halves for scratches or deformation, taking partic-

ular with the surfaces that mate with the cylinder

and the mating surfaces between the crankcase

halves.

- Defects in the crankcase coupling gasket or the

surfaces indicated in the figure can cause a drop

in the oil pressure and affect the lubricating pres-

sure for the main bushings and the connecting rod.


ENG - 107

- Check the main bearing seats that limit axial

clearance in the crankshaft show no signs of wear.

The dimension between these seats is measured

by way of the procedure described previously for

measuring the crankshaft axial clearance and di-

mensions.

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is neces-

sary to have both an optimal lubricating pressure

(4 bar) and a good oil flow rate; the bushings must

be correctly positioned so as not to obstruct the oil

supply channels.

- The main bushings are comprised of two half-

bearings, one with holes and channels for lubrica-

tion whereas the other is solid.

- The solid half-bearing is intended to stand the

thrusts caused by combustion, and for this reason

it is arranged opposed the cylinder.

- To prevent shutters in the oil feeding channels,

the matching surface of the two half-bearings must

be perfectly orthogonal to the cylinder axis, as


- The oil feeding channel section is also affected

by the bushings driving depth compared with the

crankshaft axial clearance of the limiting surface.N.B.TO KEEP THIS POSITION OF THE BUSHINGS ON THECRANKCASE, FITTING IS FORCED ON STEEL RINGS IN-SERTED IN THE CASTING OF BOTH CRANKCASEHALVES.

CharacteristicStandard driving depth1.35 to 1.6

- Check the inside diameter of the main bushings in the three directions indicated in the diagram.

- Repeat the measurements for the other bushing half. see diagram.

- The standard bushing diameter after driving is variable on the basis of a coupling selection.


ENG - 108

- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like

those for the crankshaft.

- The main bushings are subdivided into 3 thickness categories; see the table below:N.B.

DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCETHE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.

MAIN BEARINGSSpecification Desc./Quantity

B BlueC YellowE Green

Refitting the crankcase halves

- Fit the internal bulkhead by locking the two

screws to the prescribed torque.


- Fit the oil filter joint and tighten it to the prescribed

torque.

- Place a new gasket on one of the crankcase

halves, preferably on the transmission side, to-

gether with the alignment dowels.



ENG - 109

- Lubricate the main bushings and insert the crank-

shaft in the transmission side crankcase half.

- Reassemble both crankcase halves.

- Fit the 11 screws and tighten them to the pre-

scribed torque.N.B.WHEN FITTING THE HALF CASING AND THE CRANK-SHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREA-DED TANGS.


- Lubricate the flywheel oil seal.

- Use the appropriate tool to assemble the oil seal.

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

- Insert the pre-filter on the engine with its corre-

sponding cover to the specific torque.N.B.REMOVE ANY EXCESS FROM THE CRANKCASE COU-PLING GASKET ON THE CYLINDER PLANE, TO ENSUREBETTER SEALING PERFORMANCE.N.B.FAILURE TO USE THE SPECIFIC TOOL CAN RESULT INAN INCORRECT DEPTH POSITION AND AS A CONSE-QUENCE IN INADEQUATE OIL SEAL.

Specific tooling020425Y Punch for flywheel-side oil seal


Lubrication


ENG - 110

Conceptual diagrams


ENG - 111

Oil pressure check

- After removing the cover protections as descri-

bed in the "Flywheel" chapter, disconnect the elec-

trical connexion of the minimum oil pressure

switch and then remove the switch.

- With the engine idling at 1650 rpm and the oil

temperature at ~90°C, check that the oil pressure

is between 0.5 to 1.2 atm.

- With the engine idling at 6000 rpm and the oil

temperature at ~90°C, check that the oil pressure

is between 3.2 to 4.2 atm.

- Remove the appropriate tools once the meas-

urement is complete, refit the oil pressure switch

and washer, tightening it to the prescribed torque

and fit the flywheel cover.

- If the oil pressure is not within the specified limits,

in the following order, check: the oil filter, the oil

by-pass valve, the oil pump and the crankshaft

seals.N.B.THE CHECK MUST BE CARRIED OUT WITH OIL AT THECORRECT LEVEL AND WITH AN OIL FILTER IN PROPERCONDITION.

CharacteristicMinimum pressure admitted3.2 atm.

Locking torques (N*m)Locking torque 12 to 14 (also valid for the control con-nector).

Crankshaft oil seals


ENG - 112

Removal

- Remove the transmission cover and the com-

plete drive pulley beforehand

- Install the base of the appropriate tool on the oil

seal using the screws provided.

- Screw the threaded bar onto the base of the tool

and extract the oil seal.

Specific tooling020622Y Transmission-side oil seal punch

Refitting

- Prepare the new oil seal, lubricating the sealing

lip. Warning: do not lubricate the surface for keying

onto the engine crankcase.CAUTIONDO NOT LUBRICATE THE KEYING SURFACE ONTO THEENGINE CRANKCASE.


ENG - 113

- Preassemble the oil seal with the appropriate

tool, positioning the screws

- Place the sheath over the crankshaft

- Insert the tool with the oil seal on the crankshaft

until it comes into contact with the crankcaseCAUTIONORIENT THE OIL SEAL BY POSITIONING THE CHAINHOUSING CHANNEL FACING DOWNWARDS. WHEN THEPOSITION IS REACHED, DO NOT RETRACT THE OILSEAL. FAILURE TO COMPLY WITH THIS RULE CANCAUSE A WRONG POSITIONING OF THE OIL SEALSHEATH.

- Orientate the oil seal by inserting the bracket

which is part of the specific tool.

