Piaggio Carnaby 250ie (EN)

SERVICE STATION MANUAL633986 IT-633987 EN-633988 FR-633989 DE-633990

ES-633991 PT-633992 OL-633993 EL

Carnaby 250ie

SERVICE STATIONMANUAL

Carnaby 250ie

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

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

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

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

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

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

SERVICE STATION MANUALCarnaby 250ie

This service station manual has been drawn up by Piaggio & C. SpA to be used by the workshops ofPiaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed tohave a basic knowledge of mechanics principles and of vehicle repairing techniques and procedures.Any significant changes made to the vehicle characteristics or to specific repair operations will bepromptly communicated by updates to this manual. Nevertheless, no work can be satisfactory if thenecessary equipment and tools are not available. It is therefore advisable to read the sections of thismanual relating to special tools as well as the tool catalogues.

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

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL 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.

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

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

coupling members and tools may damage the 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.

Carnaby 250ie Characteristics

CHAR - 7

Vehicle identification

The chassis prefix «A» is located near the right

shock absorber connection to the frame.

The engine prefix «B» is stamped near the left

shock absorber lower support.

VEHICLE IDENTIFICATIONSpecification Desc./QuantityChassis prefix ZAPM 60300Engine prefix M603M

Characteristics Carnaby 250ie

CHAR - 8

Dimensions and mass

WEIGHTS AND DIMENSIONSSpecification Desc./QuantityKerb weight 163 kg ± 5 kg

Maximum weight allowed 350 kgMaximum height 1,270 mm

Width 755 mmWheelbase 1,370 mm

Length 2,025 mm

Engine

ENGINESpecification Desc./Quantity

Type Single-cylinder, 4-strokeEngine capacity 244 cm³Bore x Stroke 72 x 60 mm

Compression ratio 11 ± 0.5 : 1Engine idle speed 1,700 ± 100 rpm

Timing system 4 valves, single overhead camshaft, chain-driven.Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm

Max. power 16.3 kW at 8,000 rpmMAX. torque 21 Nm at 6,750 rpmLubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.Lubrication pressure 4 bar

Minimum lubrication pressure (100° C) 0.8 bar


CHAR - 9

Specification Desc./QuantityFuel system Electronic injection with Ø 32-mm throttle body and electric fuel

pump.Cooling Forced coolant circulation system.

Fuel Unleaded petrol (95 RON)Exhaust silencer Absorption-type exhaust silencer with a 3-way catalytic con-

verter and lambda probe.Emissions compliance EURO 3

Transmission

TRANSMISSIONSpecification Desc./QuantityTransmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmissionhousing with forced-circulation air cooling.

Final reduction gear Gear reduction unit in oil bath.

Capacities

CAPACITYSpecification Desc./Quantity

Engine oil 1.3 lTransmission oil 250 cm³

Cooling system fluid 1.75 lFuel tank (reserve) ~ 10 l (2 l)

Electrical system

ELECTRICAL SYSTEMSpecification Desc./Quantity

Electric starterIgnition Electronic inductive discharge ignition, high efficiency, with

separate HV coil.Ignition advance α/N three-dimensional map managed by control unit

Spark plug CHAMPION RG 4 PHPAlternative spark plug -

Battery 12V-12AhGenerator alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONSpecification Desc./Quantity

Chassis Tubular and steel sheets.Front suspension Hydraulic telescopic fork with Ø 35-mm stem

Front suspension travel 104 mmRear suspension Two double-acting shock absorbers with preloading adjust-

ment in 4 positions.Rear suspension travel - mm


CHAR - 10

Brakes

BRAKESSpecification Desc./QuantityFront brake Ø 260-mm disc brake with hydraulic control activated by han-

dlebar right-side lever.Rear brake Ø 260-mm disc brake with hydraulic control activated by han-

dlebar left-side lever.

Wheels and tyres

WHEELS AND TYRESSpecification Desc./QuantityWheel rim type Light alloy wheel rims.Front wheel rim 16'' x 3.00Rear wheel rim 16'' x 3.00

Front tyre Tubeless, 110/70 - 16'' 52PRear tyre Tubeless, 130/70 - 16'' 61P

Front tyre pressure (with passenger) 1.9 bar (-)Rear tyre pressure (with passenger) 2.3 bar (-)

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-LATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES

Tightening Torques

STEERINGName Torque in Nm

Steering tube lower ring nut 14 ÷ 17Steering tube upper ring nut 40 ÷ 45Handlebar fixing screw (*) 45 to 50

Fixing screws for the handlebar control unit U-bolts 7 to 10

CHASSIS ASSEMBLYName Torque in Nm

Bolt of the Silent block support plate 54Frame arm-engine arm coupling pin nut 61

Frame-swinging arm pin nut 60Engine-swinging arm pin 40

Centre stand bolt 25 ÷ 30

FRONT SUSPENSIONName Torque in Nm

Fixing screw for pumping elements to lower fork plate 20 to 25Front wheel axle 45 to 50Fork leg screw 6 - 7

front mudguard to plate fixing screw 4.5 ÷ 7Fixing screw for mudguard plate to fork 9 ÷ 11

FRONT BRAKEName Torque in Nm

Brake fluid pump-hose fitting 16 - 20Brake fluid tube-calliper fitting 16 - 20

Calliper to fork tightening screw 20 to 25Disc tightening screw (°) 5 to 6

Oil bleed screw 12 - 16Pad fastening pin 19.6 ÷ 24.5


CHAR - 11

REAR SUSPENSIONName Torque in Nm

Left lower shock absorber support bolt 20 to 25Shock absorber upper clamp 33 to 41

Shock absorber lower clamping 33 to 41Rear wheel axle 104 to 126

Fixing screw for wheel rim to hub 34 ÷ 38Silencer supporting arm to engine screws (*) 20 to 25

REAR BRAKEName Torque in Nm

Brake fluid pump-hose fitting 16 - 20Brake fluid tube-calliper fitting 16 - 20Flexible/ rigid oil pipe coupling 9 ÷ 11

Rear disc tightening bolt 11 to 13Oil bleed screw 12 - 16

Screw tightening calliper to support 20 to 25Screw fixing rear brake calliper support to engine 20 to 25

Pad fastening pin 20 to 25

SILENCERName Torque in Nm

Screw fixing manifold to silencer 15.5 ÷ 18.5Silencer heat guard fixing screw 5 to 6

Exhaust fumes inlet screw 22 ÷ 26Screw fixing silencer support arm to crankcase 33 to 41

Nuts fixing silencer to supporting arm 27 - 30Nut fixing silencer to cylinder head 16 to 18

LUBRICATIONName Torque in Nm

Hub oil drainage plug 15 to 17Oil filter on crankcase fitting 27 to 33

Engine oil drainage plug/ mesh filter 24 to 30Oil filter 4 to 6

Oil pump cover screws 0.7 - 0.9Screws fixing oil pump to the crankcase 5 to 6

Oil pump command sprocket screw 10 to 14Oil pump cover plate screws 4 to 6

Oil sump screws 10 to 14Minimum oil pressure sensor 12 to 14

CYLINDER HEADName Torque in Nm

Spark plug 12 to 14Nuts fixing head to cylinder (1) (^) 9 ÷ 11 + 180°

Head fixing side screws 11 - 12Starter ground screw 7 to 8.5

M5 side screw locking washers on camshaft 7 to 8.5Tappet adjustment check nut 6 - 8

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

M6 central screw locking washers on camshaft 11 to 15Timing chain tensioner support screw 11 to 13Timing chain tensioner central screw 5 to 6

Camshaft retention plate screw 4 to 6

TRANSMISSIONName Torque in Nm

Belt support roller screw 11 to 13Clutch unit nut on driven pulley 45 to 50

Drive pulley nut 75 - 83


CHAR - 12

Name Torque in NmTransmission cover screws 11 to 13

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

FLYWHEELName Torque in Nm

Flywheel cover fixing screws 5 to 6Stator assembly screws (°) 3 to 4

Flywheel nut 52 to 58Pick-up fixing screws 3 to 4

Screw fixing freewheel to flywheel 13 - 15

CRANKCASE AND CRANKSHAFTName Torque in Nm

Internal engine crankcase bulkhead (transmission-side halfshaft) screws

4 to 6

Engine-crankcase coupling screws 11 to 13Starter screws 11 to 13

Crankcase timing system cover screws (°) 3.5 ÷ 4.5

COOLINGName Torque in Nm

Water pump rotor cover 3 to 4Screws for water pump rotor driving link 3 to 4

Thermostat cover screws 3 to 4bleed screw: 3

(°) Apply LOCTITE 242 medium-strength threadlock

(*) The two screws must be tightened to the prescribed torque after having done so with the rear wheel

axle nut. Safety locks: see "Pre-delivery operations".

