piaggio nrg power dd scooter motorcycle bike workshop service repair manual cd

WORKSHOP MANUAL633325

NRG Power DD

WORKSHOPMANUAL

NRG Power DD

The descriptions and illustrations given in this publication are not binding. While the basic features asdescribed and illustrated in this manual remain unchanged, PIAGGIO - GILERA reserves the right, atany time and without being required to update this publication beforehand, to make any changes to

components, parts or accessory supplies, which it considers necessary to improve the product or whichare required for manufacturing or construction reasons.

Not all versions shown in this publication are available in all Countries. The availability of individualversions should be confirmed with the official Piaggio sales network.

" Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publicationin whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-SalesV.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

WORKSHOP MANUALNRG Power DD

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have abasic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any importantchanges made to the vehicles or to specific fixing operations will be promptly reported by updates to thismanual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools areunavailable. It is therefore advisable to read the sections of this manual relating to specific tools, alongwith the specific tool catalogue.

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

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

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

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

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

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

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

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

Safety rules

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

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

fumes are toxic.

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

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

and seek immediate medical attention.

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

or flames near the battery, especially when charging it.

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

area, and avoid open flames or sparks.

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

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

contains no asbestos, inhaling dust is harmful.

Maintenance rules

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

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

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

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

work surfaces except the tapered couplings before refitting.

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

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English measurement. Using unsuitable

coupling members and tools may damage the scooter.

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

sure the electric connections have been made properly, particularly the ground and battery connections.

Characteristics NRG Power DD

CHAR - 2

Vehicle identification

Frame prefix: ZAPC45100 1001

Engine prefix: C451M

Dimensions and mass

DIMENSIONS AND MASSSpecification Desc./Quantity

Max length 1790 mm.Max width 850 mm.

Seat height 795 mm.Wheelbase 1280 mmDry weight 99 kg.

NRG Power DD Characteristics

CHAR - 3

Engine

ENGINESpecification Desc./QuantityType of engine One-cylinder 2 speed Piaggio Hi-PER2 PROBore x stroke 40 X 39.3 mm

Cubic capacity 49.40 ccCompression ratio 11.3 12.8 : 1

Carburettor DELL'ORTO PHVA 17.5 IDCO adjustment 3.5% 0.5

Engine idle speed 1800 to 2000 r.p.m.Air filter Sponge impregnated with fuel mixture (50% SE-

LENIA air filter oil and 50% unleaded petrol).Starting system electric starter/kickstarter

Lubrication With blend and variable oil variable according tothe engine revolutions and the throttle valve open-ing by means of a pump controlled by the driving

shaft with toothed belt.Fuel supply: With the fuel pump in depression, lead-free gaso-

line (with 95 octane minimum) by means of thecarburettor

Cooling system Through circulation of cooling liquid


CHAR - 4

Transmission

TRANSMISSIONSpecification Desc./QuantityTransmission With automatic expandable pulley variator, torque

server, V belt, automatic clutch, gear reductionunit.

Capacities

CAPACITYSpecification Desc./QuantityRear hub oil Quantity : ~ 85 cc

Mixer oil 1.2 litresFuel tank capacity 6.5 litres (1.5 litres of reserve)

Electrical system

ELECTRIC SYSTEMSpecification Desc./Quantity

Type of ignition Capacitive discharge type electronic ignition, withincorporated high voltage coil

Spark advance (Before T.D.C.) 201 at 4000 rpmSparkplug (One-cylinder two-stroke liquid cooled) CHAMPION RN1C

Battery 12V-4AhMain fuse 7.5 AGenerator In alternate current with three output sections

Frame and suspensions

FRAME AND SUSPENSIONSSpecification Desc./QuantityChassis type Welded tubular steel chassis with stamped sheet

reinforcementsFront suspension upside-down hydraulic telescopic fork.

Front suspension travel 75 mmRear suspension With coaxial spring and hydraulic shock absorber.

Chassis to engine support with swinging arm.

Brakes

BRAKESSpecification Desc./QuantityFront brake 220 mm disc brake with hydraulic linkage (r.h.

brake lever).Rear brake 175 mm disc (hydraulically controlled via lever

on left hand-side of handlebar)


CHAR - 5

Wheels and tyres

WHEELS AND TYRESSpecification Desc./Quantity

Front tyre Tubeless 120/70-13"Rear tyre Tubeless 140/60 x 13''Wheels With circles of 3.50 x 13" in light alloy.

Secondary air

To clean the sponge filters of the secondary air

system, proceed as follows:

Unscrew the two studs ( 2) of the aluminium lid of

the secondary air box to access the polyurethane

sponge contained inside the box; after cleaning

with water and neutral soap, dry the sponge with

a clean cloth and reassemble the system, check-

ing that the steel blade is not warped and/or does

not guarantee the seal on its strike surface; re-

place if necessary.N.B.

UPON REFITTING, MAKE SURE TO CORRECT-LY FIT THE TAB IN ITS FITTING ON THE TWOPLASTIC AND ALUMINIUM COVERS.CAUTION

DURING THE OPERATION, CHECK THE IN-TEGRITY AND SEAL OF THE TWO SLEEVES(3) IN RUBBER LOCATED AT THE ENDS OFTHE SECONDARY AIR HOSE; IF NECESSARY,REPLACE THEM USING NEW CLAMPS TOFASTEN.

Carburettor

50cc Version

Dell'Orto

DELL'ORTO CARBURETTORSpecification Desc./Quantity

Type PHVA 17.5 IDDiffuser diameter 17.5

Reference number of adjustment 8439


CHAR - 6

Specification Desc./QuantityMaximum nozzle: 53

Maximum air nozzle (on the body): 1.5Tapered pin stamped code: A22

Pin position (notches from above): 1Diffuser: 209 HA

Minimum nozzle: 32Minimum air nozzle (on the body): Free

Secondary minimum air hole 2.5Initial minimum mix screw opening: 1 1/2

Starter jet 50Starter air nozzle (on the body): 1.5

Stroke of starter pin: 11 mmFuel inlet hole 1.0

Tightening Torques

STEERING ASSEMBLYName Torque in Nm

Upper steering ring nut (safety locks) 35 to 40 NmLower steering ring nut (safety locks) 8 to 10 Nm

Handlebar fixing pin (safety locks) 45 to 50 Nm

FRAME ASSEMBLYName Torque in Nm

Swinging arm-engine pin (safety locks) 33 to 41 NmSwinging arm-frame pin (safety locks) 64 to 72 Nm

Shock absorber - frame nut (safety locks) 20 to 25 NmShock absorber-engine pin (safety locks) 33 to 41 Nm

Rear wheel axis (safety locks) 104 to 126 NmBolt holding stand to the engine 18 to 19 Nm

Side stand fixing screw 12 20Side stand bracket fixing screw 15 20

Rear rim fixing screw 2025

FRONT SUSPENSIONName Torque in Nm

Front wheel axle nut (safety locks) 45 to 50 NmWheel axle clamp screw 6 7 Nm

Lower leg screw 15 to 20 NmHydraulic cartridge stem nut 15 to 18 Nm

FRONT BRAKEName Torque in Nm

Viti fissaggio coperchio pompa freno 1,5 2 NmBrake pump support fixing screw 7 to 10 Nm

Brake fluid pump - hose fitting 13 to 18 NmBrake fluid tube - calliper fitting 20 to 25 Nm

Calliper tightening screw 20 to 25 NmDisc tightening screw (safety locks - lock with

LOCTITE THREADLOCK MEDIUM TYPE 243)6 7 Nm

Oil bleed screw 7 to 10 Nm


CHAR - 7

Name Torque in NmCalliper coupling screw 20 to 25 Nm

REAR BRAKEName Torque in Nm

Fastening screws calliper to the crankcase 20 - 25Brake reservoir cover fixing screw 24 Nm (Grimeca) - 0,81,5 Nm (Brembo) -

1,52 Nm (Hengtong)Brake pump support fixing screw 7 to 10 Nm

Brake fluid pump - hose fitting 13 to 18 NmBrake fluid tube - calliper fitting 20 to 25 Nm

Oil bleed screw 7 to 10 Nm

ENGINE ASSEMBLYName Torque in Nm

Clutch bell nut 40 to 44 NmClutch lock ring nut 55 60

nut locking driving pulley on the crankshaft 40 to 44 NmStart-up lever screw 12 13

Flywheel nut 40 to 44 NmFlywheel fan screws 3 4

Half-crank case joint bolts 12 13Bolts holding exhaust pipe to the crankcase 22 24

Screws holding the filter box to the crank case 4 5Head nuts 10 11

Starter screws 12 13Ignition spark plug 25 30

Hub oil drainage cap 3 5Oil hub level dipstick ManualRear hub cap screws 12 13

Transmission cover screws 12 13Inlet manifold screws 8 9

Flywheel hood fixing screws 1 2Cylinder hood fixing screws 3.5 5

Stator clamping screws 3 4Pick-Up clamping screw 4 5Mixer clamping screws 3 4

Screw fixing brake lever to the journal on the en-gine

12 13

Overhaul data

Assembly clearances

Cylinder - piston assy.

