Piaggio Typhoon 125 4T MY 2010 (en)

MANUALE STAZIONE DI SERVIZIO677205(IT)-677206(EN)-677207(FR)-677208

(DE)-677209(ES)-677210(NL)-677211(PT)-677212(EL)

Typhoon 125 4T (MY 2010)

MANUALESTAZIONE DI

SERVIZIO


The descriptions and illustrations given in this publication are not binding. While the basic specificationsas described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes tocomponents, parts or accessories, which it considers necessary to improve the product or which are

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

model should be checked at the official Piaggio sales network."© Copyright 2010 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

www.piaggio.com

MANUALE STAZIONE DISERVIZIO


Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionarie sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoliPiaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione deiveicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicateattraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se nonsi dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manualeriguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici.

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

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

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

Safety rules

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

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

fumes are toxic.

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

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

and seek immediate medical attention.

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

or flames near the battery, especially when charging it.

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

area, and avoid naked flames or sparks.

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

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

contains no asbestos, inhaling dust is harmful.

Maintenance rules

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

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

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

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

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

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

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

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

unsuitable coupling members and tools may damage the vehicle.

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

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

tions.

Typhoon 125 4T (MY 2010) Characteristics

CHAR - 7

Vehicle identification

Chassis prefix LBMM701

Engine prefix M701M

Dimensions and mass

WEIGHTS AND DIMENSIONSSpecification Desc./Quantity

Maximum length 1947Overall width 730

Max. height to the windshield 1130 mmWheelbase 1355Kerb weight 117 kg

Engine

ENGINESpecification Desc./Quantity

Engine Single cylinder 4-stroke

Characteristics Typhoon 125 4T (MY 2010)

CHAR - 8

Specification Desc./QuantityTiming system Single overhead camshaft (SOHC) with 2 valves

Valve clearance intake 0.10exhaust 0.15

Bore x stroke 57 x 48.6 mmEngine capacity 124 cm³

Compression ratio (10.6+/-0.5):1carburettor KEIHIN CVEK26

Engine idle speed approx. 1.600 ÷ 1.800 rpmStarter starter

Max power to the shaft 10.5 CV at 8000 rpmCooling Forced-circulation air cooling.

Transmission

TRANSMISSIONSpecification Desc./QuantityTransmission With continuously variable expandable pulley transmission

with torque server, V belt, automatic clutch, gear reduction unitand transmission housing with forced air circulation cooling.

Capacities

CAPACITYSpecification Desc./Quantity

Engine oil 1.10 lRear hub oil approx. 250 cc

Fuel tank capacity ~ 7.0 litres (2.0 l of which is reserve)Fork stem (oil level height without spring, compressed fork) 85 mm

Electrical system

ELECTRICAL SYSTEMSpecification Desc./Quantity

Starter starterSpark plug Champion NGK CR7EB - RG6YC

Ignition advance 15° ± 1° at 2,000 rpmBattery 12 V / 10 AhFuses No. 1 20A, No. 1 15A, No. 1 7.5A

Ignition type Electronic capacitive discharge ignition (CDI) and variable ad-vance, with separate HV coil.

Alternator alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONSpecification Desc./Quantity

Chassis Tubular steel frameFront suspension Ø 35 Hydraulic telescopic fork - travel: 90 mmRear suspension Hydraulic single shock absorber and spring adjustable to 4 po-

sitions at preloading; travel: 80 mm.


CHAR - 9

Brakes

BRAKESSpecification Desc./QuantityFront brake Disc brake (Ø 220 mm) with hydraulic control (lever on the far

right of the handlebar) and floating calliper.Rear brake Ø 110mm drum brake

Wheels and tyres

WHEELS AND TYRESSpecification Desc./Quantity

Front wheel rim Die-cast aluminium alloy; 3.50 x 10"Front tyre Tubeless 120/80 -10"

Rear wheel rim Die-cast aluminium alloy: 3.50"x10"Rear tyre Tubeless 120/80 - 10"

Front tyre pressure 1.5 barRear tyre pressure 1.8 bar

Rear wheel pressure (rider and passenger): 2.0 bar

Secondary air

In order to reduce polluting emissions, the vehicle

is furnished with a catalytic converter in the silenc-

er.

To favour the catalytic process, an extra amount

of oxygen is added via a secondary air system

(SAS).

This system allows more oxygen to be added to

the unburned gases before they reach the con-

verter, thus improving the action of the catalytic

converter.

The air enters the exhaust duct from the head, and

is purified by a black filter.

The system is fitted with a control valve that disa-

bles operation while decelerating to avoid unwan-

ted noise.

To ensure the best functioning of the SAS system,

every 12,000 km the vehicle should be taken to an

Authorised Piaggio Service Centre to have the

filter cleaned (Scheduled maintenance operations

section).


CHAR - 10

The filter sponge should be cleaned with water and

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

slight blows of compressed air.CAUTION

CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRETO CARRY OUT THESE OPERATIONS.

Carburettor

125cc Version

Kehin

CARBURETTOR SETTINGSpecification Desc./Quantity

Type CVEK26Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4Setting stamping 262A

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

Tapered pin stamping NELAThrottle valve spring 130 ÷ 180 gr.

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

Idle mixture adjustment screw initial opening 1 ¾Starter nozzle 42

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

Tightening Torques

HEAD AND CYLINDERName Torque in Nm

Ignition spark plug 18 NmHead cover screws 11 to 13

Nuts fixing head to cylinder (*) 28 to 30Head fixing screws (external) 11 to 13

Starter ground screw 7 to 8.5Flywheel air duct screw 3 to 4

Pressure reducer counterweight retainer 7 to 8.5Camshaft pulley screw 12 to 14

Timing chain tensioner slider screw 10 to 14Starter counterweight support screw 11 to 15

Tightener screw: 5 to 6Timing chain tensioner central screw 5 to 6

Camshaft retention plate screw 5 to 6Nut fixing silencer to cylinder head 16 to 18

Head intake manifold screw 11 to 13(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.


CHAR - 11

TRANSMISSIONName Torque in Nm

Drive pulley nut (°) 75 - 83Transmission cover screw 11 to 13

Driven pulley shaft nut 54 to 60Rear hub cap screws 24 to 27

Clutch unit nut on driven pulley 55 to 60(°) Apply LOCTITE 243 threadlock

FLYWHEELName Torque in Nm

Flywheel fan screws 3 to 4Stator assembly screws (°) 3 to 4

Flywheel nut 52 to 58Pick-up screw 3 to 4

(°) Apply LOCTITE 243 threadlock

CRANKCASE AND CRANKSHAFTName Torque in Nm

Internal engine crankcase bulkhead (transmission-side halfshaft) screws

4 to 6

Oil filter on crankcase fitting 27 to 33Rear brake cam tightening screw 11 to 13

Engine-crankcase coupling screws 11 to 13Pre-filter cap 24 to 30

Starter screws 11 to 13Silencer to crankcase fixing screws 24 to 27

Engine oil drainage cap 24 to 30Oil sump screws 11 to 13

Oil pump central screw 12 to 14Oil pump cover screws 0.7 - 0.9

Minimum oil pressure switch 12 to 14

STEERING ASSEMBLYName Torque in Nm

Upper steering ring nut 30 to 36Lower steering ring nut 10 - 13 (loosen by 90°)Handlebar fixing screw 45 to 50Mirror fastening spacer 25

CHASSIS ASSEMBLYName Torque in Nm

Engine arm pin - chassis arm 45.5Centre stand pivot on engine 42.5

Silent block-swinging arm retaining bolts 42.5

FRONT SUSPENSIONName Torque in Nm

Piston tightening fork lower screw 25 - 35Front wheel axle nut 45 - 50

Fork clamp screw 20 to 25Fork stanchion upper cap 15 ÷ 30Safety screw on fork leg 6 - 7

FRONT BRAKEName Torque in Nm

Brake fluid hose-pump fitting 20 to 25Brake fluid pipe-calliper fitting 20 to 25

Calliper to fork tightening screw 20 to 25Disc tightening screw 8 to 12

Oil bleed screw 8 to 12


CHAR - 12

Name Torque in NmPump U bolt screw 8

Brake pad fastening screw 15 to 20

REAR SUSPENSIONName Torque in Nm

Rear wheel axle 115Shock absorber nut 22.5

FUEL TANK UNITName Torque in Nm

Fuel tank to chassis fixing screw 10

SADDLE UNITName Torque in Nm

Saddle plate fixing nut 10

BODYWORK UNITName Torque in Nm

Helmet compartment fixing screw 3Rear grab handle fixing screw 20.5

Battery cover fixing screw 6Front wheel housing to chassis fixing screw 6

Front wheel housing to leg shield back plate fixing screw 3Front mudguard fixing screw 6

Footrest fixing screw 6Screw fixing leg shield back plate to chassis 6

Leg shield back plate to leg shield fixing screw 3Footrest spoiler fixing screw 6

Passenger footrest protection fixing screw 3Passenger footrest to side body panel fixing screw 6

Rear mudguard fixing screw 6Rear brake adjustment nut 5

Overhaul data

Assembly clearances

Cylinder - piston assy.125 version

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

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

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


CHAR - 13

Name Initials Cylinder Piston Play on fittingCoupling 3rd oversize N3 57.604 to 57.611 57.551 to 57.558 0.046 to 0.060Coupling 3rd oversize O3 57.611 to 57.618 57.558 to 57.565 0.046 to 0.060Coupling 3rd oversize P3 57.618 to 57.625 57.565 to 57.572 0.046 to 0.060

Piston rings

SEALING RINGS (125)Name Description Dimensions Initials Quantity

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

Compression ring 1stoversize

57.2 x 1 A 0.15 to 0.30

Oil scraper ring 1stoversize

57.2x1 A 0.10 to 0.30

Oil scraper ring 1stoversize

57.2x2.5 A 0.10 to 0.35

Compression ring 2ndoversize

57.4x1 A 0.15 to 0.30

Oil scraper ring 2ndoversize

57.4x1 A 0.10 to 0.30

Oil scraper ring 2ndoversize

57.4x2.5 A 0.10 to 0.35

Compression ring 3rdoversize

57.6x1 A 0.15 to 0.30

Oil scraper ring 3rdoversize

57.6x1 A 0.10 to 0.30

Oil scraper ring 3rdoversize

57.6x2.5 A 0.10 to 0.35

Maximum clearance after use: 1 mm

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING RODName Description Dimensions Initials Quantity

Transmissionside half-shaft

16.6 +0-0.05 A D = 0.20 to 0.50

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

Crank pin width 51.400 E

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGSName Description Dimensions Initials Quantity

Crankshaft Category 1 28.998 to 29.004Crankshaft Category 2 29.004 to 29.010


CHAR - 14

Name Description Dimensions Initials QuantityCrankcase Category 1 32.953 to 32.959Crankcase Category 2 32.959 to 32.965

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

E - E

Crankshaft category 1 -Crankcase category 2

C - C


C - C


B - B

Crankshaft/crankcase axial clearance: 0.15 to 0.40

Slot packing system

- Provisionally fit the piston into the cylinder, without any base gasket.

- Assemble a dial gauge on the specific tool

- Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping

the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.

- Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation)

- Calculate the difference between the two measurements: use the chart below to identify the thickness

of the cylinder base gasket to be used for refitting. Correctly identify the cylinder base gasket thickness

to keep the correct compression ratio.

- Remove the special tool and the cylinder.

CharacteristicCompression ratio

10.6: 1


CHAR - 15

SHIMMING SYSTEMSpecification Desc./Quantity

Value measured 0 to 0.1Thickness 0.8 ± 0.05

Value measured 0.1 to 0.3Thickness 0.6 ± 0.05

Value measured 0.3 - 0.4Thickness 0.4 ± 0.05

Products

RECOMMENDED PRODUCTS TABLEProduct Description Specifications

AGIP ROTRA 80W-90 rear hub oil SAE 80W/90 Oil that exceeds the re-quirements of API GL3 specifications

AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions(brakes, throttle control and odometer)

Oil for 4-stroke engines

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

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

AGIP GREASE MU3 Grease for odometer transmission gearcase

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

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluidAGIP GREASE PV2 Grease for steering bearings, bolt seat-

ings for swinging arms and faying surfaceof driven pulley spring (only pulley side)

Soap-based lithium and zinc oxidegrease containing NLGI 2; ISO-L-

XBCIB2AGIP GP 330 Grease for brake lever, gas White calcium complex soap-based

spray grease with NLGI 2; ISO-L-XBCIB2AGIP FORK 7.5 W Fork oil Grade 7.5 W


CHAR - 16

INDEX OF TOPICS

TOOLING TOOL

SPECIFIC TOOLSStores code Description

001330Y Tool for fitting steering seats

001467Y009 Driver for OD 42-mm bearings

001467Y013 Calliper to extract ø 15-mm bearings

002465Y Calliper for circlips

005095Y Engine support

006029Y Punch for fitting fifth steering bearing onsteering tube

008564Y Flywheel extractor

Tooling Typhoon 125 4T (MY 2010)

TOOL - 18

Stores code Description020004Y Punch for removing steering bearings

from headstock

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crankshaftalignment

020150Y Air heater mounting

020151Y Air heater

020193Y Oil pressure check gauge

020201Y Spacer bushing driving tube

Typhoon 125 4T (MY 2010) Tooling

TOOL - 19

Stores code Description020262Y Crankcase splitting plate

020263Y Driven pulley assembly sheath

020271Y Tool for removing-fitting silent bloc

020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing


TOOL - 20

Stores code Description020331Y Digital multimeter

020332Y Digital rpm indicator

020334Y Multiple battery charger

020335Y Magnetic mounting for dial gauge

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


TOOL - 21

Stores code Description020360Y 52x55-mm Adaptor

020363Y 20-mm guide

020364Y 25-mm guide

020368Y driving pulley lock wrench

020375Y 28 x 30 mm adaptor

020376Y Adaptor handle


TOOL - 22

Stores code Description020382Y Valve cotters equipped with part 012 re-

moval tool

020382Y011 adapter for valve removal tool

020409Y Multimeter adaptor - Peak voltage detec-tion

020412Y 15-mm guide

020423Y Driven pulley lock wrench


TOOL - 23

Stores code Description020424Y Driven pulley roller casing fitting punch

020425Y Punch for flywheel-side oil seal

020426Y Piston fitting fork

020427Y Piston assembly band

020428Y Piston position check mounting

020430Y Pin lock fitting tool


TOOL - 24

Stores code Description020431Y Valve oil seal extractor

020434Y Oil pressure check fitting

020439Y 17-mm guide

020444Y Tool for fitting/ removing the driven pulleyclutch

020456Y Ø 24 mm adaptor020565Y Flywheel lock calliper spanner

020622Y Transmission-side oil seal punch


TOOL - 25


TOOL - 26

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance

of your vehicle.

To this end, a series of checks and maintenance operations (at the owner's expense) have been sug-

gested, which are included in the summary table on the following page. Any minor faults should be

reported without delay to an Authorised Service Centre or Dealer without waiting until the next

scheduled service to solve it.

It is indispensable to have your vehicle serviced to the prescribed intervals of time, even if you have

not reached the predicted mileage. Punctual vehicle servicing is necessary for the correct use of the

guarantee. For all further information regarding the Guarantee application modes and the execution of

the "Programmed Maintenance" refer to the "Guarantee Booklet".

SCHEDULED MAINTENANCE TABLEI: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE* Check level every 3000 km** Replace every 2 years*** Replace every 4 years

Km x 1,000 1 6 12 18 24 30 36 42 48 54 60Safety fasteners I I I I I ISpark plug I R I R I R I R I RTransmission cables and controls A A A A A ADriven pulley roller casing L L L L LDrive belt I R I R I R I R I RAir filter C C C C C C C C C CRear brake shoes I I I I I I I I I IElectrical system and battery I I I I I I I I I I IBraking systems I I I I I I I I I I ILight circuit I I I I I I I I I I IBrake fluid ** I I I I I I I I I I IExhaust muffler/ silencer I I I I IEngine oil filter R R R R R R R R R R RValve clearance R R R R R R R R R R RHub oil R I I I R I I I R I IEngine oil* R R R R R R R R R R RRear brake cam pin L L L L L L L L L LHeadlight A A A AVehicle test and brake test - Road test I I I I I I I I I I IBrake pads I I I I I I I I I I IElectric starter gear pins L L L L LWheels/tyres I I I I I I I I I I ICVT rollers / Sliding shoes R R R R RIdle speed A A A A A ASuspension I I I I ISteering I I I I I IBraking system pipes*** I I I I I I I I I I ITransmission L L L L LFuel pipes *** I I I I I I I I I I

Checking the spark advance

- To check ignition advance, use the stroboscopic light with induction pincers connected to the spark

plug power wire.

