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Derbi Scooter Service Manual

1. w lt lt 4 T7323 Y GR AA Hi 08 OFF Lo OFF ON LIGHTS 12 HON mol S407 HEADLIGHT 12V 35 35W DASHBOARD 2A TURN SIGNAL INDICATOR LIGHT 12V 2W 28 FUEL INDICATOR LIGHT 12 1 2W 2C OIL INDICATOR LIGHT 12V 2W 20 DASHBOARD LIGHT 12V 1 2W 2E CONTROL PILOT LIGHT 12V 1 2W 2F HIGH BEAM CONTROL PILOT LIGHT 12V 1 2W IGNITION SWICHT FRONT RIGHT TURN SIGNAL 12 10W FRONT LEFT TURN SIGNAL 12V 10W REAR RIGHT TURN SIGNAL 12V 10W REAR LEFT TURN SIGNAL 12 19W TAIL BRAKE LIGHT 12V 5W 12V 10W ENGINE STOP ENGINE SWICHT Orange Orange Orange VC LIGHTS TURN INDICATORS HORN SWICHT BRAKE LIGHT SWICHT HORN 12V ELECTRICAL ASSEMBLY FUEL LEVEL SENSOR OIL LEVEL SENSOR STARTER RELAY STARTER MOTOR FUSE 4Amp BATTERY 12V 4AH FLYWHEEL MAGNETO 12V 80W ELECTRONIC CONVERTER A T SPARK PLUG CAP ANTI RADIO INTERFERENCES ENGINE STOP RELAY SPARK PLUG Arancio Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris
2. 1 LACH ya n se se gg Y GR eH L J O H Eva 6 eg 3 11 an ee 88 i 4 CRB ann mn i BL 8 W BL i Ze Y Y GR To UR D 0 M Ml Lt GR i e Ofe ii Y GR i s Jes FE amp 69 0 i BB eue Ed Y o T a o O ap un ENT Y GR O et Bi Ip 57 I ken e en biss CEJ INDICATORS O HEADLIGHT ASSEMBLY I amp BRAKE LIGHT SWITCH tA BULB 2V 25 250 9 LIGHTS SWITCH IB INDICATOR BULB 12V 10W ID TURN INDICATORS SWITCH 2 DASHBOARD L1 HORN SWITCH 2A OIL RESERVE CONTROL PILOT LIGHT 12 2W 12 HORN 28 FUEL RESERVE CONTROL PILOT LIGHT 12V AN 34 ree 2C TURN INDICATOR CONTROL PILOT LIGHT 12V 2W In FUEL LEVEL SENSOR 2D HIGH BEAM CONTROL PILOT LIGHT 12Y 1 20 IS OIL LEVEL SENSOR 2E DASHBOARD LIGHT 2V 1 2N 16 CARBURATOR HEATER KIT OPTIONAL 3 IGNITION SWITCH II STARTER RELAY TURN INDICATOR CENTRAL CONTROL 12Y 10 10W REGULATOR 12V 18 STARTER MOTOR 5 TAIL LIGHT ASSEMBLY 19 FUSE 4A SA BRAKE BULB 2V 10W 20 BATTERY 2V 58 TAIL BULB 12V SW 2 FLYWHEEL MAGNETO 12 80W SC INDICATOR BULB 12 10W 22 ELECTRONIC CONVERTER A T 6 ENGINE SWITCH 23 SPARK PLUG CAP ANTI RADIO INTERFERENCES 1 BRAKE LIGHT SWITCH
3. kc 1 8 kgf mm 10 Maintenance of the shock absorber swinging arm The part should be kept cleaned and well grea sed If the swinging arm seizes up check the bushing and the swinging arm linkage seals When fitting the bushing and the swinging arm seals they should be well greased using lithium grease The torque setting for tightening up the shock absorber swinging arm and main linkage assembly screws and nuts is 38 40 Nw x m PREDATOR O2 Hydraulic shock absorber Length of shock absorber 297 mm Shock absorber travel 65 mm Length of spring 237 mm If the shock absorber is losing hydraulic fluid it should be replaced ATLANTIS LC Hydraulic shock absorber with spring regulation Length of shock absorber 245 mm Shock absorber travel 60 mm Length of Spring 191 mm Length of spring LC 171 mm Spring compression force to 30 mm 142 kg m Spring compression force to 60 mm 282 kg m ATLANTIS 100 Hydraulic shock absorber with spring regulation for one or two passengers Length of shock absorber 290 mm Shock absorber travel 60 mm Leng
4. 2 o90 005 Headlight 12V 355 35 W Dashboard 2A Oil Indicator Light 12V 2W 2B Fuel Indicator Light 12V 2W 2D High Beam tndicator Light I2V 1 2W 2E Dashboard Light 12V 1 2W 2F Fuel Level G uge 2G Water Temperature Gauge Ignition Switch Mobil phone connector Front Right Turn Signal Ligh 12V IOW Front Left Turn Signal Ligh I2V Rear Right Turn Signal Ligh l2V IOW Rear Left Turn Signal Ligh 12V Tail Brake Light I2V 21W 5W Engine Stop Engine Switch Lights Horn Turn Indicators Switch Orange Orange Orange Brake Light Switch Horn 2 DC Fuel Sensor Oil Sensor Electric Choke Starter Relay Starter Motor Fuse 4A Battery 12V 4A 20 Flywheel Magneto 12V 21 Electronic Converter 2 2 Spark Plug Cap Anti Radio interferences 23 Spark Plug 24 Regulator AC DC Turn signal central control 25 Stand switch 26 Temperature thermoresistance 27 Engine Stop Relay 28 Carburator Heater KIT OPTIONAL Arancio Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blue Blau Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Pink Rosa Rosa Rosa
5. Remove the clutch belt mm 12 Loosen the clutch hub nut using the special tool 0 0G 053 0 001 1 and remove the nut the was her the hub and the clutch club Loosen the reduction gear oil drain plug with the washer and remove Loosen and remove the 6 screws to the reduction gear box cover and immediately remove the reduction gear cover complete with the clutch pulley shaft and the gasket Withdraw the washer the gear wheel shaft and the intermediate shaft Withdraw the water pump drive gear nut using special tool 0 0G 053 0 098 1 Withdraw the pump drive gear and the pump drive pinion together with the toothed belt Withdraw the water pump body locking piece 2 countersunk Allen head screws In order to extract the water pump body the follo wing special tools are required 0 0G 056 0 042 1 and 0 0G 056 0 036 1 Loosen and remove the bendix starter pinion bracket 2 screws Loosen and withdraw the 6 securing screws for the right hand crankcase half In order to split the crankcase halves it is neces sary to make use of the special tool 0 0G 053 0 015 1 Next separate the crankcase halves Loosen the 2 screws to extract the starter motor the gasket and the O ring Withdraw the rear brake shoes Loosen and remove the rear wheel bearing loc king piece Use an impact hammer to loosen these screws Withdraw the wheel axle seal and using special
6. B LUBRICATE APPLY THE PRODUCT A CAUTION HANDLE WITH CARE 4 GREASE CLEAN WITH CARE 8 ALWAYS REPLACE mm 102 Disassembly of Secondary Air System Cover To disconnect the metallic tube indicated in the figure of the rubber seat on the cover without unplugging the same tube of the cover Remove screws of cover SAS in aluminum Remove the plastic cover the lamina and the foam Atenci n To each assembly to replace the O Ring lodged in its own lodging in the cover Disassembling the Secondary Air System SAS housing Remove the two screws securing the SAS hou sing to the crankcase loosen the clip from the hose and withdraw the hose without cracking it Checking the SAS reed Caution Verify that the steel reed seals herme tically If it does not seal correctly it must be repla ced In order to check the oil pump withdraw the rub ber cover levering off by means of a screwdriver Cleaning the filter Wash both filters with soap and water Dry using compressed air before re installing Remove the securing clamp and then withdraw the hose from the secondary air filter to the exhaust pipe 103 m CYLINDER HEAD CYLINDER PISTON Models air cooled APPLY THE PRODUCT A CAUTION HANDLE WITH CARE n LUBRICATE 4 GREASE IST 5 mm 104 CLEAN WITH CARE 8 ALWAYS REPLACE Cylinder cooling cover Withdraw the screws shown in the figure
7. 0 007 Piston 12 0 012 0 002 0 011 Gudgeon Pin Axial tolerance between crankshaft and connecting rod DESCRIPTION DIMENSION PLAY ASSEMBLY TOLERANCE Connecting rod 11 75 05 Stop washer 205 Half shaft transmission side C 13 7579 E 0 25 0 50 Half shaft magneto side D 13 75 094 Distance tool H 40 64 Bearing cage 11 8 0 Stop washer G 0 5 Half shaft transmission side C 13 75 0 F 0 20 0 75 Half shaft magneto side D 13 7579 Distance tool H 40 64 Connecting rod big end bearing cage gudgeon pin ep FE mE CONNECTING ROD BIG END BEARING CAGE GUDGEON PIN DESCRIPTION DIMENSIONS PLAY ASSEMBLY Zum Categories i thousandths of rnm TOLERANCE VON big end Cage Ey CAT 917mm CAT 25mm Option pin Y 2 5 mm G g17 0011 1 11 1 0 1 Connecting Rod I 0 002 7 Roja 2 3 5 F 92 59 2 2 ya 2 P 2 0 012 3 Azul 4 5 1 d H 12 0 005 3 3 3 4 5 Gidgeon pin 1 Gris 6 7 Crankshaft alignment check Using the special tool indicated check the surfa ce of diameters A B for eccentricity they should fall within 0 08 mm maximum limit of rea ding on comparator dial Also check eccentricity of diameter D for which the maximum permitted reading is 0 02 mm Where the eccentricity is slightly grea
8. Violett Violet Violet Violeta ECHEMA ELECTRIQUE ATLANTIS 100 Y GR WBL Y GR ilr Yen VC W BL 2 T ER OFF QD TURN INDICATORS e HEADLIGHT ASSEHBLY lA BULB 12 25 258 18 INDICATOR BULB 12V 0W Ic POSITION BULB 12V SW DASHBOARD 2A OIL RESERVE CONTROL PILOT LICHT 12V 2W 28 FUEL RESERVE CONTROL PILOT LIGHT 12Y 2W 2C TURN INDICATOR CONTROL PILOT LIGHT 12Y 2W 2D HIGH BEAM CONTROL PILOT LIGHT 12V 2W 2E DASHBOARD LIGHT 12V 2W IGNITION SWITCH TURN INDICATOR CENTRAL CONTROL TAIL LIGHT ASSEMBLY SA BRAKE BULB 12V 10 58 TAIL BULB 121 SW 5C INDICATOR BULB 12V 100 LICENCE PLATE LIGTH ASSEMBLY WITH REFLECTOR LICENCE PLATE BULB 12V DN ENGINE SWITCH Orange Orange Orange 2V 10 104 REGULATOR 12V 80W Arancio 8 BRAKE LIGHT SWITCH 9 LIGHTS SWITCH 10 TURN INDICATORS SWITCH 11 HORN SWITCH 12 HORN 14 FUEL LEVEL SENSOR 15 OIL LEVEL SENSOR 16 CARBURATOR HEATER KIT 17 STARTER RELAY 18 STARTER MOTOR 19 FUSE 4A 20 BATTERY 12 21 FLYWHEEL MAGNETO 12 80W 22 ELECTRONIC CONVERTER 23 SPARK PLUG CAP ANTI RADIO INTERFERENCES 2 SPARK PLUG Naranja Gr
9. CARBURETOR MODELS 2 2 2 2 DELL ORTO PHVA 14 DD ATLANTIS F 57 34 210 GA 1 3 4 Turns 50 14 3 0 5 DELL ORTO 1400 ATLANTIS WVTA 50 34 211 GA 2 Turns 45 14 3 0 5 DELL ORTO PHVA14DD ATLANTIS LC E 57 34 210 GA 134 Turns 50 14 3 0 5 DELL ORTO PHVA14DD ATLANTIS LC I CAT 50 34 211 GA 2 Turns 45 14 3 0 5 DELL PHVA14DD ATLANTIS LC F 57 S 34 210 GA 1 3 4 Turns 50 14 3 0 5 DELL ORTO 1400 ATLANTIS LC WVTA 50 34 211 GA 2 Turns 45 14 3 0 5 DELL ORTO PHVA 17 5 DD ATLANTIS 100 WVTA 69 36 210 GA 2 Turns 50 14 3 0 5 DELL ORTO 14 00 ATLANTIS 30 Km 50 5 34 211 GA 2 Turns 45 14 3 0 5 In PREDATOR LC models there is an automatic choke In PREDATOR O2 ATLANTIS and ATLANTIS LC models the choke is manually operated Maintenance and cleaning of the carburettor are extremely important for the correct performance of the scooter Cleaning and maintenance of the filter box are also vital to keep fuel consumption within normal limits Inspection of the float needle inspect the float needle for wear a worn needle may cause dama ge to the engine ELECTRICAL SYSTEM GENERAL CHARACTERISTICS Component Battery Type Special electrolyte Maintenance free Standard values 12V 4 Ah Specific gravity 1 32 at 20 C Battery c
10. 25 30 3 4 10 11 6 7 95 mm Thermostat cylinder head by pass tube Detail of the thermostat Cylinder head Cylinder Caution Every time the cylinder head is strip ped down replace the two seals and the cylinder head gasket Cylinder Cylinder Checking the thickness of the cylinder base gasket Assemble the cylinder without using the cylinder base gasket Fit a hundredths comparator on special tool 19 1 20268 and bring the needle to zero on a rec tified surface Fit the tool to the upper part of the cylinder and secure it with two nuts to the studs observing the torque setting of 10 11 N m and bring the piston to TDC The thickness of the gasket which is required will vary according to the value observed For this reason 3 gaskets are supplied in the following thicknesses 0 75 mm 0 5 mm 0 4 mm Cylinder head torque setting 10 11 N x m Special tool 19 1 20268 VALUE OF A mm Thickness of gasket 2 85 3 10 435602 3 10 3 25 0 5 289499 3 25 3 45 0 75 435603 CRANKCASE HALVES CRANKSHAFT APPLY THE PRODUCT A CAUTION HANDLE WITH CARE LUBRICATE 4 GREASE CLEAN WITH CARE 8 ALWAYS REPLACE TORQUE 12 13 HE mm 98 Automatic mixer drive gearing and belt Strip the gearing and belt If it is difficult to remove the mixer gearing use the special tool Caution Do not twist the belt Special tool 19
11. it should be cleaned and greased using lithium grease of the following specification 250 ASTM D 217 Working temperature 160 C 25 C using a quantity of 3 to 3 5 grams Torque setting clutch nut Torque setting pulley shaft nut Torque setting variable speed unit nut 65 70 Nw x m 35 40 Nw x m using loctite 35 40 Nw x m using loctite CARBURETTORS Adjustment Table MAIN JET IDLE STARTER NEEDLE POSITION EMULSIFIER JET WEBER 14 PREDATORIC E 66 G8 Turns 55 16 5 1 WEBER 140M1FA_ PREDATOR O2 E 66 G8 Turns 55 16 5 1 WEBER 120 10 PREDATORLC I 66 G8 Turns 55 16 5 1 WEBER 12 15 PREDATOR I 66 G8 Turns 55 16 5 1 DELL ORTO PHVA14DD PREDATORLC E 57 34 210GA 134 Turns 45 143 0 5 DELL ORTO PHVA14DD PREDATOR O2 E 57 34 210GA 134 Turns 45 14 3 0 5 DELL ORTO PHVA12DD PREDATORLC I 57 34 212GA 13 4Tums 45 14 3 0 5 DELL ORTO PHVA12DD PREDATOR 2 57 34 212GA 134 Turns 45 14 3 0 5 DELL ORTO PHVA12DD PREDATORLC I CAT 49 3 32 212 GA 134 Turns 45 14 3 0 5 DELL ORTO PHVA12DD PREDATOR 02 1 CAT 49 32 212GA 134 Turns 50 143 0 5 DELL ORTO PHVA14DD PREDATORLC A 50 34 211GA 2 Tums 45 143 0 5 DELL ORTO PHVA14DD PREDATOR Oe A 50 4 34 211GA 2 Turns 45 143 0 5 DELL ORTO PHVA14DD PREDATORLCWVTA 50 34 211GA 2 Tums 45 143 0 5 DELL ORTO PHVA14DD PREDATORO2WVTA 50 34 211GA 2 Turns 45 143 0 5
12. 80881158407 fourth edition May 2002 A 2 INDEX Hunter Paddock Vamos Models Technical specifications of the engine 4 Assembly of sliding weight hub 22 Special tools 5 Clutch assembly 23 Regular maintenance table 6 Reduction gear 24 Torque settings 7 Left hand crankcase cover 24 Front forks HUNTER 8 Cylinder head cylinder Front forks PADDOCK 9 andpiston 97 Front forks VAMOS 9 GCarburettor____________ 30 Withdrawing the engine Cylinder sleeve cover from the frame 10 radiator and filler box 33 Stripping the engine 11 Fitting the engine in the frame 35 Assembly of the engine 16 Electrical system 36 Crankshaft inspection 18 Electrical wiring diagrams 11145 Assembly of right hand crankcase bearing 19 Water pump 20 Predator LC O2 Atlantis LC 02 100 Models Regular Maintenance Table 50 Magneto 57 Torque settings 51 Cylinder head cylinder and piston 58 Front forks 52 Crankshaft Variable speed unit 60 Rear suspension 54 Carburettor 61 Removing the engine Electrical system 62 from the frame 56 Electrical wiring diagrams 65 Engine Piaggio Models Special tools 74 Crankcase halves crankshaft 98 Regular Maintenance Table 77 Secondary air system 102 Torque settings 78 Cylinder head cylinder piston Paioli front forks 79 Air cooled models 104 Engine 80 Vehicle service data 107 E 81 Carburettors 110 Electronic ignition 983 Electrical system 111 Transmissi