- Tighten the threaded bar onto the crankshaft as

far as it will go.


ENG - 114

- Use the nut to move the base of the tool until you

can see end of the oil seal driving stroke

- Remove all of the tool components following the procedure in reverse orderCAUTION

FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THEENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.

Oil pump

Removal

- Remove the chain cover acting on the 3 retaining

screws as shown in the figure and the relevant

copper washer.

- Extract the cover using the appropriate appen-

dages.N.B.WITH THE AIM OF AVOIDING DAMAGING THE APPEN-DAGES PRACTICE A RUN PARALLEL TO CRANKSHAFT.

- Remove the cover of the pump control pulley us-

ing the two retainers, as shown in the figure.

- Block the rotation of the oil pump control pulley

using a screwdriver inserted through one of its two

holes.


ENG - 115

- Remove the central screw with cup washer, as

shown in the diagram.

- Remove the chain with the pulley.

- Remove the crankshaft control pinion.

- Remove the oil pump acting on the 2 retainers as


- Remove the oil pump seal.IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-SURE THAT THE INITIAL DIRECTION OF ROTATION ISMAINTAINED.

Inspection

- Remove the two screws and the oil pump cover.

- Remove the circlip retaining the innermost rotor.

- Remove and wash the rotors thoroughly with pet-

rol and compressed air.

- Reassemble the rotors in the pump body, keep-

ing the two reference marks visible Replace the

retainer ring.

- Using a feeler gauge, check the distance be-

tween the rotors in the position shown in the figure.

CharacteristicMaximum clearance admitted0.12 mm


ENG - 116

Measure the distance between the outer rotor and

the pump body; see figure.

CharacteristicAdmissible limit clearance:0.20 mm

Check the axial clearance of the rotors with a trued

bar as reference, as shown in the figure.

CharacteristicLimit values admitted:0.09 mm

Refitting

- Check there are no signs of wear on the oil pump

shaft or body.

- Check there are no signs of scoring or wear on

the oil pump cover.

- If you detect non-conforming measurements or

scoring, replace the faulty parts or the assembly.

- Fit the pulley to the pump, the central screw to

the specified torque and the cup washer.

-Fit the oil pump cover, by tightening the two

screws to the prescribed torque.N.B.FIT THE CUP WASHER SO THAT ITS OUTER (CURVED)RIM TOUCHES THE PULLEY.

Locking torques (N*m)Central screw 12 to 14 Nm Cover screws 0.7 to 0.9Nm


ENG - 117

Removing the oil sump

- Remove the oil filler plug, the transmission cover,

the complete drive pulley assembly with belt and

the sprocket wheel, as described in the Transmis-

sion chapter.

- Drain the oil from the sump as described above.

- Remove the 7 screws indicated in the figure and

the 2 rear brake transmission fixing brackets.

- Remove the spring, the by-pass piston and the

gasket shown in the second image.

Inspecting the by-pass valve

- Check the unloaded spring length.

- Check that the small piston is not scored.

- Ensure that it slides freely on the crankcase and

that it guarantees a good seal.

- If not, eliminate any impurities or replace defec-

tive parts.

CharacteristicBy-pass check up: Standard length54.2 mm


ENG - 118

Refitting the oil sump

- Refit the by-pass piston in its housing.

- Insert the pressure-regulating spring.

- Fit a new sump seal.

- Refit the sump, taking care to locate the spring in

the appropriate recess machined into the inside of

the sump.

- Refit the rear brake transmission mounting brack-

ets and the screws in the reverse order from which

they were removed.

- Tighten the screws to the prescribed torque.

- Refit the driving pulley assembly, the drive belt,

the sprocket wheel and the transmission cover, as

described in the "Transmission" chapter.

- When testing the lubrication system, refer to

the "Crankcase and Crankshaft" chapter, re-

garding lubrication of the connecting rod as-

sembly


Fuel supplySOLO VERSIONE150 cm³ EURO 3

Remove the air cleaner housing valve


ENG - 119

After having removed the cable harness protec-

tion, remove the connector as indicated in the

photograph

Check the solenoid resistance inside the valve

with a multimeter.

Electric characteristicSolenoid resistance35.5 ÷ 40.5 mm at 20°C

Apply 12V DC to the connector ends as indicated

in the photograph. Check that the solenoid valve

opens.

Check that air intake pipe, on the carburettor

shown in the photograph, is not blocked.


ENG - 120

With the multimeter, check if the potentiometer is

working correctly by placing the probes on both

contactors indicated in the photograph .

With throttle valve completely closed, the resist-

ance value should be approx. 1.3 kOhm.

With throttle valve completely open, the resistance

value should be approx. 4.05 kOhm.

Removing the carburettor

- To detach the carburettor from the engine, it is

necessary to move the air filter and remove the

throttle control transmission, the automatic starter

connection, the clamps anchoring the carburettor

to the filter housing and to the intake manifold, the

air delivery pipe to the diaphragm, the heater, the

intake fitting and the TPS cable.

- Remove the heater

- Remove the protection, the bracket and the start-

er acting on the screw shown in the figure.


ENG - 121

- Remove the 2 screws and the starter support with

the gasket.

- Remove the 4 fixing screws shown in the figure

and the vacuum chamber cover.WARNINGDURING THE REMOVAL OF THE CARBURETTOR COVERTAKE SPECIAL CARE NOT TO RELEASE THE SPRINGACCIDENTALLY.

- Remove the vacuum valve together with the di-

aphragm.


ENG - 122

- Unscrew the bayonet joint 1/8 of a turn and re-

move, take out the spring and vacuum valve nee-

dle

- Remove the 4 screws indicated in the figure.