Maintenance Typhoon 125 4T (MY 2010)

MAIN - 28

- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the

pincers must be pointing at the spark plug).

- Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines).

- Start the engine and check that the light works properly and the rpm indicator can read also the high

rpm (e.g. 8000 rpm).

- If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive

load on the spark plug power line (10 ÷ 15 KΩ in series to HV wire).

- Operating on the flash bulb phase difference cal-

ibrator, make the reference on the flywheel cover

coincide with the fan reference as shown in the

photograph. Read the advance degrees indicated

by the stroboscopic light and compare them with

those specified.

CharacteristicIgnition advance check15° ± 1° at 2000 rpm - 28° ± 1° at 6000 rpm

Spark advance variation

ADVANCE VARIATIONSpecification Desc./Quantity

Operation threshold First threshold: 9000±50Second threshold: 9300±50

Reactivation threshold First threshold: 8900±50Second threshold: 9200±50

Typhoon 125 4T (MY 2010) Maintenance

MAIN - 29

Specification Desc./QuantitySpark elimination First threshold: 1 spark on 7

Second threshold: 2 sparks on 3

Spark plug

Place the vehicle on its central stand

- Remove the central cover;

- Detach the coil from the chassis, leaving it con-

nected to the system, and disconnect the spark

plug H.V. cable cap

- Unscrew the spark plug using the socket wrench

supplied.

-Examine the condition of the spark plug, check

that the insulating material is whole and measure

the distance between the electrodes using a feeler

gauge.

-Adjust the distance if necessary by bending the

side electrode very carefully.

In the case of defects, replace the spark plug with

one of the specified type.


MAIN - 30

- Engage the spark plug with the due inclination

and screw it right down by hand, then do it up with

the wrench at the prescribed torque.

- Fit the cap on the spark plug as far as it will go.

- Refit the coil and the central cover.CAUTIONTHE SPARK PLUG MUST BE REMOVED WHEN THE EN-GINE IS COLD. THE SPARK PLUG MUST BE REPLACEDEVERY 5,000 KM. USE OF STARTERS NOT CONFORMINGOR SPARK PLUGS NOT THOSE DESCRIBED CAN SERI-OUSLY DAMAGE THE ENGINE.

Electric characteristicRecommended spark plugNGK CR7EB

Alternative spark plugCHAMPION RG6YC

Electrode gap0.6 to 0.7 mm.

Locking torques (N*m)Ignition spark plug 18 Nm

See alsoChassis

Hub oil


MAIN - 31

Check

Do the following to check the correct level:

- Ride a few kilometres until the regular working

temperature is reached, then stop the engine.

- Park the vehicle on level ground and rest it on the

centre stand.

- Unscrew the oil filler dipstick, dry it with a clean

cloth and reinsert it.

- Remove the dipstick and make sure that the oil

level reaches the indicated reference notch.

- Screw up the oil dipstick back in and make sure

it is locked properly in place.

Recommended productsAGIP ROTRA 80W-90 Rear hub oilSAE 80W/90 Oil that exceeds the requirements of

API GL3 specifications

Replacement

- Ride a few kilometres until the regular working

temperature is reached, then stop the engine.

- Park the vehicle on level ground and rest it on the

centre stand.

- Remove the oil filler dipstick and drain out the oil

completely.

- Screw in the drainage cap again and fill the hub

with the prescribed oil.

- Check the level.

- Screw the oil filler dipstick back into place, being

sure it is completely blocked.

CharacteristicRear hub oilQuantity: approx. 250 cc


MAIN - 32

Air filter

- Remove the cap of the air cleaner, unscrewing

the five screws and the fixing knob.

- Take out the filtering element.

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 filtering element and then squeeze it

with your hands without wringing.

-Let it dry and refit it again.CAUTIONNEVER RUN THE ENGINE WITHOUT THE AIR FILTER,THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THEPISTON AND CYLINDER.

Recommended productsAGIP FILTER OIL Oil for air filter spongeMineral oil with specific additives for increased ad-

hesiveness

FILTER BOX REMOVAL

- Undo the two screws indicated.

- Loosen the indicated clamps and slide off the fil-

ter box.


MAIN - 33

Engine oil

Replacement

Change oil as indicated in the scheduled mainte-

nance table. The engine must be emptied by drain-

ing off the oil through the drainage plug of the

mesh pre-filter, flywheel side; furthermore to facil-

itate oil drainage, loosen the cap/dipstick. Once all

the oil has drained through the drainage hole, un-

screw the oil cartridge filter and remove it.

Since a certain quantity of oil still remains in the

circuit, fill adding approx. 600 - 650 cm³ of oil

through the cap. Then start up the vehicle, leave it

running for a few minutes and switch it off: After

about five minutes, check the level and, if neces-

sary, top-up but never exceeding the MAX level

reference mark.N.B.THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended productsAGIP CITY HI TEC 4T Engine oilSAE 5W-40 Synthetic oil that exceed the require-

ments of API SL, ACEA A3, JASO MA specifica-

tions

Locking torques (N*m)Engine oil drainage cap 24 to 30

See alsoEngineoil filter

Check

In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and

the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all

four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be

considered normal, especially if during the run-in period. Consumption can particularly reflect the con-

ditions of use (i.e. when driving at 'full acceleration' all the time, oil consumption increases).


MAIN - 34

This operation must be carried out with the engine

cold and following the procedure below:

1) Rest the vehicle on the central stand and on a

flat ground.

2) Undo cap/dipstick, dry it off with a clean cloth

and reinsert it, screwing down completely.

3) Remove the cap/dipstick again and check that

the level is between the max. and min levels; top-

up, if required.

The MAX level reference mark indicates the

amount of oil in the engine. If the check is carried

out after the vehicle has been used, and therefore

with a hot engine, the level will be lower; in order

to carry out a correct check, wait at least 10 mi-

nutes after the engine has been stopped so as to

get the correct level.

CharacteristicEngine oil1.10 l

The oil should be topped up after having checked the level and in any case by adding oil without ever

exceeding the MAX. level.

Restoring the level between the MIN and MAX reference marks requires ~ 400 cm³ of oil.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended

type for topping up and changing purposes.

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the

mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge

filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended productsAGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Oil pressure warning light

The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to

the «ON» position. However, this light should switch off once the engine has started.


MAIN - 35

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to

check the oil level and the lubrication system.

transmissions

Put the vehicle in gear and regulate the idling by

turning the adjustment screw on the left-hand side

of the carburettor.

Adjust the control cables as follows.

Handlebar control:

- remove the front handlebar cover leaving it con-

nected to the system;

- remove the rubber hoods and regulate the cable

adjustments in such a way that they cause a min-

imum clearance on the throttle.

Carburettor control:

- remove the inspection cover of the helmet com-

partment;

- remove the rubber hoods and regulate the cable

adjustments in such a way that the sheaths have

a minimum clearance.


MAIN - 36

Checking the ignition timing

-Remove the flywheel fan.

-Rotate the flywheel until the reference (arrow)

matches the crankcase operation end as shown in

the figure (TDC). Make sure that the 2V reference

point on the camshaft control pulley is aligned with

the reference point on the head as shown in the

second figure. If the reference mark is opposite the

indicator on the head, make the crankshaft turn

once more.

-The TDC reference mark is repeated also be-

tween the flywheel cooling fan and the flywheel

cover.

To use this reference mark, remove the spark plug

and turn the engine in the opposite direction to the

normal direction of rotation using a compass span-

ner applied to the camshaft drive sprocket hous-

ing.N.B.TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.

Checking the valve clearance

-To check valve clearance, centre the reference marks of the timing system

- Use a feeler gauge to check that the clearance between the valve and the register corresponds with

the indicated values. When the valve clearance values, intake and exhaust respectively, are different

from the ones indicated below, adjust them by loosening the lock nut and operate on the set screw with

a screwdriver.

Intake: 0.10 mm (when cold)

Exhauste: 0.15 mm (when cold)

Braking system


MAIN - 37

Level check

Proceed as follows:

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

dlebars perfectly horizontal;

- Check the fluid level through the corresponding

sight glass.

A certain lowering of the level is caused by wear

on the brake pads.

Top-up

Proceed as follows:

- Undo the two screws and remove the cover with

the seal.

- Top-up using only the fluid specified, without ex-

ceeding the maximum level.CAUTIONONLY USE DOT 4-CLASSIFIED BRAKE FLUID.CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUREYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTALCONTACT, WASH WITH WATER.CAUTIONBRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKESURE THAT IT DOES NOT COME INTO CONTACT WITHTHE PAINTWORK.CAUTIONBRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBSMOISTURE FROM THE SURROUNDING AIR. IF THE CON-TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS ACERTAIN VALUE, BRAKING WILL BE INEFFICIENT.NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLYUSED CONTAINERS.UNDER NORMAL CLIMATIC CONDITIONS, THE FLUIDMUST BE CHANGED EVERY 20,000 KM OR ANYWAY EV-ERY TWO YEARS.N.B.SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TOTHE CHANGING OF BRAKE FLUID AND THE BLEEDINGOF AIR FROM THE CIRCUITS.

Recommended productsAGIP BRAKE 4 Brake fluidFMVSS DOT 4 Synthetic fluid


MAIN - 38

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;

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

derline of the projected light beam on the screen

is no higher than 9/10 or lower than 7/10 of the

distance from the ground to the centre of the ve-

hicle's headlamp;

3. Otherwise, adjust the headlight by turning the

knobs of the body inside the wheel housing.

- Tighten the screw (clockwise) to raise the light

beam;

- undo the screw (anticlockwise) to lower the light

beam.N.B.THE ABOVE PROCEDURE COMPLIES WITH THE EURO-PEAN STANDARDS REGARDING MAXIMUM AND MINI-MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-TORY REGULATIONS IN FORCE IN EVERY COUNTRYWHERE THE VEHICLE IS USED.

CO check

- Remove the inspection cover of the SAS valve,

by undoing the three indicated screws.

- Remove the clamp and the secondary air valve

as shown in the photograph.

- Connect the exhaust fumes outlet tube with the

secondary air tube rubber sleeve. This connection

should guarantee the system tightness to avoid

distorting the CO value readingN.B.IN CASE OF 1000 PPM UNBURNED HYDROCARBONS(HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYS-TEM, THE VALVE CLEARANCE AND THE EXHAUSTVALVE TIGHTNESS.N.B.


MAIN - 39

IN CASE OF UNSTABLE CO, CHECK THAT THE CARBU-RETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYS-TEM AND THE DEPRESSION SEALS WORK ADEQUATE-LYN.B.OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT INTHE TANK AND THE FUEL CIRCUIT.N.B.ALSO CHECK THE CARBURETION ADJUSTMENT IS OB-TAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND4 TURNS.N.B.CHECK THAT THE RESULT IS OBTAINED WITH THEVALVE GAS IN CLOSED POSITION.

Specific tooling020332Y Digital rpm indicator

CharacteristicCO Check3.8±0.7 to 1650±50 RPM

SAS filters inspection and cleaning

- Remove the screw fixing the SAS valve to the

flywheel cover, indicated in the photograph.

- Remove the 4 flywheel cover screws indicated in

the photograph and remove the flywheel cover.


MAIN - 40

- Remove the filter indicated in the photograph.

- Check the condition of the fan cover gasket and

its correct positioning.

- Check the SAS filter housing for dents or defor-

mations

- Clean the SAS filter carefully. Replace the filter if

it is damaged or deformed.

To refit, carry out the removal operations but in re-

verse order.CAUTIONWHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTERMUST BE CLEANED MORE OFTEN THAN SHOWN IN THESCHEDULED MAINTENANCE CHART.CAUTIONNEVER RUN THE ENGINE WITHOUT THE SECONDARYAIR FILTER


MAIN - 41

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Engine

Poor performance

POOR PERFORMANCEPossible Cause Operation

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, thensoak it in a mixture of 50% petrol and 50% of specific oil (AGIPFilter Oil), then hand dry without squeezing, allow to drip dry

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

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

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

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

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

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

aged parts and lubricate the driven pulley moveable guide withMontblanc Molybdenum Grease

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

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

Rear wheel spins at idle

REAR WHEEL ROTATES WITH ENGINE AT IDLEPossible Cause Operation

Idling rpm too high Adjust the engine idle speed and the CO%, if necessary.Clutch fault Check the springs / clutch masses

Starting difficulties

START-UP PROBLEMSPossible Cause Operation

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

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

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

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

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

agedCheck starter motor

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

plying a vacuum to the vacuum pipe

Typhoon 125 4T (MY 2010) Troubleshooting

TROUBL - 43

Possible Cause OperationFailing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace

if necessary.Start-up enabling buttons failure Check continuity using an Ohm meter, with the switch pressed;

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

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, thensoak it in a mixture of 50% petrol and 50% of specific oil (AGIPFilter Oil), then hand dry without squeezing, allow to drip dry

and then reassemble.

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUSTPossible Cause Operation

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

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

fitted properlyReplace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure

LOW LUBRICATION PRESSUREPossible Cause Operation

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

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

Engine tends to cut-off at full throttle

THE ENGINE TENDS TO STOP AT MAXIMUM THROTTLEPossible Cause Operation

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

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

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

Engine tends to cut-off at idle

THE ENGINE TENDS TO STOP AT IDLE SPEEDPossible Cause Operation

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

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

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

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

Troubleshooting Typhoon 125 4T (MY 2010)

TROUBL - 44

High fuel consumption

EXCESSIVE FUEL CONSUMPTIONPossible Cause Operation

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

power supplyLoose nozzles Check the maximum and minimum nozzles are adequately

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

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

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible Cause Operation

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

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

Never run the engine without the clutch housing

Insufficient braking

INEFFICIENT OR NOISY BRAKINGPossible Cause Operation

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

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

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

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

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

Brakes overheating

BRAKE OVERHEATPossible Cause Operation

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

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

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


TROUBL - 45

Electrical system

Battery

BATTERYPossible Cause Operation

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

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

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

chapter for the recharging of the batteries.

Turn signal lights malfunction

TURN INDICATORS NOT WORKINGPossible Cause Operation

Electronic ignition device failure With the ignition switch set to "ON" jump the contacts 1 (Blue-Black) and 5 (Orange) on the control unit connector.

If by operating the turn indicators control the lights are notsteadily on, replace the control unit; otherwise, check the cable

harness and the switch.

Steering and suspensions

Heavy steering

STEERING HARDENINGPossible Cause Operation

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

tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCEPossible Cause Operation

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

place if they are recessed.

Troubleshooting Typhoon 125 4T (MY 2010)

TROUBL - 46

Noisy suspension

NOISY SUSPENSIONPossible Cause Operation

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

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

work properly.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSIONPossible Cause Operation

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


TROUBL - 47

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Key:

1. Multiple connectors

2. Horn

3. Horn button

4. Fuel level transmitter

5. Diagnostic socket

6. Oil level warning light

7. Instrument panel lighting bulbs

8. High beam warning light

9. Turn indicator warning light

10. Fuel level instrument

11. Instrument panel

12. NTC temperature sensor

13. Low fuel warning light

14. Light switch

15. Key switch

16. Turn indicator switch

17. Starter button

18. Front stop switch

19. Rear stop switch

Typhoon 125 4T (MY 2010) Electrical system

ELE SYS - 49

20. Rear left turn indicator

21. Rear light

22. License plate light

23. Rear right turn indicator

24. Start-up relay

25. Starter motor

26. Battery

27. Main fuse

28. Auxiliary fuses

29. Coil

30. Spark plug

31. Throttle sensor

32. CDI control unit

33. Automatic starter

34. Carburettor PTC heater

35. Regulator

36. Oil pressure sensor

37. Pick-up

38. Generator

39. Front right turn indicator

40. High beam light

41. Front position light

42. Low beam light

43. Front left turn indicator

44. Front headlamp

45. Ground point on chassis

Colours of the electrical cables:

B = White

Bl = Blue

G = Yellow

Mr = Brown

N = Black

BV = White-Green

GN = Yellow-Black

Gr = Grey

Rs = Pink

R = Red

Vi = Violet

Electrical system Typhoon 125 4T (MY 2010)

ELE SYS - 50

V = Green

VN = Green-Black

BN = Black-White

BBl = White-Blue

GV = Yellow-Green

Ar = Orange

Az = Sky blue

GrBl = Grey-Blue

GrN = Grey-Black

RBl = Red-Blue

GR =Yellow-Red

BlN = Blue-Black


ELE SYS - 51

Components arrangement


ELE SYS - 52

1. Air temperature sensor - Remove the leg

shield, as described in the «BODYWORK» chap-

ter to reach it.