(^) Fasten the nuts in two crossed passes.

(1) Before fitting the nuts lubricate them with engine oil

Overhaul data

Assembly clearances


CHAR - 13

Cylinder - piston assy.

ENGINE COUPLING CATEGORYName Initials Cylinder Piston Play on fitting

Cylinder M 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064Cylinder N 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064Piston O 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 - 0.064Piston P 72.031 ÷ 72.038 71.974 ÷ 71.981 0.050 - 0.064

Crankcase - crankshaft - connecting rod

- Measure the diameter of bushings «A» in the

three directions shown in the figure.

- Measure the diameter of the crankshaft bearings

«B».

- Check that the diametral clearance «A-B» is be-

tween the pre-set interval.

CharacteristicDiameter clearance0.023 - 0.041 mm


CHAR - 14

If value «A-B» is above the limit, check that value «B» is within the admissible values of the categories.

CRANKSHAFTSpecification Desc./Quantity

Category 1 28.998 to 29.004Category 2 29.004 to 29.010

If the crankshaft is within the set limits, replace the crankshaft half-bearings mounting the crankcase

so as to suit the specified couplings. The crankcase halves can be mounted with three types of crank-

shaft half-bearings identified by letters A (red), B (blue), C (yellow), E (green).

CRANKCASESpecification Desc./Quantity

Category 1 32.959 to 32.965Category 2 32.953 to 32.959

CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGSSpecification Desc./Quantity

Crankshaft category 1 - Crankcase category 1 E - ECrankshaft category 2 - Crankcase category 1 C - CCrankshaft category 1 - Crankcase category 2 C - CCrankshaft category 2 - Crankcase category 2 B - B


CHAR - 15

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCEName Description Dimensions Initials Quantity

Transmissionside half-shaft

16.6 +0-0.05 A D = 0.20 ÷ 0.50

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

Spacer tool 51.4 +0.05 E D = 0.20 ÷ 0.50

Slot packing system

The shimming system allows the compression ra-

tio to be adjusted correctly.

CharacteristicCompression ratio11 ± 0.5 : 1

Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed

by the piston crown falls below the plane formed by the top of the cylinder. The further the piston travels

inside the cylinder, the thinner the washer "B" of the base gasket to be applied (to obtain the required

compression ratio) and vice versa.N.B.

MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK-CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ONA GROUND PLANE

ENGINE 250 SHIMMINGName Measure A Thickness

SHIMMING 3.70 - 3.60 0.4 ± 0.05SHIMMING 3.60 - 3.40 0.6 ± 0.05SHIMMING 3.40 - 3.30 0.8 ± 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(throttle control)

Oil for 4-stroke engines

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

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

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

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluidAGIP PERMANENT SPECIAL coolant Monoethylene glycol-based antifreeze

fluid, CUNA NC 956-16


CHAR - 16


CHAR - 17

INDEX OF TOPICS

TOOLING TOOL

SPECIFIC TOOLSStores code Description

001330Y Tool for fitting steering seats

001467Y014 Calliper to extract ø 15-mm bearings

005095Y Engine support

002465Y Calliper for circlips

006029Y Punch for fitting fifth wheel seat on steer-ing bearing

020004Y Punch for removing steering bearingsfrom headstock

020055Y Wrench for steering tube ring nut

Carnaby 250ie Tooling

TOOL - 19

Stores code Description020074Y Support base for checking crankshaft

alignment

020150Y Air heater mounting

020151Y Air heater

020193Y Oil pressure check gauge

020262Y Crankcase splitting plate

020263Y Driven pulley assembly sheath

Tooling Carnaby 250ie

TOOL - 20

Stores code Description020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020332Y Digital rpm indicator


TOOL - 21

Stores code Description020648Y Single battery charger

020335Y Magnetic mounting for dial gauge

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

020360Y 52x55-mm Adaptor

020363Y 20-mm guide


TOOL - 22

Stores code Description020375Y 28 x 30 mm adaptor

020376Y Adaptor handle

020382Y Valve cotters equipped with part 012 re-moval tool

020382Y011 adapter for valve removal tool

020393Y Piston assembly band

020412Y 15-mm guide


TOOL - 23

Stores code Description020423Y Driven pulley lock wrench

020424Y Driven pulley roller casing fitting punch

020426Y Piston fitting fork

020431Y Valve oil seal extractor

020434Y Oil pressure check fitting

020444Y Tool for fitting/ removing the driven pulleyclutch


TOOL - 24

Stores code Description020456Y Ø 24 mm adaptor020477Y 37 mm adaptor

020483Y 30-mm guide

020489Y Hub cover support stud bolt kit

020428Y Piston position check mounting

020680Y Diagnosis Tool


TOOL - 25

Stores code Description020621Y HV cable extraction adaptor

020481Y Control unit interface wiring

001467Y035 Bearing housing, out ø 47 mm

020626Y Driving pulley lock wrench

001467Y013 Calliper to extract ø 15-mm bearings

020627Y Flywheel lock wrench


TOOL - 26

Stores code Description020467Y Flywheel extractor

020454Y Tool for fitting piston pin stops (200 - 250)

020622Y Transmission-side oil seal punch

020480Y Petrol pressure check kit

020244Y 15-mm diameter punch

020115Y Ø 18 punch


TOOL - 27

Stores code Description020271Y Tool for removing-fitting silent bloc

020469Y Reprogramming kit for scooter diagnostictester

020487Y Fork oil seal extractor

020458Y Puller for lower bearing on steering tube


TOOL - 28

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

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

Km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60Safety fasteners I I I I ISpark plug I R I R I RDrive belt R R RThrottle control A A A A A A AAir filter C C C C C CBelt compartment air filter I I I I I IOil filter R R R R R R RValve clearance A A AElectrical system and battery I I I I I I IBrake fluid * I I I I I I ICoolant * I I I I I I IEngine oil R I R I R I R I R I R I RHub oil R I R I R I RBrake pads I I I I I I I I I I I I ISliding shoes / CVT rollers R R R R R RTyre pressure and wear I I I I I I IVehicle road test I I I I I I ISuspension I I I I I ISteering A A A A A A A

MAINTENANCE TABLE - TIMEKm x 1000 1 5 10 15 20 25 30 35 40 45 50 55 60

Operation Time 60' 10' 140' 10' 150' 10' 140' 10' 150' 10' 140' 10' 190'

Checking the spark advance

The ignition advance is determined electronically

on the basis of parameters known by the control

unit. For this reason it is not possible to interpret

the reference values based on the engine rpm.

The ignition advance value is detectable at any

time using the diagnostic tester. It is possible to

check whether the ignition advance determined by

the injection system matches the value actually

activated on the engine, by means of the strobo-

scopic light.

Proceed as follows:

- Remove the spark plug.

- Remove the plastic cover on the flywheel cover

shown in the picture.

Maintenance Carnaby 250ie

MAIN - 30

- Remove the transmission compartment air intake

cover shown in the picture.

- Rotate the driving pulley fan using a screwdriver

until the reference marks between the flywheel

and flywheel cover coincide as shown in the pic-

ture.

- Bring the reference mark onto the transmission

side between the fan and the transmission cover

as shown in the picture.

- Refit the spark plug.

- Refit the plastic cap on the flywheel cover.

- Adjust the spark gap to the contact position (no

reference mark visible) and install it on the engine

between the spark plug and spark plug cap

- Connect the induction clamp on the spark gap

cable respecting the proper polarity (the arrow on

the clamp must be pointing at the spark plug).

- Connect the diagnostic tester.

- Start the engine.

- Select the «Parameters» function in this menu.

- Set the stroboscopic light control to the traditional

four-stroke engine position (1 spark, 2 revs).

- Check that the real values of rpm and ignition

advance match those measured using the diag-

nostic tester.

If the values do not correspond, check:

- distribution timing

- engine speed sensor

- injection control unit

Specific tooling020680Y Diagnosis Tool

020330Y Stroboscopic light to check timing

020621Y HV cable extraction adaptor

Carnaby 250ie Maintenance

MAIN - 31

Spark plug

To remove the spark plug, proceed as follows:

- Undo the two screws « A» and remove the cover.