- Remove the chamber with the accelerating

pump, its control and gasket.

- Remove the oil pump seal.

- Remove the intake and exhaust valves of the in-

take pump from the tankN.B.CAUTION, THE ACCELERATION PUMP VALVES AREMADE UP OF NOZZLES, SPRING AND BALL.N.B.AVOID REMOVING THE PISTON OF THE PUMP AND ITSCONTROL.


ENG - 123

Adequately support the carburettor and using a

rod and hammer remove the float pin acting from

the throttle control side.

- Remove the float and the plunger.

- Remove the maximum nozzle

-Remove the maximum nozzle.


ENG - 124

-Remove diffuser.

- Remove the sprayer.N.B.WHEN CLEANING THE CARBURETTOR BODY REMOVETHE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY-ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TOREMOVE IT AS THIS WILL ONLY DAMAGE IT.

-Remove the minimum nozzle.

- Remove the minimum flow set screw and the

spring.CAUTIONDO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THECARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FORPROGRESSIONS AND INTAKE NOZZLE, MINIMUM ANDMAXIMUM AIR GAUGE, THROTTLE VALVE CONTROLSHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNEC-TION SCREWS. THE FIXING SCREWS ARE CAULKED AF-TER FITTING AND THEIR REMOVAL DAMAGES THESHAFT.


ENG - 125

Refitting the carburettor

- Before refitting, wash the carburettor body accu-

rately with petrol and compressed air.

- Pay special attention to the fuel supply pipe and

the plunger seat.

- For maximum circuit, check the air adjustment is

correct as shown in the figure.

- For the minimum circuit, make sure the following

points are properly cleaned: air gauging, exhaust

section controlled by flow screw, progression

holes near the throttle valve.

- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the

nozzle support hides other inaccessible internal calibrations.

- Blow the intake nozzle properly.N.B.

THE ACCELERATION NOZZLE EXHAUST IS EXTREMELY SMALL AND IS ORIENTED TO THETHROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAY-ING.


ENG - 126

- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.

- Check that the coupling surfaces, the chamber and the diaphragm are not dented.

-Check that the depression valve housing pipe is not scratched.

- Check that the throttle valve and the shaft do not show abnormal wear.

- Check that the plunger seat does not show abnormal wear.

- Replace the carburettor in case of irregularities.

- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.N.B.TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.- Wash and blow the minimum nozzle properly and

reassemble it.

- Properly wash and blow the components of the

sprayer maximum circuit, the diffuser and the noz-

zle.

- Introduce the sprayer in the carburettor body with

the shortest cylindrical part directed to the diffuser.

- Assemble the diffuser making sure the sprayer is

being adequately inserted and lock it.

-Assemble the maximum nozzle.

- Check that the tapered pin does not show signs

of wear on the sealing surfaces of the shock ab-

sorber pin and the return clamp.

- Replace the rod if worn out.

- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that

there are no fuel infiltration.


ENG - 127

- Replace it in case of failures.

- Introduce the float with the rod on the fuel feeding tube side.N.B.

INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY

- Remove the drainage screw from the tank, wash

and blow it properly and make sure the accelera-

tion pump pipes are clean.

- Operate the acceleration pump piston repeatedly

and blow with compressed air.

- Reassemble the acceleration pump valves fol-

lowing this order:

INTAKE VALVE (A)

• Spring

• Ball

• Nozzle

IN VALVE (M)

• Ball

• Spring

• NozzleN.B.THE IN VALVE NOZZLE, CORRESPONDING TO THE AC-CELERATION PUMP, IS MILLED.

-Check the screw tightness introducing a small

amount of fuel in the tank.

- Assemble a new gasket on the tank.

- Assemble the tank on the carburettor body fas-

tening the 4 screws.

- Check that the control roller is free to rotate in its

own seat.N.B.MAKE SURE THE TANK GASKET IS CORRECTLY INTRO-DUCEDN.B.AVOID DEFORMING THE ACCELERATION PUMP CON-TROL ROCKER.


ENG - 128

- Wash and blow the flow screw properly.

- Check that screw is not deformed and/or rusty.

- Assemble the spring on the screw.

- Screw the flow screw on the carburettor body.

- The screw final position should be determined by an exhaust fume analysis.

- Adjust the carburettor by turning the screw twice from the close position.

Level check

- Place the carburettor inclined as shown in the

figure.

- Check that the float reference is parallel to the tank coupling surface

- If different positions are detected, change the plunger control metal plate direction to obtain the position

described above.

Inspecting the valve and needle

- Check that the tapered pin of the vacuum valve

does not show wear.

- Check that the depression valve does not show

threads on the external surfaces.

- Check that the vacuum intake hole is not clogged.

- Check that the diaphragm is not damaged or has

hardened, otherwise replacement the whole valve.

- Insert the tapered pin into the vacuum valve

housing.


ENG - 129

- Reassemble the vacuum valve on the carburettor

body taking care that the tapered pin is inserted

into the sprayer.N.B.THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLEPOSITION.

- Reassemble the spring with the pin lock.

- Remove the cover of the vacuum chamber being

careful to correctly insert the spring in its place on

the cover.

- Tighten the screws.

- Wash and blow dry the filter sponge of the am-

bient pressure intake.


ENG - 130

- Reassemble the filter with its clamp.

- Wash and blow dry the starter support.

Assemble a new gasket on the carburettor body

and tighten the 2 fixing screws.

Inspecting the automatic choke device

- Check that the automatic starter piston is not de-

formed or rusty.

- Check that the piston slides freely from the seat

to the support.

- Check that the piston sealing gasket is not de-

formed.