2. Voltage regulator - 3. Coil - Remove the rear

central cover to reach it.

4. Battery - 5. Main fuse - Lift the saddle and re-

move the cover to reach it.

6. Start-up solenoid - Remove the side fairings to

reach it.


ELE SYS - 53

7. Secondary fuses - Open the glove-box lid to

reach them.

8. Horn - Remove the footrest to reach it.

9. Ignition switch - Remove the leg shield back

plate to reach it.

10. Fuel level transmitter - 11. Diagnosis con-

nector - Remove the battery inspection cover to

reach them.


ELE SYS - 54

12. Oil pressure sensor - 13. Engine speed sen-

sor - Remove the fan cover cap to reach them, as

described in the ENGINE chapter.

14. Starter motor - Remove the helmet compart-

ment to reach it.

15. CDI control unit - Remove the leg shield to

reach it.

16. Right brake switch - 17. Left brake switch -

Remove the front handlebar cover to reach them.


ELE SYS - 55

18. Automatic starter - 19. PTC heater - 20.

Throttle position sensor - Remove the helmet

compartment to reach them.

21. Horn button - 22. Light switch - 23. Turn in-

dicator switch - They are fixed inside the rear

handlebar cover, on the left-hand side.

24. Engine starter button - It is fixed inside the

rear handlebar cover, on the right-hand side.


ELE SYS - 56

Ground points

- On the vehicle there is a chassis ground point,

beneath the rear central cover.

• On the engine there is a ground point

on the starter motor.

Electrical system installation

Front side


ELE SYS - 57

1. Upper branch of the main cable harness

2. Front brake stop switch cable

3. Engine starter button cable

4. Front left turn indicator cable

5. Front right turn indicator cable

6. Rear brake stop switch cable

7. Instrument panel connectors

8. Light switch connector

9. Central branch of the main cable harness

10. Air temperature sensor connector

11. Ignition switch connector

12. Front light cable

13. Secondary fuse cable

14. CDI control unit cable


ELE SYS - 58

15. Horn cable

16. Transverse branch of the main cable harness

Back side

17. Ground cable on chassis


ELE SYS - 59

18. Regulator cable - chassis ground

19. Coil cable

20. Spark plug cable

21. Branch of devices on engine

22. Rear branch of the main cable harness

23. Start-up solenoid cable

24. Rear lights and fuel level transmitter connecting branch

25. Battery positive and main fuse connecting cable

26. Battery negative connecting cable

27. Diagnosis connector cable

28. Fuel level transmitter cable


ELE SYS - 60

29. Battery positive lead

30. Main fuse connecting cable

31. Battery negative lead

32. Diagnosis connector

33. Rear right turn indicator cable

34. Rear left turn indicator cable

35. Rear light cable

36. License plate lamp cable

37. Ground cable on engine

38. Starter motor positive wire

39. Connector for stator, pick-up and oil pressure sensor

40. Branch connecting devices on carburettor

41. Automatic starter connector


ELE SYS - 61

42. PTC resistor connector

43. Throttle position potentiometer connecting cable

Conceptual diagrams

Ignition

Key:


5. Diagnostic socket

15. Key switch

26. Battery

27. Main fuse

28. Auxiliary fuses

29. Coil

30. Spark plug

31. Throttle sensor


37. Pick-up


ELE SYS - 62

Battery recharge and starting

Key:


15. Key switch

17. Starter button



21. Rear light

24. Start-up relay

25. Starter motor

26. Battery

27. Main fuse

28. Auxiliary fuses

35. Regulator

38. Generator



ELE SYS - 63

Level indicators and enable signals section

Key:


4. Fuel level transmitter

6. Oil level warning light

10. Fuel level instrument


12. NTC temperature sensor

13. Low fuel warning light

15. Key switch

26. Battery

27. Main fuse

28. Auxiliary fuses


36. Oil pressure sensor



ELE SYS - 64

Instruments and warning lights control board

A= High beam warning light;

B = Oil pressure warning light;

C= Turn indicator warning light;

D= Low fuel warning light;

E = Odometer;

F= Rpm indicator;

G= Fuel gauge

LIGHT BULBS TABLESpecification Desc./Quantity

1 High/low beam light bulb Type: Halogen (H8)Power: 12V - 35W

Quantity: 22 Front side light bulb Type: All glass

Power: 12V 3WQuantity: 2

3 Instrument panel bulb, indicator warning lights, oil pres-sure and high beams

Type: All glassPower: 12V - 1.2W

Quantity: 54 Front turn indicator light bulb Type: SPHERICAL (amber colour)

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

5 Rear turn indicator light bulb Type: SPHERICAL (amber colour)Power: 12V - 10W

Quantity: 1 RHS + 1 LHS6 Stop light/rear daylight running light bulb Type: ALL GLASS (twin-filament)

Power: 12V - 21/5WQuantity: 1

7 License plate bulb Type: All glassPower: 12V - 3W

Quantity: 1


ELE SYS - 65

Devices and accessories

Key:


2. Horn

3. Horn button

15. Key switch

26. Battery

27. Main fuse

28. Auxiliary fuses


33. Automatic starter

34. Carburettor PTC heater



ELE SYS - 66

Lights and turn indicators

Key:


7. Instrument panel lighting bulbs

8. High beam warning light

9. Turn indicator warning light


14. Light switch

15. Key switch

16. Turn indicator switch



20. Rear left turn indicator

21. Rear light

22. License plate light

23. Rear right turn indicator

26. Battery

27. Main fuse

28. Auxiliary fuses


ELE SYS - 67


39. Front right turn indicator

40. High beam light

41. Front position light

42. Low beam light

43. Front left turn indicator

44. Front headlamp

Checks and inspections

Ignition circuit

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

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

might be irretrievably damaged.

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

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

system.

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

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

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

ground connection bonding is efficient.

No spark plug

Once the lack of power to the spark plug has been

detected and the LED indicates it can be ignited,

follow this procedure:

- Check the Pick-Up.

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

Disconnect the control unit connector and meas-

ure the resistance between terminal No. 10 (Blue/

Yellow) and terminal No. 12 (Blue).

If the value measured is incorrect, repeat the

check directly on the component. Disconnect the

pick-up connector on the engine and measure the

resistance between the pin corresponding to the


ELE SYS - 68

Blue-Yellow cable of the wiring and the ground

connection on the engine.

If correct values are detected, check that the cable

is not interrupted.

Electric characteristicPick-up resistance value~ 130 Ohm

- HV primary coil check

Disconnect the control unit connector and check

that the cable between terminal No. 4 (White/Vio-

let) and terminal No. 12 (Blue) is not interrupted

(see figure).

If non-conforming values are measured, check

again the HV coil primary directly on the positive

and negative terminals.

If the values are correct, repair the cable harness

or reset the connections; otherwise, replace the

HV coil

Electric characteristicHigh voltage coil primary resistance valueHigh voltage coil primary resistance value: ~ 0.5

Ohm

- HV coil secondary check

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

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

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

check the peak voltage with the multimeter adaptor.

Specific tooling020409Y Multimeter adaptor - Peak voltage detectionElectric characteristicHigh voltage coil secondary resistance valueHigh voltage coil secondary resistance value: ~ 3000 ± 300 Ohm


ELE SYS - 69

- H.V. coil

With the control unit and HV coil connected to the

circuit, measure the voltage of the coil primary dur-

ing the start-up test with the voltage peak adaptor

and connect the positive terminal to the ground

one and the negative to the coil positive connector.

If non-conforming values are measured, replace

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

Electric characteristicHigh voltage coil voltage valueHigh voltage coil voltage value: > 100 Volt

Battery recharge circuit

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

The generator is directly connected to the voltage regulator.

This, in its turn, is connected directly to the ground and the battery positive terminal passing through

the 20A main protection fuse.

This system therefore requires no connection to the ignition switch.

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

ieved between generated power and idle stability.

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

Specific tooling020334Y Multiple battery charger

Switches check

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

correct as indicated in the following charts.

KEY

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

Gre: Green Pr: Purple


ELE SYS - 70

STARTER BUTTON

LIGHT SWITCH

TURN INDICATOR SWITCH

HORN BUTTON


ELE SYS - 71

Stator check

Disconnect the connector from the voltage regu-

lator and check there is continuity between any

yellow cable and the other two cables.

Electric characteristicOhm value:1 ± 1 Ohm

Also check that all yellow cables are insulated from

the ground connection.

If non-conforming values are detected, repeat the

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

etitions of incorrect values replace the stator or

repair the wiring.

Voltage regulator check

With a perfectly charged battery and lights off,

measure voltage at the battery poles with a high

running engine.

The voltage should not exceed 14.5 Volt.

In case higher voltages are detected, replace the

regulator.

In case of voltage values lower than 14 Volt, check

the stator and the corresponding cable harness.


ELE SYS - 72

Recharge system voltage check

Connect the ammeter induction clamp to the volt-

age regulator positive terminal (Red/Orange),

measure the battery voltage and turning on the

vehicle lights with the engine off, wait for the volt-

age to settle at about 12 Volt. Start the engine and

measure the current generated by the system with

the lights on and a high running engine.

In case the generated current value is lower than

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

tor alternatively.

CharacteristicDistributed current13A at 6000 rpm

Starter motorWARNING

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

If it does not work:

- Check the continuity of the Green/Red cable between the 7.5A fuse (B) and stop buttons.

- Check the continuity between the starter button Green/Red cable and the stop button Green/Yellow

cables.

- Check continuity between the Yellow/Red cable between the starter button and the start-up solenoid.

- Check that the Red cable between the battery and the start-up solenoid, and the latter and the starter

motor are not interrupted.

- Check the start-up solenoid.

- Check the contacts of the ignition switch, the starter button and the stop buttons.

- Check the efficiency of the fuses.

- Check that the starter motor is grounded.

- If all the tests are positive, replace the starter motor.


ELE SYS - 73

Horn control

KEY

1. Battery

2. Main fuse (A) 20A

3. Ignition switch contacts

4. Secondary fuse (C) 15A

5. Horn button

6. HornWARNING


If the horn does not work:

- Check the efficiency of the fuses.

- Check the ignition switch and the horn button contacts.

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

- Check the continuity of the Green cable which connects the horn button to 15A fuse (C).

- Check the continuity of the Grey cable which connects the switch to the horn.

- If all the tests are positive, replace the horn.


ELE SYS - 74

Choke Inspection

Refer to the engine section to check the resistance

and operating conditions of the component. As re-

gards voltage supply, keep the connector connec-

ted to the system and check that the two terminals

receive battery voltage when the engine is on

(see figure).

If no voltage is detected, connect the multimeter

negative probe to the ground lead and the positive

probe to the automatic starter Yellow cable; with

the ignition switch set to "ON" check whether there

is battery voltage; if there is no voltage, check the

wiring connections to the ignition switch.

If there is voltage, check again the ignition control unit connector.

After disconnecting the starter, start up the engine and keep it at idle speed and check there is voltage

when the multimeter positive terminal is connected to terminal No. 9 (Green/Red) and the negative one

to terminal No. 11 (Green/Black).

Replace the control unit if there is no voltage; otherwise, check the wiring connections between the

starter and the control unit.

Turn signals system checkWARNING


Check that bulb operates properly.

Check continuity of the Blue-Black cable between the CDI control unit and the turn indicators switch.

Check that the turn indicator switch works properly.

Check continuity of the Red and Blue cables which connect the switch to the bulbs.

level indicatorsWARNING



ELE SYS - 75

If faults are detected:

- With a multimeter, check resistance values be-

tween the Grey-Green cable and the Blue cable of

the fuel level transmitter by moving the arm with

the float.

- If the transmitter operates correctly but the indi-

cation on the instrument panel is not exact, check

that the cable harnesses between them are not in-

terrupted.

- Check continuity of the Green cable which con-

nects the instrument panel to the 15A secondary

fuse (C).

- Check continuity of the Grey/Green cable which

connects the instrument panel to the probe check-

ing fuel level.

Electric characteristicResistance value when the tank is full~ 7.4 Ω

Resistance value when the tank is empty~ 101 Ω

Fuses

The electrical system is protected by a main fuse

(A) connected on the left-hand side of the helmet

compartment next to the battery. For access it is

necessary to remove the battery cover and the

transparent protection over the fuse block. Starter

circuit, light circuit, horn and instrument panel are

protected by two secondary fuses (B) and (C) lo-

cated inside the glove-box.CAUTIONBEFORE REPLACING THE BLOWN FUSE, SEARCH ANDSOLVE THE PROBLEM THAT CAUSED IT TO BLOW.NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSEOF A DIFFERENT RATING THAN THAT SPECIFIED OR US-ING OTHER MATERIAL (FOR EXAMPLE, A PIECE OFELECTRICAL WIRE).


ELE SYS - 76

FUSE CHARTSpecification Desc./Quantity

1 FUSE A Capacity:20AProtected circuits: Recharge circuit, oil pressure sen-

sor, oil pressure warning light.2 Fuse B Capacity:7.5 A

Protected circuits: Start-up circuit, starter motor, stoplight bulb, ECU power supply.

3 Fuse C Capacity:15AProtected circuits: Rear light bulb, license plate light

bulb, turn indicator bulb, turn indicator warning light, fuelgauge, instrument panel lighting bulb, horn, low beam

bulb, high beam bulb, high beam warning light.

Sealed batteryCommissioning sealed batteries

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 standard tester.

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

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

2) Constant voltage battery charge mode

-Constant voltage equal to 14.40÷14.70V

-Initial charge voltage equal to 0.3÷0.5 for nominal capacity

-Duration of the charge: 10 to 12 h recommended

Minimum 6 h


ELE SYS - 77

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.GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CON-TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Battery installation

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

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

1) Battery preparation

Position the battery on a flat surface. Remove the

adhesive sheet closing cells and proceed as quick-

ly as possible to run the subsequent activation

phases.

2) Electrolyte preparation.

Remove the container of the electrolyte from the

pack. Remove and preserve cover strips from the

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

closing cover.

Note: Do not pierce the sealing of the container or

the container itself because inside there is sulfuric

acid.


ELE SYS - 78

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with

the six areas sealed in line with the six battery filler

holes. Push the container down with enough force

to break the seals. The electrolyte should start to

flow inside the battery.

Note: Do not tilt the container to prevent the flow

of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

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

minutes or more.

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

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

5) Take out the container.

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

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

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

6) Battery closing.

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

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

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

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

The filling process is now complete.

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

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

7) Recharging the new battery

With the above-mentioned procedure, the battery

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

electrical capacity. Before installing the battery on

the vehicle, it must be fully charged and then must

be recharged.

If the battery is to be installed on the vehicle

prior to this pre-charged one, the battery will

not be able to exceed 75% charge without jeop-

ardising its useful life on vehicle.

The dry charge battery MF like the completely loa-

ded YTX, must have a no-load voltage between


ELE SYS - 79

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

ing the 020648Y battery charger:

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

the left of the panel battery charger panel

b - select NEW on the yellow timer

c - connect the clamps of the battery charger to the

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

red clamp to positive pole (+)).

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

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

tery recharge Maintenance Free as shown in fig-

ure.

f - Check the ignition of the green LED indicated

with a red arrow in figure.


ELE SYS - 80

g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED

has taken place

h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less

than 12.8 V, proceed with a new recharge of the

battery starting from point c of the recharge pro-

cedure of the new battery, otherwise go to point i

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

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


ELE SYS - 81

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the

head

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

ing; then remove the whole muffler paying atten-

tion to the interference between its supporting

bracket and the cooling cover.

Locking torques (N*m)Nut fixing silencer to cylinder head 16 to 18 Si-lencer to crankcase fixing screws 24 to 27

Removal of the engine from the vehicle

- Remove the side fairings.

- Remove the helmet compartment.

- Remove the full silencer unit.

- Remove the fastening screw of the rear brake

transmission shown in the photograph and slide off

the cable of the retainer brackets.

Typhoon 125 4T (MY 2010) Engine from vehicle

ENG VE - 83

- Loosen the throttle control cables by acting on

the carburettor set screws and slide them off the

pulley.