- Operating on both sides of the vehicle, undo the

screws «B».

- Remove the inspection cover «C» by pulling it

upwards.

- Disconnect the cap «D» from the spark plug HV

wire.

- Unscrew the spark plug using the wrench sup-

plied.


MAIN - 32

- Check the conditions of the spark plug, make

sure the insulation is intact and the electrodes are

not excessively worn or sooty, check the condi-

tions of the sealing washer and measure the elec-

trode gap using the appropriate feeler gauge.

- If necessary, adjust the gap by bending the side

electrode very carefully. In case of anomaly (as

described before), replace the spark plug with an-

other one of the recommended type.CAUTIONTHE SPARK PLUG MUST BE REMOVED WHEN THE EN-GINE IS COLD. CHECK AND REPLACE THE SPARK PLUGAS INDICATED IN THE SCHEDULED MAINTENANCE TA-BLE. USING NON-COMPLYING IGNITION CONTROLUNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRI-BED MAY SERIOUSLY DAMAGE THE ENGINE.

CharacteristicSpark plugCHAMPION RG 4 PHP

Electrode gap0.7 to 0.8 mm

Locking torques (N*m)Spark plug 12 to 14

When refitting, place the spark plug into the hole at the due inclination and tighten it manually all the

way down. Use the wrench only to tighten it. Once locked, insert the cap «D» on the spark plug. Refit

the covers.

Hub oil

Check

-Place the vehicle on its centre stand on flat

ground;

- Remove the oil dipstick «A», dry it with a clean

cloth and put it back into its hole tightening it

completely;

-Take out the dipstick checking that the oil level

reaches the dipstick lower notch; if the level is un-

der the MAX. mark, it needs to be filled with the

right amount of hub oil.


MAIN - 33

-Screw up the oil dipstick again and make sure it

is locked properly into place.

The notches on the hub oil level dipstick, except

for the notch indicating the MAX level, refer to oth-

er manufacturer's models and have no specific

function for this model.

Replacement

-Remove the oil filler cap «A».

- Remove the exhaust silencer.

- Remove the rear wheel.

- Remove the brake calliper and the rear brake

disc.

- Unscrew the oil drainage plug «B» and drain out

all the oil.

- Screw the drainage plug again to the prescribed

torque and refill the hub with the recommended oil.

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

API GL3 specifications

CharacteristicTransmission oil250 cm³

Locking torques (N*m)Hub oil drainage screw 15 to 17 Nm


MAIN - 34

Air filter

- Remove the air cleaner cover after undoing the

nine fixing screws «A».

- Take out the filtering element.N.B.CHECK THE AIR FILTER AND, IF NECESSARY, CLEAN ITAS INDICATED IN THE SCHEDULED MAINTENANCE TA-BLE. THE AIR JET MUST BE DIRECTED FROM THE INSIDETO THE OUTSIDE OF THE FILTER (I.E. OPPOSITE TO THESENSE THE AIR FLOWS AT REGULAR ENGINE RUN-NING). UPON SERVICING, REMOVE THE LOCK AND THERUBBER HOOD UNDER THE FILTER HOUSING ASSHOWN IN THE FIGURE AND DRAIN ALL POSSIBLE OILDEPOSITS.

Cleaning

- Wash with water and car shampoo.

- Dry with short blasts of compressed air and a clean cloth.

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

- Drip dry the filtering element and then squeeze it with your hands without wringing.

- Refit the filtering element.CAUTION

NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WILL RESULT IN AN EXCESSIVECYLINDER AND PISTON WEAR AND ALSO IN CARBURETTOR DAMAGE.CAUTION

WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTENTHAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

Recommended productsAGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Engine oil


MAIN - 35

Replacement

Change oil as indicated in the scheduled mainte-

nance table. The engine must be emptied by drain-

ing the oil through the drainage plug «B» of the

mesh pre-filter, flywheel side. Moreover, to facili-

tate oil drainage, remove the mesh pre-filter and

loosen the cap/dipstick «A». Once all the oil has

drained through the drainage hole, unscrew and

remove the oil filter «C ». Before filling, carry out

the operations described in the "Engine oil filter"

paragraph.

Since a certain quantity of oil still remains in the

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

through the cap «A». 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

necessary, 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 plug 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 - 36

This operation must be carried out with the engine

cold and following the procedure below:

- Place the vehicle on its centre stand and on flat

ground.

- Unscrew the cap/dipstick «A», dry it with a clean

cloth and reinsert it, screwing it all the way

down.

- Remove the cap/dipstick again and check that

the level is between the min and max reference

marks; 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 line will be lower; in

order to carry out a correct check, wait at least 10

minutes after the engine has been stopped so as

to get the correct level.

CharacteristicEngine oil1.3 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


MAIN - 37

Oil pressure warning light

The vehicle is equipped with a warning light «F»

on the instrument panel that lights up when the key

is turned to «ON». However, this light should

switch off once the engine has been started.

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 sys-

tem.

Checking the ignition timing

-Remove the 4 fixing screws and move away from

the engine the flywheel cover fitted with a water

pump and cooling manifolds.

-Rotate the flywheel until the reference matches

the crankcase operation end as shown in the figure

(TDC). Make sure that the 4V reference point on

the camshaft control pulley is aligned with the ref-

erence point on the head as shown in the second

figure. If the reference mark is opposite the indi-

cator 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 using a calliper spanner applied

to the camshaft command pulley casing.N.B.TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.


MAIN - 38

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 set screw corresponds

with the indicated values. When the valve clear-

ance 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 as shown in the fig-

ure.

CharacteristicValve clearanceIntake: 0.10 mm (when cold)Exhaust: 0.15 mm (when cold)

Cooling system

Level check

- To check the level, it is necessary to look inside

the expansion tank: a mark on the side of the filler

indicates the level required.


MAIN - 39

Top-up

Check coolant level when the engine is cold as in-

dicated in the scheduled maintenance table, fol-

lowing the steps below.

Place the vehicle on its centre stand and on flat

ground.

- Undo the screw and remove the expansion tank

cap located on the vehicle left side.

- Remove the expansion tank cap «A » and, if

necessary, top-up if the coolant level is near or

below the mark in the expansion tank. Coolant lev-

el must always reach the mark.

-The coolant consists of an ethylene glycol and

corrosion inhibitor based 50% de-ionised water-

antifreeze solution mix.CAUTIONTO PREVENT THE COOLANT FROM LEAKING OUT OFTHE EXPANSION TANK WHEN THE VEHICLE IS IN USE,DO NOT EXCEED THE LEVEL INDICATED BY THE INTER-NAL MARK.

Braking system

Level check

The brake fluid tanks for the front and rear brakes

are located on the pumps under the handlebar

cover. Proceed as follows:

- Bring the vehicle onto the centre stand and with

the handlebar centred;

- check the fluid level at the sight glass as shown

in the figure.

A drop in the brake fuel level may be caused by

pad wear.


MAIN - 40

Top-up

- Undo the four screws indicated and remove the

windshield.

- Remove the cover on the handlebar shown in the

photograph by undoing the screw.

- Remove the reservoir cap by loosening the two

screws, remove the gasket and top-up using only

the fluid specified without exceeding 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, REPLACE FLU-ID AS INDICATED IN THE SCHEDULED MAINTENANCETABLE.

Recommended productsAGIP BRAKE 4 Brake fluid


MAIN - 41

FMVSS DOT 4 Synthetic fluid

Headlight adjustment

Proceed as follows:

- Position the unloaded vehicle, in running order

and with the tyres inflated to the prescribed pres-

sure, onto a flat surface 10 m away from a half-lit

white screen; make sure the vehicle axis is per-

pendicular to the screen;

- Turn on the headlight and check that the border

of the projected light beam on the screen is not

higher than 9/10 or lower than 7/10 f the height

from the ground to the centre of vehicle headlamp;

- If this is not the case, adjust the headlight by op-

erating the screw «A».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.


MAIN - 42

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

This section makes it possible to find what solutions to apply when troubleshooting.

For each failure, a list of the possible causes and pertaining operations is given.

Engine

Poor performance

POOR PERFORMANCEPossible Cause Operation

Fuel pump Check the injection load relayExcess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves

Incorrect timing or worn timing system elements Time the system again or replace the worn partsSilencer obstructed Replace

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

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

Drive belt worn ReplaceInefficient automatic transmission Check the rollers, the pulley movement and make sure the

drive belt is in good conditions; replace the damaged parts andlubricate the moveable driven pulley with specific grease.