- The starter must be more or less functional de-

pending on the ambient temperature.

- Measure the protrusion of the piston as shown in

the figure and check its corresponding value.

- Make sure that the starter is adjusted for the am-

bient temperature.

- The starter should disconnect progressively by

means of electric heating.

- Check the starter resistance when adjusted to the

ambient temperature.


ENG - 131

With a 12V battery power the automatic starter and

check that the piston protrudes as much as possi-

ble.

- The correct warm up time depends on the ambi-

ent temperature.

- If protrusion, resistance or timing values are dif-

ferent from the ones prescribed, replace the start-

er.

- Assemble the starter to the carburettor being

careful to position the O-Ring correctly, insert the

plate with the machined side contacting the starter,

tighten the fixing screws.

- Position the starter as shown in the figure.

- Assemble the protection casing.N.B.TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTIONNOT TO GENERATE SHORT CIRCUITS USE A CABLESECTION WITH A TERMINAL SUITABLE TO BE CONNEC-TED TO THE STARTER.

CharacteristicStarter pin travel10 mm (at 24°)

Starter resistance20 Ohm (at 24°)

Check aut. Kehin max. time starter5 min


ENG - 132

Adjusting the idle

- The engine does not require frequent idle speed

adjustments, but it is essential to strictly follow cer-

tain rules when adjusting the idle speed.

- Before adjusting the carburettor make sure to re-

spect the lubrication requirements, valve clear-

ance, and complying timing, spark plug should be

in optimum conditions, air filter clean and sealed,

and the exhaust system tight.

- Warm up the engine by running it at least 5 mi-

nutes at approximately 50 kph.

- Connect a millimetre thermometer (020331y) on

the sump, using a cover with oil expressly pre-

pared for probes.

- Start the engine and before adjusting the idle

speed, make sure that the oil temperature is be-

tween 70÷80 °C.

- Using the rpm indicator of the analyser or an in-

dependent one (020332y), adjust the idle set

screw until 1600 ÷ 1700 rpm is obtained.N.B.THE WASTED SPARK IGNITION SYSTEM OFFERS RE-MARKABLE POWER. READINGS MAY NOT BE ACCU-RATE IF INADEQUATE RPM INDICATORS ARE USED.CORRECT COUPLING OF THE RPM INDICATOR WILL BEINDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000


ENG - 133

INDEX OF TOPICS

SUSPENSIONS SUSP

Front suspension

This section is dedicated to operations that can be

carried out on the suspensions.

Front

Front wheel hub overhaulBall bearings on wheel hub

Fit the spacer.

-Fit the ball bearings and the bushings; fit the seal-

ing rings.CAUTIONLUBRICATE THE AREAS MARKED WITH AN ASTERISKUSING THE SPECIFIC GREASE BEFORE ANY REFITTINGOPERATIONS ON SAID AREAS.

Handlebar

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 REMOVETHE STEERING, TILT THE HANDLEBAR FORWARD TOAVOIDING DAMAGING THE TRANSMISSIONS.

Liberty 125 - 150 (2009) Suspensions

SUSP - 135

Front fork

Removal

To remove the front fork, remove the front and rear handlebar covers.

Remove the handlebar from the steering tube and place it on the rear shield back plate being careful

not to damage the bodywork supporting points.

Remove the front wheel and disconnect the brake calliper and the brake pipes from the fork.

Remove the upper fifth wheel using a wrench for the steering fifth wheel ring nut.

Lower the fork and the front mudguard.

See alsoFront handlebar cover

Suspensions Liberty 125 - 150 (2009)

SUSP - 136

OverhaulSealing ring replacement and stem 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 grooves.

- Refit the stem and the lower screw (1).

- Remove the upper screw (2).

- Add 30 cm³ ±1 oil (SAE 20W fork oil).

- Refit all components.

Locking torques (N*m)Upper screw tightening torque 20 to 25 Nm Lowerscrew tightening torque: 20 to 25 Nm

Refitting

To refit the fork, carry out the removal operations but in reverse order, observing the prescribed tight-

ening torques of the steering fifth wheels.

Locking torques (N*m)Lower steering ring nut 12 ÷ 14 Upper steering ring nut 35 ÷ 40

Steering column

RefittingLower and upper seating on the chassis

Lower and upper seating on the chassis

LOWER AND UPPER SEATING ON THE CHASSISTitolo Durata/

ValoreTesto Breve(< 4000 car.)

IndirizzoImmagine

Lower andupper seatingon the chas-

sis


SUSP - 137

Steering bearingSteering bearing upper seat

Lubricate the seats and the balls with the specific

grease.

- Lock at the prescribed torque and turn the key

anticlockwise by 80°÷90°.

Steering lock ring nut

Steering lock ring nut

RemovalLower and upper seating from the chassis

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 ascrewdriver as a lever between the seating and the shell.

LOWER AND UPPER SEATING FROM THE CHASSISTitolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine

Lower and upper seating fromthe chassis

Washer and upper seating of upper bearing

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


SUSP - 138

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.

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 ANDTHE WHEEL AXLE.

Locking torques (N*m)Rear wheel axle 104 to 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.

Locking torques (N*m)Shock absorber/engine pin torque 33 to 41 N·mShock absorber/chassis nut torque 20 to 25 Nm

Centre-standEjection of the stand fixing pin from the bracket


SUSP - 139

- 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.

Fitting and caulking the stand pin to the 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, GREASETHE SPRING ATTACHMENTS AND THE PIN.

Replace complete stand

- Work on the screws shown in the figure.

- When refitting, secure to the prescribed torque.