See alsoExhaust assy. Removal

- Remove the fuel supply pipe from the carburettor

- Remove the fuel valve low-pressure pipe from the

manifold as shown in the photograph

- Remove the flywheel wiring connector, the

ground terminal and the starter motor positive ca-

ble indicated in the figure

Engine from vehicle Typhoon 125 4T (MY 2010)

ENG VE - 84

- Remove the clamp retaining the starter wiring

and the heater indicated in the figure

- Disconnect the automatic starter and carburettor

heater connectors.

- Keep the engine-swinging arm pin nut blocked on

the left-hand side of the vehicle and undo the pin

from the opposite side.

Typhoon 125 4T (MY 2010) Engine from vehicle

ENG VE - 85

- Adequately support the vehicle (i.e. with a jack)

and remove the engine-swinging arm pin and the

shock absorber lower mount.

The engine is now free.

Engine from vehicle Typhoon 125 4T (MY 2010)

ENG VE - 86

INDEX OF TOPICS

ENGINE ENG

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

Automatic transmission

Transmission cover

- To remove the transmission cover it is necessary

to remove the rear plastic cover first by inserting a

screwdriver in the corresponding slotted holes.

Using the clutch housing lock wrench, remove the

driven pulley axle locking nut and recover the

washer.

- Remove the cap/dipstick from the engine oil filling

hole.

- Remove the ten screws.

- Remove the transmission cover. If this operation

is performed directly on the vehicle, it is necessary

to remove the air filter housing retainers.

Specific tooling020423Y Driven pulley lock wrench

Air duct

- Unscrew the Torx screws fixing the air duct bulk-

head and remove the bulkhead.

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

well as the filter.

Engine Typhoon 125 4T (MY 2010)

ENG - 88

Air duct filter

- Unscrew the two fixing screws and slide off the

filter.

- Clean with water and milid soap.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Use the specific tools to remove the bearing from

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

Specific tooling020376Y Adaptor handle


Typhoon 125 4T (MY 2010) Engine

ENG - 89

Refitting the driven pulley shaft bearing

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

- Insert the bearing in its housing, refit the Seeger

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

Specific tooling020151Y Air heater


020357Y 32x35-mm Adaptor

020412Y 15-mm guide

Removing the driven pulley

- Remove the spacer, the clutch housing and the

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

Inspecting the clutch drum

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

- Measure the clutch bell inside diameter.

CharacteristicMax. value clutch bellMax. value: Ø 134.5 mm

Clutch bell standard valueStandard value: Ø 134 - 134.2 mm


ENG - 90

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2

bearings (inside diameter: 15 and 17 mm).

- Lock with the original spacer and nut.

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

the crankshaft alignment.

- Using a feeler dial gauge and the magnetic base,

measure the bell eccentricity.

- Repeat the measurement in 3 positions (Central,

internal, external).

- If faults are found, replace the bell.

Specific tooling020074Y Support base for checking crankshaftalignment


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

Removing the clutch

- Prepare the locking tool for the driven pulley with

the pins half-screwed in the tool set to «C».

- Introduce the adapter ring 11 with the chamfering

facing the inside of the tool.


ENG - 91

- Fit the driven pulley unit in the tool so as the bolt

get into the masses clutch support holes. After-

wards make the support screw make contact with

a minimum force.

- Using the specific wrench, inserted 46 mm from

the side, remove the clutch central locking nut.

- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BETIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THESPECIFIC TOOL.

Specific tooling020444Y Tool for fitting/ removing the driven pulley clutch

020444Y011 adapter ring

020444Y009 wrench 46 x 55

Inspecting the clutch

- Check the thickness of the clutch mass friction

material.

- The masses must not show traces of lubricants;

otherwise, check the driven pulley unit seals.N.B.UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-TRAL FAYING SURFACE AND MUST NOT BE DIFFERENTFROM ONE ANOTHER.VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TOTEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLS TO PREVENTA VARIATION IN THE RETURN SPRING LOAD.

CharacteristicCheck minimum thickness1 mm


ENG - 92

Pin retaining collar

- Simultaneously turn and pull the collar manually

to remove it.N.B.USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL-TY.N.B.BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOOFAR TO AVOID DAMAGE THAT COULD COMPROMISETHE O-RING SEAL.

Removing the driven half-pulley bearing

- Remove the retainer ring using two flat blade

screwdrivers.

- Using a hammer and pin, knock the ball bearing

out as shown in the figure.

- Remove the roller bearing using the specific ex-

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

Specific tooling020375Y 28 x 30 mm adaptor


020439Y 17-mm guide


ENG - 93

Inspecting the driven fixed half-pulley

- Measure the external diameter of the pulley bush-

ing.

CharacteristicMinimum diameter permittedØ 40.96 mm

Standard diameterØ 40.965 mm

Inspecting the driven sliding half-pulley

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

rings.

- Measure the inside diameter of the mobile half-

pulley bushing.

CharacteristicMinimum admissible diameter:Ø 41.08 mm

Standard diameterØ 41.035 mm

Refitting the driven half-pulley bearing

- Assemble a new roller bearing using the specific

punch, fit the bearing with the label facing outward

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

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

Specific tooling020424Y Driven pulley roller casing fittingpunch


ENG - 94

- To assemble the new ball bearing insert it com-

pletely down in its housing with the specific punch

and finally assemble the Seeger ring.

Specific tooling020375Y 28 x 30 mm adaptor


020439Y 17-mm guide

Refitting the driven pulley

- Check that the faying surfaces between the 2

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

wear, scoring and grease.

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

able half-pulley.

- Assemble the half-pulley on the ringlet with the

appropriate protection sheath.

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

assemble the pins and collar.

- Use a greaser with a curved spout to lubricate the

driven pulley unit with around 6 g of grease. This

operation must be done through one of the holes

inside the bushing until grease comes out of the

opposite hole. This operation is necessary to avoid

the presence of grease beyond the O-rings.

Specific tooling020263Y Driven pulley assembly sheath

Recommended productsMONTBLANC MOLYBDENUM GREASE -Grease with molybdenum disulphide


ENG - 95

Inspecting the clutch spring

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

laxed.

CharacteristicStandard length:106 mm

Acceptable limit after use102.5 mm (4.035 in)

Refitting 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.N.B.UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-ENT FROM ONE ANOTHER. VARIOUS CONDITIONS CANCAUSE THE CLUTCH TO TEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLS SO AS TOPREVENT A VARIATION IN THE RETURN SPRING LOAD.

CharacteristicMinimum thickness permitted:1 mm

- Support the driven pulley spring compressor spe-

cific tool with the control screw in vertical axis.

- Arrange the tool with the medium length pins

screwed in position "C" on the inside.

- Introduce the adapter ring No. 11 with the cham-

fering facing upwards.

- Insert the clutch on the adapter ring.

- Lubricate the end of the spring that abuts against

the torque server closing collar.

- Insert the spring with its plastic holder in contact

with the clutch.

- Insert the drive belt into the pulley unit according

to their direction of rotation.


ENG - 96

- Insert the pulley unit with the belt into the tool.

- Slightly preload the spring.

- Make sure that the clutch is perfectly inserted into

the adapter ring before proceeding to tighten the

clutch nut.

- Place the tool in the clamp with the control screw

on the horizontal axis.

- Fully preload the spring.

- Apply the clutch fixing nut and tighten it to the

prescribed torque using the special 46x55 wrench.

- Loosen the tool clamp and insert the belt accord-

ing to its direction of rotation.

- Lock the driven pulley again using the specific

tool.

- Preload the clutch return spring with a traction/

rotation combined action and place the belt in the

smaller diameter rolling position.

- Remove the driven pulley /belt unit from the tool.N.B.DURING THE SPRING PRELOADING PHASE, BE CARE-FUL NOT TO DAMAGE THE PLASTIC SPRING STOP ANDTHE BUSHING THREADING.N.B.FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-TED IN CONTACT WITH THE CLUTCH.

Specific tooling020444Y Tool for fitting/ removing the drivenpulley clutch

020444Y011 adapter ring

020444Y009 wrench 46 x 55

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


ENG - 97

Refitting the driven pulley

- Reassemble the clutch housing and spacer.

Drive-belt

- Make sure the drive belt is not damaged and does not show abnormal wear.

- Replace as indicated in the scheduled maintenance table.

Removing the driving pulley

- Lock the driving pulley with the specific tool as

shown in the figure. - Disassemble the central nut

and the cup washer, remove the drive and the 2

washers. - Remove the stationary half pulley and

the steel washer.

Specific tooling020368Y driving pulley lock wrench

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

ley with the relevant bush, taking care of the falling

free assembled rollers.

- Remove the return rollers plate with the relative

guide sliders.

Inspecting the rollers case

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

DO NOT LUBRICATE OR CLEAN THE BUSHING.


ENG - 98

BUSHING ROLLER HOUSINGSpecification Desc./Quantity

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

BUSH SLIDE PULLEYSpecification Desc./Quantity

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

CVT ROLLERSSpecification Desc./Quantity

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

- Check the guide shoes for the variator back-plate

are not worn.

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

the surfaces in contact with the belt on either of the

pulley halves.

- Pre-assemble the movable half-pulley with the

roller contrast plate by placing the rollers as shown

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

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

- Mount the complete bushing unit on the crank-

shaft.


ENG - 99

Refitting the driving pulley

- Reassemble the parts of the unit (internal lining,

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

spread threadlock on the thread and screw the nut

to the prescribed torque.

-Avoid the half-pulley rotation using a calliper

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

Specific tooling020368Y driving pulley lock wrench

Recommended productsLoctite 243 Medium strength threadlockMedium Loctite 243 threadlock

Locking torques (N*m)Drive pulley nut 75 - 83

Refitting the transmission cover

- Check that there are 2 alignment dowels and that

the sealing gasket for the oil sump on the trans-

mission cover is adequately fitted.

- Replace the cover and tighten the 10 screws to

the specified torque.

- Refit the oil loading cap/bar.

- Refit the steel washer and the driven pulley nut.

- Tighten the nut to the prescribed torque using the

lock wrench and the torque wrench tools.

- Refit the plastic cover.


ENG - 100

Specific tooling020423Y Driven pulley lock wrench

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

End gear

Removing the hub cover

- Empty the rear hub through the oil drainage tap

located inside the hub cover

- Remove the brake shoe and relevant spring

- Remove the 7 flanged screws as shown in the

figure.

- Remove the rubber cover and the brake shoes

lever sliding unscrewing the relevant retaining

screw to reach the rear of the cover

- Take off the hub cover and relevant gaskets

Removing the wheel axle

Remove the intermediate gear and the complete

hub cover.


ENG - 101

Removing the hub bearings

- Check the state of the bearings being examined

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

tected, do the following.

- Use the specific bearing extractor to remove the

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

the hub cover).

Specific tooling001467Y009 Driver for OD 42-mm bearings

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

Removing the wheel axle bearings

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

- Remove the bearing with the adequate tools ad-

equately supporting the hub cover, as shown in the

figure.


020364Y 25-mm guide

With the appropriate tools, remove the oil seal as

shown in the figure.



Removing the driven pulley shaft bearing

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

pulley.

- Extract the driven pulley shaft from its bearing.

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

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

- Remove the Seeger ring shown in the figure


ENG - 102

With the sectional punch, remove the driven pulley

shaft bearing.



020363Y 20-mm guide

See alsoRemoving the driven pulley

Inspecting the hub shaft

- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and

the oil seal housings.

- If faults are found, replace the damaged compo-

nents.

Inspecting the hub cover

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

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

Refitting the driven pulley shaft bearing

- Heat up the parts using the specific heat gun

Specific tooling020150Y Air heater mounting

020151Y Air heater

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

the hub cover using the adequate tools



ENG - 103

- Refit the Seeger ring with the opening facing the

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

flush with the crankcase.

Refitting the wheel axle bearing

- Heat up the parts using the specific heat gun

Specific tooling020151Y Air heater

020150Y Air heater mounting

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

Specific tooling020364Y 25-mm guide



• Assemble the Seeger ring.

• Assemble the oil seal flush with the in-

ternal surface as shown in the figure to

the hub using the adequate tools and

with the seal lip towards the inside of

the hub.



Refitting the hub cover bearings

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

specific heat gun.

Specific tooling020150Y Air heater mounting

020151Y Air heater


ENG - 104

- The three 15 mm bearings must be fitted using

the appropriate tools.

Refitting the hub bearings

- Insert the cover prepared in the crankcase taking

care of inserting the gear of the pulley shaft on the

intermediary gear.

Refitting the ub cover

- Fit a new gasket together with the alignment

dowels.

- Fit the gearbox cover, making sure the breather

pipe is in the correct position.

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

sitioning the support plate of the pipe in the posi-

tion shown in the figure.

- Remove the control pin of the shoe taking care

so as the long tooth coincides with the groove on

the control lever.

Locking torques (N*m)Rear hub cap screws 24 to 27


ENG - 105

Flywheel cover

Cooling hood

- Remove the SAS valve and the cylinder head

connecting pipe (see SAS valve).

- Remove the flywheel duct by undoing the four

fixing screws.CAUTIONUPON REMOVAL SLIDE THE CONNECTOR OFF ITS FIT-TING ON THE DUCT.

- Loosen the clamp and remove the carburettor

from the manifold.

-Remove the complete manifold acting on the 2

retainers as shown in the figure.

- Slide the access flap to the spark plug.

- Remove the two self threading screws, left and

right and the lateral left fixing screw on the crank-

case base.

- Take off the two caps from the thermal group.

- Remove the gasket seal of the housing on the

head.

Locking torques (N*m)Flywheel hood fixing screws 1 ÷ 2


ENG - 106

Cooling fan

- Remove the fan cover cap.

- Remove the cooling fan by acting on the three

fixings indicated in the figure.

Locking torques (N*m)Flywheel fan screws 3 to 4

Removing the stator

- Remove the magneto flywheel.

- Remove the electric terminal of the minimum oil

pressure switch.

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

the wiring harness bracket as well as the two stator

fixing screws shown in the figure.

- Remove the stator and its wiring.

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-

ers to the specified torque.

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

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


ENG - 107

Flywheel and starting

Removing the starter motor

- Remove the two screws indicated in the figure.

- Take the starter motor out of its seat.

Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper

spanner.

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

Specific tooling020565Y Flywheel lock calliper spanner

- Extract the flywheel with the extractor.

Specific tooling008564Y Flywheel extractor

Inspecting the flywheel components

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


ENG - 108

Refitting the flywheel magneto

- Fit the flywheel being careful to insert the key

properly.

- Lock the flywheel nut to the prescribed torque

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

to 0.76 mm.

The air gap cannot be modified when assembling

the Pick-Up.

Different values result from deformations visible

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

Locking torques (N*m)Flywheel nut 52 to 58

Refitting the starter motor

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

- Fit the starter motor on the crankcase and lock

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

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

Cylinder assy. and timing system


ENG - 109

Removing the timing system drive

- Remove the parts listed below first: transmission

cover, belt driving pulley, oil pump pulley cover and

pinion separator washer.

- Remove the tappet cover.

- Remove the central screw fastener and the au-

tomatic valve lifter retaining cover, as shown in the

figure.

- Remove the return spring of the automatic valve

lifter unit and the automatic valve lifter unit and its

end of stroke washer.

- Loosen the central screw on the tensioner first.

- Remove the two fixings shown in the figure.

- Remove the tensioner with its gasket.

- Remove the inner hexagonal screw and the counterweight

- Remove the camshaft control pulley with its washer.


ENG - 110

- Remove the command sprocket wheel and the timing chain.

- Remove the screws indicated in the figure, the spacer bar and the tensioner slider.

The tensioner pad must be removed from the transmission side. As regards the lower chain guide slider,

it may only be removed after the head has been removed.N.B.

IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTIONOF ROTATION IS MAINTAINED.

See also

Transmission coverRemoving the driving pulleyRemoval

Removing the cam shaft

- Remove the 2 screws and the camshaft retainer

shown in the diagram.

- Remove the cam shaft.

- Remove the pin of the rocking levers from the

flywheel side holes.

- Remove the rocking levers and the elastic wash-

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


ENG - 111

Removing the cylinder head

- Remove the spark plug.

- Remove the 2 side fixings shown in the figure.

- Loosen the 4 head-cylinder fastening nuts in two

or three stages and in criss-cross fashion.

- Remove the head, the two alignment dowels and

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

Removing the valves

- Using the specific tool fitted with the element

shown in the figure, remove the cotters, the caps

and the spring between the valves.