CYLINDER-PISTON FITTINGName Initials Cylinder Piston Play on fitting

Standard fitting M 39.997-40.004 39.943-39.95 0.047-0.061Standard fitting N 40.004-40.011 39.95-39.957 0.047-0.061


CHAR - 8

Name Initials Cylinder Piston Play on fittingStandard fitting O 40.011-40.018 39.957-39.964 0.047-0.061Standard fitting P 40.018-40.025 39.964-39.971 0.047-0.061

1st oversize fitting M1 40.197-40.204 40.143-40.15 0.047-0.0611st oversize fitting N1 40.204-40.211 40.15-40.157 0.047-0.0611st oversize fitting O1 40.211-40.218 40.157-40.164 0.047-0.0611st oversize fitting P1 40.218-40.225 40.164-40.171 0.047-0.0612nd oversize fitting M2 40.397-40.404 40.343-40.35 0.047-0.0612nd oversize fitting N2 40.404-40.411 40.35-40.357 0.047-0.0612nd oversize fitting O2 40.411-40.418 40.357-40.364 0.047-0.0612nd oversize fitting P2 40.418-40.425 40.364-40.371 0.047-0.061

Piston rings

SEALING RINGSName Description Dimensions Initials Quantity

Compression ring 40 A 0.10 to 0.25Compression ring

1st oversize40.2 A 0.10 to 0.25

Compression ring2nd Oversize

40.4 A 0.10 to 0.25

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING RODName Description Dimensions Initials Quantity

Connecting rod 11.750-0.05 A clearance E = 0.25to 0.50


CHAR - 9

Name Description Dimensions Initials Quantityshoulder washer 0.5 0.03 G clearance E = 0.25

to 0.50 - clearanceF = 0.20 to 0.75

Half-shaft, trans-mission side

13.75+0.040 C clearance E = 0.25to 0.50 - clearance

F = 0.20 to 0.75Flywheel-side half-

shaft13.75+0.040 D clearance E = 0.25

to 0.50 - clearanceF = 0.20 to 0.75

Lining between theshoulders

40.64 H clearance E = 0.25to 0.50 - clearance

F = 0.20 to 0.75Cage 11.800-0.35 B clearance F = 0.20

to 0.75

Slot packing system

- Fit the cylinder without installing the basic gasket.

- Apply a centimetre dial gauge on the special tool and zero it on the ground plane

- Fit the tool to the top of the cylinder fixing it with two nuts to the studbolts and take the piston to the

T.D.C.

- The thickness of the gasket to fit will change depending on the value detected. For this purpose, there

are three with different thicknesses

Specific tooling

020272Y Piston position check tool

SLOT PACKING SYSTEMName Measure A Thickness

Shimming 2.80 3.04 0,4Shimming 3.04 3.24 0,6Spacing 3,243,48 0,8


CHAR - 10

Products

TABLE OF RECOMMENDED PRODUCTSProduct Description Specifications

AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds therequirements of API GL3 specifi-

cationsAGIP CITY HI TEC 4T Oil to lubricate flexible transmis-

sions (brake, throttle control andmixer, odometer)

Oil for 2-stroke engines: SAE5W-40, API SL, ACEA A3, JASO

MAAGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives

for increased adhesivenessAGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines:

JASO FC, ISO-L-EGDAGIP GP 330 Grease for brake levers, throttle White calcium complex soap-

based spray grease with NLGI 2;ISO-L-XBCIB2

AGIP GREASE SM 2 Grease for the tone wheel revolv-ing ring

Soap-based lithium grease con-taining NLGI 2 Molybdenum di-sulphide; ISO-L-XBCHB2, DIN

KF2K-20AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

MONTBLANC MOLYBDENUMGREASE

Grease for driven pulley shaft ad-justing ring and movable driven

pulley housing

Grease with Molybdenum disul-phide

AGIP GREASE PV2 Grease for the steering bearings,pin seats and swinging arm

White anhydrous-calcium basedgrease to protect roller bearings;temperature range between -20C and +120 C; NLGI 2; ISO-L-

XBCIB2.SPECIAL AGIP PERMANENT

fluidcoolant Monoethylene glycol-based anti-

freeze fluid, CUNA NC 956-16


CHAR - 11


CHAR - 12

INDEX OF TOPICS

TOOLING TOOL

TOOLINGStores code Description

001330Y Tool for fitting steering seats

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Driver for OD 54 mm bearing

001467Y009 Driver for OD 42 mm bearings

001467Y013 Pliers to extract 15-mm bear-ings

001467Y014 Pliers to extract 15-mm bear-ings

Tooling NRG Power DD

TOOL - 2

Stores code Description001467Y017 Bell for bearings, outside 39

mm

001467Y021 Extraction pliers for 11 mmbearings

002465Y Pliers for circlips

006029Y Punch for fitting fifth wheel seaton steering tube

020004Y Punch for removing fifth wheelsfrom headstock

020209Y Spring hook

NRG Power DD Tooling

TOOL - 3

Stores code Description020055Y Wrench for steering tube ring nut

020074Y Support base for checking crank-shaft alignment

020150Y Air heater support

020151Y Air heater

020162Y Flywheel extractor

020163Y Crankcase splitting plate


TOOL - 4

Stores code Description020164Y Driven pulley assembly sheath

020165Y Start-up crown lock

020166Y Pin lock fitting tool

020167Y Arrest key for impeller pump

020168Y Water seal punch mount on half-crankcase

020169Y Water pump crankshaft fittingand removal spanner


TOOL - 5

Stores code Description020170Y Water pump/mixer command

gear extractor

020261Y Starter spring fitting

020262Y Crankcase splitting strip

020265Y Bearing fitting base

020325Y Brake-shoe spring calliper

020329Y MityVac vacuum-operated pump


TOOL - 6

Stores code Description020330Y Stroboscopic light for timing con-

trol

020331Y Digital multimeter

020332Y Digital rev counter

020334Y Multiple battery charger


TOOL - 7

Stores code Description020335Y Magnetic support for dial gauge

020350Y Electrical system check instru-ment

020357Y 32 x 35 mm adaptor020359Y 42x47-mm adaptor

020376Y Adaptor handle


TOOL - 8

Stores code Description020412Y 15 mm guide

020456Y 24 mm adaptor

020483Y 30 mm guide

020565Y Flywheel lock calliper spanner

020625Y Kit for sampling gas from the ex-haust manifold

494929Y Exhaust fumes analyser


TOOL - 9


TOOL - 10

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

EVERY 2 YEARSAction

Brake fluid - changeCoolant - change

AFTER 1000 KM50'

ActionHub oil - changeOil mixer/throttle linkage - adjustmentOdometer cable - greasingSteering - adjustmentBrake control levers - greasingBrake fluid level - checkSafety locks - checkElectrical system and battery - checkTyre pressure and wear - checkVehicle and brake test - road test

AT 5000 KM OR 12 MONTHS, 25000 KM, 35000 KM AND 55000 KM40'

ActionHub oil level - checkSpark plug/electrode gap - replacementAir filter - cleanOil mixer/throttle linkage - adjustmentCoolant level - checkBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkElectrical system and battery - checkTyre pressure and wear - checkVehicle and brake test - road test

AT 10000 KM OR 24 MONTHS AND 50000 KM95'

ActionHub oil - changeSpark plug/electrode gap - replacementAir filter - cleanIdling speed (*) - adjustmentOil mixer/throttle linkage - adjustmentVariable speed rollers - replacementOdometer cable - greasingDriving belt - checkCoolant level - checkSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wear

Maintenance NRG Power DD

MAIN - 2

ActionBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentTyre pressure and wear - checkVehicle and brake test - road test

(*) See CO regulation in the Adjusting the engine idle section

AT 15000 KM AND 45000 KM65'

ActionHub oil level - checkSpark plug/electrode gap - replacementAir filter - cleanOil mixer/throttle linkage - adjustmentDriving belt - replacementCoolant level - checkBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkElectrical system and battery - checkTyre pressure and wear - checkSAS box (sponge) (**) - cleaningVehicle and brake test - road test

(**) See the regulations of the "Secondary air system" section

AT 20000 KMS AND 40000 KMS120'

ActionHub oil - changeSpark plug/electrode gap - replacementAir filter - cleanIdling speed (*) - adjustmentCylinder cooling system - check/cleaningOil mixer/throttle linkage - adjustmentDriving belt - checkVariable speed rollers - replacementMixer belt - replacementCoolant level - checkRadiator - external cleaning/ checkOdometer cable - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentTyre pressure and wear - check

NRG Power DD Maintenance

MAIN - 3

ActionVehicle and brake test - road test

(*) See CO regulation in the Adjusting the engine idle section

AT 30000 KM130'

ActionHub oil - changeSpark plug/electrode gap - replacementAir filter - cleanIdling speed (*) - adjustmentOil mixer/throttle linkage - adjustmentDriving belt - replacementVariable speed rollers - replacementCoolant level - checkOdometer cable - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearFlexible brake tubes - replacementBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentTyre pressure and wear - checkSAS box (sponge) (**) - cleaningVehicle and brake test - road test

(*) See CO regulation in the Adjusting the engine idle section(**)See rules in the Secondary Air System section

AT 60000 KM160'

ActionHub oil - changeSpark plug/electrode gap - replacementAir filter - cleanIdling speed (*) - adjustmentOil mixer/throttle linkage - adjustmentDriving belt - replacementVariable speed rollers - replacementMixer belt - replacementCoolant level - checkRadiator - external cleaning/ checkOdometer cable - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearFlexible brake tubes - replacementBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - check


MAIN - 4

ActionElectrical system and battery - checkHeadlight - adjustmentTyre pressure and wear - checkSAS box (sponge) (**) - cleaningVehicle and brake test - road test

(*) See CO regulation in the Adjusting the engine idle sectionp>(**) Vedere norme della sezione Sistema aria secondaria

Checking the spark advance

- Check to be carried out at an engine speed of, or above, 4,000 rpm with timing light. The spark

advanced measured must be 20 before T.D.C.