Locking torques (N*m)Stand screw torque 18.5 to 19 Nm


SUSP - 140

INDEX OF TOPICS

CHASSIS CHAS

Seat

- Unscrew the 2 fixing screws and remove the sad-

dle

Side fairings

• Remove the shield back plate

• Undo the 4 fixing screws and remove the bumper

band

See alsoKnee-guard

Rear rack

• Operating from the rear and using a screwdriver,

remove the plastic cap of the central screw cover.

• Remove the central and the 2 side screws.

Chassis Liberty 125 - 150 (2009)

CHAS - 142

Driving mirrors

• With the set screw fully tightened, screw the mir-

ror stem on the handlebar until it stops. • Loosen

the mirror and set it in the desired position. • Loos-

en the set screw until the stem is locked.

Locking torques (N*m)Mirror set screw 24 ÷ 26

Rear handlebar cover

• Remove the front handlebar cover

• Unscrew the odometer transmission joint and

slide it off

• Disconnect the instrument panel and electrical

controls connections

Liberty 125 - 150 (2009) Chassis

CHAS - 143

• Cut the clamp retaining the front brake pipes to

the instrument panel

• Remove the screw fixing the instrument panel to

the handlebar


Instrument panel

• Remove the rear handlebar cover

• Unscrew the 4 fixing screws and remove the in-

strument panelN.B.THE WARNING LIGHT BULBS HAVE A BAYONET JOINTON THE BULB HOLDER; THE LATTER CAN BE REMOVEDBY ROTATING IT 30° ANTICLOCKWISE. THE CLOCK ISPOWERED BY A BATTERY TYPE

See alsoRear handlebar cover

Front handlebar cover

• Remove the 2 screws in the rear handlebar cover

and the screw under the headlamp.

• Pull up and detach the front handlebar cover,

disconnect the headlight assembly connections.


CHAS - 144

Headlight assy.

• Remove the front handlebar cover.

• Unscrew the 4 fixing screws and remove the

headlight assembly.N.B.N.B. TO REPLACE THE HIGH/LOWBEAM HEADLIGHTBULB, REMOVE THE RUBBER COVER AND TURN THESUPPORTING PLATE BY 30° ANTICLOCKWISE. TO RE-PLACE THE SIDE LIGHT BULB, JUST SLIDE IT OFF THERUBBER BULB HOLDER.


Frame central cover

• Remove the rear luggage rack

• Remove the screw under the rear luggage carrier

shown in the picture

• Remove the saddle

- Remove the rear light unit

• Remove the spark plug access cover, unscrew

the 2 screws joining the helmet compartment

clamp with the footrest.

• Remove the two screws fixing the central cover

to the footrest

• Remove the two rear screws fixing the central

cover to the license plate holder support


CHAS - 145

See alsoRear rackTaillight assy.Seat

Legshield


• Remove the footrest.

• Remove the front fork.

• Remove the front badge using a blade and op-

erating carefully from the right side.

• Undo the screw underneath and slide the cover

upwards.


CHAS - 146

• Undo the front screw fixing the shield.

• Undo the 2 lower screws and remove the shield

once the turn indicator connections have been dis-

connected.

See alsoKnee-guardFootrest

Knee-guard

• Remove the 4 external screws of the shield back

plate and the 3 screws inside the front box.

• Using the bag hook, pull the shield back plate

backwards until it slides off the fitting with the leg-

shield.


CHAS - 147

Removing the ignition key-switch when on *off*


• 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.

See alsoKnee-guard

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.

Taillight assy.

In order to reach the rear light bulb proceed as fol-

lows:

- Remove screw "B" in order to remove cover

"C". Repeat this operation also on the left side.

- Remove screw "D" on both sides of the headlight

assembly.

- Remove screw "E" located underneath the plas-

tic cover of the rear luggage rack.


CHAS - 148

- Detach the headlight assembly as shown in the

picture.

The bulbs have a bayonet coupling, to remove

them press gently and turn it anticlockwise about

30°. To refit follow the same steps but in reverse

order.

Footrest


• Remove the central frame cover.

• Remove the four screws on the footrest.

• Undo the fixing screws under the passenger

footrests.

• Remove the two screws under the spoiler shown

in the picture.


CHAS - 149

See alsoFrame central coverKnee-guard

License plate holder

• Remove the central frame cover.

• Once it has been removed from its seat, remove

the screws fixing the voltage regulator supporting

plate.

• Remove the four screws fixing the license plate

holder support to the chassis.

See alsoFrame central cover

Air filter

Take off air cleaner cover «D» after having un-

screwed the 6 fixing screws «C», then take out the

filter. Clean with water and car shampoo, after-

wards dry with compressed air and submerge in a

recommended oil and petrol mixture in ratio of

50%. Afterwards squeeze it, leave it to dry and

mount it again.


CHAS - 150

Rear mudguard

• Remove the 3 retainers on the left side (2 of which

also fix the air filter housing).

• Remove the fixing screw on the cooling cap side.

• Remove the mudguard making it come out on the

muffler side.

Helmet bay

• Remove the helmet compartment central cover.

• Remove the battery and the fuse box.

• Remove the fuel tank cap and the start-up remote

control switch.

• Unscrew the rear fixing screw and lift the helmet

compartment.

See alsoFrame central coverFrame central cover


CHAS - 151

spoiler

• Remove the footrest.

• Undo the 2 front retainers and then remove the

spoiler from the bottom.

See alsoFootrest

Fuel tank

• Remove the helmet compartment central cover.

• Undo the front and rear screws on the chassis

right side.

• Disconnect the breather pipe and remove the

float.

See alsoFrame central cover


CHAS - 152

Front mudguard

• With the front wheel mounted, remove the fork

from the vehicle.