13. C Charging the battery for the first time Cut or extract the breather tube seal and fit the tube Remove the plugs and fill the battery with elec PATE V plug l y a _ trolyte with a density of 1 28 at 20 C It is extremely important to check the density of the electrolyte before charging the battery Leave the battery to rest for about one hour after filling Then adjust the level of electrolyte by adding electrolyte Then connect the charger for 10 hours at 0 4 Ah matching the polarities connecting the and the of the charger to the and the of the battery Normal charging Remove the battery from the scooter Clean the battery with plentiful water but making sure that water does not enter the cells Inspect the cells and add distilled water to the level indicated on the battery Connect the charger taking care to match the polarities Charging current 0 4 maximum Decide the charging time according to the atta ched table Specific gravity at 20 2 4 6 8 10 12 14 16 Hours charging required Schematic and battery charging control REGULATOR RECTIFIER 4 FUSE BATTERY Wh Y 12V 4Ah TO SWITCH LIGHTS BATTERY R Or ACCESORIES ee IGNITION KEY RED MAGNETO Y YELLOW Y Gr YELLOW GREEN R Bk RED BLACK Wh Y 2 WHITE YELLOW Wh R WHITE RED Alternator voltage test at med
14. CRANKCASE COVER 6M100 12 13 OIL DRAIN PLUG 8M125 CYLINDER SLEEVE COVER 6M100 FRONT WHEEL 12M150 SCREW 17 19 4 5 35 50 REAR RIM SECURING NUT HUB TO REAR WHEEL AXLE 16M150 17 19 115 125 ENGINE SUPPORT TO FRAME 10M150 SHOCK ABSORBER UP DOWN 10M150 HANDLEBAR 8M125 EXHAUST PIPE TO CYLINDER 6M100 EXHAUST PIPE TO CRANKCASE 10M150 SCREW SCREW 30 40 30 40 15 19 9 12 15 19 FORK LEG SECURING NUT 6M100 STEERING 25M100 FRONT BRAKE CALIPER 8M125 BRAKE CALIPER TO CRANKCASE 8M125 STARTER PEDAL 6M100 SCREW SCREW SCREW NUT NUT NUT NUT 8 10 90 130 17 19 17 19 8 12 SILENCER PROTECTOR 4M70 HANDLEBAR COUNTERWEIGHT SCREW SCREW 1278 4 5 LOCTITE LOCTITE ENGINE TO SUPPORT 10M150 BRAKE DISC FRONT REAR 8M125 CENTRE STAND TO CRANKCASE mm 8 SCREW 30 40 17 19 17 19 LOCTITE PAIOLI FRONT FORKS FOR PROPER MAINTENANCE AND REPAIR OF THE PAIOLI FORKS IT IS RECOMMENDED THAT THEY SHOULD BE REMOVED FROM THE FRAME TO REMOVE THE FORKS FROM THE FRAME Remove the fairing Loosen off the screws in the upper casing Disconnect the connections in the instrument panel Speedometer sleeve instrument connec tors grip lighting switch connectors stop light indicators and cut the rear brake clip Remove upper casing Remove the shield backing plate Loosen and remove the 2 handlebar screws Loosen the front forks nut Loosen
15. Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blau Blue Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Rosa Pink Rosa Rosa Violett Violet Violet Violeta ANNEXE PREDATOR LC CAT WVTA Models PREDATOR 02 CAT WVTA Models ATLANTIS CAT WVTA Models ATLANTIS LC CAT WVTA Models ATLANTIS 100 Models REGULAR MAINTENANCE TABLE Period the period may be calcu lated by kilometres run or by time in months Reduction gear or crankcase oil Replace Replace Check Replace Check Suspensions Check Check Check Check Tighten all fastenings Check Check Check Check Check Electrical connections Check Check Check Check Check Spark plug Clean Replace Replace Replace Replace Battery with maintenance Check Check Check Check Carburettor Adjust Adjust Adjust Adjust Adjust Clean Clean Clean Clean Clean Water pump drive belt Replace Variable speed drive rollers Check Drive belt transmission Replace Oil filter Replace Check Replace Air filter Clean Clean Clean Brakes hose pads Check Check Check Braka equipment Check Check Brake fluid VERY 2 YEAR EVERY 2 YEAR Coolant Check Check Check Check Check Check Tyres Check Check Check Check Check Tyres pressures Check Check Check Check Check Check Fuel or oil hoses Replace Check Replace Check Transmission Lubricate Lubricate Lubricate Lubricate Lubricate and greasing and greasing and
16. LC models Remove the helmet carrier box 6 screws Remove the rear brake cable nut Remove the rear brake guide stop 1 screw Remove the engine earth screw Remove the throttle cable union Disconnect the electrical connectors for the mag neto the stop light the choke the starter the high tension coil and the coil earth cable On the LC models also disconnect the thermo contact spade connector Disconnect the two pipes from the connector on the carburettor the fuel pipe and the vacuum line Disconnect the oil hose at the reservoir outlet In PADDOCK LC models extract the antifreeze drain plug Remove the cooling hoses where they connect to the antifreeze reservoir Remove the 2 fixing screws which secure the engine to the frame Remove the 1 shock absorber screw Separate the engine from the frame STRIPPING THE ENGINE Remove the exhaust pipe Remove the filter box together with the inlet pipe and the rear mudguard Withdraw the rear wheel nut and remove the rear wheel Withdraw the centre stand spring the pin the central shaft and the stand On PADDOCK LC models remove all hose clips radiator hoses and the radiator Remove the fan 2 screws Remove the sleeve cover On PADDOCK LC models first withdraw the anti freeze outlet connector on the cylinder head 2 screws and gasket Remove the carburettor together with the r
17. Level Gauge 18 Fuse 4A 2G Water Temperature Gouge 19 Battery 12 4A 3 ignition Switch 20 Flywheel Magneto 12 70W Mobil phone connector 21 Electronic Converter 4 Front Right Turn Signal Light 12 IOW 22 Spark Plug Anti Radio Interferences 9 Front Lefft Turn Signal Light IZV IOW 23 Spark Plug 6 Rear Right Turn Signal Light I2V IOW 24 Regulator AC DC Turn Signal Systen 7 Rear Left Turn Signal Light I2V IOW 25 Stand switch 8 Tail Brake Light I2V 21W 5W 26 Temperature thermoresistance 9 Headlight Engine Stop Switch 27 Carburator Heater KIT OPTIONAL 10 Dimmer Turn Signal Z Horn Switch Orange Orange Orange Arancio Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blau Blue Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Rosa Pink Rosa Rosa Violett Violet Violet Violeta ECHEMA ELECTRIQUE PREDATOR 02 Headlight 12 35 55 W ll Broke Light Switch 2 Dashboard 12 Horn 12V DC Oil Indicator Light I2V 2W 13 Fuel Sensor 2B Fuel Indicator Light l2V 2W 14 Oil Sensor 2C Turn Signal Indicator Light I2V 2W 15 Starter Relay 2D High Beam Indicator Light 12V I 2W 16
18. SYSTEM PLUS 30 and screw on the filler cap ELECTRICAL SYSTEM GENERAL CHARACTERISTICS Component Battery Type Electrolyte specific gravity Standard values 12V 4 Ah 1 28 a 20 C System Type Charging voltage Coil resistance Lighting system Type Regulation voltage Coil resistance Ignition system Type Magneto Resistance of stator between Black Red cables and earth High Tension coil Secondary winding resistance Suppressor cap resistance Switches and sensors Brake switches Fuel sensor Oil sensor alternator and regulator 13 5 0 5 V a 4 000 r p m and lights on 1 1 0 2 Q a 20 C Alternator and regulator 13 5 0 5 V a 4 000 r p m and lights on 0 9 0 2 a 20 C Electronic 238 30 a 20 C 5 1KQ 10 x 1 The stop light comes on after 12 mm travel of the brake levers Full co Reserve 33 Q Full Reserve 0 Q BATTERY Warnings Never reverse the polarity of the battery This could cause damage to certain electronic compo nents The battery produces explosive gases Do not make sparks or flames near the battery and parti cularly when the battery is charging The electrolyte in the battery contains sulphuric acid If this acid comes into contact with the skin it causes burns Wash the affected area with plentiful water and consult a doctor n order to avoid mechanical failures do not dis connect the battery terminals o
19. Starter Motor 2E Dashboard Light 12V 1 2W 17 Fuse 4A 2F Fuel Level Gauge 18 Battery 12 4A 19 Flywheel Magneto 12 70W 3 Ignition Switch 20 Electronic Converter A T 21 Spark Plug Anti Racio Irterferences 4 Front Right Turn Signal Light 12V IOW 22 Spark Plug 5 Front Leff Turn Signal Light 12V IOW 23 Regulator AC DC Turn Signal Systen 6 Rear Right Turn Signol Light 2V IOW 24 Carburator Heater KIT OPTIONAL 7 Rear Left Turn Signal Light i2V IOW 8 Tail Brake Light 2 21W SW 9 Headlight Engine Stop Switch 10 Dimmer Turn Signal Horn Switch Orange Orange Orange Arancio Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blau Blue Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Rosa Pink Rosa Rosa Violett Violet Violet Violeta ECHEMA ELECTRIQUE ATLANTIS 16 08 SWITCH LOCK OFF ER ON L HH e p e
20. and remove the 4 mudguard screws Loosen the wheel shaft nut remove the washer Loosen the 2 front brake caliper screws Loosen the locking screw remove the wheel shaft the wheel spacer and leave the speedome ter cable hanging free Remove the forks STRIPPING THE LEFT RIGHT FORK LEG 79 mm Suspension stroke 80 mm Diameter of fork bars 32 mm Oil capacity in each bar 100 C C Type of Agip FORK SAE 7 5 W REAR SUSPENSION GP 1 GP SERIES Hydraulic shock absorber Length of shock absorber 297 mm Shock absorber stroke 64 mm Length of spring 235 mm Spring compression at 36 127 kg m Spring compression at 64 mm 254 kg m Place the complete engine on the special stand take extreme care when working with petrol Caution when installing the battery connect the positive cable first and then the negative cable Caution The use of protective glasses is recommended when using percussion tools Tool 19 1 25095 MAGNETO Y LUBRICATE APPLY THE PRODUCT A CAUTION HANDLE WITH CARE 4 GREASE CLEAN WITH CARE 8 ALWAYS REPLACE NN 7 IL HL 81 mm Starter motor The securing nuts are the one indicated in the drawing and the one diametrically opposite Flying cover Remove the fo
21. and tighten to a torque of 100 105 Nw x m Fit the filter box using 2 screws 6 x 35 and tigh ten to a torque of 9 10 Nw x m Tighten up the drainage tank securing screw Fit the inlet tube with the spring to the carburet tor Fit the rear mudguard using 2 screws 5 1 x 18 Fit the exhaust pipe and silencer using a new exhaust pipe gasket with 2 screws 6 x 20 fit the silencer bracket using 2 screws 10 x 65 to a torque of 40 45 Nw x m and the screw securing it to the rear mudguard 5 x 15 Checking the filter box Itis important to maintain and clean the filter pro perly to ensure the proper operation of the vehi cle It is also very important that none of the hoses from the filter box to the carburettor or to the drai nage box is disconnected anbd that no holes are made in the filter box since this would alter the carburation and thus adversely affect the life and duration of the engine mm 34 FITTING THE ENGINE IN THE FRAME Fit the engine in the frame Insert the two screws securing the engine to the frame 10 X 45 and tighten to a torque of 35 40 Nw x m Insert the lower shock absorber screw 10 x 35 and tighten to a torque of 35 40 Nw x m Fit the cooling hoses at the radiator water reser voir LC models Fit the fuel tubes to the fuel cock outlet and fit them to the carburettor Fit the oil hose to the carburettor and secure with a p
22. beween terminals 1 Yellow Green cable and Blue Black cable Values of the resistance Position A 00 A Position B Fuel tank reserve sensor Remove the plastic caps from the tanks and 1 remove the sensor from the tank Disconnect the sensor terminals and check conti nuity between terminals 1 Yellow Green cable B and White Blue cable Values of the resistance 8 e 43 mm SCHEMATIC AND CARBURETTOR HEATING CONTROL PIC CONTROL THERMOSTAT PTC CARBURETTOR HEATING YELLOW ALTERNATING CURRENT SUPPLY FROM REGULATOR Checking the thermostat Check that power reaches the thermostat by con necting a lamp between the Yellow Green and Yellow cables In order to check the output of the black cables it is necessary to lower the temperature of the ther mostat to 5 C and then check the output betwe en the black cableS with a 12V lamp Checking the thermoresistance of the carburet tor Check the resistance of the PTC at a temperature of between 15 and 20 C Values of the resistance 80 3 ECHEMA ELECTRIQUE PADDOCK LC e aS 2 58 5 at W Bi A d 1 r CH e Y Gi Y GR ai HH EEES m HT H M nE CC E i 23 8 lA ot 3 a M LI ca N R CCD t08 8 ADE LO GA
23. crankshaft should be centred to the follo wing tolerances Minimum 0 30 Maximum 0 84 Fit the new crankshaft seal in the left hand crank case half with guide bush 0 0F 053 0 084 1 and special tool 0 0F 054 0 045 1 WATER PUMP Stripping Unscrew the water pump the water pump has a left handed screw Withdraw the two rubber O rings Using special tool 0 0H 056 0 025 1 and a rubber mallet strike the pump drive shaft in order to extract it complete with its two bearings Extract the pump drive body seal Withdraw the 10 mm shim washer Using special tool 0 0F 054 0 045 1 place the bearing on top and using special tool 0 0H 056 0 025 1 strike the shaft with a rubber mallet to extract Withdraw the bearing the 10 mm shim washer and the shaft and finally withdraw the circlip from the shaft Assembly Fit the circlip to the pump drive shaft Using special tool 0 0F 054 0 045 1 place the first bearing on the tool then the washer the second bearing the washer and then assemble the shaft using a rubber mallet Fit the pump drive body on the special tool 0 0F 054 0 045 1 Next apply heat to the pump drive body and fit the pump drive shaft with the bearings With the aid of special tool 0 0H 056 0 025 1 insert the shaft in the pump drive body Next fit the seal using special tool 0 0H 056 0 025 1 The spring of this seal faces outwards Fit the fan Fit