Specific tooling020382Y Valve cotters equipped with part 012removal tool


- Remove the oil seals with the appropriate tool.

- Remove the lower spring supports.

Specific tooling020431Y Valve oil seal extractor


ENG - 112

Removing the cylinder - piston assy.

- Remove the chain guide slider.

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

- Remove the two retainer rings, the wrist pin and

the piston.

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

Inspecting the small end

- Measure the internal diameter of the connecting

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

CharacteristicConnecting rod small end check-up: Maximumdiameter15.030 mm

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


ENG - 113

Inspecting the wrist pin

- Check the outer diameter of the gudgeon pin.

CharacteristicStandard pin diameter14.996 to 15 mm

Minimum diameter permittedØ 14.994 mm

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

CharacteristicPiston pin bore - standard diameterØ 15+0.001 +0.006

- Measure the outside diameter of the piston, per-

pendicular to the gudgeon pin axis.

- Measure 36.5 mm from the piston crown's shown

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

- Using a bore meter, measure the inner cylinder

diameter at three different points according to the

directions shown in the figure.

- Check that the coupling surface with the head is

not worn or misshapen.

- Pistons and cylinders are classified into catego-

ries based on their diameter. The coupling is car-

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

CharacteristicMaximum allowable run-out:0.05 mm


ENG - 114

- The cylinder rectifying operation should be car-

ried out with a surfacing that respects the original

angle.

- The cylinder surface roughness should be 0.9

micron.

- This is indispensable for a good seating of the

sealing rings, which in turn minimises oil consump-

tion and guarantees optimum performance.

- The pistons are oversized due to cylinder rectifi-

cation and are subdivided into three categories

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

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

C, D-D.

Inspecting the piston

- Carefully clean the sealing ring housings.

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

sensors, as shown in the diagram.

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

STANDARD COUPLING CLEARANCEName Description Dimensions Initials Quantity

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

oil scraper 0.015 to 0.060

MAXIMUM ADMITTED CLEARANCE AFTER USEName Description Dimensions Initials Quantity

Top piston ring 0.080 mmMiddle piston ring 0.070 mm

oil scraper 0.070 mm


ENG - 115

Removing the piston

- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-

wards the exhaust.

- Fit the pin retainer ring onto the appropriate tool.

Specific tooling020430Y Pin lock fitting tool

- With the opening in position indicated on the tool,

take retainer ring in the closed position using the

punch.

- Fit the wrist pin retainer ring using the plug as

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


ENG - 116

Refitting the piston rings

- Place the oil scraper spring on the piston.

- Refit the oil scraper ring with the join of spring

ends on the opposite side from the ring gap and

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

pered side of the middle piston ring should always

be facing away from the piston crown.

- Fit the middle piston ring with the identification

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

must be facing opposite the piston crown.

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

reference mark facing the crown of the piston.

- Offset the piston ring gaps on the three rings by

120° to each other as shown in the figure.

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

Refitting the cylinder

- Insert the cylinder base gasket with the thickness

determined above.

- Using the fork support and the piston ring retain-

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

Specific tooling020426Y Piston fitting fork


ENG - 117

020427Y Piston assembly band

Inspecting the cylinder head

- Using a trued bar check that the cylinder head

surface is not worn or distorted.

- Check that the camshaft and rocking lever pin

bearings show no signs of wear.

- Check that the cylinder head cover surface, the

intake manifold and the exhaust manifold are not

worn.

CharacteristicMaximum admitted unevenness: Cylinderhead check0.05 mm

STANDARD DIAMETERSpecification Desc./Quantity

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

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.

- Ensure that the camshaft drive pulley, the chain

assembly and the sprocket wheel are not worn.

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

chain, pinion or pulley are worn, replace the whole

assembly.


ENG - 118

- Remove the central screw and the tensioner

spring. Check that the one-way mechanism is not

worn.

- Check the condition of the tensioner spring.

- If examples of wear are found, replace the whole

unit.

Inspecting the valve sealings

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

VALVE SEAL SURFACESpecification Desc./Quantity

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

Inspecting the valve housings

- Remove any carbon formation from the valve guides.

- Measure the inside diameter of each valve guide.

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

CharacteristicStandard drainage guide diameter

5.012 mm

Standard intake guide diameter

5.012 mm


ENG - 119

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

the diameter of the valve guide exceed the speci-

fied limits, replace the cylinder head.

- Check width of the impression on the valve seat

«V»

CharacteristicWear limits:Max. 1.6 mm.

Inspecting the valves

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

- Calculate the clearance between valve and valve

guide.

CharacteristicMinimum diameter admitted - Intake:4.96 mm

Minimum diameter admitted - Exhaust:4.95 mm

Standard clearance - Intake:0.013 to 0.040 mm

Standard clearance - Exhaust:0.025 to 0.052 mm

Maximum clearance admitted- Intake:0.062 mm

Maximum clearance admitted - Exhaust:0.072 mm

- Check that there are no signs of wear on the

contact surface with the articulated register termi-

nal.

- If the sealing surface on the valves is wider than

the specified limit, damaged in one or more points

or curved, replace the valve with a new one.

CharacteristicStandard valve length - Intake:80.6 mm

Valve standard length: Exhaust


ENG - 120

79.6 mm

- If no faults are found during the above checks,

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

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

valves gently with a fine-grained lapping com-

pound. During grinding, keep the cylinder head in

a horizontal position. This will prevent the lapping

compound residues from penetrating between the

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

- Insert the valves into the cylinder head.

- Test the 2 valves alternatively.

- The test is carried out by filling the manifold with

petrol and checking that the head does not ooze

through the valves when these are just pressed

with the fingers.

Inspecting the springs and half-cones

- Check that the upper spring caps and the cotter

halves show no signs of abnormal wear.

- Check the unloaded springs length.

CharacteristicValve spring length33.9 to 34.4 mm


ENG - 121

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the lower caps of the valve spring on the

head.

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

time.

Specific tooling020306Y Punch for assembling valve sealrings

- Fit the valves, the springs and the spring retaining

caps. Using the appropriate tool with adapter 11,

compress the springs and insert the cotters in their

seats.

Specific tooling020382Y Valve cotters equipped with part 012removal tool


Inspecting the cam shaft

- Inspect the cam shaft for signs of abnormal wear

on the cams.

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

Standard diameter Bearing B20 -0.020 -0.041 mm

Minimum admitted diameter bearing AØ: 32.440 mm

Minimum admitted diameter bearing BØ: 19.950 mm

Intake cam height27.512 mm

Exhaust cam height27.212 mm


ENG - 122

- Check there is no wear on the cam shaft retaining

plate and its associated groove on the cam shaft.

- If any of the above dimensions are outside the

specified limits, or there are signs of excessive

wear, replace the defective components with new

ones.

CharacteristicMaximum axial clearance admitted0.42 mm

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

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

or the rubber buffer on the automatic valve-lifter

retaining cover.

- Check that the valve lifter spring has not yielded.

- Replace any defective or worn components.

- Check there are no signs of scoring or wear on

the rocking lever bolt.

Check there are no signs of wear on the pad from

contact with the cam and on the jointed adjustment

plate.

- Measure the internal diameter of each rocking

lever.

-Check that the elastic washer dedicated to the

axle clearance of the rocking levers is not worn. -

In case of failure, replace the damaged compo-

nents.

CharacteristicMinimum diameter permittedØ 11.970 mm

Maximum diameter allowedØ 12.030 mm

Refitting the head and timing system components

- Fit the timing chain guide slider.

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


ENG - 123

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

Locking torques (N*m)Nuts fixing head to cylinder 28 to 30

- Fit the two screws on the outside of the timing

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

Locking torques (N*m)Head fixing screws (external) 11 to 13

- Fit the timing chain sprocket wheel on the crank-

shaft, with the chamfer facing the insertion side.

- Loop the timing chain around the sprocket on the

crankshaft.

- Fit the tensioner pad by the cylinder head.

- Fit the spacer and the screw fastener.

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

washer and the intake rocking lever.

- Lubricate the 2 rocking levers through the holes

at the top.

- Lubricate the 2 bearings and insert the camshaft

in the cylinder head with the cams opposing the

rocking levers.

- Insert the retention plate and tighten the two

screws shown in the figure to the prescribed tor-

que.

Locking torques (N*m)Camshaft retention plate screw 5 to 6


ENG - 124

- Refit the spacer on the cam shaft.

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

centre, using the reference marks on the flywheel

and the crankcase.

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

shaft pulley and keep the reference 2V in corre-

spondence with the reference mark on the head.

- Fit the pulley onto the camshaft.

- Assemble the counterweight with the corre-

sponding fixing screw and tighten to the specified

torque.

Locking torques (N*m)Pressure reducer counterweight retainer 7 to 8.5

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

cam and fit the automatic valve lifter cam to the

cam shaft.

- Fit the automatic valve lifter return spring.

- During this operation the spring must be loaded

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

- Fit the automatic valve-lifter retaining dish, using

the counterweight screw fastener as a reference.

- Tighten the clamping screw to the prescribed tor-

que.

Locking torques (N*m)Camshaft pulley screw 12 to 14

- Set the tensioner cursor in the rest position.

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

torque.


ENG - 125

Locking torques (N*m)Tightener fastening screws: 11 to 13

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

torque.

Locking torques (N*m)Timing chain tensioner central screw 5 to 6

- Adjust the valve clearance.

- Fit the spark plug

Electric characteristicRecommended spark plugNGK CR7EB

Electrode gap0.6 ÷ 0.7 mm

Locking torques (N*m)Ignition spark plug 18 Nm

- Assemble the casing sealing gasket on the head.

On the fitting direction, use the supplements on the

timing side as reference.

- Assemble the screw fixing the housing to the

crankcase to the specified torque and the 2 self-

tapping screws joining the half-shells.

- Take care that the gasket is well inserted in its

housing during the assembly stage.

- Place the spark plug access cap.

Locking torques (N*m)Flywheel air duct screw 3 to 4

- Fit the intake manifold and lock the 2 screws to

the specified torque.

- Fit the carburettor onto the intake manifold and

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

Locking torques (N*m)Head intake manifold screw 11 to 13


ENG - 126

- Refit the cylinder head cover, tightening the 4

clamping screws to the prescribed torque.

- Refit the fan and the housing.

- Reassemble the oil pump control, the chain com-

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

described in the lubrication chapter.

- Reassemble the driving pulley, the belt and the

transmission cover as described in the transmis-

sion chapter.

Locking torques (N*m)Head cover screws 11 to 13

Crankcase - crankshaft

- Precautionary remove the following units:

transmission cover, driving pulley, driven pulley

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

seals as described in the transmission chapter.

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

compartment cover and the oil pump as in the lu-

brication chapter.

- Remove the flywheel cover, the fan, the flywheel

and the stator as described in the magneto fly-

wheel chapter.

- Remove the oil filter and the oil pressure bulb.

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

bed in the cylinder head timing system chapter.

- Remove the 2 retainers indicated in the figure

and the starter motor.

- Before opening the crankcase, it is advisable to

check the axial clearance of the crankshaft. To do

this, use a plate and a support with specific tool

dial gauge.

Specific tooling020262Y Crankcase splitting plate


CharacteristicStandard clearance


ENG - 127

0.15 to 0.40 mm

Splitting the crankcase halves

Remove the 11 coupling screws to the crankcase.

- Separate the crankcase while keeping the crank-

shaft in one of the two halves of the crankcase.

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

- Remove the coupling gasket of the crankcase

halves.

- Remove the two screws and the internal shield

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

- Remove the oil seal on the flywheel side.

- Remove the oil filter fitting shown in the diagram

- Check the axial clearance on the connecting rod.

CharacteristicStandard clearance0.20 to 0.50 mm


ENG - 128

- Check the radial clearance on the connecting rod.

-Check the surfaces that limit the axial clearance

are not scored and measure the width of the crank-

shaft between these surfaces, as shown in the

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

CharacteristicStandard clearance0.036 to 0.054 mm

- If the axial clearance between crankshaft and

crankcase is exceeding and the crankshaft does

not have any defect, the problem must be due to

either excessive wear or wrong machining on the

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

CharacteristicDistance between the shoulders55.67 to 55.85 mm

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

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

below.

STANDARD DIAMETERSpecification Desc./Quantity

Category 1 28.998 to 29.004Category 2 28.004 to 29.010


ENG - 129

Inspecting the crankshaft alignment

To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated

in figure.

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

oil seal capacity, the toothed gear and the threa-

ded tangs are in good working order.

- In case of failures, replace the crankshaft.

The big end bushings cannot be replaced. For the

same reason, the connecting rod may not be re-

placed and, when cleaning the crankshaft, be very

careful that no impurities get in through the shaft's

lubrication holes.

In order to prevent damaging the connecting rod

bushings, do not attempt cleaning the lubrication

duct with compressed air.

- Make sure that the 2 caps on the crankpin are

properly fitted.

- A wrong installation of a cap can seriously affect

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

Specific tooling020074Y Support base for checking crankshaftalignment

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


ENG - 130

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.

- On the transmission side crankcase half, take

particular care cleaning the housing and oil ducts

for the following components: the oil pump, the oil

by-pass valve, the main bushings and the cooling

jet on the transmission side (see diagram).

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

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

Lubrication), as this could prevent a good seal in

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

- On the flywheel side crankcase half, take partic-

ular care cleaning the oil ducts for the main bush-

ings, the oil duct for the jet that lubricates the

cylinder head and the oil drainage duct at the fly-

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

- Inspect the mating surfaces on the crankcase

halves for scratches or deformation, taking partic-

ular with the surfaces that mate with the cylinder

and the mating surfaces between the crankcase

halves.

- Defects in the crankcase coupling gasket or the

surfaces indicated in the figure can cause a drop

in the oil pressure and affect the lubricating pres-

sure for the main bushings and the connecting rod.


ENG - 131

- Check the main bearing seats that limit axial

clearance in the crankshaft show no signs of wear.

The dimension between these seats is measured

by way of the procedure described previously for

measuring the crankshaft axial clearance and di-

mensions.

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is neces-

sary to have both an optimal lubricating pressure

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

be correctly positioned so as not to obstruct the oil

supply channels.

- The main bushings are comprised of two half-

bearings, one with holes and channels for lubrica-

tion whereas the other is solid.

- The solid half-bearing is intended to stand the

thrusts caused by combustion, and for this reason

it is arranged opposed the cylinder.

- To prevent shutters in the oil feeding channels,

the matching surface of the two half-bearings must

be perfectly orthogonal to the cylinder axis, as


- The oil feeding channel section is also affected

by the bushings driving depth compared with the

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

CharacteristicStandard driving depth1.35 to 1.6

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

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

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


ENG - 132

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

those for the crankshaft.

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

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

MAIN BEARINGSSpecification Desc./Quantity

B BlueC YellowE Green

Refitting the crankcase halves

- Fit the internal shield by locking the two screws

to the prescribed torque.

Locking torques (N*m)Internal engine crankcase bulkhead (transmis-sion-side half shaft) screws 4 to 6

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

torque.

- Place a new gasket on one of the crankcase

halves, preferably on the transmission side, to-

gether with the alignment dowels.

Locking torques (N*m)Oil filter on crankcase fitting 27 to 33


ENG - 133

- Lubricate the main bushings and insert the crank-

shaft in the transmission side crankcase half.

- Reassemble both crankcase halves.

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

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

Locking torques (N*m)Engine-crankcase coupling screws 11 to 13

- Lubricate the flywheel oil seal.

- Use the appropriate tool to assemble the oil seal.

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

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

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

Specific tooling020425Y Punch for flywheel-side oil seal

Locking torques (N*m)Pre-filter cap 24 to 30

Lubrication


ENG - 134

Conceptual diagrams


ENG - 135

Oil pressure check

- After removing the fan cover duct as described in

the "Flywheel Cover" chapter, remove the electric

connection of the minimum oil pressure switch and

then remove the switch.

- With the engine idling at 1650 rpm and the oil

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

is between 0.5 to 1.2 atm.

- With the engine idling at 6000 rpm and the oil

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

is between 3.2 to 4.2 atm.

- Remove the appropriate tools once the meas-

urement is complete, refit the oil pressure switch

and washer, tightening it to the prescribed torque

and fit the flywheel cover.

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

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

by-pass valve, the oil pump and the crankshaft

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

CharacteristicMinimum pressure admitted3.2 atm.