- This figure is correct when the reference on the flywheel shroud is aligned with that on the cooling fan

and the out-of-phase on the light is set to 20.N.B.

IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS PROVIDED FOR IN THE ELECTRICALSYSTEM CHAPTER.CAUTION

BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK THE CORRECT KEYING OF THE FLY-WHEEL ON THE CRANKSHAFT.

Specific tooling

020330Y Stroboscopic light for timing control

Spark plug

- Rest the vehicle on its centre-stand;

- Detach the spark plug flap by removing the two

fixing screws;

- Detach the H.T. cable cap from the spark plug;

- Remove the spark plug using the box-spanner

provided;


MAIN - 5

- Examine the conditions of spark plug, the integ-

rity of the insulator, and measure the spark gap

with the aid of a feeler gauge.

- If required, adjust the spark gap by carefully

bending the outer electrode.

In the event of defects, replace the spark plug with

one of the recommended type;

- Engage the thread, with the correct inclination,

and the screw the spark plug by hand as far as it

will go, then tighten it using the box-spanner pro-

vided;

- Insert the spark plug cap;

- Refit the spark plug flap.CAUTION

THE SPARK PLUG MUST BE REMOVED WHENTHE MOTOR IS COLD. THE SPARK PLUGMUST BE REPLACED EVERY 5000 KM. USEOF STARTERS NOT CONFORMING OR SPARKPLUGS NOT THOSE DESCRIBED CAN SERI-OUSLY DAMAGE THE ENGINE.

CharacteristicSpark plug

CHAMPION RN1C

Electric characteristicElectrode gap

0.45 0.55 mm

Locking torques (N*m)Spark plug 25 - 30 Nm

Hub oil


MAIN - 6

Check

Do the following to check the correct level:

1) Stand the vehicle on the centre-stand on flat

ground;

2) Remove the dipstick A, and dry it with a clean

cloth. Reinsert it, screwing it in all the way;

3) Remove the stick and check that the oil level is

slightly over the second notch starting from the

lower end;

4) Screw the dipstick back in, checking that it is

locked in place.

Recommended productsAGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of

API GL3 specifications

Replacement

- Remove oil filler cap A.

- Loosen oil draining cap B and allow for the

system to drain completely.

- Refit the draining cap and refill the hub with the

prescribed oil.

CharacteristicRear hub oil

~ 85 cc


MAIN - 7

Air filter

-Remove the cap of the purifier, unscrewing the six

clamping screws and removing the filter.

Cleaning:

-Wash with water and neutral soap.

- Dry with a clean cloth and short blasts of com-

pressed air.

-Saturate with a 50% mixture of gasoline and oil.

-Drip dry the filter and then squeeze it between the

hands without wringing.

-Let it dry and refit it again.CAUTION

NEVER RUN THE ENGINE WITHOUT THE AIRFILTER, THIS WOULD RESULT IN AN EXCES-SIVE WEAR OF THE PISTON AND CYLINDER.

Recommended productsAGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased ad-

hesiveness

transmissions

- Adjust the control cables:

Mix cable: see procedure indicated in "Mixer tim-

ing".

Throttle cable: adjust the set screw on the carbu-

rettor in such a way that the sheath has no back-

lash.

Splitter control cable: adjust set screw on the throt-

tle control to the handlebar in such a way that there

is no backlash on the throttle control.

Adjust all transmissions in such a way that their

sheathings show no sign of backlash.

Mixer Timing

- Using the transmission set screw on the crank-

case, with throttle control untwisted, adjust the

reference mark on the rotating plate so that it is

lined up with the reference mark on the mixer

body, as shown in the figure.


MAIN - 8

While doing this, the engine must be fuelled with a

2 % oil mixture (0.5 litre minimum if the reservoir

is empty).CAUTION

IN CASE OF DISMANTLING OR RUNNING OUTOF OIL IN THE RESERVOIR BLEED THE MIXERAS FOLLOWS: REFILL THE OIL RESERVOIRWHEN THE MIXER IS FITTED TO THE VEHICLEAND THE ENGINE IS OFF, UNDO THE MIXERPIPE FROM THE CARBURETTOR AND LOOS-EN THE BLEED SCREWS (SEE THE ARROW INTHE FIGURE) UNTIL THE OIL BEGINS TOFLOW OUT. TIGHTEN THE SCREWS, STARTUP THE ENGINE AND WAIT FOR OIL TO FLOWOUT OF THE TUBE. RECONNECT THE DELIV-ERY PIPE TO THE CARBURETTOR AND FIX ITIN PLACE WITH THE RELEVANT METAL CLIP.

Recommended productsAGIP CITY TEC 2T Mixer oil

synthetic oil for 2-stroke engines: JASO FC, ISO-

L-EGD

Braking system

Level check

Proceed as follows:

- Rest the vehicle on its centre stand with the han-

dlebars perfectly horizontal;

- Check the level of liquid with the related warning

light A.

A certain lowering of the level is caused by wear

on the pads.


MAIN - 9

Top-up

Proceed as follows:

- Remove the tank cap by loosening the two

screws, remove the gasket and top up using only

the liquid specified without exceeding the maxi-

mum level.CAUTION

ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.CAUTION

MAKE SURE THE BRAKE FLUID DOES NOTGET INTO YOUR EYES OR ON YOUR SKIN ORCLOTHES. IF THIS HAPPENS ACCIDENTALLY,WASH WITH WATER.CAUTION

BRAKE CIRCUIT FLUID IS VERY CORROSIVE;MAKE SURE THAT IT DOES NOT COME INTOCONTACT WITH THE PAINTWORK.CAUTION

THE BRAKE FLUID IS HYGROSCOPIC, IN OTH-ER WORDS, IT ABSORBS MOISTURE FROMTHE SURROUNDING AIR. IF THE CONTENT OFMOISTURE IN THE BRAKING FLUID EXCEEDSA CERTAIN VALUE, BRAKING WILL BE INEF-FICIENT.NEVER USE BRAKE LIQUID IN OPEN OR PAR-TIALLY USED CONTAINERS.UNDER NORMAL CLIMATIC CONDITIONS,THE FLUID MUST BE CHANGED EVERY 20,000KM OR ANYWAY EVERY TWO YEARS.N.B.

SEE THE BRAKING SYSTEM CHAPTER WITHREGARD TO THE CHANGING OF BRAKE FLU-ID AND THE BLEEDING OF AIR FROM THECIRCUITS.

Recommended productsAGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

Headlight adjustment

Proceed as follows:

1. Place the vehicle in running order and with the

tyres inflated to the prescribed pressure, on a flat

surface 10 m away from a white screen situated in

a shaded area, making sure that the longitudinal

axis of the vehicle is perpendicular to the screen;


MAIN - 10

2. Turn on the headlight and check that the bor-

derline of the projected light beam on the screen

is not lower than 9/10 of the distance from the

ground to the centre of vehicle headlamp and high-

er than 7/10;

3. Otherwise, regulate the headlight by adjusting

the screw A, after removing the front grille.N.B.

THE ABOVE PROCEDURE COMPLIES WITHTHE EUROPEAN STANDARDS REGARDINGMAXIMUM AND MINIMUM HEIGHT OF LIGHTBEAMS. REFER TO THE STATUTORY REGU-LATIONS IN FORCE IN EVERY COUNTRYWHERE THE vehicle IS USED.

CO check

In the event that the exhaust on the vehicle being

tested does not have an exhaust gases collection

port, proceed as follows:

- Remove the R.H. side fairing

- Remove the secondary air box cover with the

aluminium cap by acting upon the clamp shown in

the figure.

Attach the exhaust gas collection tube to the sec-

ondary air rubber manifold. Such joint must be

sealed in order to guarantee accurate CO read-

ings.

- Start the engine, adjust the idle speed to 1,700 100 rpm and check the CO value is equal 3.5 1%

- If the parameters found do not agree with the above figures, act upon the idle adjusting screw. Oth-

erwise, check the automatic choke device

Specific tooling

020320Y Exhaust gases analyser



MAIN - 11

The check must be carried out after having care-

fully cleaned all carburettor components, with the

air filter clean, and the spark plug in good condi-

tions.