24. is by trapezoidal belt the maxi mum width of which under working conditions must equal 16 mm in the HUNTER PADDOCK PADDOCK LC engines and 15 mm in the VAMOS MONOBLCC engines The belt must be replaced every 6 000 kms Fit the variable speed unit with 6 rollers the sli ding weight plate with the guides and then fit the hub boss bushing placing the variable speed unit onto the left hand side of the crankshaft Fit the 20 x 16 x 1 mm friction washer Next fit the drive pulley the drive washer the starter boss the washer and the nut Use special tool 0 0G 056 0 037 1 to tighten down the variable speed unit nut blocking the connecting rod tighten to a torque of 35 40 Nw x m using Loctite thread seal mm 22 CLUTCH ASSEMBLY Stripping In order to disassemble the clutch assembly the special locking tool 0 00 052 5 324 0 should be used and the clutch nut is released using a 36 mm socket spanner Disassembly of the clutch shoe plate The clutch shoe plate does not usually require to be disassembled since the wear on the shoes in minimal But if it should prove necessary to disas semble the clutch shoe plate the position of the shoes as they are originally placed should be marked because they are balanced the three locking clips should also be placed from the insi de towards the outside so that the clutch conti nues to operate normally Check the three springs The service limit
25. n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blue Blau Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Pink Rosa Rosa Rosa Violett Violet Violet Violeta WORKSHOP MANUAL GP 1 GP SERIES ATLANTIS 50 C C ENGINE PIAGGIO SPECIAL TOOLS E 5 6 Tu LI 7 8 9 10 Description Reference 155 Bearing 004499Y 2 A A PORT PR 020151Y 3 Needle bearing DUTCH ooo tano ss adie 020080Y 4 Magneto extractor eret th tet et ete he reb used 020162Y S deat g m uta diu dk 020150Y 6 Crankcase 020163Y 7 Semi pulley assembly 020164Y 8 Water pump impeller retaining Tool 020167Y 9 Starter crown wheel retaining Tool 020165Y 10 Crankcase half water seal assembly 020168Y mm 4 SPECIAL TOOLS ao 19 Description Reference 11 Spring clip assembly tool beer Dco eoi d
26. pulley Fit the assembly while taking care not to damage the transmission belt It is essential to open out the rear pulley in order to fit the belt It is vitally important when tighte ning the front pulley assembly to ensure that the belt is free to move inside it otherwise the semi pulley may not be tightened correctly Mixer Starter cable Belt Fixed semi pulley Handle with care so as to avoid twisting the belt Fan Fan securing disc Washer Nut Apply recommended thread sealer Caution use only nuts supplied as original spare parts N H When assembling use new nuts in order to ensure correct engagement Torque setting 40 44 m Special tool 19 1 20165 Loctite 242 E Reduction gear cover Before carrying out this operation drain the oil from the reduction gear by means of the drain plug Follower pulley shaft oil seal Strip the oil seal Reduction gear cover bearings After removing the Seeger ring withdraw the bearing When stripping the wheel shaft bearing use the special tool Special tool 12 1 21467 13 17 for wheel shaft Reduction gear housing bearing Heat the cover using the heat gun on its stand and fit the bearing let the cover cool down and then fit the oil seal and the needle bearing using the appropriate punch Fit the follower pulley shaft bearing Seeger ring ensuring that it is posi tioned correctly The concave side of the Se
27. the closure cover and fit the grommet Fit the cover using 3 screws 6 x 16 and tighten to a torque of 9 10 Nw x m When locating the closure cover it should be positioned with the exit slot for the cables from the base plate at the top Fit the stator with 2 screws 6 x 25 and tighten to a torque of 8 10 Nw x m Fit the magneto key the magneto the washer and the nut Using special tool 0 0G 056 0 037 1 to block the connecting rod tighten the nut to a torque of 35 40 Nw x m sealing the thread with Loctite CYLINDER HEAD CYLINDER AND PISTON Fit a new oylinder gasket Fit the cage bearing to the connecting rod little end PISTON RINGS Fit the piston rings into the cylinder and use the piston to push them a little way in until they are perpendicular to the longitudinal axis of the cylin der Measure the gap between the ends of the piston rings using feeler gauges The maximum permissible value is 0 5 mm PISTON Measure the exterior diameter of the piston at a point situated 15 mm from the base of the piston Calculate the play between the cylinder and the piston The service limit is 0 06 mm Fit the piston rings onto the piston First fit the expansion ring and then the lower ring It is rectangular in section and finally fit the upper piston ring which has a trapezoidal section Fit the piston and keep the arrow on the upper surface of the pist
28. the locking ring Withdraw the right hand fork leg the lower spring washer the rubber stop and the spring This fork leg is filled only with AGIP GR MU 3 type grease Re assembly of the fork legs is carried out in the reverse order to disassembly KAYABA FRONT FORKS For all ATLANTIS models hydraulic Kayaba is incorporated Disassemble fork legs Withdraw 4 mudguard screws and remove the mudguard Slacken off the wheel shaft withdraw the washer loosen the 2 front brake caliper screws loosen the locking nut withdraw the wheel shaft the wheel spacer piece and leave the transfer box hanging loose Slacken off the plate lock screw and withdraw the hand fork leg assembly Do the same with the other hand fork leg Now we can substitute any front fork element or we simply can change the hydraulic oil of it Front fork route 65 mm Hand fork leg diameter 26 mm Oil capacity for each hand fork leg 47 OI typ sirep ern edi Agip FORK SAE 7 5 W Re assembly of the fork legs is carried out in the reverse order to disassembly REAR SUSPENSION PREDATOR LC Progressive hydraulic shock absorber with linkage Length of shock absorber 300 mm Shock absorber travel 80 mm Length of spring 228 mm Spring compression
29. the two O rings Fit the water pump drive unit with great care into the left hand crankcase Fit the water pump unit locking piece with 2 Screws 5 x 12 Fit the bendix pinion Fit the starter motor support bracket 2 screws 6 x 30 tightened to a torque of 9 10 Nw x m using Loctite type 240 Fit the pump pinion assembly with the toothed belt and the pump drive pinion and tighten down the nut for this assembly To fit the pump pinion use should be made of the special tool 0 0G 053 0 098 1 and tightened to a torque of 10 Nw x m Fit the starter motor gear wheel with the concave side facing outwards 21 mm ASSEMBLY OF SLIDING WEIGHT HUB The working surfaces of the pulleys should be carefully inspected where the drive belt runs if these faces are deformed or show signs of wear the useful life of the drive belt is extremely seriously affected Disassemble the variable speed unit withdrawing the sliding weight plate Confirm that the 6 rollers maintain their original profile and show no signs of wear of abrasion which might affect the correct operation of the variable speed unit Check that the guides mounted on the sliding weight plate show no signs of wear which would cause excessive noise and problems in the correct operation of the unit Check the bronze bush in the sliding weight hub and that the bush is tightened to the correct tor que The transmission
30. tool 0 0H 054 0 045 1 and heating the part to a temperature of 80 C by means of a hot air paint stripper extract the rear wheel axle bearing mm 14 Remove the crankshaft seal in the left hand side crankcase using special tool 0 0H 054 0 058 1 Extract the rear brake lever and the brake opera ting arm Extract the crankshaft from the crankcase half or right hand crankcase half using special tool 0 0G 053 0 015 1 Extract the crankshaft seal in the right hand side crankcase Extract the crankshaft bearing from the crankca se half using special tool 0 0H 054 0 058 1 after heating the part to a temperature of 80 C with a hot air gun If the bearings remain on the crankshaft they should be removed using a tool similar to the Kawasaki tool reference number 57001 158 thus withdrawing the bearings from the crankshaft Withdraw the pulley shaft from the reduction gear cover and extract the 2 bearings from the reduc tion gear cover by applying heat ASSEMBLY OF THE ENGINE Assembly of the wheel shaft bearing heat up the housing by means of a hot air gun to approximately 80 C and use special tool number 0 0F 054 0 045 1 to insert the bearing number 6204 2RS1 Fit the wheel shaft bearing locking piece with the 2 screws using a thread sealer such as Loctite 243 and tighten to a torque of 9 10 Nw x m Assembly of the pulley shaft bearing Heat up the left hand side crankcase half
31. 1 14499 7 Special tool 19 1 21467 6 7 Main bushings on the crankshaft Heat up the bushings to approximately 100 C in an oil bath and fit them onto the crankshaft if necessary use a piece of tube to exert pressure on the internal track of the bushing In the event that it is necessary to replace the connecting rod when assembling it must be fit ted with the lubrication hole situated on the head of the connecting rod towards the transmission side Base 19 1 20265 Joining the crankcase halves Heat up the transmission side crankcase half around the area where the main bushing is to be fitted Fit the crankshaft Allow the crankcase half to cool Fit the special tool to the transmission side crank case half and push the crankshaft gently to reco ver axial play Apply joint sealer Loctite 510 to the mating surfa ces As before heat up the magneto side crankcase half Join the crankcase halves Support 19 1 20150 Heat gun 19 1 20151 Special tool 19 1 20163 Closing the crankcase half Magneto side oil seal 8 off securing nuts Remove special tool 19 1 20163 Allow the crankcase to cool and check that the axial play of the crankshaft is 0 03 0 09 mm Use tool 19 1 20340 when fitting the magneto side seal and tool 19 1 20340 part 2 for the transmission side seal Torque setting 12 13 N x m Comparator and comparator holder base 19 1 20335 SECONDARY AIR SYSTEM
32. 1 20170 Drain hole Transmission side crankcase half In the event of loss of fluid through the drain hole carry out a revision of the pump as shown below Replacing the water pump seal in the clutch side crankcase half Strip the pick up and remove the water feed hose to the pump Fit the special tool in the pick up securing holes Caution when re assembling the pump feed water hose use a new seal Special tool 19 1 20167 Unscrew the pump drive shaft and withdraw the unit Caution The water pump drive shaft has a left hand thread Special tool 19 1 20169 Water pump drive shaft Note on spare parts The shaft is supplied com plete as shown in the figure 99 mm Disassembling the seal Common tools Frame type ABC 3065 8 Extractor type USAG A 17 10 When assembling clean the surface scrupu lously Lubricate the surface and the seal and check that the seal is correctly inserted and that the drain hole is not blocked Special tool 19 1 20168 Remove the joint screws Remove the eight crankcase half joint securing Screws Separating the crankcase halves Special tool 19 1 20163 Extracting the Crankshaft Special tool 19 1 20163 mm 100 Crankcase bushings The same procedure is used to remove the magneto side main bushing Caution n the event that the main bushings were to remain fitted to the crankshaft use special tool 19
33. 10 Nw x m and the 2 distan ce pieces of 35 5 mm Fit the gasket and the cylinder head water outlet connector using 2 screws 6 x 20 and tighten up to a torque of 9 10 Nw x m applying Loctite thread seal Next fit the water hose from the connector to the radiator using 2 hose clips Fit the starter motor with the supporting plate gasket the 24 mm exterior diameter and 2 2 mm thick O ring using 2 screws 6 x 25 and tighten to a torque of 9 10 Nw x m applying Loctite Fit the cooling hose from the water pump to the radiator with an O ring using 1 screw 6 x 16 and tighten to a torque of 9 10 Nw x m applying Loctite Then also fit 1 screw 6 x 10 to a torque of 9 10 Nw x m which is secured to the crankcase applying Loctite At the lowest part of the cooling hose the cooling liquid drain screw and washer are to be found The washer must be replaced every time the screw is touched Fit the oil drain plug 8 x 16 screw with a new washer and tighten to a torque of 17 19 Nw x m Fill the reduction gearbox with 110 cc of AGIP GEAR SYNTH SAE 75w 90 oil Next fit the filler cap and tighten to hand tight only Fit the rear brake shoes where the assembled position of the shoes must be with the bevelled edges facing outwards Fit the centre stand inserting the shaft from left to right complete with washer pin and stand spring Fit the rear wheel on its shaft with washer and nut