Clutch slipping Check the clutch system and/or the bell and replace if neces-sary

Overheated valves Remove the head and the valves, grind or replace the valvesWrong valve adjustment Adjust the valve clearance properly

Valve seat distorted Replace the head unit

Starting difficulties

DIFFICULT STARTINGPossible Cause Operation

Rpm too low at start-up or engine and start-up system dam-aged

Check the starter motor, the system and the torque limiter

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearanceEngine flooded Try starting-up with the throttle fully open. If the engine fails to

start, remove the spark plug, dry it and before refitting, makethe engine 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.

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

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit componentsFlat battery Check the charge of the battery, if there are any sulphur marks,

replace and use the new battery following the instructionsshown in the chapter

Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-ened

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTIONPossible Cause Operation

Wrong valve adjustment Adjust the valve clearance properlyOverheated valves Remove the head and the valves, grind or replace the valves

Troubleshooting Carnaby 250ie

TROUBL - 44

Possible Cause OperationMisshapen/worn valve seats Replace the head unit

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston ringsWorn or broken piston rings or piston rings that have not been

fitted properlyReplace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling sealWorn valve oil seal Replace the valve oil sealWorn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSUREPossible Cause Operation

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

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

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible Cause Operation

Faulty clutch Check that there is no grease on the masses. Check that theclutch mass faying surface with the bell is mainly in the centrewith equivalent characteristics on the three masses. Check thatthe clutch housing is not scored or worn in an anomalous way

Insufficient braking

INEFFICIENT BRAKING SYSTEMPossible Cause Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs arenot worn, scored or warped. Check the correct level of fluid inthe pumps and change brake fluid if necessary. Check there isno air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shiftof the disc with a dial gauge and with wheel mounted on the

vehicle.

Brakes overheating

BRAKE OVERHEATPossible Cause Operation

Defective plunger sliding Replace the calliper.Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and

a wheel mounted on the vehicle to measure the axial shift ofthe disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed airSwollen or stuck rubber gaskets Replace the calliper.

Carnaby 250ie Troubleshooting

TROUBL - 45

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 rotation seats and the steering

fifth wheels.

Excessive steering play

EXCESSIVE STEERING CLEARANCEPossible Cause Operation

Torque not conforming 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 rotation seats and the steering

fifth wheels.

Noisy suspension

NOISY SUSPENSIONPossible Cause Operation

Malfunctions in the suspension system If the front suspension is noisy, check: tightening torques,headstock components, inspect forks.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSIONPossible Cause Operation

Faulty or broken seals Replace the shock absorber

Troubleshooting Carnaby 250ie

TROUBL - 46

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Components arrangement

Electrical system Carnaby 250ie

ELE SYS - 48

1. Injection ECU

Remove the helmet compartment to reach it.

2. Diagnostics socket

Remove the rear light cover to reach it.

3. Voltage regulator

Located under the rear light unit.

4. Magneto flywheel

Remove the left side fairing to reach the connector.

Carnaby 250ie Electrical system

ELE SYS - 49

5. Main fuses

6. Auxiliary fuses

7. Battery

In order to reach these components, remove the

lid located on the footrest.

8. Horn

Remove the leg shield back plate to reach it.

9. Front solenoids

Remove the spoiler to reach them.

A. Start-up solenoid

B. Electric fan solenoid

C. Headlight solenoid

10. Oil pressure sensor

Placed at the bottom on the engine RHS.


ELE SYS - 50

11. Turn indicator control device

12. HV coil

In order to reach these components, remove the

right side fairing.

13. Rear solenoids

Remove the right side fairing to reach it.

A. Injection load solenoid

B. Stop light remote control switches

14. Fuel level transmitter

Placed on the tank.

15. Ignition switch

Remove the leg shield back plate to reach it.


ELE SYS - 51

16. Electric fan

Remove the front shield to reach it.

Ground points

Ground points on engine

A. Placed on the starter motor. Remove the helmet

compartment to reach it.

B. Placed on the engine LHS. Remove the footrest

to reach them.

Ground points on chassis

C. Placed on the vehicle RHS. Remove the right

side fairing to reach it.

Checks and inspections


ELE SYS - 52

Ignition circuit

No spark plugWARNING

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

HV coil primary resistance value:

Disconnect the connector of the HV coil and meas-

ure the resistance between the two terminals.

CharacteristicHV coil resistance primary value:~ 0.9 Ω

HV coil secondary resistance value:

1) Disconnect the HV cable from the spark plug

and measure the resistance between the spark

plug cap and the HV coil negative terminal.

2)Disconnect the spark plug cap from the HV cable

and measure the resistance between the HV cable

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

3) Measure the resistance between the 2 ends of

the spark plug cap.

CharacteristicHV coil secondary resistance value with sparkplug cap~ 8.4 kΩ

HV coil secondary resistance value:~ 3.4 kΩ

Spark plug cap resistance value~ 5 kΩ


ELE SYS - 53

Remote controls check

To check the operation of a solenoid:

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

continuity between terminals 87 and 30.

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

85 of the solenoid.

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

tinuity between terminals 87 and 30.

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

surely damaged and, therefore, it should be re-

placed.

Switches check

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

correct as indicated in the following charts.

KEY

Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

STARTER BUTTON

ENGINE STOP SWITCH


ELE SYS - 54

LIGHT SWITCH

TURN INDICATOR SWITCH

HORN BUTTON

Stator check

Disconnect the connector from the voltage regu-

lator and check if there is continuity between any

Black cable and the other two cables.

Electric characteristicOhm value:0.7 ÷ 0.9 Ohm


ELE SYS - 55

Also check that all Black cables are insulated from

the ground connection.

If non-conforming values are detected, repeat the

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

etitions of incorrect values replace the stator or

repair the wiring.

Voltage regulator check

With a perfectly charged battery and lights off,

measure voltage at the battery poles with a high

running engine.

The voltage should not exceed 15.2 Volt.

In case higher voltages are detected, replace the

regulator.

In case of voltage values lower than 14 Volt, check

the stator and the corresponding cable harness.

Recharge system voltage check

The charging circuit consists of three-phase alter-

nator and a permanent magneto flywheel.

The generator is directly connected to the voltage

regulator.

In turn, the voltage regulator is directly connected

to the ground connection and to the battery posi-

tive terminal passing through the 30A protection

fuse (No. 7).

This system therefore requires no connection to

the ignition switch.

The three-phase alternator provides good re-

charge power and at low revs a good compromise

is achieved between generated power and idle

stability. For this reason, it is very important that

the idle speed is adjusted as prescribed.

Connect the ammeter induction clamp to the volt-

age regulator positive terminal, measure the bat-


ELE SYS - 56

tery voltage and, turning on the vehicle lights with

the engine off, wait for the voltage to settle at about

12 Volt. Start the engine and measure the current

generated by the system with the lights on and

high running engine.

In case the generated current value is lower than

10A, repeat the test using a new regulator and/

stator alternatively.

Starter motor

KEY

1. Battery

2. Fuse No. 10

3. Ignition switch contacts

4. Fuse No. 4

5. Left stop button

6. Right stop button

7. Injection ECU

8. Starter button

9. Starter solenoid

10. Starter motorWARNING


ELE SYS - 57

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.1) Check that fuses No. 10 and 4 operate properly.

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

3) With the ignition switch set to «ON», the brake pulled and the starter button pressed, check if there

is voltage between the Orange-White cable of the start-up solenoid switch and the ground connection.

If there is not, check that the cable harnesses are not interrupted.

4) Check that the Blue-Green cable connecting the start-up solenoid switch and the control unit (pin 24)

is not interrupted.

5) Check that the Red cables of the start-up solenoid switch to the battery and the starter motor are not

interrupted.

6) Check the start-up solenoid switch.

7) Check the starter motor ground connection.

Horn control

KEY

1. Battery

2. Fuse No. 10


4. Fuse No. 4

5. Horn button

6. Horn


ELE SYS - 58

WARNING


1) Check that fuses No. 10 and 4 operate properly.

2) Check the ignition switch and horn button contacts.

3) With the ignition switch set to «ON» and the horn button pressed, check if there is voltage between

the Yellow-Pink cable of the horn and the ground connection. If there is not, check that the cable har-

nesses are not interrupted.

4) Check that the Black cable of the horn is earthed.

Turn signals system check

KEY

1. Battery

2. Fuse No. 10


4. Fuse No. 4

5. Turn indicator control device

6. Turn indicator switch

7. Right turn indicator bulbs

8. Left turn indicator bulbsWARNING



ELE SYS - 59

1) Check the bulbs.