- Remove the R.H. side fairing

- Warn-up the engine by riding the vehicle on the

road for at least 10 minutes

- Shut down the engine

- Remove the 2 secondary air box screws shown

in the figure

Place a plastic sheet between the one-way valve

and the aluminium outlet as shown in the figure

Ensure the one-way valve packing properly

seals the aluminium outlet fitting.

Refit the aluminium outlet onto the SAS box as

shown in the picture.

- Attach the special tool and move the joints as

shown in the figure.

- Start the engine, adjust the idle speed to 1,700

100 rpm and check the CO value is equal 3.5 1%

- If the parameters found do not agree with the

above figures, act upon the idle adjusting screw.

Otherwise, check the automatic choke device.

Specific tooling

020320Y Exhaust gases analyser



MAIN - 12

020625Y Kit for sampling gas from the exhaustmanifold


MAIN - 13


MAIN - 14

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

This section makes it possible to find the solutions to use in troubleshooting.

For each breakdown, a list of the possible causes and respective interventions is given.

Engine

Poor performance

POOR PERFORMANCEPossible Cause Operation

Defective fuel pump or damaged depression line Replace the pump or control linesCarburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with com-

pressed airFuel filter on the tank outlet fitting dirty or clogged Clean the fitting filterExcess of encrustations in the combustion cham-

berRemove the encrustations

Lack of compression wear of the piston rings orcylinder

Check the worn parts and replace them

Exhaust pipe clogged due to excessive encrusta-tions

Replace the exhaust pipe and check the carbura-tion and mixer timer

Air filter blocked or dirty Clean according to the procedureStarter inefficient (stays on) Check the mechanical sliding, continuity of the cir-

cuit, the presence of power and electrical wiringClutch slipping Check the centrifugal brake shoe assembly and /

or clutch bell and replace if necessaryDefective mobile pulley sliding Check the parts, change the faulty parts and lubri-

cate the driven pulley using only Montblanc-Mo-libdenum Grease (dis. 498345) grease

Transmission belt worn ReplaceRoller wear; Presence of oil; Dirt Clean the speed variator, replace the rollers if worn

out

Rear wheel spins at idle

REAR WHEELPossible Cause Operation

Idling rpms too high Check the idling speed and, if necessary, adjustthe C.O.

Clutch fault Check the spring/friction mass and the clutch bellAir filter housing not sealed Correctly refit the filter housing and replace it if it

is damaged

Starting difficulties

DIFFICULTY STARTINGPossible Cause Operation

Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with com-pressed air

Defective fuel pump or damaged depression line Replace the pump or control lines

Troubleshooting NRG Power DD

TROUBL - 2

Possible Cause OperationStarter inefficient Check: electric wiring, circuit continuity, mechani-

cal sliding and power supplyBattery flat Check the state of the battery. If it shows signs of

sulphation replace it and bring the new battery intoservice charging it for eight hours at a current of

1/10 of the capacity of the battery itself- Engine flooded. Start up keeping the throttle fully open alternating

approximately five seconds of turning it with fiveseconds still. If however it does not start, removethe spark plug, the engine over with the throttle

open being careful to keep the cap in contact withthe spark plug and the spark plug grounded but

away from its hole. Refit a dry spark plug and startthe vehicle.

Altered fuel characteristics Drain off the fuel no longer up to standard; then,refill

Defective spark plug or with incorrect electrodegap

Remove the encrustation, restore the plug gap orreplace being sure to use the types of spark plugrecommended at all times. Bear in mind that manyproblems engines have, derive from the use of the

wrong spark plugIntake joint cracked or with a bad seal Replace the intake joint and check its tightness on

the crankcase and on the carburettorPurifier-carburettor fitting damaged Replace

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUSTPossible Cause Operation

Excess of encrustations in the combustion cham-ber

Remove the encrustations

Engine tends to cut-off at full throttle

ENGINE STOP FULL THROTTLEPossible Cause Operation

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with com-pressed air

Dirty carburettor Wash the carburettor with solvent and dry withcompressed air

Water in the carburettor Empty the tank through the appropriate bleed nip-ple.

Air filter dirty Clean or replaceDefective floating valve Check the proper sliding of the float and the func-

tioning of the valveTank breather hole obstructed Restore the proper tank aeration

NRG Power DD Troubleshooting

TROUBL - 3

Engine tends to cut-off at idle

ENGINE STOP IDLINGPossible Cause Operation

Minimum nozzle dirty Wash the nozzle with solvent and dry with com-pressed air

Starter that stays open Check: electric wiring, circuit continuity, mechani-cal sliding and power supply

Reed valve does not close Check / replace the reed packWrong idling adjustment Correctly adjust the engine idling and check the

level of the C.O.Spark plug defective or faulty Replace the spark plug with one with the specified

degree and check the plug gap

Excessive exhaust noise

INCREASED NOISINESSPossible Cause Operation

Secondary metal air pipe deteriorated Check the seal of the piping on the crankcase andon the housing, check the piping between the

housing and the muffler.Good condition of the missing secondary air circuit

componentsCheck the individual components and the piping,check the precision of the fitting. Replace the dam-

aged components

High fuel consumption

HIGH FUEL CONSUMPTIONPossible Cause Operation

Air filter blocked or dirty. Clean according to the procedureStarter inefficient Check: electric wiring, circuit continuity, mechani-

cal sliding and power supply

Engine overheating

ENGINE OVERHEATINGPossible Cause Operation

Lack of liquid in the cooling circuit. Restore the level and check the absence of lossesfrom the circuit

Incorrect air bleeding Repeat the operationThermostat remains closed ReplaceLiquid leak from the radiator Replace radiatorLiquid leak from the system Overhaul of the system

Coolant leaks from crankcase draining hole Replace coolant sealing ring on half-crankcasefrom transmission-side

Bearings shaft support impeller blocked Replace the bearings and the shaft with impellerBreakage of mixer belt Replace the belt and check that the thermal unit

has not been damaged


TROUBL - 4

SAS malfunctions

SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-FLER

Possible Cause OperationSecondary air reed blocking ReplaceSecondary air filter clogging Clean the filter and the housing

Blockage of the secondary air fitting on the muffler Remove the encrustations from the joint beingcareful not to let the debris fall into the muffler

Transmission and brakes

Clutch grabbing or performing inadequately

CLUTCHPossible Cause Operation

Tear or irregular functioning Check that the masses open and return normallyCheck that there is no grease on the masses

Check that the clutch masses' contact surface withthe clutch bell is mainly in the middle with charac-

teristics equivalent on the three massesCheck that the clutch bell is not scored or worn

abnormallyNever operate the engine without the clutch bell

Insufficient braking

BRAKING SYSTEM MALFUNCTIONPossible Cause Operation

Poor braking The rear (drum type) brake is adjusted by regulat-ing the special adjustment (on the wheel) bearingin mind that, with the control levers in the rest po-

sition, the wheels must turn freely.The braking action should begin when the brake

levers are pressed by about a third.Check the brake pad wear.

If it is not possible to remove any problems by sim-ply adjusting the transmissions, check the brake

pads and front brake disc, the brake shoes and therear drum. If you encounter excessive wear orscoring, make the necessary replacements.

Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system,(there must be no flexible movement of the brake

lever).Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump break-

down, replaceThe brake fluid has lost its properties Replace the front brake fluid and top up to the cor-

rect level in the pumpDefective sliding of the cables in their sheathes Lubricate or substitute

Brake noise Check the wear of the brake pads and/or shoes


TROUBL - 5

Brakes overheating

BRAKES OVERHEATINGPossible Cause Operation

Defective piston sliding Check calliper and replace any damaged part.Brake disc or drum deformed Using a dial gauge, check the planarity of the disk

with the wheel correctly fitted or the concentricityof the rear drum.

Electrical system

Battery

BATTERYPossible Cause Operation

Battery The battery is the electrical device in the systemthat requires the most frequent inspections andthorough maintenance. If the vehicle is not used

for some time (1 month or more) the battery needsto be recharged periodically. The battery runs

down completely in the course of 5 6 months. Ifthe battery is fitted on a motorcycle, be careful notto invert the connections, keeping in mind that theblack ground wire is connected to the negative ter-minal while the red wire is connected to the termi-nal marked+. Follow the instructions in the ELEC-TRICAL SYSTEM chapter for the recharging of the

batteries.

Steering and suspensions

Rear wheel

POOR ROAD HOLDINGPossible Cause Operation

Faulty suspension Check that the rear shock absorber and/or thefront fork is/are in good working order. Replace or

overhaul the front fork and/or replace the rearshock absorbers in case of malfunction

Tyres deflated or damaged Check the correct pressure of the tyres and thecondition of the tread. Inflate to the correct pres-

sure or replace.Loosen the anchorage points of the front and/or

rear suspension unit.Check the tightness between the frame, swingingarm and engine and the fixing of the wheels to thehub and/or the axle. Check the correct tightening

of the steering ring nut.


TROUBL - 6

Heavy steering

STEERING HARDENINGPossible Cause Operation

Torque not conforming Check the tightening of the top and bottom ringnuts.