34. 24 SPARK PLUG Orange Orange Orange Arancio Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blau Blue Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Rosa Pink Rosa Rosa Violett Violet Violet Violeta ECHEMA ELECTRIQUE ATLANTIS LC le BL B Ya WAL MG HE W BL YAR YB va E BL a 1 1 va gs HEADLIGHT ASSEMBLY BULB 12V 25 25W 1B INDICATOR BULB 12V DASHBOARD 2A WATER TEMPERATURE CONTROL PILOT LIGHT 12 2W 28 OIL RESERVE CONTROL PILOT LIGHT 12V 2W 2C TURN INDICATOR CONTROL PILOT LIGHT 12Y 2W 2D HIGH BEAM CONTROL PILOT LIGHT 12V 2W 2E DASHBOARD LIGHT 12V 1 2M i 2F FUEL LEVEL GAUGE IGNITION SWITCH MOVIL PHONE CONNECTOR TURN INDICATOR CENTRAL CONTROL 12V 10 10N REGULATOR 12Y BOW TAIL LIGHT ASSEMBLY SA BRAKE BULB 12V 10W 58 TAIL BULB 2V DN SC INDICATOR BULB 12Y 10N ENGINE SWITCH BRAKE LIGH
35. 75 0 0025 40 955 000 40 980 20 009 49 971 0 0025 50 0125 0 0025 40 960 0004 40 985 0005 49 976 0 0025 50 0175 0 0025 40 965 0004 40 990 0005 49 981 0 0025 50 0225 0 0025 CYLINDER HEAD Compression Ratio 11 5 1 Compression Ratio ATLANTIS 100 9 5 1 PREDATOR LC O2 The gaskets should be replaced every time the cylinder head is removed Check that the cylin der head is gas tight There should be no more than 0 05 mm gap Cylinder head torque settings 10 12 Nw x m Cylinder head torque settings ATLANTIS 100 18 20 Nw x m PREDATOR LC Thermostat Starts to open at 55 22 Length of travel 3 5 mm 60 2 Thermoresistance For temperature gauges with needle Temperature C Resistance 10 Q Thermocontact For models with electrical fan Make contact at 97 3 G Break contact at 85 3 Cooling system Coolant antifreeze AGIP CLOSED SYSTEM PLUS 30 Cooling system capacity Predator LC 825 c c Cooling system capacity Atlantis LC 400 c c Pressure in cooling system 1 2 t1 Spark plugs PREDATOR O2 NGK B 8 HS CHAMPION L 78 C ATLANTIS NGK B 8 HS CHAMPION L 78 C PREDATOR L C NGK B 9 ES CHAMPIONN 2 C ATLANTIS L C NGK B 9 ES CHAMPIONN 2 C ATLANTIS 100 NGK B 9 ES CHAMPIONN 2 C PREDATOR L C CAT NGK B 8 ES CHAMPIONN 3C CRANKSHAFT PREDATOR ATLANTIS AT
36. Adjust Clean Adjust Clean Adjust Clean Oil pump Fuel valve Adjust Adjust Adjust Adjust Adjust Adjust Adjust Variable speed rollers Transmission belt Check Replace Oil Filter Replace Check Replace Air Filter Clean Clean Clean Secondary Air Filter Clean Clean Clean Brakes Pads Check Check Check Brake equipment Check Check Brake fluid EVERY 2 YEARS EVERY 2 YEARS Tyres Check Check Check Check Tyre pressures Check Check Check Check Fuel or oil hoses Replace Check Replace Check Transmission Lubricate Lubricate Lubricate Lubricate Lubricate Starter gears to pedal Clean Clean Clean Clean Clean grease and grease and grease and grease and grease TORQUE SETTINGS DESCRIPTION CALIPER ROTATION SHAFT TORQUE SETTING 17 19 Nwxm LOCTITE CYLINDER STUD STUD 10 12 CRANKCASE HALVES JOINT SCREW 12 13 CYLINDER HEAD INLET MANIFOLD VALVE SUPPORT NUT 10 11 1 2 LOCTITE CRANKCASE INLET MANIFOLD OIL PUMP SCREW SCREW 9 10 3 4 LOCTITE COIL TO BASE PLATE 8 10 BASE PLATE TO CRANKCASE MAGNETO PICK UP SCREW STARTER MOTOR 8 10 40 44 4 5 12 13 LOCTITE FAN TO MAGNETO 3 4 LEFT HAND CRANKCASE HALF REDUCTION GEAR COVER PULLEY SHAFT CLUTCH 40 44 12 13 40 44 50 60 LOCTITE PLASTIC OIL FILLER CAP 3 5 LEFT HAND
37. CRANKCASE 6M100 8 10 LOCTITE MAGNETO 10M100 35 40 LOCTITE STARTER MOTOR 6M100 9 10 LOCTITE FAN TO MAGNETO 6M100 8 10 LOCTITE ENGINE BRACKET PLATE A E 6M100 9 10 LOCTITE LEFT HAND SIDE CRANKSHAFT 10M100 35 40 LOCTITE REDUCTION GEAR COVER 6M100 9 10 LOCTITE PULLEY SHAFT 10M100 35 40 LOCTITE PLASTIC OIL FILLER CAP 14M150 HAND TIGHT LEFT HAND CRANKCASE COVER 6M100 9 10 LOCTITE OIL DRAIN PLUG 8M125 17 19 CYLINDER SLEEVE 6M100 9 10 FRONT WHEEL 12M150 50 60 REAR WHEEL 16M150 100 105 SWINGING ARM 10M150 40 45 SHOCK ABSORBER UPPER LOWER 10 150 40 45 HANDLEBAR 8M125 20 25 EXHAUST PIPE TO CYLINDER 6M100 8 12 EXHAUST PIPE INTERMEDIATE 6M100 8 12 EXHAUST PIPE TO CRANKCASE 10M150 40 45 FORK LEG CLOSURE 6M100 8 12 STEERING 25M100 70 90 FRONT BRAKE 8M125 SCREW 20 25 KICK START PEDAL 6M100 SCREW 08 12 LOCTITE SILENCER PROTECTOR 4M70 SCREW 1 2 LOCTITE 7 FRONT FORKS HUNTER MODELS Stripping the fork legs Withdraw the two screws from the brake caliper Withdraw the front wheel axle nut and slacken the lock screw Withdraw the front wheel axle the wheel DIS TANCE PIECE and leave the transfer box and the separator hanging free Withdraw the fork protection plate screw so as to be able to extract the external fork leg cap Loosen the 10 x 25 screw from the fork plate and while pushing upwards on the fork leg release the fork bar securing clip Withdraw the fork leg from
38. Cylinder Head Remove the 4 nuts indicated in the figure Cylinder Exercise great care when withdrawing the cylin der O Piston Remove the spring clips and withdraw the gudge a EJ on pin Caution Replace the spring clips securing the A E udgeon pin every time the assembly is stripped y p M eg 5 log x Reed Valve Caution Check that the reed assembly closes correctly no light should be seen between the reeds and the valve body 105 Piston Caution Position the arrow stamped on the crown of the piston so that it faces towards the exhaust port Caution The gudgeon pin spring clips should be fitted into the piston using the special tool Gudgeon Pin spring clips in the piston Place the spring clip in part 1 fitting it over the arrow stamped on the tool Push part 2 into part 1 fully and withdraw part 2 Fit part 3 into part 1 place the assembly over the spring clip seating area in the piston and push part 3 fully home Special tool 19 1 20166 N H Re assemble all remaining parts following the stripping procedures in reverse order Use new gudgeon pin spring clips Use a new cylinder base gasket Before re assembly clean all surfaces scrupu lously Use mixing oil Agip City 2T when re assembling the cylinder and the piston Cylinder head nuts 10 11 N x m UC do e VEHICLE SERVICE DA
39. Headlight 2 15 15 w H Brake Light Switch 2 Dashboard 12 Horn I2V DC 2D High Beam indicator light 12V 1 2w 13 Fuel Sensor 2A Water temperature indicator light 12V 1 2w 14 Oil Sensor 2E Turn Signal indicator Light 12 2W 15 Electric Choke 2B Fuel Indicator Light I2V 2W 16 Starter Relay Oil Indicator Light lev 2W Starter Motor 2F Display 18 Fuse 4A 2G Speedometer sensor 19 Battery lev 4A 2H Temperature sensor 20 Flywheel Magneto 12 7OW 3 Ignition Switch 2 Electronic Converter 4 Front Right Turn Signal Light IOW 22 Spark Plug Cap Anti Rodio Interferences 5 Front Lefft Turn Signal Light 12 IOW 23 Spark Plug 6 Rear Right Turn Signal Light I2V IOW 24 Turn signal box I2V 10 10W 7 Rear Left Turn Signal Light I2V IOW 25 Regulator AC DC 8 Tail Brake Light I2V SW i2V IOW 26 Water temperature Thermostat 9 Headlight Engine Stop Switch 27 Carburetor Heater KIT IO Dimmer Turn Signal Horn Switch 28 Check control Orange Orange Orange Arancio Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blau Blue Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Rosa Pink Rosa Rosa Violett Violet Violet Viol
40. LANTIS 100 Lateral play at conncting rod big end Maximum axial play 0 700 mm Minimum axial play 0 330 mm Maximum axial play 0 630 mm Minimum axial play 0 250 mm Crankshaft counterweight inspection and verification 39 0 3 mm 0 4 mm 43 0 2 mm 0 3 mm Inspection of radial play at bearing surfaces 0 04 mm both sides 0 04 mm both sides Lateral play in crankshaft 0 84 mm max Axial Maximum axial play 0 74 mm Minimum axial play 0 20 mm Crankshaft bearings Koyo 83299 9RTCS31 NTN 6204 px2v4 Nachi 20BC05S16 Koyo 83299 9RTCS31 NTN 6204 px2v4 Nachi 20BC05S16 VARIADOR REDUCTOR MODEL ROLLERS ROLLERS CAT WVTA SPRING REDUCTION PREDATOR 6 15x6 37 0 8 33x6 50 gr 295 Kga41 mm 12 43X14 48 ATLANTIS 5 90X6 35 5 0 7 66X6 46 gr 30 6 Kg a 45 5 mm 12 43X14 48 ATLANTIS 100 10 66X6 64 gr DRIVE Trapezoidal belt 10 66X6 64 gr The width of the belt in optimum condition should be 16 5 mm The limit for wear in the trapezoidal belt is either 0 5 mm or 10 000 km Clutch shoes The service limit of the shoes is 2 mm Clutch hub The service limit on the clutch hub is 112 5 mm The service limit on the clutch hub is 110 5 mm ATLANTIS O2 LC Inspection of the clutch pulley 29 5 Kg a 43 5 mm 12 43X15 40 In the event that the fixed pulley of the clutch is disassembled
41. OARD 3 LIGHTS SWITCH 2A FUEL RESERVE CONTROL PILOT LIGHT 12V 2M 10 TURN INDICATORS SWITCH 28 OIL RESERVE CONTROL PILOT LIGHT 12V 2W II HORN SWITCH 2C TURN INDICATOR CONTROL PILOT LIGHT 12 2W 12 HORN 20 HIGH BEAM CONTROL PILOT LIGHT 12 1 24 13 ENGINE STOP RELAY 2E DASHBOARD LIGHT 12V 2W 14 FUEL LEVEL SENSOR 3 IGNITION SWITCH 15 OIL LEVEL SENSOR 4 TURN INDICATOR CENTRAL CONTROL 12Y 10 10W REGULATOR I2V 809 t6 STARTER RELAY FRONT RIGHT TURN SIGNAL LIGHT 12Y 10W 17 STARTER MOTOR 48 FRONT LEFT TURN SIGNAL LIGHT 12V 10W 18 FUSE S TAIL LIGHT ASSEMBLY 19 BATTERY 12 SA TAIL BULB 12 SW 20 FLYWHEEL MAGNETO 12V 80W 58 BRAKE BULB 12V 10W 2 ELECTRONIC CONVERTER 5C INDICATOR BULB 12 104 22 SPARK PLUG CAP ANTI RADIO INTERFERENCES 6 ENGINE SWITCH 23 SPARK PLUG Orange Orange Orange Arancio Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blau Blue Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Rosa Pink Rosa Rosa Violett Violet Violet i Violeta ECHEMA ELECTRIQUE PREDATOR USA
42. ORT 6 100 8 12 EXHAUST PIPE TO CRANKCASE 10M150 30 35 FORK LEG SECURING 6M100 8 12 STEERING 25M100 70 90 FRONT REAR BRAKES 8M125 20 25 STARTER PEDAL 6M100 8 12 LOCTITE SILENCER PROTECTOR 4M70 1 2 LOCTITE HANDLEBAR COUNTERWEIGHT 4 5 LOCTITE ENGINE 10M150 35 40 FRONT REAR DISC BRAKES 8M125 17 19 LOCTITE SUSPENSION LINK SWINGING ARM LINKAGE 38 40 ENGINE BANANA ARM 10M150 20 25 LOCTITE 51 mm FRONT FORKS Disassemble fork legs Withdraw 4 mudguard screws and remove the mudguard Slacken off the wheel shaft withdraw the washer loosen the 2 front brake caliper screws loosen the locking nut withdraw the wheel shaft the wheel spacer piece and leave the transfer box hanging loose Left hand fork leg n order to be able to disassemble the left hand fork leg without removing the forks the following steps should be followed Remove the mudguard and withdraw the locking ring Withdraw the 2 bag carrier screws Withdraw the 7 inner front shield screws and remove the inner front shield Slacken off the 6 x 100 nut and washer and then we can withdraw the left hand fork leg which is a hydraulic cartridge complete with the bushing and silentbloc the boss rubber stop spring and guide washer If the cartridge is losing oil it must be replaced because it cannot be repaired Right hand fork leg Extract the dustguard and
43. T SWITCH Orange Orange Orange Arancio g Y cn 7 8 BRAKE LIGHT SWITCH 9 LIGHTS SWITCH 10 TURN INDICATORS SWITCH II HORN SWITCH 12 HORN 13 CHECH CONTROL 14 FUEL LEVEL SENSOR 15 OIL LEVEL SENSOR ISA WATER TEMPERATURE THERMOSTAT 16 CARBURATOR HEATER KIT OPTIONAL 17 STARTER RELAY 18 STARTER MOTOR 19 FUSE 20 BATTERY 12V 2 FLYWHEEL MAGNETO 12V 80W 22 ELECTRONIC CONVERTER A T 23 SPARK PLUG CAP ANTI RADIO INTERFERENCES 2 SPARK PLUG Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blau Blue Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Rosa Pink Rosa Rosa Violett Violet Violet Violeta ECHEMA ELECTRIQUE ATLANTIS USA e LH gs L P 5 d RA giu ots ey Y of ud Yw WR N y Yo HEADLIGHT ASSEMBLY 6A ENGINE STOP BULB 12V 35 35W BRAKE LIGHT SWITCH BRAKE LIGHT SWITCH 2 DASHB
44. TA Assembly tolerances The cylinder diameter should be checked at a level 15mm below the cylinder head mating surface Table of cylinder and piston tolerances DESCRIPTION Cylinder Piston Cylinder 1st Oversize Pist n 1st Oversize Cylinder 2nd Oversize Pist n 2nd Oversize Dimension 0 01 040 0 018 0 029 040 0 057 0 01 0402 0 018 0 029 0402 0 057 0 01 040 4 0 018 0 029 0404 oos Letter Fitting tolerances Cylinder E 39 990 39 997 39 997 40 004 40 004 40 011 40 011 40 018 40 19 40 197 40 197 40 204 40 204 40 211 40 211 40 218 40 39 40 397 40 397 40 404 40 404 40 411 40 411 40 418 Piston C 39 943 39 950 39 950 39 957 39 957 39 964 39 964 39 971 40 143 40 15 40 15 40 157 40 157 40 164 40 164 40 171 40 343 40 35 40 35 40 357 40 357 40 364 40 364 40 371 Assembly tolerance Piston Rings The verification of assembly tolerance should be carried out by inserting the piston ring into the cylinder at 15 20 mm from the cylinder head mating surface and measuring the gap between the opposite ends of the ring using a set of feeler gauges DESCRIPTION DIAMETER PLAY ASSEMBLY TOLERANCE Piston Ring Std Piston Ring 1st Oversize 0 10 0 25 Piston Ring 2nd Oversize Checking the Gudgeon Pin DESCRIPTION DIAMETER ASSEMBLY TOLERANCE
45. This manual has been prepared by DERBI Nacional Motor S A Sociedad Unipersonal for use by concessionaires and DERBI sub agency workshops lt is assumed that persons using this work for the maintenance and repair of DERBI vehicles will have a basic grounding in the principles of mechanics and the necessary technical methods used in the repair of such vehicles Major variations in the technical specifications of the vehicles or in specific repair operations will be communicated by means of updates to this manual Nevertheless completely satisfactory work cannot be performed without the necessary installations and tools for this reason we strongly recommend that you consult the pages in this manual which refer to specific tools and equip ment Information in this manual which is of particular importance is indicated by the following notes N B This indicates a note which gives key information for performing the procedure more easily and clearly Caution This indicates specific procedures which should be followed to avoid causing damage to the vehicle This indicates procedures which should be followed to avoid possible injury to the person carrying out the repairs to the vehicle All data may be changed without prior notice Derbi declines all responsibility for the use of non original parts and accessories which have not been tested and approved DERBI NACIONAL MOTOR Sociedad Unipersonal 2002 Dep Leg Gl 1302 2000 gt N