• Unscrew the 3 fixing screws and remove them.

• Slide off the odometer transmission and the

brake pipes, and then remove the mudguard.N.B.N.B. UPON REFITTING, BE CAREFUL TO PLACE THE 2METAL CABLE GROMMETS CORRECTLY SO THAT THEREIS NO RUBBING AGAINST THE WHEEL.


CHAS - 153

INDEX OF TOPICS

PRE-DELIVERY PRE DE

Aesthetic inspection

Appearance check:

- Paintwork

- Fitting of plastics

- Scratches

- Dirt

Tightening torques inspection

Lock check

- Safety fasteners

- Fixing screws

Safety fasteners:

Rear shock absorber upper fixing

Rear shock absorber lower fixing

Front wheel axle nut

Wheel hub nut

Swinging arm - chassis pin

Engine-swinging arm pin

Engine arm pin - Chassis arm

Handlebar lock nut

Lower steering 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 and temperature indicator

- Instrument panel warning lights

- Horn

- Starter

Liberty 125 - 150 (2009) Pre-delivery

PRE DE - 155

CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFOREIT 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 VEHICLE, DISCONNECTING THE NEGATIVE TERMINALFIRST.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 FORABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER ORVEGETABLE 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 CARETO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKINGCLOSE TO BATTERIES.KEEP OUT OF THE REACH OF CHILDRENCAUTION

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

Pre-delivery Liberty 125 - 150 (2009)

PRE DE - 156

Static test

Static control after the test ride:

- Starting when warm

- Starter operation

- Minimum hold (turning the handlebar)

- Uniform turning of the steering

- Possible leaksCAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.CAUTION

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Functional inspection

Functional Checks:

Braking system (hydraulic)

- Lever travel

Braking system (mechanical)

- Lever travel

Clutch

- Proper functioning check

Engine

- Throttle travel check

Others

- Check documentation

- Check the chassis and engine numbers

- Tool kit

- License plate fitting

- Check locks

- Check tyre pressures

- Installation of mirrors and any accessories

Liberty 125 - 150 (2009) Pre-delivery

PRE DE - 157

INDEX OF TOPICS

TIME TIME

Engine

ENGINECode Action Duration

1 001001 engine from frame - removal and re-fitting

Liberty 125 - 150 (2009) Time

TIME - 159

Crankcase

CRANKCASECode Action Duration

1 001133 Engine crankcase - Replacement2 001153 Crankcase halves gasket - Replace-

ment3 002031 Rear wheel hub bearings - Replace-

ment

Time Liberty 125 - 150 (2009)

TIME - 160

Crankshaft

DRIVING SHAFTCode Action Duration

1 001117 Crankshaft - Replacement2 001099 Oil seal, flywheel side - Replacement

Liberty 125 - 150 (2009) Time

TIME - 161

Cylinder assy.

CYLINDER ASSEMBLYCode Action Duration

1 001002 Cylinder-Piston - Replacement2 001107 Cylinder / piston - Inspection / clean-

ing

Time Liberty 125 - 150 (2009)

TIME - 162

Cylinder head assy.

HEAD ASSEMBLYCode Action Duration

1 001045 Valves - Replacement2 001056 Head gasket - change3 001126 Head - Replacement

Liberty 125 - 150 (2009) Time

TIME - 163

Rocker arms support assy.

ROCKERS MOUNTING UNITCode Action Duration

1 001044 Camshaft - Replacement2 001148 Rockers valves - Replacement3 001049 Valves - adjust

Time Liberty 125 - 150 (2009)

TIME - 164

Cylinder head cover

HEAD COVERCode Action Duration

1 001089 Head cover - Replacement2 001088 Head cover gasket - Replacement3 001159 Oil vapour recovery tank - Service4 001093 Spark plug - Replacement5 001097 Cooling hood - Replacement6 001091 Head cover sealing ring7 001074 Oil vapour recovery pipe - Replace-

ment

Liberty 125 - 150 (2009) Time

TIME - 165

Chain tensioner

CHAIN TIGHTENERCode Action Duration

1 001129 Chain tensioner - Service and Re-placement

2 001124 By pass lubrication - Replacement

Time Liberty 125 - 150 (2009)

TIME - 166

Oil filter

OIL FILTERCode Action Duration

1 001123 Oil filter -Replacement2 001160 Oil pressure sensor - change3 003064 Engine oil - change4 001102 Net oil filter - change / Cleaning

Liberty 125 - 150 (2009) Time

TIME - 167

Flywheel cover

FLYWHEEL COVERCode Action Duration

1 001087 Flywheel cover - Replacement2 001163 Secondary air-exhaust manifold -

Replacement3 001161 Secondary air filter - Replacement /

Cleaning4 001174 SAS valve - Replacement5 001164 Secondary air-crankcase manifold -

Replacement

Time Liberty 125 - 150 (2009)

TIME - 168

Driven pulley

DRIVEN PULLEY - CLUTCHCode Action Duration

1 001155 clutch housing - Replacement2 001022 Clutch - Replacement3 001012 Driven pulley - Overhaul4 001110 Driven pulley- Replacement

Liberty 125 - 150 (2009) Time

TIME - 169

Oil pump

OIL PUMPCode Action Duration

1 001051 Belt/Timing chain - Replacement2 001125 Chain guide pads - Replacement3 001042 Oil pump - Overhaul4 001112 Oil pump - Replacement5 001130 Oil sump - Replacement6 001100 Oil seal clutch side - Replacement7 001122 Oil pump chain - Replacement

Time Liberty 125 - 150 (2009)

TIME - 170

Final gear assy.