Locking torques (N*m)Minimum oil pressure switch 12 to 14

Crankshaft oil seals


ENG - 136

Removal

- Remove the transmission cover and the com-

plete drive pulley beforehand

- Install the base of the appropriate tool on the oil

seal using the screws provided.

- Screw the threaded bar onto the base of the tool

and extract the oil seal.

Specific tooling020622Y Transmission-side oil seal punch

Refitting

- Prepare the new oil seal, lubricating the sealing

lip. Warning: do not lubricate the surface for keying

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


ENG - 137

- Preassemble the oil seal with the appropriate

tool, positioning the screws

- Place the sheath over the crankshaft

- Insert the tool with the oil seal on the crankshaft

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

- Orientate the oil seal by inserting the bracket

which is part of the specific tool.

- Tighten the threaded bar onto the crankshaft as

far as it will go.


ENG - 138

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

can see end of the oil seal driving stroke

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

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

Assemble a new oil seal on the flywheel side using

the specific tool as shown in the photographN.B.FAILURE TO USE THE SPECIFIC TOOL CAN RESULT INAN INCORRECT DEPTH POSITION AND AS A CONSE-QUENCE IN INADEQUATE OIL SEAL.

Specific tooling020425Y Punch for flywheel-side oil seal

Oil pump

Removal

- Remove the chain cover acting on the 3 retaining

screws as shown in the figure and the relevant

copper washers.

- Extract the cover using the appropriate appen-

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


ENG - 139

- Remove the cover of the pump control pulley us-

ing the two retainers, as shown in the figure.

- Block the rotation of the oil pump control pulley

using a screwdriver inserted through one of its two

holes.

- Remove the central screw with cup washer, as

shown in the diagram.

- Remove the chain with the pulley.

- Remove the crankshaft control pinion.

- Remove the oil pump acting on the 2 retainers as


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

Inspection

- Remove the two screws and the oil pump cover.

- Remove the circlip retaining the innermost rotor.

- Remove and wash the rotors thoroughly with pet-

rol and compressed air.

- Reassemble the rotors in the pump body, keep-

ing the two reference marks visible Replace the

retainer ring.


ENG - 140

- Using a feeler gauge, check the distance be-

tween the rotors in the position shown in the figure.

CharacteristicMaximum clearance admitted0.12 mm

Measure the distance between the outer rotor and

the pump body; see figure.

CharacteristicAdmissible limit clearance:0.20 mm

Check the axial clearance of the rotors with a trued

bar as reference, as shown in the figure.

CharacteristicLimit values admitted:0.09 mm

Refitting

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

shaft or body.

- Check there are no signs of scoring or wear on

the oil pump cover.

- If you detect non-conforming measurements or

scoring, replace the faulty parts or the assembly.

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

the specified torque and the cup washer.

-Fit the oil pump cover, by tightening the two

screws to the prescribed torque.


ENG - 141

N.B.FIT THE CUP WASHER SO THAT ITS OUTER (CURVED)RIM TOUCHES THE PULLEY.

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

Removing the oil sump

- Remove the oil filler plug, the transmission cover,

the complete drive pulley assembly with belt and

the sprocket wheel, as described in the Transmis-

sion chapter.

- Drain the oil from the sump as described above.

- Remove the 7 screws indicated in the figure and

the 2 rear brake transmission fixing brackets.

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

gasket shown in the second image.

Inspecting the by-pass valve

- Check the unloaded spring length.

- Check that the small piston is not scored.

- Ensure that it slides freely on the crankcase and

that it guarantees a good seal.

- If not, eliminate any impurities or replace defec-

tive parts.

CharacteristicBy-pass check up: Standard length54.2 mm


ENG - 142

Refitting the oil sump

- Refit the by-pass piston in its housing.

- Insert the pressure-regulating spring.

- Fit a new sump seal.

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

the appropriate recess machined into the inside of

the sump.

- Refit the rear brake transmission mounting brack-

ets and the screws in the reverse order from which

they were removed.

- Tighten the screws to the prescribed torque.

- Refit the driving pulley assembly, the drive belt,

the sprocket wheel and the transmission cover, as

described in the "Transmission" chapter.

- When testing the lubrication system, refer to

the "Crankcase and Crankshaft" chapter, re-

garding lubrication of the connecting rod as-

sembly

Locking torques (N*m)Oil sump screws 11 to 13

SAS valve

Inspecting the one-way valve

- Remove the SAS valve.

- Provisionally assemble the rubber sleeve of the

SAS valve outlet to ensure tightness.

- Connect the MITYVAC vacuum pump to the rub-

ber sleeve as shown in the photograph.

- Set the pump to the low-pressure position (VAC-

UUM).

- Operate the pump slowly.

- Check that the one way valve allows the air to

pass through causing a slight vibration.

- Switch the pump to pressure mode (PRES-

SURE).


ENG - 143

- Operate the pump slowly and check if there is an

increase of pressure. A small leakage is consid-

ered to be normal.

If anomalies are detected, replace the pump.N.B.A MALFUNCTIONING ONE-WAY VALVE CAN RESULT INRUBBER SLEEVE AND FILTER OVERHEATINGN.B.ABSENCE OF VIBRATION INDICATES INEFFICIENT SEAL-ING

Specific tooling020329Y Mity-Vac vacuum-operated pump

Inspecting the cut-off

- Remove the SAS valve.

- Connect the MITYVAC pump in low-pressure

mode (VACUUM) to the CUT-OFF valve vacuum

intake.

- Apply a vacuum value higher than 0.5 BAR.

- Check that this value is kept all the time.

- If a worn seal is detected, replace it.

- With a "T" bypass and flexible rubber hoses make

a parallel connection between the rubber sleeve

and the vacuum intake of the CUT-OFF valve.

- Connect the bypass to the MITYVAC pump.

- Set the pump set to the low-pressure mode

(VACUUM).

- Using a pair of long flat pliers, choke the rubber

hose next to the valve.

- Operate the pump until vacuum is higher than 0.5

BAR.

- Release the hose and check how the vacuum re-

acts. - Under normal functioning conditions the

vacuum undergoes a slight fall and then readjusts.

Then there is a stage of gradual and slow loss of

vacuum up to a value of approx. 0.4 BAR. At this

point the valve opening and the sudden vacuum

resetting is detected.


ENG - 144

Lack of tightness or the fact that the valve opens

at different vacuum values should be regarded as

anomalies. In this case, replace it.N.B.LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTSIN EXHAUST NOISE (EXPLOSIONS IN THE SILENCER). IN-CORRECT CUT-OFF VALVE CALIBRATION CAN RESULTIN CATALYTIC CONVERTER MALFUNCTIONINGN.B.A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDESJEOPARDISING THE CORRECT OPERATION OF THECUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING


Fuel supply

- Disconnect the fuel supply and the suction taking

pipe from the carburettor.

- Check that there are no fuel leaks between the

two tubes.

- Close the fuel outlet pipe.

- By means of the MITYVAC pump apply 0.1 bar

of suction to the tap.

- Make sure that the suction is kept stable and that

and that there are no fuel leaks.

- Reconnect the vacuum pipe to the manifold.

- Position the fuel pipe with the outlet at the point

of the tap.

- Turn the engine by using the starter motor for five

seconds with the carburettor at minimum.

- Take up the fuel by means of a graded burette.N.B.THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-RECT NUMBER OF REVS OR BY THE WRONG POSITIONOF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB-TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-


ENG - 145

LET ON THE MANIFOLD HAS A SECTION INTENTIONALLYREDUCED FOR THE PURPOSE OF ENHANCING THE SUC-TION PULSATION AND THEREBY GUARANTEE A CON-STANT TAP FLOW RATE.


CharacteristicMinimum flow rate20 cc

- Completely empty the fuel tank.

- Remove the petrol delivery pipe and the low-

pressure pipe.

- Loosen the clip and remove the cock.

- Clean the tank and the filter of the cock with a

specific solvent.

- Refit the cock making sure that there is an O-

Ring.

- Turn the cock to the direction it had before it was

removed and block the clip.N.B.THE FILTER CAN BE UNSCREWED FROM THE COCK TOFACILITATE CLEANING.

Removing the carburettor

- To detach the carburettor from the engine, it is

necessary to move the air filter and remove the

throttle control transmission, the automatic starter

connection, the clamps anchoring the carburettor

to the filter housing and to the intake manifold, the

air delivery pipe to the diaphragm, the heater and

the intake fitting.


ENG - 146

With the multimeter, check if the potentiometer is

working correctly by placing the probes on both

contacts indicated in the photograph.

With throttle valve completely closed, the resist-

ance value should be approx. 1.3 kOhm.

With throttle valve completely open, the resistance

value should be approx. 4.05 kOhm.

- Remove the heater.

- Remove the protection, the bracket and the start-

er acting on the screw shown in the figure.

- Remove the 2 screws and the starter support with

the gasket.


ENG - 147

- Remove the clamp and cover with the airing filter

of the diaphragm chamber.

- Remove the 4 fixing screws shown in the figure

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

- Remove the vacuum valve together with the di-

aphragm.


ENG - 148

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

move, take out the spring and vacuum valve nee-

dle

- Remove the 4 screws indicated in the figure.

- Remove the chamber with the accelerating

pump, its control and gasket.

- Remove the oil pump seal.

- Remove the intake and exhaust valves of the in-

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


ENG - 149

Adequately support the carburettor and using a

rod and hammer remove the float pin acting from

the throttle control side.

- Remove the float and the plunger.

- Remove the maximum nozzle

-Remove the maximum nozzle.


ENG - 150

-Remove diffuser.

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

-Remove the minimum nozzle.


ENG - 151

- Remove the minimum flow set screw and the

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

Refitting the carburettor

- Before refitting, wash the carburettor body accu-

rately with petrol and compressed air.

- Pay special attention to the fuel supply pipe and

the plunger seat.

- For maximum circuit, check the air adjustment is

correct as shown in the figure.


ENG - 152

- For the minimum circuit, make sure the following

points are properly cleaned: air gauging, exhaust

section controlled by flow screw, progression

holes near the throttle valve.

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

nozzle support hides other inaccessible internal calibrations.

- Blow the intake nozzle properly.N.B.

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

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

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

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

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

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

- Replace the carburettor in case of irregularities.

- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.N.B.

TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.

- Wash and blow the minimum nozzle properly and

reassemble it.


ENG - 153

- Properly wash and blow the components of the

sprayer maximum circuit, the diffuser and the noz-

zle.

- Introduce the sprayer in the carburettor body with

the shortest cylindrical part directed to the diffuser.

- Assemble the diffuser making sure the sprayer is

being adequately inserted and lock it.

-Assemble the maximum nozzle.

- Check that the tapered pin does not show signs

of wear on the sealing surfaces of the shock ab-

sorber pin and the return clamp.

- Replace the rod if worn out.

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

there are no fuel infiltration.

- Replace it in case of failures.

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

INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY


ENG - 154

- Remove the drainage screw from the tank, wash

and blow it properly and make sure the accelera-

tion pump pipes are clean.

- Operate the acceleration pump piston repeatedly

and blow with compressed air.

- Reassemble the acceleration pump valves fol-

lowing this order:

INTAKE VALVE (A)

• Spring

• Ball

• Nozzle

IN VALVE (M)

• Ball

• Spring

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

-Check the screw tightness introducing a small

amount of fuel in the tank.

- Assemble a new gasket on the tank.

- Assemble the tank on the carburettor body fas-

tening the 4 screws.

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

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

- Wash and blow the flow screw properly.

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

- Assemble the spring on the screw.

- Screw the flow screw on the carburettor body.

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

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


ENG - 155

Level check

- Place the carburettor inclined as shown in the

figure.

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

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

described above.


ENG - 156

• Insert a transparent rubber pipe to the bleeding intake of the fuel tank.

• Keep the pipe up so that the ends are higher than the venturi pipe.

• Unscrew the bleed screw and stabilise the petrol level, then measure as shown in the dia-

gram.


ENG - 157

Inspecting the valve and needle

- Check that the tapered pin of the vacuum valve

does not show wear.

- Check that the depression valve does not show

threads on the external surfaces.

- Check that the vacuum intake hole is not clogged.

- Check that the diaphragm is not damaged or has

hardened, otherwise replacement the whole valve.

- Insert the tapered pin into the vacuum valve

housing.

- Reassemble the vacuum valve on the carburettor

body taking care that the tapered pin is inserted

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

- Reassemble the spring with the pin lock.

- Remove the cover of the vacuum chamber being

careful to correctly insert the spring in its place on

the cover.

- Tighten the screws.


ENG - 158

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

bient pressure intake.

- Reassemble the filter with its clamp.

- Wash and blow dry the starter support.

Assemble a new gasket on the carburettor body

and tighten the 2 fixing screws.


ENG - 159

Inspecting the automatic choke device

- Check that the automatic starter piston is not de-

formed or rusty.

- Check that the piston slides freely from the seat

to the support.

- Check that the piston sealing gasket is not de-

formed.

- The starter must be more or less functional de-

pending on the ambient temperature.

- Measure the protrusion of the piston as shown in

the figure and check its corresponding value.

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

bient temperature.

- The starter should disconnect progressively by

means of electric heating.

- Check the starter resistance when adjusted to the

ambient temperature.

With a 12V battery power the automatic starter and

check that the piston protrudes as much as possi-

ble.

- The correct warm up time depends on the ambi-

ent temperature.

- If protrusion, resistance or timing values are dif-

ferent from the ones prescribed, replace the start-

er.

- Assemble the starter to the carburettor being

careful to position the O-Ring correctly, insert the

plate with the machined side contacting the starter,

tighten the fixing screws.

- Position the starter as shown in the figure.

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

CharacteristicCheck the Kehin automatic starter: Protrusionvalue


ENG - 160

XX ÷ XX mm at approx. 20°C

Check max. protrusion of Kehin aut. starterXXX ÷ XXX mm

Check aut. Kehin max. time starter5 min

Adjusting the idle

- The engine does not require frequent idle speed

adjustments, but it is essential to strictly follow cer-

tain rules when adjusting the idle speed.

- Before adjusting the carburettor make sure to re-

spect the lubrication requirements, valve clear-

ance, and complying timing, spark plug should be

in optimum conditions, air filter clean and sealed,

and the exhaust system tight.

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

nutes at approximately 50 kph.

- Connect the vehicle to the exhaust fumes analy-

ser inserting the probe into a sealed extension pipe

placed at the muffler exit end.

- Connect a millimetre thermometer (020331y) on

the sump, using a cover with oil expressly pre-

pared for probes.

- Start the engine and before adjusting the idle

speed, make sure that the oil temperature is be-

tween 70÷80 °C.

- Using the rpm indicator or any other instrument

(020332y), adjust the idle screw to obtain 1600

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


ENG - 161


ENG - 162

INDEX OF TOPICS

SUSPENSIONS SUSP

Front

Removing the front wheel

- Loosen the wheel axle lock nut, by keeping the

wheel axle blocked on the opposite side.

- Loosen the two wheel axle safety screws on the

fork leg, on the odometer gear side.

- Pull out the wheel axle.

Suspensions Typhoon 125 4T (MY 2010)

SUSP - 164

- Remove the front wheel.

- Slide off the odometer gear from the wheel hub.CAUTIONDO NOT ACT ON THE FRONT BRAKE LEVER ONCE THEFRONT WHEEL IS REMOVED. BY DOING SO, THE CAL-LIPER PISTONS COULD COME OUT FROM THEIR HOUS-ING AND ALSO THE BRAKE FLUID MIGHT SPILL OUT.

Front wheel hub overhaul

Check that the wheel bearings do not show signs

of wear.

If you have to replace the wheel bearings, proceed

as follows:

- Remove the bearing on the odometer drive side

using the pliers 14 and the bell detail 9.

Specific tooling001467Y013 Calliper to extract ø 15-mm bear-ings

001467Y009 Driver for OD 42-mm bearings

Typhoon 125 4T (MY 2010) Suspensions

SUSP - 165

- Remove the internal spacer.

- Support the front wheel with two wooden shims

that make it possible to avoid scratching in the

case of contact with the rim.

- Insert the punch (consisting of adaptor handle,

24 mm adaptor and 15 mm guide) from the odom-

eter drive side to permit the removal of the brake

disc side bearing and the spacer bushing.


020456Y Ø 24 mm adaptor

020412Y 15-mm guide


SUSP - 166

- Heat the bearing seat on the side the brake disc

with the heat gun.

- Grease one side of the new bearing to make it

stay together with the adaptor.