46. battery state recharge battery Voltage at 11 9 or less Unserviceable replace battery g STARTER RELAY Check the resistance between each of the termi nals 50 75 100 Resistance between 85 and 86 55 15 Battery Charge gt n order to measure continuity between the Recharging necessary Battery Charged tacts connect poles 85 and 86 to the battery and pole 30 and 87 to the tester the result of this test should be a reading of 0 ohms closed circuit 30 When poles 85 and 86 are disconnected from the battery the tester should read infinity or open cir 85 86 cuit If there is any variation from these readings the 87 relay should be replaced WIRING DIAGRAM AND CONTROL OF THE FAN CIRCUIT THERMOCONTACT FUSE 4 AMP 4AMP IGNITION SWITCH BATTERY R BL RED BLACK FROM IGNITION SWITCH WH WHITE FROM FAN mm 64 ECHEMA ELECTRIQUE PREDATOR 9 2 8 8 ENEE gt R78 GR T WIR s F N R p 8B Ma WAR Headlight 12V 35 35 W Il Brake Light Switch 2 Dashboard 12 Horn 12 2 Oil Indicator Light I2V 2W 13 Fuel Sensor 28 Fuel Indicator Light I2V 2W 14 Sensor 2C Turn Signal Indicator Light I2V 2W 15 Electric Choke 2D High Beam Indicator Light I2V 1 2W 16 Starter Relay ZE Dashboard Light I2V 1 2W 17 Starter Motor 2F Fuel
47. ctor Withdraw the starter protector plate three screws 6x12 By operating the starter pedal it is posssible to extract the starter sliding pinion complete with the spring Withdraw the starter pedal the circlip and the washer so as to be able to extract the starter shaft the stop boss the spring retainer ring and the spring Assembly of the left hand side crankcase cover Insert the spring The spring retainer washer Starter sector stop bush Starter shaft with O ring and corium 55 type grease Washer and circlip Starter pedal Bendix pinion and spring applying grease to the sliding pinion Fit the starter protection plate 3 screws 6 x 12 using Loctite thread seal Fit the left hand crankcase centring pins Fit the left hand crankcase cover gasket Fit the left hand crankcase cover 10 screws 8 of 6 x 25 and 2 of 6 x 30 apply Loctite and tighten to a torque of 9 10 Nw x m Using special tool 0 0F 054 0 045 1 fit the seal 20 x 38 x 7 on the right hand side of the cranks haft Fit the circlip the pump drive guide pin in the seating on the crankshaft fit the pump drive the washer and the circlip Fit the oil pump with 2 screws 5 x 15 and tighten to a torque of 4 5 Nw x m fill this part with AGIP GR MU 3 type grease Replace the 18 9 x 30 x 5 seal in the pump drive closure cover using a new part Pass the stator cable through
48. dgeon pin circlip assembly Tool 0 0G 056 0 041 1 8 Water pump pinion blocking oo 0 0G 053 0 098 1 9 Engine splitting MOO MM CP S 0 0G 053 0 015 1 5 m REGULAR MAINTENANCE TABLE Period the period may be calcu lated by kilometres run or by time in months 24 Reduction gear or crankcase oil Replace Replace Replace Suspensions Tighten all fastenings Electrical connections Spark plug Replace Replace Replace Replace Replace Carburettor Adjust Adjust Adjust Adjust Adjust Clean Clean Clean Clean Clean Water pump drive belt Replace Variable speed drive rollers Check drive belt transmission Replace Oil filter Replace Check Replace Air filter Brakes hose pads Brake equipment Brake fluid VERY 2 YEARS VERY 2 YEAR Tyres Check Check Check Check Check Tyres pressures Check Check Check Check Check Check Check Fuel or oil hoses Check Replace Check Replace Check Transmission Lubricate Lubricate Lubricate Lubricate Lubricate Cylinder head nuts Tighten up Tighten up Inlet valve reeds Check Check mm O OEE TORQUE SETTINGS PART NAME TORQUE SETTING Nw x m BRAKE SHOE ROTATION SHAFT 8M125 17 19 LOCTITE CYLINDER STUD 6M100 10 12 CRANKCASE HALVES 6M100 9 10 LOCTITE CYLINDER HEAD 6M100 10 12 INLET MANIFOLD VALVE BRACKET 4 70 1 2 LOCTITE CRANKCASE INLET MANIFOLD 6M100 9 10 LOCTITE OIL PUMP 5M80 4 5 LOCTITE COIL TO BASE PLATE 6M100 8 10 LOCTITE BASE PLATE TO
49. e Index Position Tolerance on the moving magnet principle 82 120 5 C 0 C 190 80 C 511 Checking the thermistor Temperature 40 C 5 C 0 C Resistance 60 c 600 470 Q 90 c 215 175 9 120 Checking the fuel sensor 93 73 Q FUEL SENSOR Reserve FULL Indicator A V BL AZ 10 EMPTY Analogue level indicator A V BL AZ 33 10 A V BL RO 2 2 7 Q 10 Checking the oil sensor A V BL RO 96 Q x 10 Check Yellow Green Check that the oil sensor pilot light lights up for about 10 seconds and then switches off Sensor After carrying out the check function the light goes out for approximately 1 minute Then it should light up again Once the device is active it should not deac tivate until power is shut off Blue Black mrxsssr sm I aN ssrr am 11 w Checking the voltage regulator Breakdown of the voltage regulator may lead Grey Blue Black depending on the type of breakdown to the follo wing types of failure 1 Burnt out bulbs in the lighting circuit 2 Lighting circuit fails to operate 3 Excessive battery charging 4 Battery fails to charge 5 Direction indicators fail to operate FAILURE 1 Replace the regulator as it is certainly ineffective 25 30 V a 3000 rpm FAILURE 2 a Check for proper distribu
50. eed valve 4 screws Remove the magneto nut using the special tool 0 0G 0 530 001 1 Remove the magneto using the special magneto extractor tool 0 0G 053 0 015 1 Remove the stator 2 screws in order to be able to extract the stator completely the base plate should be withdrawn 3 countersunk Allen head Screws using an impact screwdriver withdraw the grommet and the magneto key Withdraw the spark plug NGK 8 HS or CHAM PION L 78 C On LC models NGK B9 ES or CHAMPION N 2 C Withdraw the cylinder head 4 screws and the cylinder head gaskets Withdraw the cylinder the cylinder gasket the piston and the cylinder studs Remove the oil pump 2 screws Remove the pump drive gear wheel the safety ring the washer the gear wheel the key and the safety circlip replace the gear wheel with a new one Withdraw the cooling hose from the pump to the radiator 2 screws and the O ring Remove the left hand side crankcase cover or clutch cover 10 screws Loosen the variable speed drive nut blocking the connecting rod using special tool 0 0G 056 0 037 1 Extract the nut the washer the starter boss the drive washer the drive pulley the washer the bush the sliding weight hub with the plate and the 6 rollers Extract the washer the starter gear wheel the washer and the bush On L C models only withdraw the starter gear wheel there are no washers or bushes
51. eger ring must face the bearing Special tool 19 1 20151 heat gun Special tool 19 1 20150 holder Special tool 19 1 20080 Assembly of follower pulley shaft Assemble the pulley shaft onto the bush cover by tapping lightly with a rawhide hammer mm 92 Reduction gearing N B If necessary when withdrawing the reduction gearing use a plastic hammer tapping lightly on the opposite side to that shown in the figure Crankcase bearings Wheel shaft bushing Withdraw the oil seal and the Seeger ring extract the bushing Follower pulley shaft bushing Use the special tool N B Perform the same operations on the bea rings in the crankcase cover Extractor tool 19 1 21467 21 17 Crankcase bearings Heat up the crankcase halves to approximately 80 C and then assemble the bearings 19 1 20150 19 1 20151 Support Heat gun Crankcase bearings Caution place the stop washers correctly on the intermediate shaft NE As ME Mating the crankcase halves Apply Loctite 510 to the mating surfaces Tighten the screws to the prescribed torque set ting N B Always check that the compensator ring is correctly in place and well greased Torque settings 12 13 N x m Replacing the starter pedal Remove the screw as shown in the figure and withdraw the starter pedal For re assembly follow the same operation in re
52. emove the central nut while holding the pulley rigid using the special tool Caution During the stripping operation on the clutch unit securing nut take care to keep the unit itself in its housing it may be ejected by the force of the clutch spring Special tool 19 1 20565 Stud retaining collar Withdraw the retaining collar Guide roller studs Extract the guide roller studs and withdraw the mobile follower semi pulley from the fixed follo wer semi pulley Fixed follower semi pulley Measure the external diameter of the pulley bush Minimum permissible diameter 33 96 mm Mobile follower semi pulley Measure the internal diameter of the moving semi pulley bush Maximum wear limit 34 08 mm mm 98 Spring Measure the length of the moving follower semi pulley spring Minimum permissible length limit 110 mm Fixed follower semi pulley bushing Extract the old bushings and insert new replace ments using a piece of tubing of the right diame ter as a punch Checking the Clutch The clutch assembly should be replaced when the joint is less than 1 mm at its thinnest part This assembly should be replaced as a complete unit because it is balanced after assembly of the clutch weights Re assembly of the semi pulley Insert the mobile semi pulley into the fixed semi pulley using the protective sleeve after replacing the sealing rings and the O rings fit the studs with their respec
53. enmove the 2 choke screws Remove the choke Wothdraw the throttle valve cover screw Remove the cable from the throttle valve Extract the spring and the spring guide Extract the throttle valve Extract the spray needle Loosen and withdraw the 2 carburettor float chamber screws Extract the main jet Extract the idle jet Remove the cold start jet Remove the float pin Remove the float needle Remove the spray Inspection and maintenance of the carburettor It is important to check the float needle to ensure correct operation of the vehicle Wear in the float needle may even produce flooding of fuel directly into the crankcase which may cause damage to the crankshaft seals as well as problems with the piston the connecting rod and cause flooding in the exhaust pipe CARBURETTOR FLOAT LEVEL 1 Model WEBER 165 H 1 0 mm 0 5 Model DELL ORTO 143 0 5 mm Carburettor float chamber When disassembling and reassembling the car burettor to carry out inspection and cleaning attention should be paid to ensure that the gasket is correctly located in its place and that it is not deformed or torn if it is not perfect it should be replaced otherwise fuel will leak out Cleaning the jets is advisable to clean the main jet the idle jet and the cold start jet as well as the airways with a compressed air pistol Checking the electric choke Use a vernier cali
54. eta ECHEMA ELECTRIQUE HUNTER Headlight IZV 25 25 W ll Brake Light Switch 2 Dashboard 12 Horn I2V DC Bashboard Light 2V 1 2W 15 Fuel Sensor 28 High Beam Indicalor Light 1 2W 14 Oi Sensor 2C Turn Signal Indicator Light 12 2W 15 Electric Choke 2D Fuel Indicator Light 12V 2W 15 Starter Relay 2E Indicator Light 12 2W 17 Starter Motor 2F Display 18 Fuse 44 26 Speedometer sensor 19 Battery 12V 4 3 Ignition Switch 20 Flywhee Magneto 2 70W 4 Fron Right Turn Signal Light 12V IOW 2 Electronic Converter A T 5 Fron Lefft Turn Signal Light 12 IOW 22 Spark Plug Cap Anti Radio inlerferences 6 Rear Right Turn Signal Light 12V 23 Spark Plug 7 Rear Left Turn Signal Light 12V 10W 24 Regulator AC DC B Tail 8rake Light IZV SW IZV 25 Turn signal box 12V 10 10W 9 Headlight Engine Stop Switch 26 Stand switch assy Dimmer Turn Signal Z Horn Switch Orange Orange Orange Arancio Naranja Gr n Vert Green Verde Verde Schwarz Noir Black Nero Negro Braun Marron Brown Marrone Marron WeiB Blanc White Bianco Blanco Grau Gris Gray Grigio Gris Gelb Jaune Yellow Giallo Amarillo Blau Blau Blue Azzurro Azul Rot Rouge Red Rosso Rojo Rosa Rosa Pink Rosa Rosa Violett Violet Violet Violeta ECHEMA ELECTRIQUE MANHATTAN USA
55. eto Inspecting the coil Withdraw the spark plug cap Check the resistance of the secondary winding of the coil between points A and B The correct value between A and B 5 6 If the value of the resistance of the secondary winding and the magneto are correct the coil assembly should be replaced Checking the spark plug cap Check the value of the resistance between the terminals of the spark plug cap The correct value of the resistance 9 11 SWITCHES AND SENSORS Ignition switch Remove the panels so as to be able to reach the ignition lock connectors Remove the ignition lock to carry out the conti nuity check as in the attached diagram Code and function of the colours BL Blue Earth input Wh R White Red Engine stop Or Orange Output and for battery accessories Gr Green Input and Battery If the continuity test is not satisfactory replace the ignition lock If the test is satisfactory check the general condi tion of the cables in the wiring 41 mm Connection of lighting switch turn indicators and horn Remove the panel so as to be able to disconnect the switch connectors If the continuity test is not satisfactory replace the switch If the test is satisfactory check the general condi tion of the cables in the wiring Horn Left Turn indicator Right Turn indicator H