FINAL REDUCTION GEARCode Action Duration

1 004125 Rear wheel axle - Replacement2 001156 Gear reduction unit cover - Replace-

ment3 003065 Gear box oil - Replacement4 001010 Geared reduction unit - Service

Liberty 125 - 150 (2009) Time

TIME - 171

Driving pulley

DRIVING PULLEYCode Action Duration

1 001066 Driving pulley - Removal and refitting2 001086 Driving half-pulley - Replacement3 001177 Variator rollers / slides - Replace-

ment4 001011 Drive belt - Replacement

Time Liberty 125 - 150 (2009)

TIME - 172

Transmission cover

Starter motor

Liberty 125 - 150 (2009) Time

TIME - 173

STARTING MOTORCode Action Duration

1 001020 Starter motor - Replacement2 001017 Start-up pinion - Replacement

Flywheel magneto

MAGNETO FLYWHEELCode Action Duration

1 001109 Cooling fan - Replacement2 001173 Rotor - Replacement3 001067 Stator - Removal and Refitting4 001058 Flywheel - Replacement

Time Liberty 125 - 150 (2009)

TIME - 174

Belt cooling duct

BELT COOLING PIPECode Action Duration

1 001131 Transmission air inlet - Replacement2 001132 Transmission air intake pipe - Re-

placement3 001170 Air manifold - replacement

Liberty 125 - 150 (2009) Time

TIME - 175

Carburettor

CARBURETTORCode Action Duration

1 001082 Carburettor heating resistor - Re-placement

2 001013 Intake hose - Replacement3 004122 Carburettor-filter bellow - Replace-

ment4 001081 Automatic choke - Replacement5 001008 Carburettor - Inspection6 001063 Carburettor - Replacement

Time Liberty 125 - 150 (2009)

TIME - 176

Exhaust pipe

SILENCERCode Action Duration

1 001009 Silencer - Replacement2 001136 Exhaust emissions - Adjustment3 001095 Silencer heatshield - Replacement

Silencer fixing

Please take note that, starting from chassis serial number ZAPM3810000003971, the two M8 x 50

silencer fixing flaged head screws have been replaced by two M8 x 50 internal hexagonal cylindrical

head screws.

Liberty 125 - 150 (2009) Time

TIME - 177

Air cleaner

AIR CLEANERCode Action Duration

1 001014 Air filter - Replacement/Cleaning2 001015 Air filter box - Replacement

Time Liberty 125 - 150 (2009)

TIME - 178

Frame

CHASSISCode Action Duration

1 004001 Chassis - Replacement2 004004 Stand - Replacement3 001053 Stand pin - Replacement

Liberty 125 - 150 (2009) Time

TIME - 179

Legshield spoiler

MUFFLER - GLOVE COMPARTMENTCode Action Duration

1 004159 Plates / Stickers - Replacement2 004149 Shield central cover - Replacement3 004064 Front shield, front section - Removal

and refitting4 004079 Rear footrest - Replacement5 004053 Spoiler - Replacement6 004015 Footrest - Disassembly and reas-

sembly7 004143 Footrest support - Replacement

Time Liberty 125 - 150 (2009)

TIME - 180

Rear cover

REAR COVERCode Action Duration

1 004174 Glove-box remote opening linkage -Replacement

2 004065 Knee-guard - Removal and refitting3 004131 Rear rack mounting bracket - Re-

placement4 004082 Glove-box packing - Replacement5 004081 Glove comparment door - Replace-

ment

Liberty 125 - 150 (2009) Time

TIME - 181

Central cover

CENTRAL COVERCode Action Duration

1 004059 Spark plug inspection flap - Replace-ment

2 004106 Helmet compartment band - Re-placement

3 004085 Fairing (1) - Replacement4 004013 Side/rear bumper pipes - Replace-

ment

Time Liberty 125 - 150 (2009)

TIME - 182

Underseat compartment

UNDERSEAT COMPARTMENTCode Action Duration

1 005046 Battery cover - change2 004016 Helmet compartment - Removal and

Refitting3 001027 Filter bellow - Replacement

Liberty 125 - 150 (2009) Time

TIME - 183

Plate holder

SUPPORT PLATECode Action Duration

1 004136 License plate holder mounting - Re-placement

2 005048 number plate holder - Replacement3 005131 number plate light support - Replace-

ment4 005031 number plate light bulb - Replace-

ment5 005032 number plate light glass - Replace-

ment

Time Liberty 125 - 150 (2009)

TIME - 184

Mudguard

MUDGUARDCode Action Duration

1 004002 Front mudguard - Replacement2 004009 Rear mudguard - Replacement

Liberty 125 - 150 (2009) Time

TIME - 185

Fuel tank

FUEL TANKCode Action Duration

1 004168 Fuel tank cap - Replacement2 005010 Tank float - Replacement3 004112 Cock-carburettor hose - Replace-

ment4 004005 Fuel tank - Replacement5 004007 Fuel valve - Replacement6 004109 Fuel tank breather - Replacement

Time Liberty 125 - 150 (2009)

TIME - 186

Rear shock-absorber

REAR SHOCK ABSORBERCode Action Duration

1 003007 Rear shock absorber - Removal andRefitting

Liberty 125 - 150 (2009) Time

TIME - 187

Steering column bearings

STEERING COLUMN BEARINGSCode Action Duration

1 003002 Steering bearing - Replacement2 003073 Steering clearance - Adjustment

Time Liberty 125 - 150 (2009)