- Insert the bearing using the punch consisting of

adaptor handle, 42x47 mm adaptor and 15 mm

guide, and drive it up to the stop.

- Reinsert the spacer bushing on the brake disc

side using the appropriate tool and take it to the

stop.



020412Y 15-mm guide

020201Y Spacer bushing driving tube


SUSP - 167

- Turn the wheel upside-down and insert the inner

spacer.

- Heat the bearing seat on the odometer drive side with the heat gun.

- Grease one side of the new bearing to make it

stay together with the adaptor.

- Insert the new bearing on the odometer drive side

by using a punch consisting of adaptor handle,

32x35 adaptor and 15 mm guide and drive it fully

home.



020412Y 15-mm guide


SUSP - 168

WHEEL RIM INSPECTION

- Make sure that the rim is not deformed or

cracked. Replace it if necessary.

- Check wheel eccentricity. If tolerance limits are

exceeded, check the wheel rim and the bearings.

If necessary, replace the wheel.

CharacteristicEccentricity limits:Vertical: 2 mmHorizontal: 2 mm

- Check the wheel balance.

- Check wheel on the wheel balancer and turn it several times, paying attention to its position when it

stops. If the wheel is steadily balanced, it will not always stop at the same point. If it always stops at the

same point, the wheel is not balanced and must be balanced. Place weights on the lightest part of the

wheel so that it does not stop any more at a particular point after being turned several times.


SUSP - 169

Refitting the front wheel

- First shift by 90° the inner stop of the odometer

drive with respect to the one on the wheel.

- Insert the wheel axle after greasing it from the

brake disc opposite side, centring the retainer on

the fork leg onto the projecting parts of the odom-

eter drive.

- Holding the wheel axle, lock the nut on the op-

posite side to the specified torque.


SUSP - 170

- Make the fork travel to adjust the fork legs on the

wheel axle.

- Lock the two safety screws located on the fork

leg to the specified torque, according to the se-

quence 1-2-1.

Locking torques (N*m)Front wheel axle nut 45 - 50 Safety screw on forkleg 6 - 7

Handlebar

Removal

- Remove the front and rear handlebar cover.

- Detach the front brake pump from the handlebar.

- Disconnect the rear brake, throttle control and

odometer control cables.

- Remove the screw fixing the handlebar to the

steering tube.

- Remove the handlebar.

See alsoFront handlebar coverRear handlebar coverFrontbrake pump

Refitting

- Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on the

handlebar with that on the steering tube as shown in the figure.

- Tighten the handlebar fixing screw on the steering tube to the prescribed torque.

Locking torques (N*m)Handlebar fixing screw (*) 45 to 50


SUSP - 171

(*) Lubricate the nut with engine oil before instal-

lation

Front fork

Removal

REMOVING THE STANCHIONS

- Remove the legshield.

- Remove the brake calliper.


- Remove circlip «7», the two screws «8» and slide

off the stanchion.

- Unscrew the upper cap «6».

- Remove the components including the spring.

- Drain the oil into a collecting container.


SUSP - 172

- Undo screw «3», remove the stanchion and the

piston.

See alsoLegshieldRemovalRemoving the front wheel

Overhaul

STANCHION INSPECTION

- Check the sliding surface for scorings and/or

scratches.

- If the scorings are deep, replace the stanchion.

SLEEVE INSPECTION

- Check that it is not damaged and/or cracked.

- If there are signs of excessive wear or damage,

replace the affected component.

- Replace the oil seal «4» and the dust gaiter «5»

and fit it once you have lubricated their seat.

- Replace the O-ring on the inner cap «1»

- Replace sealing washer «2».

Refitting

- Refit the stanchion and the piston and tighten

screw «3» with its washer «2» to the specified tor-

que.

- Pour the recommended quantity of specific oil in-

to the stanchion unit.

- Insert the spring and the components.

- Tighten the upper cap «6» to the specified torque.

- Introduce the stanchion in the bottom yoke and

install the circlip «7».


SUSP - 173

- Push on the upper cap «6» until the circlip touch-

es the bottom yoke.

- Tighten the screws «8» to the prescribed torque.

CharacteristicFork stem (oil level height without spring, com-pressed fork)85 mm

Locking torques (N*m)Fork clamp screw 20 to 25 Fork stanchion uppercap 15 ÷ 30 Piston tightening fork lower screw25 - 35

Steering column

Removal


SUSP - 174

- Position the vehicle on centre stand.

- Set a support under the vehicle in such a way that

the wheel is able to move freely and the vehicle

does not fall.

- Remove the handlebar.


- Remove the front brake calliper.

- Release the fork from the odometer cable and

from the front brake calliper pipe.

- Loosen the upper ring nut «1» and collect the

shim washer «2».

Specific tooling020055Y Wrench for steering tube ring nut

Locking torques (N*m)Upper steering ring nut 30 to 36

- Remove the upper ring (or lower ring nut) «3» of

the upper bearing «A».

- Slide the fork and collect the cage with the balls

«4» of the upper bearing «A».

Locking torques (N*m)Lower steering ring nut 10 - 13 **

When the specified torque of the lower ring nut is reached, loosen by 90°.

See alsoRemovalLegshieldRemoval

- Remove the balls retainer «7» of the lower bear-

ing «B» from the steering tube.

- Wash carefully all the parts removed.

- To refit, carry out the removal operations but in reverse order.


SUSP - 175

- Appropriately lubricate the bearings with recommended products.

BEARING SEAT REPLACEMENT ON CHASSIS

- Only remove the seats if it is strictly necessary.

- Using the special tool remove the upper bearing

«A» seat «5» by putting the special tool into the

lower part of the headstock as indicated in the fig-

ure.

- Remove the lower bearing «B» seat «6» on the

headstock by inserting the punch from the top on

the headstock.

Specific tooling020004Y Punch for removing steering bearingsfrom headstock

- Using the special tool, refit the upper «A» and

lower «B» bearing seats on the headstock.

Specific tooling001330Y Tool for fitting steering seats

LOWER BEARING SEAT REPLACEMENT ON

FORK

Check the condition of the lower bearing «B» seat

«8» on the fork (steering tube). Replace if there are

faults.

- Support the fork properly.

- Using the special tool, remove the seat «8» on

the steering tube as shown in the photograph by

applying small mallet blows.

Specific tooling020004Y Punch for removing steering bearingsfrom headstock


SUSP - 176

Always use a new seat on refitting.

- Using the special tool, refit the seat «8» with the

aid of a few mallet blows and bring it as far as the

stop shown in the photo.

Specific tooling006029Y Punch for fitting fifth steering bearingon steering tube

Steering bearing

CHECKING THE BEARINGS CLEARANCE

To check the steering, it is necessary to:


- Place a support under the motorcycle in such a

way that the front wheel is able to move freely and

the vehicle does not fall.

When carrying out this operation, pay attention not

to mistake the centre stand clearance with that of

the steering. Repeat this test many times before

deciding if the steering clearance must be adjus-

ted.

- Hold the fork sleeves and pull the fork forwards

and backwards, with the steering in forward posi-

tion.

- There should be no clearance forward or back-

ward If there is clearance, the steering must be

adjusted.

ADJUSTING THE BEARING CLEARANCE


- Loosen the upper ring nut «1» using the specific

wrench.

- Screw in the lower ring nut «3» until the bearing

clearance is totally eliminated.CAUTIONDO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT«3» BECAUSE THE STEERING BEARINGS COULD GETDAMAGED.

- Check clearance as described above. Make sure the front fork can move all long its stroke, from left

to right or vice versa, rotating freely and smoothly.


SUSP - 177

- Keep the lower ring nut «3» in position, by using a specific wrench and tighten the upper ring nut «1»

to the specified torque. Check again the bearings clearance.

Specific tooling020055Y Wrench for steering tube ring nut

Locking torques (N*m)Lower steering ring nut 10 - 13 ** Upper steering ring nut 30 to 36

When the specified torque of the lower ring nut is reached, loosen by 90°.

See alsoLegshield

Rear

Removing the rear wheel


- Remove the silencer.

- Use a screwdriver to remove the plastic cap.

- Remove the cotter pin.

- Remove the cap.


SUSP - 178

See alsoExhaust assy. Removal

- Pull the rear brake and keep it pulled with a

clamp.

- Unscrew the wheel fixing nut and collect the

washer.

- Take out the wheel from its housing.

- To refit, carry out the removal operations but in reverse order, be careful to use a new cotter pin.

Locking torques (N*m)Rear wheel axle 115

Swing-arm

Removal

- Rest the vehicle on its centre stand.

- Support the engine adequately.

- Unscrew the nut on the left-hand side of the en-

gine and slide off the bolt from the opposite side.


SUSP - 179

- Loosen the nut on the inside of the frame from

the left-hand side and remove the relevant pin.

- Remove the Seeger ring shown in the picture.

- Remove the helmet compartment.

- Slide off the support spring by using a normal

spring puller.


SUSP - 180

- Lower the front end of the engine to free the

swinging arm.

- Slide off the swinging arm from the right-hand

side of the vehicle.

- To replace the silent block it is necessary to re-

move the support bracket, after removing the

swinging arm and the side fairings.

- Unscrew the two indicated retainers and remove

the bracket with silent block from chassis.

- To remove the silent block from the bracket,

please use the specific tool.

Specific tooling020271Y Tool for removing-fitting silent bloc

Locking torques (N*m)Engine arm pin - chassis arm 45.5 Silent block-swinging arm retaining bolts 42.5

Overhaul

Regularly check the clearance of the swinging arm

retainer pins. To carry out these operations, pro-

ceed as follows:


- Hold the rear wheel firmly and try to move it per-

pendicularly to the travel direction.

- If there is any clearance, check all the fastening

elements that connect the swinging arm to the en-

gine and chassis as well as the condition of the

silent block.

Shock absorbers


SUSP - 181

Removal


- Support the vehicle adequately.

- Undo the inner nut and slide off the shock-ab-

sorber to chassis upper fixing screw.

- Undo the inner nut and slide off the shock-ab-

sorber to engine lower fixing screw.

- Remove the shock absorber.

- To refit tighten the screws to the prescribed tight-

ening torque.

Locking torques (N*m)Shock absorber nut 22.5

See alsoSide fairings

Centre-stand

- Support the vehicle adequately.

- Undo the nut on the left-hand side of the engine.


SUSP - 182

- Remove the stand pin and collect the return

springs.

- When refitting lubricate the pin and the springs with the specified grease and tighten the nut to the

specified tightening torque.

Locking torques (N*m)Centre stand pivot on engine 42.5


SUSP - 183

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Front brake calliper

Removal

- Check that the brake piping, gasket and fitting are

in good condition. If you see any oil on the brake

calliper and/or the components of the system, it is

necessary to replace them.

- Detach the oil brake pipe from the calliper; pour

the fluid inside a container.

- Remove the two clamps shown in the figure.

- Remove the brake calliper from the fork.

Refitting

- Refit the calliper on the support and tighten the

screws to the specified torque.

- Refit the tube complete with fitting with new cop-

per gaskets.

- Place the tube joint in the original position and

tighten it to the specified torque.

- Bleed the air from the system.

Locking torques (N*m)Brake fluid pipe-calliper fitting 20 to 25 Calliperto fork tightening screw 20 to 25 Oil bleedscrew 8 to 12

See alsoFront

Front brake disc

Typhoon 125 4T (MY 2010) Braking system

BRAK SYS - 185

Removal

Proceed as follows:

- remove the front wheel.

- Undo the five screws fixing the disc.

- Remove the brake disc.

Refitting

When refitting, position the disc correctly, following

the direction indicated on the same disc.

Locking torques (N*m)Disc tightening screw 8 to 12

Disc Inspection

- Check the disc thickness.

CharacteristicDisc minimum thickness:3.5 mm

Braking system Typhoon 125 4T (MY 2010)

BRAK SYS - 186

• Using the appropriate tool, measure

how much the disc protrudes when the

wheel is fitted properly. The protrusion,

measured near the external edge of

the disc, must be less than 0.1 mm.

• If a value other than that prescribed is

detected, remove the front wheel and

check how much the disc protrudes.

Maximum permissible out of true is 0.1

mm. If the value measured is greater,

fit a new disc and repeat the check.

• If the problem persists, check and re-

place the wheel rim if necessary.

Specific tooling020335Y Magnetic mounting for dial gauge

See alsoRemoving the front wheel

Front brake pads

Removal

- Remove the brake calliper.

- Undo and remove the two screws indicated.

- Remove the pads.

- Remove the inner spring.CAUTIONAFTER REMOVING THE PADS, DO NOT OPERATE THEBRAKE LEVER OR THE CALLIPER PLUNGERS COULDGO OUT OF THEIR SEATS RESULTING IN BRAKE FLUIDLEAKAGE.


BRAK SYS - 187

See alsoFrontbrake calliper

- Check the thickness of the friction material. If

thinner than the minimum value, replace it.

CharacteristicMinimum friction material thickness1.5 mm

- In case of uneven wear, replace the brake pads

when the friction material thickness difference is

0.5 mm.CAUTIONALWAYS REPLACE BOTH PADS AND MAKE SURE THEYARE CORRECTLY POSITIONED INSIDE THE CALLIPER.


BRAK SYS - 188

Refitting

- To refit, carry out the disassembly operations in

the inverse order, fitting the inner spring correctly

and tightening the fixing screws to the specified

torque.

Locking torques (N*m)Brake pad fastening screw 15 to 20

Fill

FrontN.B.

IF THERE IS AIR IN THE HYDRAULIC SYSTEM, THE WATER WILL ABSORB MOST OF THEPOWER OF THE BRAKE MAIN CYLINDER AND THEREFORE, IT WILL REDUCE THE CALLIPERPERFORMANCE WHEN BRAKING. THE PRESENCE OF AIR IS SIGNALLED BY THE 'SPONGI-NESS' OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY.CAUTION

CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARYTO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REG-ULAR MAINTENANCE OPERATIONS.

- Once the bleed valve is closed, fill the system

with brake fluid to the maximum level.

-Undo the bleed screw.

-Apply the tube of the special tool to the bleed

screws.

When bleeding it is necessary to fill the oil tank in

continuation while working with a MITYVAC pump

on the bleed screws until no more air comes out of

the system.

The operation is finished when just oil comes out

of the bleed screws.

-Do up the bleed screw.

-When the operation is over, tighten up the oil

bleed screw to the prescribed torque.N.B.IF AIR CONTINUES TO COME OUT DURING PURGING, EX-AMINE ALL THE FITTINGS:


BRAK SYS - 189

IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAUL-TY, LOOK FOR THE AIR INPUT AMONG THE VARIOUSSEALS ON THE PUMP AND CALLIPER PISTONS.CAUTION- DURING THE OPERATIONS, THE VEHICLE MUST BE ONTHE STAND AND LEVEL.N.B.DURING PURGING FREQUENTLY CHECK THE LEVEL TOPREVENT AIR GETTING INTO THE SYSTEM THROUGHTHE PUMP.WARNING- BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT AB-SORBS HUMIDITY FROM THE SURROUNDING AIR.IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX-CEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BEREDUCED.THEREFORE, ALWAYS USE FLUID FROM SEALED CON-TAINERS.UNDER NORMAL DRIVING AND CLIMATIC CONDITIONSYOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS.IF THE BRAKES ARE USED INTENSELY AND/OR INHARSH CONDITIONS, CHANGE THE FLUID MORE FRE-QUENTLY.CAUTIONWHEN CARRYING OUT THE OPERATION, BRAKE FLUIDMAY LEAK FROM BETWEEN THE BLEED SCREW AND ITSSEAT ON THE CALLIPER.CAREFULLY DRY THE CALLIPER AND DEGREASE THEDISC SHOULD THERE BE OIL ON IT.


Recommended productsAGIP BRAKE 4 Brake fluidFMVSS DOT 4 Synthetic fluid

Locking torques (N*m)Oil bleed screw 8 to 12

Front brake pump

- Remove the front and rear handlebar cover.

- Disconnect the tube, collecting the brake oil in a

container.


BRAK SYS - 190

- Operate on the two U bolt clamps (see figure).

- On refitting, perform the operation in reverse.

- Tighten the hydraulic line to the prescribed torque

and then fill and purge the system.

Locking torques (N*m)Brake fluid hose-pump fitting 20 to 25 Pump Ubolt screw 8

See alsoFront handlebar coverRear handlebar cover

Rear drum brake

Drum brake adjustment

Regulate the point where the rear drum brake in-

tervenes, using the adjustment indicated in the

figure.