If irregularities continue in turning the steeringeven after making the above adjustments, checkthe seats in which the ball bearings rotate: replace

if they are recessed.

Excessive steering play

EXCESSIVE STEERING CLEARANCEPossible Cause Operation

EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ringnuts.

If irregularities continue in turning the steeringeven after making the above adjustments, checkthe seats in which the ball bearings rotate: replace

if they are recessed.

Noisy suspension

NOISY SUSPENSIONPossible Cause Operation

Components of the front suspension damaged. Check the quiet operation in the compression orrelease phases of the fork and if necessary over-

haul it. Check that there is no noise or seizingduring the wheel rotation; if there is, change the

wheel bearing.Components of the rear suspension damaged. Check the absence of noise in the compression or

release of the suspension, if necessary check theproper tightness to the swinging arm unit and theabsence of rust or replace the entire shock ab-sorber. Check that there is no noise or seizing

during the wheel rotation; if there is noise or seiz-ing overhaul the final reduction assembly.

Suspension oil leakage

SUSPENSION LEAKS OILPossible Cause Operation

Rear shock absorption malfunctioning Replace the complete shock absorption unitHydraulic cartridge in the fork damaged. Replace the hydraulic cartridge


TROUBL - 7


TROUBL - 8

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

LEGENDASpecification Desc./Quantity

1 Voltage regulator2 Horn button3 Turn signal switch4 Light switch5 Rear brake stop button6 Front L.H. turn signal light7 Front headlight8 Two rear parking light bulbs 12V - 3W9 Horn10 Light bulb 12V - 35W for high-beam lamp11 Light bulb 12V - 35W for low-beam lamp12 Front R.H. turn signal light13 Front brake stop light switch14 Wheel rpm sensor15 Starter button16 Ignition key-switch17 Fuel level sender

Electrical system NRG Power DD

ELE SYS - 2

Specification Desc./Quantity18 Mixture oil warning light switch19 Thermistor20 Magneto flywheel21 Control device ignition22 Automatic starter23 Starter motor24 Taillight resistor25 Rear R.H. turn signal light26 Taillight assembly27 Choke device continuity check light28 Battery 12V - 4Ah29 Rear L.H. turn signal light30 License plate light pre-wiring31 Fuse 7,5A32 Starter remote control

Electrical cables color:

B = White, Bl = Blu, G = Yellow, Mr = Brown, N = Black, Gr = Gray,

Rs = Pink, R = Red, Vi = Purple, V = Green

Conceptual diagrams

Ignition

IGNITIONSpecification Desc./Quantity

1 Electronic control unit2 Magneto flywheel3 Pick - up

NRG Power DD Electrical system

ELE SYS - 3

Specification Desc./Quantity4 Key switch5 Spark plug

Headlights and automatic starter section

LIGHTS AND AUTOMATIC CHOKE DEVICESpecification Desc./Quantity

1 Flywheel magneto2 Voltage regulator3 Automatic starter4 LED taillight5 Digital instrument unit6 Headlamp sidelight bulbs7 Headlamp low-beam light bulb8 Headlamp high-beam light bulb


ELE SYS - 4

Battery recharge and starting

BATTERY RECHARGE AND STARTINGSpecification Desc./Quantity

1 Flywheel magneto2 Voltage regulator3 Fuse 7,5A4 Battery 12V-14Ah5 Starter remote control6 Starter motor7 LED taillight8 Ignition key-switch9 Start up button10 Stoplight switches11 Mixture oil level sender


ELE SYS - 5

Level indicators and enable signals section

SAFETY SWITCHES AND LEVEL GAUGESSpecification Desc./Quantity

1 Voltage regulator2 Ignition key-switch3 Fuse 7,5A4 Battery 12V-14Ah5 Starter button6 Starter remote control7 Starter motor8 Stoplight switches9 Fuel level sender10 Coolant temperature sensor11 Mixture oil level sender12 Phonic wheel13 Digital instrument unit


ELE SYS - 6

Turn signal lights

TURN SIGNALS AND HORNSpecification Desc./Quantity

1 Voltage regulator2 Ignition key-switch3 Fuse 7,5A4 Battery 12V-14Ah5 Horn button6 Horn7 Turn signal lights8 Turn signal switch9 Digital instrument unit

Digital instrument panel

INSTRUMENT UNIT CONNECTORSpecification Desc./Quantity

1 + Battery


ELE SYS - 7

Specification Desc./Quantity2 + permanent power supply3 Earth4 Grounding for phonic wheel5 Power supply to phonic wheel6 Phonic wheel signal7 Instrument light and parking light indicator8 Instrument temperature mass9 Not connected10 Rpm indicator signal11 Instrument temperature signal12 Fuel level sensor13 High-beam warning light14 + Right direction indicator15 + Left direction indicator16 Low-oil warning light17 Low-fuel warning light18 Not connected19 Not connected20 Not connected

Checks and inspections

Checks to be made in the case of ignition ir-

regularities and/or no spark on the spark plug

1. Check the condition of the spark plug (clean

it with a metal brush, remove the encrusta-

tions, blast it with compressed air and, if

necessary, replace it).

2. Without removing the stator, carry out the

following checks:

CHECK ON THE PICK UPSpecification Desc./Quantity

1 Red and white cable 90140 ohm

After visually checking the electrical wiring, per-

form measurements on the loading reel, the pickup

(see chart) and the continuity using the appropri-

ate tester.

If checks on the loading reel, pickup and continuity

show abnormalities, replace the stator; otherwise

replace the central unit. Remember that discon-

nections due to replacement of the central unit

must be done with the engine off.

Specific tooling


ELE SYS - 8


CHECKING THE RECHARGE COILSpecification Desc./Quantity

1 White/green cable 8001100 ohm

CHECK CONTINUITYSpecification Desc./Quantity

1 White cable-frame continuity2 White cable-engine continuity

Ignition circuit

All the control operations of the system that require

the disconnection of cables (checks of the con-

nections and the devices making up the ignition

circuit) must be done with the engine off: if this is

not done, the controls might be irreparably dam-

aged.

Stator check

- Using a tester, check the resistance between the

brown-earth and black-earth terminal.N.B.

VALUES ARE STATED AT AMBIENT TEMPER-ATURE. A CHECK WITH THE STATOR AT OP-ERATING TEMPERATURE LEADS TO VALUESHIGHER THAN THOSE STATED.

Electric characteristicStator : Brown-earth

approx. 170 (Pick-Up)

Stator : Black-earth

~ 1 (Stator)

Voltage regulator check

The fault to the voltage regulator may cause, according to the type of fault, the following inconvenients:

1. Bursting of head and taillight bulbs.

2. Head and taillight not operational.

3. Excessive battery recharge (bursting of main fuse).


ELE SYS - 9

4. Battery not recharging.

5. Turn signals not operational.

6. Dashboard check not operational.

Interventions

FAULT 1

Replace the regulator as definitely faulty.

FAULT 2

a) Check the output from the stator gives the cor-

rect voltage: detach the stator connector, inter-

pose an AC tester between the grey-blue and

black cables, and check the output voltage is with-

in the prescribed limits. If anomalies are found,

replace the stator.

b) If no anomalies are identified, replace the reg-

ulator.

c) If the replacement of the regulator does not

solve the fault, check the electric connections.

Specific tooling


CharacteristicVoltage distributed at 3000 rpms

25 to 30V

FAULT 3

After checking that there are no short circuits in the

system towards the earth, replace the regulator

because it is certainly inefficient and replace it with

a protective fuse.

Following the replacement, measure the current

and the recharging voltage on the battery end.


ELE SYS - 10

FAULT 4

a) Interposing the AC tester between the black and

yellow cables on the regulator, check the genera-

tor output voltage is within the prescribed values

(this measurement must be carried out with the

battery detached). In the event of anomalies, re-

place the stator; otherwise proceed to point b).

b) Insert an ammeter between the stator (blue ca-

ble) and the battery and check with the tester that

the current output, at 3,000 rpm and with the bat-

tery kept between 12 and 13V, is as shown. If the

values thus obtained are lower than prescribed,

proceed by replacing the regulator.N.B.

BEFORE CARRYING OUT THE CHECKS ONTHE REGULATOR AND RELATIVE SYSTEM, ITIS ALWAYS GOOD PRACTICE TO CHECKTHAT THERE IS CONTINUITY BETWEEN THEBLACK CABLE AND THE GROUND.N.B.

TO KEEP THE BATTERY BETWEEN 12 AND13V, CAUSING CURRENT ABSORPTION BYTHE SYSTEM, A 12V - 35W BULB CONNECTEDBETWEEN THE + BATTERY AND GROUNDCAN BE USED.

Specific tooling


CharacteristicVoltage output at 300 rpm

2630V

Distributed current

1.5 to 2A

FAULT 5

In the event that the turn signal lights are not op-

erational, proceed as follows:

Remove the regulator connector and

insert the tester terminals between pin

5 and ground.

Turn the ignition switch onto ON and

check for battery voltage. If no voltage


ELE SYS - 11

is found, check wiring and terminals on

key-switch and battery.