56. ff and starter Disconnect the electrical connectors to the Withdraw the 2 engine frame anchorage magneto cut off starter and automatic securing screws choke Withdraw the lower rear shock absorber Withdraw the 2 engine frame anchorage screw SOMO SEEMS Remove the engine from the frame 19 SUSPENSII Scion Remove the antifreeze liquid drain plug Remove the engine from the frame Atlantis LC Disconnect the thermo contact Atlantis LC Withdraw the cylinder head water outlet hose connector and clip Atlantis LC Withdraw the coolant hose at the connection to the radiator Atlantis LC MAGNETO CHECKING THE IGNITION Inspecting the magneto Pull out the connector block which is located at the rear left hand side of the frame Disconnect the magneto cables The red black high tension coil feeder cable and the 2 way connector with red white and white yellow cables Check the resistance readings as per the follo wing table KOKUSAN DENKI LEONELLI Black red White red White yellow Green Red White 224 0 70 Q 0 55 5409 180 Earth Earth 20 20 20 15 15 15 IDM Black red White red White yellow 298 Q 1 7 Q 150 Earth 20 20 20 The readings for this table should be taken bet ween 20 and 30 C If the values prescribed in the tables are not met check the wiring before replacing the magneto Hi
57. gh Tension Coil The resistance of the secondary winding of the high tension coil should read from 5 to 6 KQ Spark plug cap The resistance between the terminals for the spark plug cap should read from 4 to 5 KQ CYLINDER HEAD CYLINDER AND PISTON PISTON RINGS Checking Fit the rings into the cylinder Using feeler gauges measure the play at the ends of the rings The maximum value should be 0 5 mm Fitting the piston rings onto the piston Fit the expansion ring Then fit the lower ring this has a rectangular section and finally the upper piston ring this has a trapezoidal section Atlantis 100 with semitrapezoidal rings and without expander ring PISTON Checking Measure the outside diameter of the piston at a point situated 15 mm from the base of the piston Calculate the play between the cylinder and the piston The service limit is 0 06 mm When replacing the piston with a new one take C 09 98 3 care to use one with the same family identifica tion letter This letter may be found marked on the upper surfaces of the piston and of the cylinder FAMILY 09 MONTH WHEN MANUFACTURED 98 YEAR WHEN MANUFACTURED 3 OPERATIVE Table of Cylinder and Piston tolerances PREDATOR ATLANTIS ATLANTIS 100 LC 02 CAT WVTA O2 WVTA FAMILY PISTON CYLINDER FAMILY PISTON CYLINDER ASSO SP348 ASSO 40 95 0004 40 975 20098 49 966 0 0025 50 00
58. gher that the value quoted above then it will be necessary to grind down the surface on abrasive paper resting on a surface plate moving it in figures of eight as shown in the diagram Models HUNTER PADDOCK and VAMOS in these models the cylinder head gasket should be fitted with the convex exterior border facing upwards In the case of the PADDOCK LC model the gas kets must be changed every time the cylinder head is removed Fit the cylinder head gaskets Fit the cylinder head and tighten up the four 6 mm nuts to a torque of 10 12 Nw x m using a torque spanner Fit the copper gasket and the thermocontact to a torque of 18 20 Nw x m Fit the spark plug and tighten to a torque of 18 20 Nw x m SPARK PLUG B 8HS CHAMPION L 78C MODELS VAMOS HUNTER PADDOCK SPARK PLUG B 9HS CHAMPION N 2C CARBURETTOR MANIFOLD Check that there are no cracks in the manifold Check that the reeds are not broken and that they open correctly Checkl that the 4 x 20 securing screws for the reed valve support are tightened to a torque of 1 2Nwxm Fit the reed valve in the crankcase and then the new carburettor manifold gasket Fit the carburettor manifold to the crankcase four 6 x 20 screws tightened to a torque of 9 10 Nw x m using Loctite thread seal MODELS PADDOCK LC 29 mm CARBURETTOR Stripping the carburettor Remove the choke cap R
59. greasing and greasing and greasing Cylinder head cylinder piston Clean Segments piston Replace Check Check Cylinder head nuts Tighten up Tighten up Inlet valve reeds Check Check Rear suspension links Clean Clean Greasing Greasing Speedometer transfer box Clean Clean Greasing Greasing TORQUE SETTINGS PART NAME TORQUE SETTINGS Nw x m SHOE ROTATION SHAFT 8M125 17 19 LOCTITE CYLINDER STUD 6M100 10 12 CRANKCASE SECURING SCREWS 6M100 9 10 LOCTITE CYLINDER HEAD 6M100 10 12 INLET VALVE MANIFOLD BRACKET 4 70 1 2 LOCTITE CRANKCASE INLET MANIFOLD 6M100 9 10 LOCTITE OIL PUMP 5M80 4 5 LOCTITE COIL TO BASE PLATE 6M100 8 10 LOCTITE BASE PLATE TO CRANKCASE 6M100 8 10 LOCTITE MAGNETO 10M100 35 40 LOCTITE STARTER MOTOR 6M100 9 10 LOCTITE FAN TO MAGNETO 6M100 8 10 LOCTITE ENGINE PLATE SUPPORT BRACKET 6 100 9 10 LOCTITE LEFT HAND CRANKSHAFT 10M100 35 40 LOCTITE REDUCTION GEAR COVER 6M100 9 10 LOCTITE PULLEY SHAFT 10M100 35 40 LOCTITE PLASTIC OIL FILLER CAP 14M150 HAND TIGHT LEFT HAND CRANKSCASE HALF COVER 6 100 9 10 LOCTITE OIL DRAIN PLUG 8M125 17 19 CYLINDER CASING COVER 6M100 9 10 FRONT WHEEL 12M150 40 45 REAR WHEEL 16M150 100 105 SWINGING ARM 10M150 40 45 UPPER LOWER SHOCK ABSORBER 10M150 38 40 CLIP ON HANDLEBARS 8M125 20 25 EXHAUST PIPE TO CYLINDER 6M100 8 12 EXHAUST PIPE TO INTERMEDIATE SUPP
60. gro B Braun Marron Brown Marrone Marron BR WeiB Blanc White Bianco Blanco W Grau Gris Gray Grigio Gris G Gelb Jaune Yellow Giallo Amarillo Y Blau Blau Blue Azzurro Azul BL Rot Rouge Red Rosso Rojo R Rosa Rosa Pink Rosa Rosa P Violett Violet Violet Viola Violeta VI ECHEMA ELECTRIQUE GP Series D F UK Orange Orange Arancio Naranja Gr n Vert Green Verde Verde GR Schwarz Noir Black Nero Negro B Braun Marron Brown Marrone Marron BR WeiB Blanc White Bianco Blanco W Grau Gris Gray Grigio Gris G Gelb Jaune Yellow Giallo Amarillo Y Blau Blau Blue Azzurro Azul BL Rot Rouge Red Rosso Rojo R Rosa Rosa Pink Rosa Rosa P Violett Violet Violet Viola Violeta VI
61. harging system Type Voltage under load Coil resistance Lighting system Type Regulation voltage Coil resistance Alternator and regulator 13 5 0 5 V at 4 000 r p m with lights on 1 1 0 2 at 20 C Alternator and regulator 13 5 0 5 V at 4 000 r p m with lights on 0 9 0 2 at 20 C Ignition system Type Magneto Resistance of stator between Black Red cables and earth High Tension Coil Resistance of secondary winding Resistance of anti interference cap Switches and Sensors Brake light switches Fuel sensor Oil sensor Temperature thermo resistance Cooling fan thermo contact Electronic 224 Q 20 a 20 C 5t1Ko 4 1 Light operates after 12 mm travel at brake levers Full ee Reserve 33 Q Full Q Reserve 0 Q 25 C 788 Q 1096 80 980 10 OFF ON 97 3 G ON OFF 85 3 G CHECKING THE ELECTRICAL SYSTEM IN THE SCOOTER BATTERY When the battery is used for the first time it is necessary to fill with the acid which comes toget her with the battery First remove the sealing strip Next place the container of electrolyte upside down with the six sealed parts aligned with the six filler holes on the battery Push the container firmly down to break the seals Check that all the electrolyte has gone into the battery Sealing up the battery Push the sealing strip firmly into each of the filler holes Never remove the sea
62. igh Beam Dipped Beam Colours PADDOCK LC Switch Horn Left Turn indicator Right Turn indicator Colours Codes and Functions of the colours Y Gr Yellow Green Earth Bk Black Horn P Pink Rear right hand turn indicator Or Orange Turn indicator common line Vi Violet Rear Left hand indicator BI Headlight High beam Wh Y White Yellow Headlight Dipped beam Dr Brown Lighting switch supply Lighting Switch and Electric Start Codes and functions of the colours Y Gr Yellow Green Earth Y Yellow Supply Wh Bk White Black Relay Operation Br Brown Rear light and lighting dip switch Front and rear brake switch Disconect the terminals of the press switch and check continuity between contacts A and B B With the press button closed the resistance is E infinite and with the press button at rest the value of the resistance is 0 Side Stand switch im Disconnect the 2 way connector situated below A the saddle Check continuity between the Yellow Green and Green Black cables Values of the resistance Stand deployed 00 Stand closed Oil reserve sensor Remove the plastic caps from the reservoirs and 1 extract the tank sensor Disconnect the terminals from the sensor and check continuity
63. ium revs Tester White Yellow White Red Connections Cable Cable Earth Minimum voltage 25V AC Minimum voltage 30V AC Alternator resistance Test Tester White Yellow White Red Connections Cable Cable Earth 0 9 0 0 2 1 1 Q 0 2 Regulator Test at medium revs Tester Alternating current Positive cable Connections Yellow cable Red cable SCHEMATIC AND IGNITION CIRCUIT CONTROL Service information The ignition timing does not need any maintenance The spark is distributed at 20 before TDC at 4 000 rpm Schematic wiring diagram IGNITION KEY GREEN BLACK YELLOW GREEN l GREEN BLACK L D BLACK RED YELLOW GREEN ALTERNATOR SPARK PLUG Function of the colours Colour Function Green Black stopping the engine and feeding the ignition Yellow Green Earth Green Coil feed Black Red Spark lead CHECKING THE IGNITION Inspecting the magneto Remove the inspection cover so as to be able to reach the magneto connectors Black Red White Red White Yellow Disconnect the Black Red feed cable from the 238 110 0 9 coil and the 2 way connector in the White Red 10 15 15 the White Yellow cables Check that the resistance values are in line with the following tables The values for consulting the table should be read between 20 and 30 C If the actual values are not the same as those on the table check the wiring before replacing the mag
64. l 020166Y 12 Water pump drive shaft dis assembly wrench 020169Y 13 Mixer drive gear extractor oo 020361Y 14 Starter spring assembly TOO 22 2 a 020261Y 15 Comparator and holder in ct 020335Y 16 Crankshaft support e A 020163Y 17 Crankshaft seal punch aeter 020340Y 18 Valve separation e EE 020341Y 19 Piston ring assembly Tool 020344Y SPECIAL TOOLS Description Reference 20 Compressor crankshaft pulley retaining Tool 020342Y 21 Magneto retaining tool 020346Y 22 Starter crown wheel retainer EEN 020343Y 23 Crown wheel 020565Y 24 c Engine SUBD ON oco tame Ge A Lo 005095Y 25 Extractor LOO MP TN SARKO A RR 001467Y REGULAR MAINTENANCE CHART GP1 GP Series O2 ATLANTIS Period this period can be calculated by kilometres run or by time in months Months 2 24 Reduction gear or crankcase oil Replace Replace Replace Check cylinder air Clean Suspensions Check Check Check Check Check Tighten fastenings Check Check Check Check Check Check Electrical Connections Check Check Check Check Check Check Spark plug Adjust Replace Replace Replace Replace Replace Battery Check Check Check Check Check Check Carburettor Adjust Clean Adjust Clean Adjust Clean Adjust Clean
65. ling strip and never add water to the electrolyte The battery is a 12V 4 Ah type When installing the battery it is important not to reverse the pola rity of the terminals since this could cause dama ge to some sensitive electronic components Using the battery for the first time This battery is a sealed type and the cell covers should never be removed and water must never be added After 30 minutes test the voltage at the terminals Standard voltage 12 5 volts minimum Under normal circumstances it is not necessary to charge the battery Once charged it is normally at 7596 capacity Special conditions under which the battery should be charged When the temperature falls below 0 After a long period in storage When the original seal has been broken In general the battery should be charged whene ver the voltage after charging remains below the standard reading of 12 5 V CHARGING SYSTEM Standard battery charging times It is necessary to use a charger with constant vol tage and current Standard charge 0 3 Ah for 10 hours if the voltage is below 12 5 volts Carry out battery charging in accordance with the accompanying table 11 5 12 0 12 5 13 0 V Standard values for determining the Voltage at the battery terminals condition of the battery Voltage is 12 5 or higher Correct Control diagram to determine Voltage between 12 0 12 4 Insufficient charge
66. ls between 26 30V this test should be carried out with the battery disconnected OOOOO 15524 13V a 3000 mm Before carrying out any checks on the regu lator and the related wiring it is recommended that a continuity check is run between the black cable Fig 4 and ground mm 112 ECHEMA ELECTRIQUE ATLANTIS D F UK Orange Orange Arancio Naranja Gr n Vert Green Verde Verde GR Schwarz Noir Black Nero Negro B Braun Marron Brown Marrone Marron BR WeiB Blanc White Bianco Blanco W Grau Gris Gray Grigio Gris G Gelb Jaune Yellow Giallo Amarillo Y Blau Blau Blue Azzurro Azul BL Rot Rouge Red Rosso Rojo R Rosa Rosa Pink Rosa Rosa P Violett Violet Violet Viola Violeta VI ECHEMA ELECTRIQUE GP1 D F UK Orange Orange Arancio Naranja Gr n Vert Green Verde Verde GR Schwarz Noir Black Nero Negro B Braun Marron Brown Marrone Marron BR WeiB Blanc White Bianco Blanco W Grau Gris Gray Grigio Gris G Gelb Jaune Yellow Giallo Amarillo Y Blau Blau Blue Azzurro Azul BL Rot Rouge Red Rosso Rojo R Rosa Rosa Pink Rosa Rosa P Violett Violet Violet Viola Violeta VI ECHEMA ELECTRIQUE GP1 USA D F UK Orange Orange Arancio Naranja Gr n Vert Green Verde Verde GR Schwarz Noir Black Nero Ne