With the brake lever at rest, the wheel must turn

freely.

Drum brake removal

- Remove the rear wheel.

- Hold the lower shoe and slide it out with the upper

one.

For fitting:

- First assembly two shoes and the springs then

place them on the pin and on the cam.

See alsoRemoving the rear wheel


BRAK SYS - 191

Transmission replacement

- Remove the front handlebar cover.

- Remove the leg shield and the footrest.

- Loosen the brake set screw

- Release the transmission from its retainers to the

engine.

See alsoFront handlebar coverLegshieldFootrest

- Release the transmission from the retainers on

chassis and from the control lever.

- Fit the new transmission, fixing and positioning it

like the one replaced.

- Adjust the drum brake activation point.

Locking torques (N*m)Rear brake adjustment nut 5


BRAK SYS - 192


BRAK SYS - 193

INDEX OF TOPICS

CHASSIS CHAS

Seat

- Undo the four nuts indicated in the figure and

collect the washers.

Locking torques (N*m)Saddle plate fixing nut 10

Driving mirrors

- Lift the rubber cover.

- Loosen the indicated nut, keeping the lower

spacer blocked.

- Undo the mirror from the lower spacer.

- Remove the lower spacer, if necessary.N.B.THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCK-WISE.

Locking torques (N*m)Mirror fastening spacer 25

Rear handlebar cover


- Undo the four screws indicated.

Typhoon 125 4T (MY 2010) Chassis

CHAS - 195

- Disconnect the connectors of the instrument pan-

el and the odometer cable.

- Remove the handlebar cover together with the

instrument panel and controls.

See alsoFront handlebar cover

Instrument panel

- Remove the rear handlebar cover.


See alsoRear handlebar cover

Chassis Typhoon 125 4T (MY 2010)

CHAS - 196

Front handlebar cover

- Remove the rear-view mirrors and the lower

spacers.


- Undo the front screw.

- Lift the upper edge to release and separate it from

the rear handlebar cover.

- Disconnect the turn indicators connections and

remove the front handlebar cover.

See alsoDrivingmirrors


CHAS - 197

Headlight assy.



FRONT TURN INDICATORS


- Undo the three screws indicated.

See alsoLegshieldFront handlebar cover

Legshield

- Remove the leg shield back plate.

- Working from the front wheel housing internal

side, undo the two screws from both sides of the

vehicle.


CHAS - 198

- Undo the indicated screw, beneath the leg shield

lug.

- Move the leg shield forward, opening the lower

ends and detach the headlight bulb connections.

Knee-guard


- Undo the five side screws on the sides of the leg

shield back plate as shown.


CHAS - 199

- Undo the screw in the glove-box and the one un-

der the chassis number lid.

- Before refitting the leg shield back plate, loosen

the footrest fixing screws, so as to fit the two com-

ponents in the best conditions.N.B.WHILE REFITTING, PLEASE REMEMBER TO ATTACH THEGLOVE-BOX OPENING LEVER TO THE KEY-OPERATEDDEVICE.

See alsoFront handlebar cover

Front wheel housing


- Remove the front mudguard



- Undo the upper screw.

- Slide the housing off the fork stanchions.

See alsoLegshieldFront mudguardRemoving the front wheel


CHAS - 200

Footrest

- Remove the leg shield back plate.


- Undo the indicated screws and remove the pro-

tections.


See alsoKnee-guardSide fairings

Side fairings

- Remove the rear handles.

- Remove the rear central cover.



CHAS - 201

- Undo side screw from both sides of the vehicle.

- Undo the two screws on the helmet compartment.

- Undo the two upper screws.

- Undo from both sides of the vehicle the screw

placed under the footrest.


CHAS - 202

- Open the front ends of the side fairings to slide

off the indicated upper inserts.

- Disconnect the connections of the turn indicators

and of the rear light unit.

See alsoHandles and top side fairingsRear central cover

License plate holder


- Disconnect the connections of the turn indicators

and of the license plate light.


CHAS - 203

- Undo the rear screw outside the license plate

support.


- Remove the license plate support together with

the turn indicators.


Rear mudguard

- Undo the right-hand side screw.

- Undo the rear screw that fixes also the air filter

box.


CHAS - 204

Helmet bay


- Remove the battery cover and the battery.

- Undo the two screws inside the helmet compart-

ment.

- Disconnect the fuse box and free the helmet

compartment from the cables.


Battery

spoiler

- Remove the footrest.



CHAS - 205

- Undo from both sides of the vehicle the screw

placed under the footrest.

See alsoFootrest

Fuel tank

Remove the side fairings and the helmet compart-

ment.

- Detach the pipes from the vacuum-operated

cock.

- Undo the indicated screw on both sides of the

vehicle.


CHAS - 206

- Undo the central screw and loosen the two side

screws on the license plate support frame.

- Disconnect the fuel probe connector and detach

the breather pipe from the filler.

Locking torques (N*m)Fuel tank to chassis fixing screws 10

See alsoSide fairingsHelmet bay

Rear central cover

- Remove the saddle.

- Undo the four indicated screws and remove the

cover by sliding it upwards so as to detach the

locking tabs on the sides.

See also


CHAS - 207

Seat

Front mudguard

- Operating from both sides of the vehicle, undo

the three indicated screws.

Handles and top side fairings

- Remove the three screws indicated in the figure

and collect the washers.

- Remove the rear handles.

Locking torques (N*m)Rear grab handle fixing screw 20.5

Battery

- Undo the three indicated screws and remove the

battery cover.


CHAS - 208

- Disconnect the negative and positive cables.

- Slide off the breather pipe.


CHAS - 209

INDEX OF TOPICS

PRE-DELIVERY PRE DE

Aesthetic inspection

Appearance check:

- Paintwork

- Fitting of plastics

- Scratches

- Dirt

Tightening torques inspection

Lock check

- Safety fasteners

- Fixing screws

Safety fasteners:

Rear shock absorber upper fixing

Rear shock absorber lower fixing

Front wheel axle nut

Wheel hub nut

Swinging arm - chassis pin

Engine-swinging arm pin

Engine arm pin - Chassis arm

Handlebar lock nut

Lower steering ring nut

Upper steering ring nut

Electrical system

Electrical system:

- Main switch

- Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights

- Adjusting the headlights according to the regulations currently in force

- Rear light, parking light, stop light

- Front and rear stop light switches

- Turn indicators and their warning lights

- Instrument panel lights

- Instrument panel: fuel gauge

- Instrument panel warning lights

- Horn

- Starter

Typhoon 125 4T (MY 2010) Pre-delivery

PRE DE - 211

CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFOREIT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINALFIRST.CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-ATIVE ONE.WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FORABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER ORVEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARETO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKINGCLOSE TO BATTERIES.KEEP OUT OF THE REACH OF CHILDRENCAUTION

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

Levels check

Level check:

- Hydraulic braking system fluid level.

- Rear hub oil level

- Engine oil level

Road test

Test ride

- Cold start

- Instrument operations

- Response to the throttle control

- Stability on acceleration and braking

- Rear and front brake efficiency

- Rear and front suspension efficiency

- Abnormal noise

Pre-delivery Typhoon 125 4T (MY 2010)

PRE DE - 212

Static test

Static control after the test ride:

- Starting when warm

- Starter operation

- Minimum hold (turning the handlebar)

- Uniform turning of the steering

- Possible leaksCAUTION

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

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Functional inspection

Functional Checks:

Braking system (hydraulic)

- Lever travel

Braking system (mechanical)

- Lever travel

Clutch

- Proper functioning check

Engine

- Throttle travel check

Others

- Check documentation

- Check the chassis and engine numbers

- Tool kit

- License plate fitting

- Check locks

- Check tyre pressures

- Installation of mirrors and any accessories

Typhoon 125 4T (MY 2010) Pre-delivery

PRE DE - 213

INDEX OF TOPICS

TIME TIME

Engine

ENGINECode Action Duration

1 001001 Engine from chassis - Removal andrefit.

Typhoon 125 4T (MY 2010) Time

TIME - 215

Crankcase

CRANKCASECode Action Duration

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

ment3 002031 Rear wheel hub bearings - Replace-

ment

Time Typhoon 125 4T (MY 2010)

TIME - 216

Crankshaft

CRANKSHAFTCode Action Duration

1 001117 Crankshaft - Replacement2 001099 Flywheel-side oil seal - Replacement


TIME - 217

Cylinder assy.

CYLINDER ASSEMBLYCode Action Duration

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

ing


TIME - 218

Cylinder head assy.

HEAD ASSEMBLYCode Action Duration

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


TIME - 219

Rocker arms support assy.

ROCKERS MOUNTING UNITCode Action Duration

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


TIME - 220

Cylinder head cover

HEAD COVERCode Action Duration

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

ment


TIME - 221

Chain tensioner

CHAIN TENSIONERCode Action Duration

1 001129 Chain tensioner - Service and Re-placement

2 001124 By pass lubrication - Replacement


TIME - 222

Oil filter

OIL FILTERCode Action Duration

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


TIME - 223

Flywheel cover

FLYWHEEL COVERCode Action Duration

1 001087 Flywheel cover - Replacement2 001163 Silencer secondary air connection -

Replacement3 001161 Secondary air filter - Replacement /

Cleaning4 001174 SAS valve - Replacement5 001164 Crankcase secondary air connection

- Replacement


TIME - 224

Driven pulley

DRIVEN PULLEYCode Action Duration

1 001155 clutch housing - Replacement2 001022 Clutch - Replacement3 001012 Driven pulley - overhaul4 001110 Driven pulley- Replacement


TIME - 225

Oil pump

OIL PUMPCode Action Duration

1 001051 Belt/Timing chain - Change2 001125 Chain guide pads - Replacement3 001042 Oil pump - overhaul4 001112 Oil pump - change5 001130 Oil sump - change6 001100 Clutch-side oil seal - Replacement7 001122 Oil pump chain - Replacement


TIME - 226

Final gear assy.

FINAL REDUCTION GEARCode Action Duration

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

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


TIME - 227

Driving pulley

DRIVING PULLEYCode Action Duration

1 001066 Driving pulley - Removal and refitting2 001086 Driving half-pulley - Replacement3 001177 CVT rollers / sliders - Replacement4 001011 Drive belt - Replacement


TIME - 228

Transmission cover

TRANSMISSION COVERCode Action Duration

1 001096 Transmission crankcase cover - Re-placement

2 001135 Transmission cover bearing - Re-placement

3 001065 Transmission cover - Removal andRefit


TIME - 229

Starter motor

STARTER MOTORCode Action Duration

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


TIME - 230

Flywheel magneto

Belt cooling duct


TIME - 231

BELT COOLING PIPECode Action Duration

1 001170 Air duct - replacement2 001132 Transmission air intake pipe - Re-

placement3 001131 Transmission air intake - Replace-

ment

Carburettor

CARBURETTORCode Action Duration

1 001082 Carburettor heating resistor - Re-placement

2 001013 Intake manifold - change3 004122 Air cleaner carburettor fitting - Re-

placement4 001081 Automatic choke - Replacement5 001008 Carburettor - Inspection6 001063 Carburettor - Replacement


TIME - 232

Exhaust pipe

SILENCERCode Action Duration

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


TIME - 233

Air cleaner

AIR CLEANERCode Action Duration

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


TIME - 234

Frame

CHASSISCode Action Duration

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


TIME - 235

Legshield spoiler

SPOILER LEGSHIELDCode Action Duration

1 004159 Plates / Stickers - Replacement2 004149 Shield central cover - Replacement3 004064 Leg shield, front part - Removal and

refitting4 004015 Footrest - Removal and Refitting5 004053 Spoiler - Replacement


TIME - 236

Rear cover

REAR SHIELDCode Action Duration

1 004174 Trunk levers - Replacement2 004065 Legshield, rear part - Removal and

refitting3 004081 Top box lid - Replacement


TIME - 237

Central cover

CENTRAL COVERCode Action Duration

1 004059 Spark plug inspection flap - Replace-ment

2 004106 Helmet compartment band - Re-placement

3 004085 Fairing (1) - Replacement4 004105 Right side clamp - Replacement5 004131 Luggage rack mounting - Replace-

ment


TIME - 238

Underseat compartment

HELMET COMPARTMENTCode Action Duration

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

Refitting3 001027 Body / air cleaner union - Replace-

ment


TIME - 239

Plate holder

LICENSE PLATE HOLDERCode Action Duration

1 004136 License plate holder mounting - Re-placement

2 005048 number plate holder - Replacement


TIME - 240

Mudguard

MUDGUARDSCode Action Duration

1 004002 Front mudguard - change2 004009 Rear mudguard - Replacement


TIME - 241

Fuel tank

FUEL TANKCode Action Duration

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

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


TIME - 242

Rear shock-absorber

REAR SHOCK ABSORBERCode Action Duration

1 003007 Rear shock absorber - Removal andRefitting


TIME - 243

Steering column bearings

STEERING BEARINGCode Action Duration

1 003002 Steering bearing - Replacement2 003073 Steering clearance - Adjustment


TIME - 244

Handlebar covers

HANDLEBAR COVERSCode Action Duration

1 004019 Handlebar rear section - Replace-ment

2 004018 Handlebar front section - Replace-ment

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

- Replacement


TIME - 245

Handlebar components

HANDLEBAR COMPONENTSCode Action Duration

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

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

ment9 004162 Mirror mounting and/or brake pump

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

placement


TIME - 246

Swing-arm

SWINGING ARMCode Action Duration

1 001072 Engine / frame swinging arm fitting -Replacement

2 003080 Swinging arm on chassis - Replace-ment


TIME - 247

Brake hoses

BRAKE PIPINGCode Action Duration

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

2 002039 Front brake calliper - Removal andRefitting

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

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


TIME - 248

Seat

SADDLECode Action Duration

1 004003 Saddle - Replacement2 004068 Passenger handgrip - Replacement


TIME - 249

Turn signal lights

INDICATOR LIGHTSCode Action Duration

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

ment4 005008 Headlight bulbs - Replacement5 005005 Taillight - change6 005066 Rear light bulbs - Replacement7 005022 Rear turning indicators - Replace-

ment8 005068 Rear turning indicator bulb - Re-

placement9 005131 number plate light support - Replace-

ment10 005031 number plate light bulb - Replace-

ment11 005032 number plate light glass - Replace-

ment


TIME - 250

Front wheel

FRONT WHEELCode Action Duration

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

fitting6 004123 Front wheel - Replacement7 002041 Brake disc - Replacement

Tone wheel or drive greasing

Please take note that the code has been intro-

duced:

900001 - Tone wheel / drive greasing - 15'.

Never mistake the codes 002011 (movement sen-

sor replacement) and 005089 (tone wheel replace-

ment) in the event of noise of the indicated

components. The grease recommended is TUTE-

LA MRM 2 (soap-based lithium grease with Mo-

lybdenum disulphide).

In the following points, the area to be greased is

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


TIME - 251

Rear wheel

REAR WHEELCode Action Duration

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

ting


TIME - 252

Electric devices

ELECTRICAL DEVICESCode Action Duration

1 001023 Control unit - Replacement2 005035 Headlight solenoid - Replacement3 005001 Electrical system - Replacement4 001094 Spark plug cap - Replacement5 001069 HV coil - Replacement6 005052 Fuse - Replacement7 005025 Battery fuse box - Replacement8 005009 Voltage regulator - Replacement9 005011 Start-up solenoid - Replacement10 005007 Battery - change11 005114 Electrical system - Service

Electronic controls

ELECTRIC CONTROLSCode Action Duration

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

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


TIME - 253

Front suspension

FRONT SUSPENSIONCode Action Duration

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


TIME - 254

AAir filter: 33

BBattery: 46, 63, 70, 77, 78, 205, 208Brake: 171, 185, 187, 188, 190, 191, 248Bulbs:

CCarburettor: 11, 146, 152, 232Checks: 68

EElectric: 253Engine oil: 34

FFuel: 45, 145, 206, 242Fuses: 76

HHeadlight: 39, 198Horn: 74Hub oil: 31

IIdentification: 8Instrument panel: 196

MMaintenance: 7, 28Mirrors: 195, 197

OOil filter: 34, 35, 223

RRecommended products:

SSaddle: Shock absorbers: 181Spark plug: 30, 68Start-up: Suspension: 47, 254

TTank: 206, 242Transmission: 9, 45, 88, 100, 111, 229Turn indicators: 67Tyres: 10

VVehicle: 8, 83

Documents

Piaggio Typhoon 125 4T MY 2010 (en)