3) Check ignition switch contacts.

4) With the ignition switch set to «ON», check if there is intermittent voltage between the Blue-Black

cable of the turn indicator switch and the ground connection. If there is not, check that the cable har-

nesses are not interrupted.

5) Check the turn indicator switch contacts.

6) Check that the cable harnesses of the bulbs are not interrupted.

7) Check that the Black cables of the bulbs are earthed.

level indicatorsWARNING


If faults are detected:

1) With a multimeter, check resistance values be-

tween the White-Green cable and the Black cable

of the fuel level transmitter under different condi-

tions.

2) If the transmitter operates correctly but the in-

dication on the instrument panel is not exact,

check that the cable harnesses between them are

not interrupted.

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

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


ELE SYS - 60

Lights list

KEY

1. Battery

2. Fuse No. 10

3. Fuse No. 11


5. Headlight solenoid

6. Light switch

7. Fuse No. 12

8. Fuse No. 5

9. Low beam bulb

10. High beam bulb and high beam warning light

11. Fuse No. 3

12. Daylight running light bulbs, license plate light and instrument panel lighting

A. To the Injection electronic control unit (pin 19)WARNING


LINE FOR DAYLIGHT RUNNING LIGHTS, LICENSE PLATE LIGHT AND INSTRUMENT PANEL

LIGHTING - CHECK

1) Check the bulbs.



ELE SYS - 61


4) With the ignition switch set to «ON», check if there is voltage between the Yellow-Black cable of fuse

No. 3 and the ground connection. If there is not, check that the cable harnesses are not interrupted.



HIGH/LOW BEAM LIGHTS LINE - CHECK

1) Check the bulbs.



4) With the ignition switch set to «ON», check if there is voltage between the Blue cable of the headlight

solenoid and the ground connection, and afterwards between the Orange cable and the ground con-

nection. If there is not, check that the cable harnesses are not interrupted.

5) Check that the White-Black cable connecting the headlight solenoid and the control unit (pin 19) is

not interrupted.

6) Check the headlight solenoid and the light switch contacts.


8) With the ignition switch set to «ON» and the light switch in high beam position, check if there is voltage

between the Purple cable of fuse No. 5 and the ground connection. If there is not, check that the cable

harnesses are not interrupted.

9) With the ignition switch set to «ON» and the light switch in low beam position, check if there is voltage

between the Brown cable of fuse No. 12 and the ground connection. If there is not, check that the cable

harnesses are not interrupted.



LINE FOR HIGH BEAM LIGHTS IN PASSING (FLASHING) MODE - CHECK

1) Check the bulbs.


3) Check the ignition switch and light switch contacts.

4) With the ignition switch set to «ON» and the high beam light switch in passing mode pressed, check

if there is voltage between the Purple cable of fuse No. 5 and the ground connection. If there is not,

check that the cable harnesses are not interrupted.



LIGHT BULBS TABLESpecification Desc./Quantity

1 High beam light bulb Type: HALOGEN (H11)Power: 12V - 55W

Quantity: 12 Low beam bulb Type: HALOGEN (H11)

Power: 12V - 55W


ELE SYS - 62

Specification Desc./QuantityQuantity: 1

3 Front side light bulb Type: Incandescent (W2.1 x 9.5D)Power:12V - 5W

Quantity: 24 Front turn indicator light bulb Type: Incandescent (BAU 5s)

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

5 Rear turn indicator light bulb Type: Incandescent (BAU 5s)Power: 12V - 10W

Quantity: 1 RHS + 1 LHS6 Twin-filament stop/rear daylight running light Type: Incandescent (BAW 15 d)

Power:12V - 5/21WQuantity:1

7 License plate bulb Type: Incandescent (W2.1 x 9.5D)Power: 12V - 5W

Quantity: 1

Fuses

The electrical system features twelve protection

fuses plus two spare fuses. To reach the board of

fuses, undo the two screws «A» and remove the

battery cover «B».CAUTION

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


ELE SYS - 63

FUSE TABLESpecification Desc./Quantity

Fuse No. 1 Capacity:3 AProtected circuits:Oil pressure warning light, fuel gauge andreserve warning light, coolant temperature gauge, pre-instal-

lation for anti-theft device.Fuse No. 2 Capacity:7.5 A

Protected circuits:Injection load remote control, electric fansolenoid, immobilizer, live ECU.

Fuse No. 3 Capacity: 7.5 AProtected circuits:Daylight running lights, license plate light,

instrument panel lighting.Fuse No. 4 Capacity: 7.5 A

Protected circuits:Horn, turn indicators, stop lights (via sole-noid), start-up circuit.

Fuse No. 5 Capacity: 7.5 AProtected circuits:High beam light and relevant warning light

Fuse No. 6 Capacity:3 AProtected circuits:Clock, pre-installation for antitheft device.

Fuse No. 7 Capacity: 7.5 AProtected circuits: Low beam lights.

Fuse No. 8 Capacity:15 AProtected circuits:Fuses No. 5; 7 (via solenoid).

Fuse No. 9 Capacity: 15 AProtected circuits (live): Headlight solenoid switch, fuses No.

1; 2; 3; 4, high beam light in passing mode.Fuse No. 10 Capacity: 15 A

Protected circuits: Injection load (via solenoid), battery-pow-ered ECU.

Fuse No. 11 Capacity: 15 AProtected circuits: Electric fan (via solenoid)

Fuse No. 12 Capacity: 30 AProtected circuits: Battery recharge.

Fuse No. 13 Capacity: 30 AProtected circuits: Free.

Fuse No. 14 Capacity: 15AProtected circuits: Free.

Fuse No. 15 Capacity:3 AProtected circuits: Free.

Fuse No. 16 Capacity:7.5 AProtected circuits: Not used

Sealed battery

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

and recharging, if necessary.

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

the vehicle is stored in open circuit.

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

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

INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE

1) Voltage check

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

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

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

2) Constant voltage battery charge mode


ELE SYS - 64

- Constant voltage charge equal to 14.40 to 14.70V

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

- Charge time:

10 to 12 h recommended

Minimum 6 h

Maximum 24 h

3) Constant current battery charge mode

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

- Charge time: 5 hCAUTIONNEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF AFUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-HICLE OR EVEN CAUSE A FIRE.CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATECHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USEDSHORTENS THE LIFE OF THE BATTERY.IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDSTO BE RECHARGED PERIODICALLY. THE BATTERY RUNS DOWN COMPLETELY IN THECOURSE OF THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE vehicle,BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THEGROUND WIRE (BLACK) MARKED (-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL,WHEREAS THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMI-NAL MARKED WITH THE +POSITIVE SIGNWARNINGWHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURSOF RECHARGING 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.The battery should always be kept clean, especially on its top side, and the terminals should be coated

with Vaseline.

Normal bench charging must be carried out using the specific battery charger 020333Y (single) or

020334 (multiple), setting the battery charge selector to the type of battery that needs recharging (i.e.,

at a current equal to 1/10 of the battery rated capacity). Connections to the power supply source must

be implemented by connecting corresponding poles (+ to + and - to - ).

Battery installation

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


ELE SYS - 65

ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.KEEP OUT OF 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 sulphu-

ric acid.

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.


ELE SYS - 66

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

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.


ELE SYS - 67

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.