Repeat the same procedure with the

ends of the tester inserted between

contact 5 (+) and 6 (-) and check the

presence of the battery voltage with the

key switch at on. If this does not hap-

pen, check the regulator's ground ca-

ble.

If the checks given above are unsuc-

cessful, jump pins 5 and 7 on the con-

nector, turn the key-switch onto ON

and turn the turn signal switch alter-

nately from left to right to visualize the

continuous operation of the lights (as

powered directly by the battery). If the

lights do not go on, check the switch

and its cable, if these are not damaged

or faulty; replace the regulator as defi-

nitely faulty.

Specific tooling


FAULT 6

Dashboard check light does not go on. Detach the

connector to the voltage regulator.

Apply a tension of 12V to the pin

marked with the number 5, check, us-

ing the digital tester; there is an equiv-

alent output (12V) from pin 3 for at least

5 seconds.

If pins no. 4 and/or no. 3 give no output

voltage, replace the regulator.

If pin no. 3 gives output voltage, check

the system and the low-oil or low-fuel

warning lights.

Specific tooling


ELE SYS - 12


Fuses

The electrical system is protected by a fuse loca-

ted on the r.h.s. of the battery bay. To replace it,

lift the seat, remove the battery access door and

then the transparent fuse cover. Ignition system,

headlight, and taillight are not protected by the

fuses.CAUTION

BEFORE REPLACING THE BLOWN FUSE,SEARCH AND ELIMINATE THE BREAKDOWNTHAT HAS LED TO THE BLOW OUT.NEVER TRY TO REPLACE A FUSE USING DIF-FERENT MATERIAL (FOR EXAMPLE A PIECEOF ELECTRIC WIRE) OR A FUSE FOR A HIGH-ER AMPERAGE THAN THE INDICATED ONE.

Electric characteristicFuse

7.5 A

Sealed batteryPutting the sealed battery into service

INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT

1) Voltage check

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

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

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

2) Constant voltage battery charge mode

-Constant voltage equal to 14.4014.70V

-Initial charge voltage equal to 0.30.5 for nominal capacity

-Duration of the charge: 10 to 12 h recommended

Minimum 6 h

Maximum 24 h

3) Constant current battery charge mode

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

-Duration of the charge: 5 hWARNING

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OFRECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.


ELE SYS - 13

IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON-TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Dry-charge batteryWARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IFCOMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP-PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGEQUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.SEEK IMMEDIATE MEDICAL ATTENTION.THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS ORCIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.KEEP OUT OF REACH OF CHILDREN

Use of dry-cell batteries :

1. Having removed the short, closed tube and removed the caps, put into the elements sulphuric

acid of the type for specific weight 1.26 accumulators corresponding to 30 B at a temperature

of no less than 15, until you reach the upper level.

2. Leave to stand for at least 2 hours; afterwards top-up to the level with sulphuric acid.

3. Within twenty four hours, recharge with the special (single or multiple) battery charger that re-

charges at an intensity the same as approximately 1/10 the rated capacity of the said battery. At

the end of the charge, make sure that the density of the acid is around 1.27, corresponding to 31

B and that these values are stabilised.

4. Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.

5. Once the above operations have been performed, install the battery in the vehicle ensuring that

it is wired up properly..WARNING

- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACETHE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE-SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TOENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

Specific tooling

020333Y Single battery charger



ELE SYS - 14

1 Hold the vertical tube

2 Look at the level

3 The float must be freed

Battery maintenance

The battery is an electrical device which requires careful monitoring and diligent maintenance. The

maintenance rules are:

1) Check the level of the electrolyte

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled

water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical

system: the battery works overcharged and is subject to quick wear.

2)Load status check

After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure).

When the battery is charged, you should detect a density of 30 to 32 B corresponding to a specific

weight of 1.26 to 1.28 at a temperature of no lower than 15 C.

A density reading of less than 20 B indicates that the battery is completely flat and it must therefore

be recharged.

If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge

the battery.

The battery runs down completely in the course of three months. If it is necessary to refit the battery in

the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked

(-) must be connected to the -negative clamp while the other two red wires marked (+) must be con-

nected to the clamp marked with the +positive sign.

3) Recharging the battery

Remove the battery from the vehicle removing the negative clamp first.

The normal bench charging must be carried out with the specific (single or multiple) battery charger,

placing the battery charger selector on the type of battery to be recharged. The connections to the power

supply must be made by connecting to the corresponding poles (+ with+ and -with -).

4) Battery cleaning

The battery should always be kept clean, especially on its top side, and the terminals should be coated

with Vaseline.WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKSAND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.CAUTION


ELE SYS - 15

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

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FORTHE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.CAUTION

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATECHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRSTUSED SHORTENS THE LIFE OF THE BATTERY.

Specific tooling


020333Y Single battery charger


ELE SYS - 16

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Removal of the engine from the vehicle

1. Detach the battery.

2. Remove the exhaust assy.

3. Remove the rear wheel.

4. Remove the rear brake cable.

5. Detach the electrical connection to the fly-

wheel.

6. Detach the throttle and mixer cables.

7. Detach the mixture oil, fuel, and vacuum

pump outlet tubing.

8. Detach the H.T. cable from the spark plug.

9. Remove the rear shock-absorber fixing bolt

from the engine.

10.Remove the nut on the l.h.s., and hence re-

move the engine - swing-arm fixing bolt.

Locking torques (N*m)Engine-swinging arm bolt 33 41 Shock ab-sorber-engine pin 33 to 41 Nm Rear wheel axlenut 104 126

Engine from vehicle NRG Power DD

ENG VE - 2

INDEX OF TOPICS

ENGINE ENG

Automatic transmission

Transmission cover

- Loosen the 15 screws and remove the transmis-

sion cover with the aid of a mallet.N.B.

THE CRANKCASE IS SLIGHTLY BLOCKED BYTHE TIGHT FIT BETWEEN THE SHAFT OF THEDRIVEN HALF-PULLEY AND THE BEARINGHOUSED ON THE CRANKCASE.

Kickstart

- Remove the seeger ring located on the exterior

of the crankshaft.

- Dismantle the dog gear from its seat, slackening

the tension that the toothed sector applies to it by

means of the spring; to do this, it is necessary to

rotate the toothed sector slightly (see the figure).CAUTION

WHILE REMOVING THE TOOTHED SECTOR,BE VERY CAREFUL OF THE SPRING TEN-SION: IT COULD CONSTITUTE A HAZARD FORTHE OPERATOR.

- Remove the screws shown in the figure and re-

move the engine starting lever.

- For the assembly, work in reverse and tighten the

screws to the prescribed torque..

Locking torques (N*m)Starter lever replacement 12 to 13 Nm

Engine NRG Power DD

ENG - 2

- Upon refitting, apply the recommended grease to

the bushing, to the spring and along the toothed

sector.

- Use the special tool for the charging of the spring,

as shown in the figure.

- Refit the seeger ring after checking that it is in

good condition.

Specific tooling

020261Y Starter spring fitting

Recommended productsAGIP GREASE MU3 Grease for odometertransmission gear case

Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side

to avoid damaging the coated surface and use the

driven pulley shaft or a pin of the same diameter

to remove the bearing.N.B.

IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DIAMETER EXTRACTOR CAN BEUSED.

Refitting the driven pulley shaft bearing

-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing

after slightly heating the crankcase from the inside.N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTEDSURFACE.

NRG Power DD Engine

ENG - 3

Removing the driven pulley

- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the

whole of the driven pulley assembly.N.B.

THE UNIT CAN ALSO BE REMOVED WITH THEDRIVE PULLEY MOUNTED.

Specific tooling


Inspecting the clutch drum

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

- Measure the inner diameter of the clutch bell.

CharacteristicClutch bell diameter/standard value

107+0.2 +0 mm

Clutch bell diameter/max. value allowed afteruse

107.5 mm

Eccentricity measured /max.

0.20 mm

Removing the clutch

- Equip the tool with long pins screwed into position

A from the outside, insert the entire driven pulley

in the tool and put the central screw under stress.CAUTION

THE TOOL WILL BE DEFORMED IF THE CEN-TRAL SCREW IS TIGHTENED UP TOO FAR.

Engine NRG Power DD

ENG - 4

- Using a 34 mm socket wrench remove the clutch

locking nut.

- Loosen the central screw thereby undoing the

driven pulley unit

- Separate the components.

Specific tooling

020444Y Tool for fitting/ removing the drivenpulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction

material.

- The masses must not show traces of lubricants;

otherwise, check the driven pulley unit seals.N.B.

UPON RUNNING-IN, THE MASSES MUST EX-HIBIT A CENTRAL CONTACT SURFACE ANDMUST NOT BE DIFFERENT FROM ONE AN-OTHER.VARIOUS CONDITIONS CAN CAUSE THECLUTCH TO TEAR.CAUTION

DO NOT OPEN THE MASSES USING TOOLSTO PREVENT A VARIATION IN THE RETURNSPRING LOAD.