67. o Dell orto Dell orto Dell orto Dell orto PHVA 12DD Diffusor 12 mm Main jet Idle jet PHVA 12DD 12 mm PHVA 14DD 14 mm PHVA 14DD 14 mm 58 54 55 50 34 34 36 34 PHVA 14DD PHVA 10GD 14 OM 1AA Needle type number Spray Throttle valve 40 30 30 40 30 30 5 Float 3 5 gr 3 5 gr 3 5 gr 3 5 gr 3 5 gr 3 5 gr 4 5 gr Air screw openin 2 5 turns 3 0 turns 2 5 turns 2 0 turns 2 5 turns 2 3 4 turns 2 turns Cold start jet 45 Float level 45 45 45 45 45 45 CYLINDER SLEEVE COVER RADIATOR AND FILTER BOX Fit the oil tube from the oil pump to the carburet tor Fit the cylinder sleeve cover with the two securing screws 6 x 16 and tighten up to a torque set ting of 9 10 Nw x m Check the oil pump bleed screw It is extremely important when fitting the fan cover to check the rubber protector profile of the fan cover since if it is broken there will be leakage from the cooling circuit and noise will be produced by the vibrations of the vehicle Fit the fan using two 6 x 16 securing screws and tighten to a torque of 9 10 Nw x m applying Loctite thread seal Fit the fan cover using 2 screws 6 x 16 and cross head screws 6 3 x 19 and tighten to a tor que of 9 10 Nw x m Fit the radiator using 2 screws 6 x 60 and tigh ten to a torque of 9
68. on mixer 84 Electrical wiring diagrams 113 Cylinder head cylinder piston Liquid cooled models 95 TECHNICAL SPECIFICATIONS OF THE ENGINE Engine Cubic capacity Fuel admission Compression ratio Starter system Engine cooling system Atlantis 100 Stroke and Bore Cubic capacity Compression ratio Carburettor Ignition advance Spark plug Battery electric start fan driven pressurised air LC liquid cooling Unleaded fuel petrol oil mixture using constant flow pump driven lubrication 50 x 43 mm 85cc 9 5 1 DELL ORTO PHVA 10 GD PHVA12 DD PHVA 14 DD PHVA 17 5 WEBER 14 OM 1 AA WEBER 14 OM 1 BA WEBER 12 OM 1 QA WEBER 12 OM 1 SA WEBER 14 OM 1 FA automatic variable speed unit through trapezoidal belt drive automatic centrifugal dry clutch magneto 12V 80W 18 before T D C NGK B8 HS CHAMPION L 78 C NGK B9 ES CHAMPION N 2 C NGK B8 ES CHAMPION N3C 12V 4Ah SPECIAL TOOLS S4 Part Name Reference Number 1 Magneto disassembly tool 0 0G 053 0 001 1 2 Connecting rod blocking Tool 0 0G 056 0 037 1 3 Water pump shaft extractor Tool 0 0G 056 0 042 1 4 Crankshaft assembly tool use for water pump shaft 0 0G 056 0 036 1 5 Crankshaft seal guide bush EE 0 0F 053 0 084 1 6 Crankshaft seal assembly punch 0 0F 054 0 045 1 7 Gu
69. on facing towards the exhaust port The piston is assembled onto the connecting rod by first inserting the little end cage bearing into the little end of the connecting rod then the gud geon pin and securing it by means of the circlips using special tool 0 0G 056 0 041 1 When fitting the cylinder it is recommended to apply a little oil to the part and to the piston rings and to the piston so as to make assembling the cylinder over the piston easier The recommen ded oil is that used for the fuel mixture 27 mm The cylinders of the monobloc models cannot be rectified and there are no oversizes There are only families of cylinders and pistons which go in steps of 0 005 mm When replacing the piston the family identifica tion stamped on the cylinder should be identified and a piston of the same letter as on the cylinder should be used Table of tolerances for cylinder and piston TABLE OF FAMILIES FAMILY PISTON CYLINDER ASSO SP348 40 95 0 004 d 0 40 955 Se 40 960 000 40 985 40 965 000 40 990 CYLINDER HEAD Check the contact surface the sealing surface of the cylinder head by resting it on a surface plate using a feeler gauge check that there is no grea ter gap than 0 05 mm For the engine to run properly it is very important that the cylinder head cylinder joint and the she athing should be perfectly gas tight If the gap between the two parts is hi
70. on the shoes is 2 mm Assembly Take the moving pulley and insert the 2 seals 33 x 39 x 4 Using the special tool 0 0F 054 0 045 1 the two grease retaining rings fit the moving pulley into the fixed pulley checking that the lip of the seal is not damaged when the pulley is inserted Insert the three guide pins in the slot on the moving pulley Fill the spring guide bush with AGIP GR MU 3 grease and fit then the spring slider bushing the spring the spring guide boss the clutch shoe plate and the nut Using special tool 0 00 052 5 324 0 and a 36 mm Socket spanner tighten up to a torque of 65 70 Nw x m Fit the clutch assembly onto the pulley shaft together with the toothed belt Fit the clutch hub onto the pulley shaft the was her and the nut Using special tool 0 0G 053 0 001 1 lock the clutch hub and tighten up the nut to a torque of 35 40 Nw x m sealing the thread with Loctite 243 The service limit for the clutch hub is 112 5 mm REDUCTION GEAR BELT CLUTCH SHOES REDUCTION GEAR Length Grams Grams DREBI 6 583X6 107 12 55X13 37 100 80X10 VAMOS 39 5 VAMOS 6 583X6 12 43X14 45 100 80X10 CHINA 39 5 HUNTER 6 583X6 12 43X12 49 130 90X10 PADDOCK 6 583X6 12 43X13 49 130 60X13 PADDOCK LC 6 333X6 12 43X14 48 130 60X13 LEFT HAND LEFT HAND CRANKCASE COVER COVER Disassembly of the starter se
71. onnec tions measure the characteristics of the coil and the pick up see table If any anomalies appear when checking the coil and the pick up replace the stator and the dama ged parts Remember that in order to replace the central unit cables must only be disconnected with the engine switched off CHECKING THE PICK UP Fig 2 Instrument connected between Value 1 Red and White Cables CHECKING for Continuity CHECKING THE Coil Fig 3 1 White Cable and Frame Continuity 1 White and Green Cables 83 TRANSMISSION MIXER APPLY THE PRODUCT A CAUTION HANDLE WITH CARE IR LUBRICATE 4 GREASE CLEAN WITH CARE 8 ALWAYS REPLACE d ne THERE mm 84 Transmission Cover Unscrew the 15 screws and remove the trans mission cover using a raw hide hammer the crankcase remains lightly secured by the driven semi pulley shaft in the bushing fitted into the crankcase itself Follower Pulley Remove the nut Withdraw the complete unit Special tool 19 1 20165 Starter gearing Drive pulley Special tool 19 1 20165 Controls Drive belt Verify that the drive belt is not deteriorated Control the width of the drive belt Minimum permissible 17 5 mm N B to control the drive belt and the container of rollers each 20 000 km Belt Starter cable Variable speed unit Mixer Movil semi pulley Rem
72. ot be repaired Right hand fork bar Remove the dustguard and the safety circlip Withdraw the right hand fork leg the lower spring washer the rubber stop and the spring This fork leg should be filled with AGIP GR MU 3 type grease only Re fitting the two fork legs is carried out in the reverse order from stripping VAMOS MODELS Stripping the fork legs Withdraw the 2 front brake caliper screws separate the caliper Remove the wheel axle nut the spring washer and the washer Withdraw the wheel axle the transfer box bushing and the whole transfer box assembly Loosen the end piece screws and with draw the end pieces Extract the fork leg dustguard and the safety circlip Withdraw the fork leg the stop and the spring When re assembling carry out the same procedures in reverse order The fork legs should be filled with AGIP GR type grease a WITHDRAWING THE ENGINE FROM THE FRAME STRIPPING Remove the luggage carrier 4 screws In PADDOCK models separate the electrical con nectors on the turn indicators The left hand footrest cover 1 screw The left hand side panel 2 screws The right hand footrest cover 1 screw The right hand side panel 2 screws Raise the saddle Remove the side panels 5 screws Remove the oil reservoir cap Remove the fuel tank filler cap Remove the anti freeze reservoir cap on PAD DOCK
73. ove the three screws and the cover Variable speed plate Remove the O ring and the variable speed plate Rollers Withdraw the rollers Lift out the rollers marking them with a felt pen to ensure correct re assembly Rollers Check that the rollers are not damaged or worn Limit of wear 18 5 mm minimum diameter Transmission mixer variable speed unit Check that the interior bushing shows no sign of unusual wear and measure the interior diameter Maximum permitted diameter 20 12 mm max N B Do not lubricate or clean the anti friction bushing mm 96 Pulley displacement bush Measure the external diameter of the sliding pulley bush Minimum permissible diameter 19 95 mm Variable Speed unit roller ramps Grease the working surfaces of the rollers using Agip GR MU 3 grease and re assemble the rollers N H For correct assembly if the rollers are not being replaced re fit them into their original sea tings Variador guide Assemble the roller cover the oil plate and the cover securing with the three screws Assemble the roller backing plate the oil seal and the cover securing with the three screws Follower Pulley Check that the clutch casing is not worn or dama ged Measure the internal diameter of the clutch casing Maximum diameter value 107 5 mm N B Mount it on the appropriate shaft and check for eccentricity maximum value 0 20 mm Clutch R
74. per to check the choke the length of the choke piston should be measured when cold It should measure approximately 11 mm To test it a battery must be used After connecting the two terminals wait 3 minutes and the piston should have extended by about 4 mm and the total measurement should be around 15 mm Models like the MANHATTAN are fitted with a manual choke Assembly of the Carburettor Fit the spray Fit the float needle Fit the float and float pin Fiot the cold start jet Fit the idle jet Fit the main jet Fit the float chamber using the 2 securing screws Fit the throttle cable into the carburettor cap Pass the throttle cable through the centre of the spring Fit the throttle cable into the throttle valve Insert the carburettor needle into the throttle valve Fit the spring guide bushing Insert the complete valve assembly into the body of the carburettor Insert the carburettor cap screw and close the carburettor cap Insert the automatic choke into the carburettor Fit the locking piece the two screws and tighten up the automatic choke Adjust the air screw it should be opened approxi mately 2 5 turns Install the carburettor into the engine Carburettors VAMOS HUNTER ITALIA PADDOCK HUNTER HUNTER DG MANHATTAN HUNTER 50 Germany Austria Holland MXR HUNTER 25 Germany Holland Finland Dell orto Dell ort
75. r other connec tions unless the ignition switch is in the OFF position Always use a slow charge whenever possible A rapid charge should only be used in cases of emergency and then only for a short time since it may damage the battery It is advisable to remove the battery fropm the vehicle in order to charge it Keep the breather tube clear of obstructions par ticularly during charging IMPORTANT Batteries lose charge when they are not used Do not leave the battery for more than a month wit hout recharging and reduce the recharging inter val to a fortnight after the first month Battery Standard values Type 12V 4 Ah Electrolyte specific gravity 1 28 a 20 Charging amperage 0 4 Amps maximum Charging coil resistance 1 1 Q 0 2 a 20 Inspecting the battery Check periodically the level of the elec trolyte and if the level is low add disti lled water Check that the density of the electrolyte in each cell is between 1 26 and 1 28 If it is below 1 26 charge the battery accor ding to the attached table If the density is low after charging the battery or that there are variations bet ween the different cells the battery should be replaced The density of the electrolyte varies with the temperature Please refer to the table below 1 29 128 TN 1 27 SEH o R 1 24 echar 9 123 1 22 1 21 0 5 10 15 20 25 30 35 40 Temperature in
76. rake disc then the distance piece the washer the spring washer and nut tightening to a torque of 50 60 Nw x m Tighten the fork leg closure screw to a torque of 8 12 Nw x m Locate the two brake caliper securing screws 8 x 60 to a torque of 20 25 Nw x m using Loctite Finally turn the wheel and operate the brake lever m 2 w sCs wsrssr as ss PADDOCK MODELS Stripping the fork legs Withdraw the four mudguard screws and remove the mudguard Slacken off the wheel axle nut withdraw the was her loosen the 2 front brake caliper screws loo sen the locking screw extract the wheel axle the axle distance piece and leave the transfer box and the separator hanging free Stripping the left hand fork bar To disassemble the left hand fork bar without stripping the fork the following procedure should be followed Remove the dustguard and extract the safety cir clip Withdraw the two screws securing the bag carrier hook Withdraw the seven screws securing the inner shield and remove the inner shield Drill a hole using a 15 mm drill through the fork plate protector so as to be able to insert a tube spanner and loosen the 6 x 100 nut and washer this way it is possible to withdraw the left hand fork leg with the hydraulic cartridge with bushing and silentbloc the boss the rubber stop spring and the guide washer If the hydraulic cartridge loses oil it must be replaced since it cann