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 - 68

Connectors

INJECTION ELECTRONIC CONTROL UNIT

CONNECTOR

1. Injection telltale light (Brown-Black)

2. Not connected

3. Not connected

4. Lambda probe negative (Sky blue-Black)

5. Live power supply (Green-Red)

6. Battery-powered (Orange-Blue)

7. Not connected

8. Electric fan solenoid (Green-White)

9. Temperature sensor (Yellow-Pink)

10. Not connected

11. Lambda probe positive (Light blue-Yellow)

12. Engine stop switch (Orange)

13. Engine speed sensor positive (Red)

14. Injector negative (Yellow-Red)

15. Engine speed sensor negative (Brown)

16. Diagnosis (Orange-Black)

17. Not connected

18. Ground lead (Grey-Green)

19. Headlight solenoid (White-Black)

20. Injection load solenoid (Black-Purple)

21. Not connected

22. HV coil negative (Pink-Black)

23. Not connected

24. Starter solenoid (Blue-Green)

25. Not connected

26. Ground lead (Black)

COOLANT TEMPERATURE SENSOR CON-

NECTOR

1. Control unit (Yellow-Pink)

2. Instrument panel (Sky blue-Black)

3. Ground (Grey-Green)

4. Ground (Black)


ELE SYS - 69

INJECTOR CONNECTOR

1. Power via solenoid (Black-Green)

2. Negative from control unit (Yellow-Red)

LAMBDA PROBE CONNECTOR

1. Positive from control unit (Sky blue-Yellow)

2. Negative from control unit (Sky blue-Black)

FUEL LEVEL TRANSMITTER CONNECTOR

1. Fuel level indicator (White-Green)

2. Ground (Black)

3. Low fuel warning light (Yellow-Green)

ANTI-THEFT DEVICE PRE-INSTALLATION

CONNECTOR

1. LHS Turn indicator bulbs (Pink)

2. RHS Turn indicator bulbs (White-Blue)

3. Ground (Black)

4. Battery-powered (Blue-Red)

5. Live power supply (White-Red)

6. Not connected

7. Not connected

8. Not connected


ELE SYS - 70

FLYWHEEL CONNECTOR

1. Engine speed sensor positive (Red)

2. Engine speed sensor negative (Brown)

3. Oil pressure sensor (White-Pink)

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red)

2. Ground (Black)

3. Battery positive (Red)

4. Ground (Black)

DIAGNOSIS CONNECTOR

1. Not connected

2. Ground (Black)

3. Control unit (Orange-Black)

HV COIL CONNECTOR

1. Control unit negative (Pink-Black)

2. Power via solenoid (Black-Green)


ELE SYS - 71

INSTRUMENT PANEL CONNECTOR «A»

1. Instrument panel lighting (Yellow-Black)

2. Temperature warning light (Sky blue-Black)

3. Injection telltale light (Brown-Black)

4. Oil pressure warning light (White-Pink)

5. Clock (Blue-Red)

INSTRUMENT PANEL CONNECTOR «B»

1. Low fuel warning light (Yellow-Green)

2. Live power supply (White-Red)

3. Right turn indicator warning light (White-Blue)

4. Ground (Black)

INSTRUMENT PANEL CONNECTOR «C»

1. High beam warning light (Purple)

2. Fuel level indicator (White-Green)

3. Left turn indicator warning light (Pink)

ELECTRIC FAN CONNECTOR

1. Ground (Black)

2. Power via solenoid (Red)

IGNITION SWITCH CONNECTOR

1. Live power supply (Orange)

2. Battery-powered (Red-Black)

3. Not connected

4. Not connected


ELE SYS - 72


ELE SYS - 73

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

- Undo the two exhaust manifold fixings on the

head.

- Disconnect the lambda probe connector and re-

lease the cable harness.

- Undo the three screws fixing the silencer to the

supporting arm.

- Remove the full silencer unit.

To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.

Locking torques (N*m)Nuts fixing silencer to supporting arm 27 - 30 Nut fixing silencer to cylinder head 16 to 18

Removal of the engine from the vehicle

- Disconnect the battery

- Remove the helmet compartment.

- Remove the side fairings and the footrests.

- Remove the full silencer unit.CAUTION

Carnaby 250ie Engine from vehicle

ENG VE - 75

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.


- Remove the pipe that feeds coolant into the pump

as shown in the photograph and then empty the

system.

- Remove the engine coolant outlet pipe as indi-

cated.

- Disconnect the fuel delivery pipe from the injector

by removing the screw locking the retaining clamp.

- Disconnect the injector wiring and the throttle

body control unit wiring.

- Disconnect the coolant temperature sensor con-

nector.

- Release the cable harnesses and pipes from the

engine.

- Remove the coolant outlet pipe from the engine

as indicated.

- Remove the spark plug cap.

Engine from vehicle Carnaby 250ie

ENG VE - 76

- Remove the throttle control cables from the throt-

tle body by unscrewing the nuts highlighted in the

photograph and release the cable harness.

- Disconnect the starter motor ground lead and re-


- Disconnect the starter motor power cable and re-


- Disconnect the engine oil pressure sensor con-

nector.


ENG VE - 77

- Remove the ground lead on the engine.

- Disconnect the connectors from the flywheel wir-

ing harness.

- Disconnect the relevant cable from the retaining

clamps.

- Remove the screws indicated in the figure.

Remove the retaining bolts of the rear brake calliper.

Remove the lower screw of the left-hand shock

absorber.

Engine from vehicle Carnaby 250ie

ENG VE - 78

- Use a jack to support the vehicle properly. Re-

move the engine-swinging arm fixing pin by undo-

ing the nut and the head of the pin as shown in the

photograph.

- The engine is now free.

When refitting the engine onto the vehicle, carry out the removal operations but in reverse order and

respect the tightening torques shown in the Specifications Chapter.

- Check the engine oil level and if necessary, top it up with the recommended type.

- Fill and bleed the cooling circuit.

- Check accelerator and electric devices for correct functioning.CAUTION

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSIONPROPERLY.


ENG VE - 79

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 plastic cover first, by inserting a

screwdriver in the slotted holes. Using the clutch

housing lock wrench shown in the figure, remove

the driven pulley shaft locking nut and washer.

Specific tooling020423Y Driven pulley lock wrench

- Remove the cap/dipstick from the engine oil filling

hole.

- Remove the ten screws.

- Remove the transmission cover.N.B.WHEN YOU ARE REMOVING THE TRANSMISSION COVERYOU MUST BE CAREFUL NOT TO DROP THE CLUTCHHOUSING.

Air ductVersion 250

- Remove the transmission compartment air intake

cover shown in the picture.

Carnaby 250ie Engine

ENG - 81

- Remove the 5 screws, found on two different lev-

els, as well as the small casing.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by

means of:

Specific tooling020376Y Adaptor handle

020375Y 28 x 30 mm adaptor

020412Y 15-mm guide

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase from the inside so as

not to damage the painted surface.

- Insert the bearing in its seat.

- Refit the Seeger ring.CAUTIONUSE AN APPROPRIATE REST SURFACE TO AVOID DAM-AGING THE COVER PAINT.N.B.ALWAYS REPLACE THE BEARING WITH A NEW ONEUPON REFITTING.



020412Y 15-mm guide

Baffle roller

Engine Carnaby 250ie

ENG - 82

Plastic roller

- Check that the roller does not show signs of wear

and that it turns freely.

- Remove the special clamping screws as indica-

ted in the photograph

- Check the outer diameter of the roller does not

have defects that could jeopardise belt functioning

- For refitting, place the roller with the belt contain-

ment edge on the engine crankcase side

- Tighten the wrench to the prescribed torque.

Locking torques (N*m)Anti-flapping roller 12 - 16

Removing the driven pulley

- Remove the clutch housing and the driven pulley

assembly.N.B.THE UNIT CAN ALSO BE REMOVED WITH THE DRIVINGPULLEY MOUNTED.


ENG - 83

Inspecting the clutch drum

- Check that the clutch housing is not worn or dam-

aged.

- Measure the clutch housing inside diameter.

CharacteristicMax. value clutch housingMax. value: Ø 134.5 mm

clutch housing standard valueStandard value: Ø 134 - 134.2 mm

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 housing inspection: Limit eccentricity.Admissible limit eccentricity: 0.15 mm


ENG - 84

Removing the clutch

Fit the driven pulley spring compressor specific

tool with medium length pins screwed in position

«C» on the tool internal side.

- Introduce the adapter ring 11 with the chamfering

facing the inside of the tool.

- Fit the driven pulley unit on the tool with the in-

sertion of the 3 pins in the ventilation holes in the

mass holder support.

- Make sure that the clutch is perfectly inserted into

the adapter ring before proceeding to loosen/tight-

en the clutch nut.

- Use the special 46x55 wrench component 9 to

remove the nut fixing the clutch in place.

- Dismantle the driven pulley components (Clutch

and spring with its plastic holder)CAUTIONTHE TOOL MUST BE FIRMLY FIXED IN THE CLAMP ANDTHE CENTRAL SCREW MUST BE BROUGHT INTO CON-TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSETHE SPECIFIC TOOL TO BUCKLE.

Specific tooling020444Y011 adapter ring

020444Y009 wrench 46 x 55

020444Y Tool for fitting/ removing the drivenpulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction

material.

- The masses must not show traces of lubricants;

otherwise, check the driven pulley unit seals.N.B.UPON RUNNING-IN, THE MASSES MUST 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.

Characteristic


ENG - 85

Check minimum thickness1 mm

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.