CharacteristicCheck minimum thickness

1 mm

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

NRG Power DD Engine

ENG - 5

- Remove the three guide pins and the mobile half

pulley.

Removing the driven half-pulley bearing

- Remove the roller bearing with the special ex-

tractor inserted from the bottom of the fixed half-

pulley.CAUTION

POSITION THE HOLDING EDGE OF THE EX-TRACTION PLIERS BETWEEN THE END OFTHE BEARING AND THE BUILT IN SEALINGRING.

Specific tooling

001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch

housing by means of the special tool.N.B.

PROPERLY SUPPORT THE HALF-PULLEY SOAS NOT TO DEFORM THE SLIDING SURFACEOF THE DRIVING BELT

Specific tooling


020363Y 20 mm guide

Engine NRG Power DD

ENG - 6

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work

surface of the belt. If there are, replace the half-

pulley..

- Make sure the bearings do not show signs of un-

usual wear.

- Measure the external diameter of the pulley bush-

ing.

CharacteristicStationary driven half-pulley/Standard diame-ter

33.965 to 33.985 mm

Stationary driven half-pulley / Minimum diam-eter admitted after use

33.96 mm

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two O-

rings.

- Measure the inside diameter of the mobile half-

pulley bushing.

CharacteristicMobile driven half-pulley/ Maximum diameterallowed

34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile

half-pulley.

- Fitting the half-pulley on the bushing.

Recommended productsAGIP GREASE SM 2 Grease for the tone wheelrevolving ring

Soap-based lithium grease containing NLGI 2 Mo-

lybdenum disulphide; ISO-L-XBCHB2, DIN

KF2K-20

- Make sure the pins and collar are not worn, reassemble the pins and collar.

NRG Power DD Engine

ENG - 7

- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This

operation must be done through one of the holes inside the bushing until grease comes out of the

opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended productsAGIP GREASE SM 2 Grease for the tone wheel revolving ring

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible

from the outside.CAUTION

PROPERLY SUPPORT THE HALF-PULLEY TOPREVENT DAMAGE TO THE THREADED ENDWHILE THE BEARINGS ARE BEING FITTED.

Specific tooling


020456Y 24 mm adaptor

020362Y 12 mm guide

020171Y Punch for 17 mm roller case

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley

does not show signs of deformation

- Measure the free length of the spring

CharacteristicStandard length

118 mm

Minimum length allowed after use

XXXX

Engine NRG Power DD

ENG - 8

Refitting the clutch

- Preassemble the driven pulley group with spring,

sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the

spring being careful not to damage the plastic

sheath and the end of the threaded bar.

- Reassemble the nut securing the clutch and tight-

en to the prescribed torque.CAUTION

SO AS NOT TO DAMAGE THE CLUTCH NUTUSE A SOCKET WRENCH WITH SMALLCHAMFER.CAUTION

POSITION THE NON-CHAMFERED SURFACESOF THE NUT IN CONTACT WITH THE CLUTCH

Locking torques (N*m)Nut locking clutch unit on pulley 55 60 Nm

Refitting the driven pulley

-Refit the driven pulley assembly, the clutch bell

and the nut, using the specific tool.

Specific tooling


Locking torques (N*m)Driven pulley shaft nut 40 to 44 Nm

NRG Power DD Engine

ENG - 9

Drive-belt

- Make sure the driving belt is not damaged and

does not have cracks in the toothed grooves.

- Check the width of the belt.

CharacteristicTransmission belt/Minimum width

17.5 mm

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer,

then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the

rollers and contrast plate fitted loosely on it do not come off.

Specific tooling


Mixer gears and belt

- Remove gear and belt.CAUTION

PAY PARTICULAR ATTENTION TO NOTTOUCHING OR BENDING THE BELT BE-CAUSE THIS COULD BREAK SUDDENLY DUR-ING OPERATION.CAUTION

ON REFITTING, MAKE SURE THAT DIRT DOESNOT GET INTO THE INNER BUSHING OF THEMIXER CONTROL GEAR AND THAT IT DOESNOT EXERT ANY STRESS ON THE CRANK-CASE PIN.N.B.

REPLACE THE BELT EVERY 20000 KM.

Engine NRG Power DD

ENG - 10

Inspecting the rollers case

1) Check that the bushing and the sliding rings of

the mobile pulley do not show signs of scoring or

deformation.

2) Check the roller running tracks on the contact

pulley; there must not be signs of wear and check

the condition of the contact surface of the belt on

the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of

marked facetting on the sliding surface and that

the metallic insert does not come out of the plastic

shell borders.

4) Check the integrity of the sliding blocks of the

contact plate.

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inside

diameter A.

- Measure outside diameter B of the pulley slid-

ing bushing shown in the figure.CAUTION

DO NOT LUBRICATE OR CLEAN THE BUSH-ING.

CharacteristicDriving pulley / Maximum diameter:

20.12 mm

Driving pulley/ Standard diameter:

20.021 mm

Driving pulley bushing/ Diameter maximum:

XXX mm

Driving pulley bushing/ Standard diameter:

20 -0.020/-0.041mm

NRG Power DD Engine

ENG - 11

Refitting the driving pulley

- Manually move the mobile driven half-pulley

away pulling it towards the clutch unit and insert

the belt repeating the direction of rotation of the

first fitting.N.B.

IT IS GOOD PRACTICE ALWAYS TO FIT THEBELT SO THE WORDING CAN BE READ, INTHE CASE THAT THIS DOES NOT SHOW AFITTING SIDE.

- Refit the particular components of the assembly

(roller container assembly with bushing, limiting

washer, stationery half-pulley, cooling fan belt with

drive, washer and nut).

- Tighten the lock nut to torque 20 Nm and then

perform a final 90 lock preventing the rotation of

the drive pulley with the specific tooling.N.B.

REPLACE THE NUT WITH A NEW ONE AT EV-ERY REFITCAUTION

IT IS MOST IMPORTANT WHEN FITTING THEDRIVING PULLEY UNIT THAT THE BELT ISFREE INSIDE IN ORDER TO AVOID MAKING AWRONG TIGHTENING WITH THE POSSIBLELATER DAMAGE OF THE CRANKSHAFTKNURLING.

Specific tooling


Locking torques (N*m)Crankshaft pulley nut 18 to 20 + 90 N.m

End gear

Engine NRG Power DD

ENG - 12

Removing the hub cover

Remove the transmission cover

Remove the clutch assembly

Discharge the rear hub oil.

Remove the 5 screws indicated in the figure.

Remove the hub cover with driven pulley shaft.

See alsoRefitting the clutch

Removing the wheel axle

- Remove the intermediate gear and the complete

gear wheel axle.

- When removing the intermediate gear pay atten-

tion to the various shim adjustments.

Removing the wheel axle bearings

- Remove the oil seal and the seeger ring.

- Remove the bearing by pushing from the outside

towards the inside of the gear compartment, using

the appropriate punch.

Specific tooling

020363Y 20 mm guide


020358Y 37x40-mm adaptor

NRG Power DD Engine

ENG - 13

Removing the driven pulley shaft bearing

- Remove the seeger ring inside the cover.

- Remove the oil seal from the outside.

- Remove the centring dowels and position the

cover on a plane.

- Position the special tool on the internal track of

the bearing and remove said bearing with the aid

of a press.

Specific tooling

020452Y Tube for removing and refitting thedriven pulley shaft

- Position the special tube on the internal raceway

of the bearing and from the shaft toothed side as

indicated in the figure. Expel the driven pulley shaft

with the aid of a press.

Specific tooling


Inspecting the hub shaft

- Check that the three shafts exhibit no wear or

deformation on the toothed surfaces, at the bear-

ing housings and at the oil guards.

- In case of anomalies, replace the damaged com-

ponents.

- Check that the fitting surface is not dented or dis-

torted.

- If faults are found, replace the hub cover.

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.

Engine NRG Power DD

ENG - 14

Refitting the driven pulley shaft bearing

- Support the inner track of the bearing from the

outside of the hub cover with the specific tool posi-

tioned under the press and insert the driven pulley

axle.

- Refit the oil seal flush with the cover.

Specific tooling


Heat the hub cover and insert the bearing with

the specific punch.

Fit the snap ring with the concave or radial part

on the bearing side.N.B.

FIT THE BALL BEARING WITH THE SHIELDFACING THE OIL SEAL.

Specific tooling

020151Y Air heater


020439Y 17 mm guide


Refitting the wheel axle bearing

- Heat the half crankcase on the transmission side

using a thermal gun.

- After lubricating its outer strip, insert the bearing

with the special adapter with the aid of a hammer.

- Refit the seeger ring and the oil seal using the 42

x 47 mm adapter and the handle.

Specific tooling

020151Y Air heater


020363Y 20 mm guide


NRG Power DD Engine

ENG - 15

Refitting the ub cover

- Refit the whole wheel axle.

- Refit the intermediate gear paying attention to the

two shim thicknesses.

- Apply LOCTITE 510 for surfaces to the hub cov-

ers and refit the same with driven pulley shaft.

- Refit the 5 screws and tighten them to the speci-

fied torque.N.B.