TIME - 188

Handlebar covers

HANDLEBAR COVERSCode Action Duration

1 004019 Handlebar rear section - Replace-ment

2 004018 Handlebar front section - Replace-ment

3 005078 Odometer glass - Replacement4 005076 Clock \ Pile - Replacement5 005014 Odometer - Replacement6 005038 Instrument panel warning light bulbs

- Replacement7 004099 Odometer housing - Replacement

Liberty 125 - 150 (2009) Time

TIME - 189

Handlebar components

HANDLEBAR COMPONENTSCode Action Duration

1 004066 Driving mirror - Replacement2 002037 Brake or clutch lever - Replacement3 002071 Left hand grip - Replacement4 003001 Handlebar - Removal and refitting5 005017 Stop switch - Replacement6 002024 Front brake pump - Removal and Re-

fitting7 003061 Accelerator transmission - adjust8 002060 Complete throttle control - Replace-

ment9 004162 Mirror mounting and/or brake pump

fitting U-bolt - Replacement10 002059 Right hand grip - Replacement11 002063 Throttle control transmission - Re-

placement

Time Liberty 125 - 150 (2009)

TIME - 190

Swing-arm

SWINGING ARMCode Action Duration

1 001072 Engine / frame swinging arm fitting -Replacement

2 003080 Swinging arm on chassis - Replace-ment

Liberty 125 - 150 (2009) Time

TIME - 191

Brake hoses

BRAKE PIPINGCode Action Duration

1 002007 Front brake shoes/pads - Remov.and Refitt

2 002039 Front brake calliper - Removal andRefitting

3 002021 Front brake hose - Remov. and Re-fitt.

4 002047 Front brake fluid and system bleed-ing plug - Repl.

Time Liberty 125 - 150 (2009)

TIME - 192

Seat

SEATCode Action Duration

1 004003 Saddle - Replacement2 004008 Luggage rack - Replacement3 004062 Luggage rack cover - Replacement

Liberty 125 - 150 (2009) Time

TIME - 193

Turn signal lights

TURN SIGNAL LIGHTSCode Action Duration

1 005002 Front headlamp - Replacement2 005012 Front turn indicator - Replacement3 005067 Front turn indicator bulb - Replace-

ment4 005008 Headlight bulbs - Replacement5 005005 Taillight - change6 005066 Rear light bulbs - Replacement7 005028 Rear light assembly glass - Replace-

ment8 005022 Rear turning indicators - Replace-

ment9 005068 Rear turning indicator bulb - Re-

placement

Time Liberty 125 - 150 (2009)

TIME - 194

Front wheel

FRONT WHEELCode Action Duration

1 003038 Front wheel axle - Remov. and Refit.2 002011 Odometer drive - Replacement3 003040 Front wheel bearings - Replacement4 003047 Front tyre - Replacement5 003037 Front wheel rim - Removal and Re-

fitting6 004123 Front wheel - Replacement7 002041 Brake disc - Replacement

Tone wheel or drive greasing

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, the area to be greased is

indicated with an arrow (1 - Drive, 2 - Tone wheel)

Liberty 125 - 150 (2009) Time

TIME - 195

Rear wheel

REAR WHEELCode Action Duration

1 002002 Rear brake pads/shoes - Repl.2 004126 Rear wheel tyre - Replacement3 001016 Rear wheel - Replacement4 001071 Rear wheel rim - Removal and Refit-

ting

Time Liberty 125 - 150 (2009)

TIME - 196

Electric devices

ELECTRICAL DEVICESCode Action Duration

1 001023 Control unit - Replacement2 005035 Headlight remote control - Replace-

ment3 005001 Electrical system - Replacement4 001094 Spark plug cap - Replacement5 001069 HV coil - replace6 005052 Fuse - Replacement7 005025 Battery fuse box - Replacement8 005009 Voltage regulator - Replacement9 005011 Start-up solenoid - Replacement10 005007 Battery - change11 005114 Electrical system - Service

Liberty 125 - 150 (2009) Time

TIME - 197

Electronic controls

ELECTRIC CONTROLSCode Action Duration

1 005039 Lights switch - Replacement2 005006 Light or turning indicator switch - Re-

placement3 005040 Horn button - Replacement4 005003 Horn - Replacement5 005041 Starter button - Replacement6 005016 Key switch - Replacement7 004096 Lock series - Replacement8 005072 Immobilizer aerial - Replacement

Time Liberty 125 - 150 (2009)

TIME - 198

Transmissions

TRANSMISSIONSCode Action Duration

1 002051 Odometer transmission assembly -Replacement

2 002049 Odometer cable - Replacement3 002053 Rear brake transmission complete -

replacement

Liberty 125 - 150 (2009) Time

TIME - 199

Front suspension

FRONT SUSPENSIONCode Action Duration

1 003010 Front suspension - Service2 003048 Fork oil seal - Replacement3 003076 Fork sleeve - Replacement4 003079 Fork stem - Replacement5 003051 Complete fork - Replacement6 003069 Front fork oil - Replacing

Time Liberty 125 - 150 (2009)

TIME - 200

AAir filter: 150

BBattery: 35, 39, 47, 56, 57Brake: 192Bulbs:

CCarburettor: 11, 121, 126, 176Checks: 44

EElectric: 197

FFuel: 34, 119, 152, 186Fuses: 55

HHeadlight: 145Horn: 51Hub oil: 30

IIdentification: 7Instrument panel: 144

MMaintenance: 6, 30Mirrors: 143

OOil filter: 167

RRecommended products:

SShock absorbers: 139Spark plug: 45Start-up: Suspension: 36, 200

TTank: 152, 186Transmission: 9, 34, 65, 76, 86, 173Tyres: 10

VVehicle: 7, 62

Documents

Piaggio Liberty 125 - 150 MY 2009 (en))