- Remove the 4 torque server pins and pull the

pulley halves apart.

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noisi-

ness; - Replace with a new one if there are.

- Remove the retainer ring using two flat blade

screwdrivers.

- Support the pulley bushing adequately from the

threaded side using a wooden surface.

- Using a hammer and pin, knock the ball bearing

out as shown in the figure.


ENG - 86

- Support the pulley properly using the bell as

shown in the figure.

Specific tooling001467Y035 Bearing housing, out ø 47 mm

- Remove the roller bearing using the modular punch.


020456Y Ø 24 mm adaptor

020363Y 20-mm guide

Inspecting the driven fixed half-pulley

Version 250

- Measure the outside diameter of the pulley bush-

ing.

- Check the faying surface with the belt to make

sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

CharacteristicHalf-pulley minimum diameterMinimum admissible diameter: Ø 40.96 mm

Half-pulley standard diameterStandard diameter: Ø 40.985 mm

Wear limit0.3 mm


ENG - 87

Inspecting the driven sliding half-pulley

- Remove the two seal rings and the two O-rings.

- Measure the movable half-pulley bushing inside

diameter.

- Check the faying surface with the belt to make

sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

MOVABLE DRIVEN HALF-PULLEY DIMENSIONSSpecification Desc./Quantity

Wear limit 0.3 mmstandard diameter Ø 41.000 - 41.035 mm

maximum allowable diameter Ø 41.08 mm

Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the

threaded side using a wooden surface.

- Fit a new roller bearing as shown in the figure.

- For the fitting of the new ball bearing, follow the

example in the figure using a modular punch.

Fit the retainer ringWARNINGN.B.FIT THE BALL BEARING WITH THE VISIBLE SHIELDING



020424Y Driven pulley roller casing fittingpunch


ENG - 88

Refitting the driven pulley

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

able half-pulley.

- Lightly grease the O-rings «A» shown in the fig-

ure.

- Fit the half-pulley over the bushing using the spe-

cific tool.

- Check that the pins are not worn and proceed to

refitting them in their slots.

- Refit the torque server closure collar.

- Using a curved-spout grease gun, lubricate the

driven pulley unit with approximately 6 grams of

grease. Apply grease through one of the holes in

the bushing until it comes out through the hole on

the opposite side. This operation is necessary to

avoid the presence of grease beyond the O-rings.N.B.THE TORQUE SERVER CAN BE GREASED WHETHERWITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-PLACED; UNDERTAKING THE OPERATION WHEN THEBEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling020263Y Driven pulley assembly sheath

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

lybdenum disulphide; ISO-L-XBCHB2, DIN

KF2K-20


ENG - 89

Inspecting the clutch spring

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

laxed.

CharacteristicStandard length123 mm

Acceptable limit after use:118 mm

Refitting the clutch

- 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.

- 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.


ENG - 90

- 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)Clutch unit nut on driven pulley 45 to 50

Refitting the driven pulley

- Refit the clutch bell.


ENG - 91

Drive-belt

- Check that the drive belt is not damaged.

- Check the width of the belt.

Characteristic250 four stroke Transmission belt - minimumwidth19.5 mm

250 four stroke Transmission belt - standardwidth21.3 ± 0.2 mm

During the wear checks in foreseen in the sched-

uled maintenance program, you are advised to

check that the rim bottom of the toothing does not

show signs of incisions or cracking (see figure):

The rim bottom of the tooth must not have incisions

or cracking; if it does, change the belt.

Removing the driving pulley

- Turn the crankshaft until the ropes of the pulley

are on a horizontal axis

- Insert the adaptor sleeve of the appropriate tool

in the hole shown in the picture


ENG - 92

- Insert the tool in the hollows and apply the reten-

tion ring

- Bring in the ring's clamping screws while keeping

the tool to support the pulley

Specific tooling020626Y Driving pulley lock wrench

- Remove the fixing nut and the washer

- Remove the stationary drive pulley half.

Inspecting the rollers case

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner

diameter A.

- Measure outer diameter B of the pulley sliding

bushing shown in the figure.

- Check that the rollers are not damaged or worn.

- Check the guide shoes for the variator back-plate

are not worn.

- Check the wear of the roller housings and of the

belt faying surfaces on both pulley halves.

- Check that stationary driving pulley does not

show signs of abnormal wear on the grooved edge

and on the surface in contact with the belt.

- Check that the O-ring is not pushed out of shape.CAUTIONDO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristicmovable driving half-pulley bushing: StandardDiameter26.000 - 26.021 mm


ENG - 93

movable driving half-pulley bushing: Maxi-mum allowable diameterØ 26.12 mm

Sliding bushing: Standard DiameterØ 25.959 ÷ 25.98 mm

Sliding bushing: Minimum admissible diame-terØ 25.95 mm

Roller: Standard DiameterDiameter 20.5 - 20.7 mm

Roller: Minimum diameter permittedØ 20 mm

Refitting the driving pulley

- Preassemble the movable half-pulley with the

roller contrast plate by putting the rollers in their

housings with the larger support surface touching

the pulley according to the direction of rotation.

- Check that the roller contact plate does not have

flaws and is not damaged on the grooved edge.

- Mount the complete bushing unit on the crank-

shaft.

- Fit the driven pulley/Clutch/belt unit on the en-

gine.


ENG - 94

- Fit the steel shim in contact with the bushing and

the stationary drive pulley.

- Install the appropriate tool as described in the re-

moval phase.

-Tighten the nut with washer to the prescribed tor-

que.

Specific tooling020626Y Driving pulley lock wrench

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.

Specific tooling020423Y Driven pulley lock wrench

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


ENG - 95

End gear

Removing the hub cover

- Empty the rear hub through the oil drainage plug.

- Remove the 7 flanged screws indicated in the

figure.

- Remove the hub cover and its gasket.

Removing the wheel axle

- Remove the wheel axis complete with gear.

- Remove the intermediate gear.


ENG - 96

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 tooling001467Y013 Calliper to extract ø 15-mm bear-ings

Removing the wheel axle bearings

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

- Support the hub cover and expel the bearing.

By means of the appropriate tools, remove the oil

seal as in the figure.


020477Y 37 mm adaptor

020483Y 30-mm guide


020489Y Hub cover support stud bolt kit


ENG - 97

Removing the driven pulley shaft bearing

- As you need to remove the driven pulley shaft, its

bearing and oil seal, remove the transmission cov-

er as described above.

- 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

- Remove the driven pulley shaft bearing using the

modular punch.



020363Y 20-mm guide

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 bearing bearings.

- In case of faults, replace the damaged components.


ENG - 98

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface.

- Heat the crankcase cover with the specific heat

gun.

- Fit the wheel shaft bearing with a modular punch

as shown in the figure.

- Fit the Seeger ring.

- Fit the oil seal with seal lip towards the inside of

the hub and place it flush with the internal surface

by means of the appropriate tool used from the 52-

mm side.

The 52-mm side of the adapter must be turned to-

wards the bearing.



020483Y 30-mm guide


ENG - 99

Refitting the hub cover bearings

In order to fit the hub box bearings, the engine

crankcase and the cover must be heated with the

special heat gun.

- The three 15-mm bearings must be fitted using

the appropriate tools:

- The 42-mm side of the adapter must be turned

towards the bearing.

Specific tooling020150Y Air heater mounting

020151Y Air heater

020376Y Adaptor handle


020412Y 15-mm guide

N.B.

TO FIT THE BEARING ON THE COVER, ADEQUATELY SUPPORT THE COVER WITH THE STUDBOLT KIT.

- Refit the driven pulley shaft bearing with a mod-

ular punch as shown in the figure.N.B.IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROMTHE HUB INNER SIDE.



020363Y 20-mm guideN.B.

WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASEPREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.

- Refit the Seeger ring with the opening facing the bearing and fit a new oil seal flush with the crankcase

from the pulley side.


ENG - 100

Refitting the hub bearings

- Install the three shafts in the engine crankcase


Refitting the ub cover

- Fit a new gasket together with the alignment

dowels.

- Seal the gasket of the breather pipe using black

silicone sealant.

- Fit the gearbox cover, making sure the breather

pipe is in the correct position.

- Position the shorter screw that can also be rec-

ognised from the different colour as shown in the

figure.

- Fix the breather tube support by means of the

lower screw.

- Fit the remaining screws and tighten the seven

screws to the prescribed torque.

Flywheel cover


ENG - 101

Removing the hub cover

- Remove the clip fixing the sleeve to the cylinder.