CLEAN THE CONTACT SURFACES OF THEHUB COVER AND THE HALF CRANKCASE OFRESIDUE FROM PREVIOUS GASKETS BE-FORE APPLYING A NEW ONE.

Locking torques (N*m)Locking torque: 11 to 13 Nm

Flywheel cover

Removing the stator

- Remove the three stator fixings shown in the

photo

- Remove the two pick-up fixings shown in the

photo

- Remove the stator with the wiring

Engine NRG Power DD

ENG - 16

Refitting the stator

- Refit the stator and flywheel proceeding in the

inverse direction, tightening the studs to the pre-

scribed torque.

THREAD THE CABLE OF THE STATOR INTOTHE SPECIFIC HOUSING OF THE CRANK-CASE AND MAKE SURE THAT IT IS LOCKEDBY THE TAB OF THE RETURN LINE OF THECOOLING SYSTEM.

Locking torques (N*m)Pick-up screws 3 4 Stator screws 3 4

Refitting the flywheel cover

Fit the rubber seal on the flywheel con-

nector and around the inlet coolant

hose.

Keeping the flywheel connector rubber

clamp on the coolant inlet hose, refit

the flywheel cover paying attention in

inserting the strap in the groove.

Tighten the 4 studs, noting that the two

longer golden screws are inserted in

the 2 top holes and are also responsi-

ble for restraining the secondary air-

box.

Flywheel and starting

NRG Power DD Engine

ENG - 17

Removing the starter motor

Remove the center stand by unscrew-

ing the four clamping screws (two per

side) of the engine block

R

emove the two clamps shown in the figure

Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper

spanner.

- Remove the nut.CAUTION

THE USE OF A CALLIPER SPANNER OTHERTHAN THE ONE SUPPLIED COULD DAMAGETHE STATOR COILS

- Extract the flywheel with the extractor.

Specific tooling


020162Y Flywheel extractor

Engine NRG Power DD

ENG - 18

Inspecting the flywheel components

- Check the condition of the flywheel and any dis-

tortions that might cause rubbing on the stator and

on the Pick-Up.

Refitting the flywheel magneto

- Fit the flywheel being careful to insert the key

properly.

- Lock the flywheel nut at the prescribed torque

- Check the Pick-Up air gap.

- The air gap may not be modified in the fitting of

the Pick-Up.

- Other values derive from deformations visible on

the Pick-Up support.N.B.

A VARIATION OF THE AIR GAP DISTANCECAN LEAD TO A VARIATION IN THE IGNITIONADVANCE SUCH AS TO CAUSE PINGING,KNOCKING ETC.

Locking torques (N*m)Flywheel nut 40 to 44 N.m

Refitting the starter motor

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

- Fit the starter on the crankcase, locking the two

screws to the prescribed torque.N.B.

REFIT THE REMAINING PARTS AS DESCRI-BED IN THE CYLINDER HEAD, TIMING, LUBRI-CATION, FLYWHEEL AND TRANSMISSIONCHAPTERS.

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

NRG Power DD Engine

ENG - 19

Cylinder assy. and timing system

Removing the intake manifold

Use an anti-tampering TORX spanner to remove

the two clamping screws of the intake manifold

Removing the cylinder head

Remove the 4 screws shown in the figure

Removing the cylinder - piston assy.

Remove the cylinder very carefully

Engine NRG Power DD

ENG - 20

Remove the snap rings and remove the pinCAUTION

AFTER EACH REMOVAL OPERATION RE-PLACE THE PIN RETENTION SNAP RINGS

Inspecting the small end

- Measure the internal diameter of the small end

using an internal micrometer.N.B.

IF THE DIAMETER OF THE ROD SMALL ENDEXCEEDS THE MAXIMUM DIAMETER AL-LOWED, SHOWS SIGNS OF WEAR OR OVER-HEATING REPLACE THE CRANKSHAFT ASDESCRIBED IN THE "CRANKCASE ANDCRANKSHAFT" CHAPTER".

CharacteristicRod small end: standard diameter

17 +0.011-0.001

Rod small end: maximum allowable diameter

17,060 mm

Inspecting the wrist pin

- Check the wrist pin external diameter using a mi-

crometer

CharacteristicWrist pin: standard diameter

12 +0.005 +0.001 mm

NRG Power DD Engine

ENG - 21

Inspecting the piston

- Measure the bearings on the piston using a bore

meter

- Calculate the piston-pin coupling clearance.

CharacteristicWrist pin housing: standard diameter

12 +0.007 +0.012

Wrist pin housing: standard clearance

0.002 0.011 mm

- Measure the outer diameter of the piston, per-

pendicular to the pin axis.

- Take the measurement in the position shown in

the figure

To classify the cylinder-piston fitting, check the ap-

propriate table

See alsoCylinder - piston assy.

Inspecting the cylinder

- Check that the cylinder does not show seizures.

Otherwise, replace it or adjust it respecting the al-

lowable increases

- Measure the internal diameter of the cylinder with

a bore meter, according to the directions given in

the figure

- Check that the fitting surface with the head is not

dented or distorted.

To classify the cylinder-piston fitting, check the ap-

propriate table

See alsoCylinder - piston assy.

Engine NRG Power DD

ENG - 22

Inspecting the piston rings

- Alternatively insert the two sealing rings in the

cylinder

Using the piston, insert the seals perpendicularly

to the cylinder axis.

- Measure the opening of the sealing rings using a

thickness gauge as shown in the photograph

- If the values are higher than the values prescri-

bed in the chart, substitute the rings

Removing the piston

- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.

-Push detail 2 into detail 1 until the stop and extract detail 2.

- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3

all the way in.N.B.

REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROMTHE REMOVAL OPERATIONS

Specific tooling

020166Y Pin lock fitting tool

Locking torques (N*m)Locking head nuts: 10 to 11 Nm

- Use new wrist pin snap rings.

- Use new cylinder base gasket.

- Before refitting carefully clean all the surfaces.

- Use oil to be mixed during the fitting of the piston

and the cylinder.CAUTION

POSITION THE ARROW PRINTED ON THE PIS-TON CROWN TOWARDS THE EXHAUSTOPENING.THE WRIST PIN SNAP RINGS MUST BE POSI-TIONED ON THE PISTON WITH THE SPECIFICTOOL

Recommended productsAGIP CITY TEC 2T Oil

Recommended oil

NRG Power DD Engine

ENG - 23

Inspecting the timing system components

CAUTION

CHECK THE CORRECT REED UNIT SEAL; NOLIGHT MUST PASS BETWEEN THE SUPPORTAND LAMELLA.

Crankcase - crankshaft

Engine NRG Power DD

ENG - 24

Splitting the crankcase halves

Remove the eight crankcase union fasteners.

Install the special strip on the half crankcase on

the flywheel side and separate the half crankcase

on the flywheel side from the transmission side

Specific tooling


Removing the crankshaft

- Install the specific tool on the half crankcase on

the transmission side using four M6 screws of an

adequate length.

- Remove the crankshaft from the transmission

side half crankcase

Specific tooling


NRG Power DD Engine

ENG - 25

Removing the crankshaft bearings

The bearings can stay on either the half crankcase

or the crankshaft indifferently

- Using the special tool, remove any bearings that

have been left on the crankshaftN.B.

The half rings must be inserted on the bearingswith a few mallet blows.

Specific tooling

004499Y001 Bearing extractor bell

004499Y006 Bearing extractor ring

004499Y002 Bearing extractor screw

004499Y007 Half rings

- Using the specific tool remove any bearings left

on the half crankcase

Specific tooling

001467Y007 Driver for OD 54 mm bearing

001467Y006 Pliers to extract 20 mm bearings

Refitting the crankshaft bearings

Heat the bearings in an oil bath at around 150C

and fit them on the crankshaft, if necessary using

a section of tube that acts on the bearing's inner

track

Specific tooling

020265Y Bearing fitting base

Engine NRG Power DD

ENG - 26

Inspecting the crankshaft alignment

With the specific tool shown check that the eccen-

tricity of the surfaces of diam. A-B- C are

within 0.03 mm. (reading limit on the dial gauge);

in addition, check the eccentricity of diam. D, for

which a maximum reading of 0.02 mm is permitted.

In the case where eccentricity is not much above

prescribed levels, straighten the shaft by acting

on the counterweights with a shim or tighten them

in a clamp (with an aluminium bushing) as re-

quired..

Specific tooling

020335Y Magnetic support for dial gauge

020074Y Support base for checking crankshaftalignment

Refitting the crankshaft

- Position the transmission side half crankcase on

two wooden supports

- Using a thermal gun, heat the bearing seat to

about 120

NRG Power DD Engine

ENG - 27

- Firmly insert the crankshaft until the bearing rea-

ches the end-of-stroke stop

- Let the temperature of the half crankcase settle

at the temperature of the crankshaft.

- Again install the special crankc

piaggio nrg power dd scooter motorcycle bike workshop service repair manual cd

Documents

piaggio gilera

vehicle intactness

workshops of piaggio

rinaldo piaggio

specific procedures

piaggio service mechanics

specific tools

specific fixing operations