77. ressure clamp In LC models connect the thermocontact electri cal spade connector Make the connections for the magneto the stop light the choke the starter and the 2 connec tions to the high tension coil and tighten up the earthing connection cable screw 6 x 25 to a tor que of 9 10 Nw x m Join the rear end of the throttle cable to the ins pection cover Fit the rear brake guide and the engine earth cable with 1 screw 6 x 16 Fit the rear brake guide stop screw 6 x 16 with the spring washer and tighten to a torque of 9 10 Nw x m Locate the helmet carrier with the lower shield using four screws 6 x 16 and 2 screws 5 x 15 Fit the side panels five crosshead screws In the PADDOCK and PADDOCK LC models pass the turn indicator cables through the hole in the left hand side panel Assemble the right hand side panel to the lower shield 2 screws Fit the right hand side footrest cover 1 screw Assemble the left hand side panel to the lower shield 2 screws Fit the left hand side footrest cover 1 screw Fit the luggage carrier with four screws In the PADDOCK and PADDOCK LC models connect up the turn indicator cables Secure the luggage carrier using 5 screws 3 6 x 14 and 4 screws 2 of 8 x 35 and 2 of 8 x 60 Fit the fuel tank and oil reservoir filler caps and check the oil level Fill the cooling reservoir with 400 cc of antifreeze AGIP CLOSED
78. ter than specifications true the crankshaft between the counterweights by shim bushing or by pressing in a screw press fitted with aluminium bushes as required In the event that it is impossible to true the shaft or where eccentricity is excessive replace the crankshaft Axial assembly tolerance Measure the axial tolerance of the crankshaft in the crankcase with the engine cold Push and pull the crankshaft from one side and measure the value using a comparator on the other side Assembly tolerance under load 3 kg 0 03 0 12 mm Special tools Comparator with magnetic support 020335Y Crankshaft alignment tool 020074Y CARBURETTOR Adjustment Table MAKE CARBURETTOR MODEL JET NEEDLE JET EMULSIFIER IDLE JET CHOKE FLOAT MAXIM POSITION MINIMUM JET LEVEL GP 1 E DELL ORTO PHVA 17 51D GP SERIES E Atlantis 2002 E 62 A 22 1 32 209HA 1 Turns 50 14 8 0 5 Atlantis 2002 LC E GP 1 WVTA DELL ORTO PHVA 17 510 GP SERIE Atlantis 2002 WVTA 56 A 22 1 32 209HA 1 Turns 50 14 8 0 5 Atlantis 2002 L C WVTA ELECTRICAL SYSTEM Checking the fuel indicator The fuel indicator needle operates on the Marking moving magnet principle Tolerances Check carried out with voltage at 13 V DC Resistance Checking the temperature indicator Value in The temperature indicator needle operates at the prob
79. th of Spring 218 mm Spring compression force to 30 mm 142 kg m REMOVING THE ENGINE FROM THE FRAME PREDATOR LC PREDATOR 02 ATLANTIS O2 ATLANTIS LC ATLANTIS 100 Remove the throttle cable from the connector Remove the antifreeze liquid drain plug Withdraw the engine inspection cover secu ring screw Withdraw the screw and the low seat body Atlantis Withdraw the screw and the engine record cover Predator Disconnect the thermo contact Withdraw the cylinder head water outlet hose connector and clip Withdraw the high tension coil securing screw Disconnect the throttle cable at the connec and coil earth tor Disconnect the crankcase coolant hose and Disconnect the oil hose at the connector clip at the connection to the crankscase Withdraw the 2 fuel and vacuum hoses from Withdraw the high tension coil securing screw the fuel cock and coil earth Withdraw the rear brake cable guide screw Disconnect the oil hose at the connector Withdraw the rear brake nut Withdraw the 2 fuel and vacuum hoses from Remove the engine earth cable screw the fuel cock Remove the carburettor access cover and Extract the 2 rear brake caliper screws and withdraw the manual choke cable leave the caliper lying on the engine Disconnect the electrical connectors to the Remove the engine earth cable screw magneto cut o
80. the vehicle Both fork legs are the same Stripping the left or right hand fork bar Withdraw the safety circlip Undo the fork leg tube cap and seal Drain the hydraulic fluid from the bar Extract the fork leg spring Loosen and extract the fork leg screw Withdraw the hydraulic tube and the bar from the fork leg Extract the dustguard the seal securing circlip and finally the seal Note Clean thoroughly all the parts which are to be re fitted it is mandatory under all cir cumstances to replace the O rings and seals Re assembly of the fork leg Fit the seal into the fork leg size 30 40 7 9 Using special tool 0 0H 054 0 045 1 and insert the seal securing circlip Insert the hydraulic tube inside the fork bar Insert the bar inside the fork leg fit the fork spring and tighten the 10 x 25 screw using a copper washer and Loctite to a torque of 35 40 Nw x m Re fill using 80 cc of AGIP FORK SAE10W hydraulic oil Insert the fork leg tube cap with the O ring seal the safety circlip and the dust guard Assemble the fork leg into the vehicle Insert the complete fork leg assembly into the fork plate Fit the safety circlip and the exterior fork leg cap Tighten the fork plate securing screw Tighten the mudguard fork plate protec tor securing screw Locate the wheel axle the transfer box the transfer box bushing the wheel and fit the brake caliper onto the b
81. tion of current from the NES stator disconnect from the regulator terminal and insert alternating current tester 020331Y between the blue green terminal and the black cable and check that the voltage distributed at 3 000 rpm falls between 25 30 Fig 1 b If there is no abnormality replace the regulator C If correct operation is impossible even with a new regulator carry out a check of the connec tions in the wiring circuit 1 5 2 13V a 3000 rpm FAILURE 3 After checking that there are no short circuits Fig 2 from the wiring circuit to ground with the engine stopped and with the regulator terminal discon nected replace the regulator because it is cer tainly ineffective also replace the protection fuse C After replacement measure charging current and voltage at the battery terminals Fig 2 FAILURE 4 a Connect an ammeter between the stator blue cable and the battery and check using tester 020331 Y that the current distributed at 3 000 rpm and with the battery at 13 V is approxima tely 1 5 2 Amps Fig 3 Fig 3 If measured values are lower than specified repla ce the regulator b If replacing the regulator does not re establish Black Yellow correct operation set the tester 020031Y for alternating current voltage connect between the regulator yellow cable terminal and the black cable Fig 4 and check that the voltage distribu ted by the generator at 3 000 rpm fal
82. tive rollers using a small quantity of Agip GR MU 3 grease After completing this operation it is necessary to apply using a curved point syringe a sufficient quantity of grease such that when it is injected through one of the holes situated in the interior of the bushing it squeezes out of the opposite hole Special tool 19 1 20164 Re assembly of the clutch Refit the stud retaining collar the spring the clutch assembly and lock the clutch nut Caution During the stripping operation on the clutch unit securing nut take care to keep the unit itself in its housing it may be ejected by the force of the clutch spring Special tool 19 1 20565 Torque setting 40 44 N x m Loctite 242 Nut sealing paste Mixer drive gear and belt Withdraw the gear and the belt Caution Do not twist or fold the belt during assembly Caution During assembly carefully lubricate the mixer drive stud and bush using only CONS TANT GLY 21000 oil and make sure that it is free to move N H Replace the belt every 20 000 kilometres Follower pulley clutch belt Assemble the follower pulley clutch belt assembly Clutch hub Assemble the clutch hub and tighten the nut while holding the hub itself rigid by means of the spe cial tool N B On assembly use new nuts and apply Loctite Super Fast type 242 E Special tool 19 1 20565 Torque setting 40 44 m mm 90 Bushing and mobile semi
83. to approximately 80 C insert the bearing number 6201 C3 and push fully home Fit the rear wheel seal using special tool number 0 0F 054 0 045 1 The seal should be fitted with the lip facing inwards or alternatively while it is being fitted the retaining spring should be visible and when it is home it should be just at the same level as the crankcase Fit the washer and intermediate shaft Fit the wheel shaft taking great care not to damage the seal spring Offer up the reduction gear cover gasket and check the locating pins for the reduction gear cover Reduction gear cover fit the bearings in the reduction gear cover using special tool 0 0F 054 0 045 1 after heating it up to approxi mately 80 C First insert the bearing number 6203 C4 then the bearing number 6204 C3 Finally heat up the core of this bearing so as to be able to fit the pulleyshaft Using special tool number 0 0F 054 0 045 1 insert the pulley cover shaft seal Fit the washer onto the intermediate shaft and locate the reduction gear cover using 4 screws size 6 x 25 and 2 screws size 6 x 30 Use thread seal such as Loctite 243 and tighten to a torque of 9 10 Nw x m Fit the oil drain plug using a new washer and tigh ten to a torque of 17 19 Nw x m Fill the crankcase with 110 cc of AGIP GEAR SYNTH SAE 75w 90 oil Fit the oil filler cap screw with an O ring and tighten manually Fit the rear brake operating arm
84. ur screws covers steering wheel Models cooled by liquid Fan Cover Remove the four screws and disengage the two lugs inserted in the cylinder cooling jacket If the vehicle is used for off road duty it is advisa ble to remove the outer part of the cover and clean the silencer element with compressed air and or water Magneto Extractor 19 1 20162 Magneto securing nut During this operation secure the magneto using the special tool for this purpose Special tool 19 1 20565 mm 82 Stator pick up N H Assemble the parts by following the stripping procedure in reverse Use a new nut to ensure proper adjustment N B It is good practice after assembling the mag neto to protect the extractor tool screw with Agip GR MU 3 grease Magneto nut torque setting 40 4 N x m ELECTRONIC IGNITION All operations to check the wiring which involve disconnecting cables checking connections and devices which form part of the ignition circuit must be performed with the engine switched off otherwise the central unit may suffer irreparable damage These checks should be performed if the ignition is irregular or if there is no spark at the spark plug 1 Check the spark plug clean with wire brush remove soot blow clean with compressed air if necessary replace 2 Without stripping the stator perform the follo wing check After visual examination of the electrical c
85. using grease followed by the foam the brake shoe wear turn indicator cover the brake lever the screws and nut Heat up the crankshaft seating in the right hand crankcase half using a hot air gun to approxima tely 80 C and insert the crankshaft bearing 6204 px2 v4 using special tool 0 0F 054 0 045 1 17 mm CRANKSHAFT INSPECTION Measure the lateral play at the connecting rod big end using feeler gauges the maximum permissible play is 0 35 to 0 60 mm Verification of the crankshaft counterweights 39 03mm 04 mm Place the crankshaft on blocks and check the radial play at the bearing seating Service limit 0 04 mm Both sides Heat up the bearing core using a hot air gun Fit the crankshaft into the left hand crankcase half Check the 2 crankcase half centring guide pins and locate the crankcase gasket using AGIP GR MU 3 type grease ASSEMBLY OF RIGHT HAND CRANKCASE BEARING After heating up the seating in the right hand side crankcase half to 80 C fit the crankshaft bearing using special tool 0 0F 054 0 045 1 The bearing is number 6204 px2 v4 Heat the bearing core in the right hand crankcase half with a hot air gun so as to be able to close the crankcase with 6 screws 4 6x35 1 6x40 1 6x50 Use thread seal Loctite 240 type and tighten to a torque of 9 10 Nw x m Fit a wedge in between the crankshaft counter weights in order to centre the crankshaft The
86. verse and tighten to the specified torque set ting Torque setting 12 13 N m Replacement of the toothed segment and star ter crankshaft gearing Remove the Seeger ring situated on the outside of the crankcase Strip the starter gearing from its housing relaxing the pressure exerted by the toothed segment through the spring in order to do this it is neces sary to rotate the toothed segment slightly see figure Caution During the stripping operation on the toothed segment take extreme care over the ten sion exerted by the spring this could injure the operator Assembling the toothed segment and starter gearing into the crankcase When assembling apply Agip GR MU to the bush to the spring and along the toothed seg ment To load the spring use the special tool as shown in the figure Fit the Seeger ring after checking that it is in per fect condition Special tool 19 1 20261 Replacing the reduction gear cover bearing In order to replace the bearing in the reduction gear cover heat up the crankcase and extract the bearing by tapping with gentle blows from a raw hide hammer Special tool 19 1 20150 Special tool 19 1 20151 mm 94 57 FN Al y LIII ER 1717 CYLINDER HEAD CYLINDER PISTON Liquid cooled models Y LUBRICATE APPLY THE PRODUCT A CAUTION HANDLE WITH CARE 4 GREASE CLEAN WITH CARE 8 ALWAYS REPLACE TORQUE N M

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