- Remove the 10 clamps

- Remove the flywheel cover.

Removing the stator

- Remove the two pickup screws and the screw

holding the wiring support and the three stator

clamping screws shown in the figure.

- Remove the stator and its wiring.


ENG - 102

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-

ers to the specified torque.

Locking torques (N*m)Stator assembly screws (°) 3 to 4

Refitting the flywheel cover

- Position the spline clip on the crankshaft and ori-

ent the end as shown in the figure.

- Orient the water pump shaft with reference to the

transmission gear seat as shown in the picture.

- Refit the cover over the engine and tighten the screws to the prescribed torque.

- Carry out the removal steps but in the reverse order.CAUTION

TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-TRING DOWELS ARE PRESENT.

Locking torques (N*m)Flywheel cover screws 11 - 13

Flywheel and starting


ENG - 103

Removing the starter motor

- Remove the two screws indicated in the figure

- Take the starter motor out of its seat

Removing the flywheel magneto

- Remove the water pump shaft and crankshaft

spline clip

- Line up the two holes in the flywheel as shown in

the picture

- Screw in the guide bushing that is part of the

special flywheel stop tool on the flywheel as shown

in the picture


ENG - 104

- Insert the special flywheel stop tool on the fly-

wheel as shown in the picture

Specific tooling020627Y Flywheel lock wrench

Remove the plate indicated in the picture.

- Remove the flywheel nut with its washer

- Do up the flywheel nut by three or four threads

so that the flywheel does not fall accidentally on

extraction

- Screw the extractor onto the flywheel and extract

it as shown in the picture

Specific tooling020467Y Flywheel extractor

Inspecting the flywheel components

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

Refitting the free wheel

- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.

- Degrease the threading of the holes in the free wheel and the clamping screws.

- Apply the recommended product to the end of the screws.

Recommended productsLoctite 243 Medium strength threadlock

Medium Loctite 243 threadlock


ENG - 105

- Fit the freewheel on the magneto flywheel making

sure that the ground side is in contact with the fly-

wheel itself, i.e. with wheel Seeger ring visible.

- Lock the six clamping screws in criss-cross fash-

ion to the prescribed torque.

Locking torques (N*m)Screw fixing freewheel to flywheel 13 - 15

- Oil the free wheel "rollers".

Refitting the flywheel magneto

- Remove the freewheel retaining plate indicated

in the picture

- Remove the transmission gear and the freewheel

- Insert the free wheel on the flywheel as shown in

the picture

- Then refit the flywheel with free wheel and trans-

mission gear


ENG - 106

- Using the special flywheel lock wrench, tighten

up the flywheel fixing nut to the prescribed torque

- Refit the retention plate

Specific tooling020627Y Flywheel lock wrench

Locking torques (N*m)Flywheel nut 94 - 102

Refitting the starter motor

- Fit a new O-ring on the starter motor and lubricate

it.

- Fit the starter motor on the crankcase and lock

the 2 screws to the prescribed torque.

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

Cylinder assy. and timing system

Removing the intake manifold

Loosen the 3 screws and remove the air intake manifold.

- Upon refitting, secure to the specified torque.


ENG - 107

Removing the rocker-arms cover

- Remove the 5 screws indicated in the figure

Removing the timing system drive

- First remove the parts listed below: transmission

cover, drive pulley with belt, oil sump with spring

and by-pass piston, oil pump pulley cover, O-ring

on the crankshaft and the sprocket wheel separa-

tion 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.


ENG - 108

- Loosen the central screw on the tensioner first.

- Remove the two fixings shown in the figure.

- Remove the tensioner with its gasket.

- Remove the internal hex screw and the counter-

weight shown in the figure.

- Remove the camshaft control pulley with its

washer.

- Remove the control sprocket wheel and the tim-

ing chain.

- Remove the screws indicated in the figure, the

spacer bar and the tensioner slider.

The chain tensioner slider must be removed from

the transmission side. As regards the lower chain

guide slider, it may only be removed after the head

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


ENG - 109

Removing the cam shaft

- Remove the 2 screws and the camshaft retainer

shown in the diagram.

- Remove the camshaft.

- Remove the pins and the rocking levers from the

flywheel side holes.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 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.


ENG - 110

Removing the valves

- Using the appropriate tool fitted with an adaptor,

remove the cotters, caps, springs and valves.

- Remove the oil guards with the appropriate tool.

- Remove the lower spring supports.CAUTIONREPLACE THE VALVES IN SUCH A WAY AS TO RECOG-NISE THEIR ORIGINAL POSITION ON THE HEAD.

Specific tooling020382Y011 adapter for valve removal tool

020382Y Valve cotters equipped with part 012removal tool

020431Y Valve oil seal extractor

Removing the cylinder - piston assy.

Removing cylinder and piston

- Remove the chain guide slider.

- Remove the 4 O-rings on the stud bolts.

- Pull out the cylinder.

- Remove the cylinder base gasket.

- Remove the two stop rings, the wrist pin and the

piston.

- Remove the piston seals.CAUTIONTO AVOID DAMAGING THE PISTON, SUPPORT IT WHILEREMOVING THE CYLINDER.N.B.BE CAREFUL NOT TO DAMAGE THE SEALING RINGSDURING REMOVAL.


ENG - 111

Inspecting the small end

- Measure the internal diameter of the connecting

rod small end using an internal micrometer.N.B.REPLACE THE CRANKSHAFT IF THE DIAMETER OF THEROD SMALL END EXCEEDS THE STANDARD DIAMETEROR IT SHOWS SIGNS OF WEAR OR OVERHEATING.

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

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

Inspecting the wrist pin

- Measure the outer diameter of the gudgeon pin.

- Calculate the coupling clearance between pin

and connecting rod small end.

CharacteristicPin diameter: Standard clearance0.015 ÷ 0.029 mm

Pin diameter Standard diameter14.996 - 15.000 mm

Inspecting the piston

- Measure the diameter of the wrist pin seat on the

piston.

- Calculate the piston pin coupling clearance.

- Measure the outside diameter of the piston, per-

pendicular to the gudgeon pin axis.

- Take the measurement at 5 mm from the base in

the position shown in the figure.

- Carefully clean the seal housings.

- Measure the coupling clearance between the

sealing rings and the piston grooves using suitable

sensors, as shown in the diagram.


ENG - 112

- If the clearance is greater than that indicated in

the table, replace the piston.N.B.MEASURE THE CLEARANCE BY INSERTING THE BLADEOF THE FEELER GAUGE FROM THE SECOND SEAL RINGSIDE.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.

CharacteristicWrist pin seat on the piston: Standard diameter15.001 ÷ 15.006 mm

Diameter of the wrist pin seat on the piston:Standard clearance0.001 - 0.010 mm

piston diameter71.953 - 71.981 mm

Fitting clearanceTop piston ring - standard coupling clearance0.015 - 0.06 mm Top piston ring - maximum clear-ance allowed after use 0.07 mm Middle pistonring - standard coupling clearance 0.015 - 0.06 mmMiddle piston ring - maximum clearance al-lowed after use 0.07 mm oil scraper ring - stand-ard coupling clearance 0.015 - 0.06 mm oil scraperring - maximum clearance allowed after use0.07 mm

Inspecting the cylinder

- Using a bore meter, measure the inner cylinder

diameter at three different points according to the

directions shown in the figure.

- Check that the head coupling surface is not worn

or misshapen.

- Pistons and cylinders are classified according to

their diameter. The coupling must be made with

those of the same type (M-M, N-N, O-O, P-P).

Characteristiccylinder: standard diameter71.990 - 72.018 mm (at 33 mm)

Maximum allowable run-out:0.05 mm


ENG - 113

Inspecting the piston rings

Sealing rings

- Alternately insert the three sealing rings into the

cylinder, in the area where it retains its original di-

ameter. Using the piston, insert the rings perpen-

dicularly to the cylinder axis.

- Measure the opening (see figure) of the sealing

rings using a feeler gauge.

- If any measurements are greater than specified,

replace the piston rings.N.B.BEFORE REPLACING ONLY THE PISTON RINGS, ENSURETHAT THE CLEARANCE BETWEEN THE PISTON RINGSAND THE PISTON RING GROOVES, AND BETWEEN THEPISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANYCASE, NEW PISTON RINGS USED IN COMBINATION WITHA USED CYLINDER MAY HAVE DIFFERENT BEDDINGCONDITIONS THAN THE STANDARD.

CharacteristicTop piston ringStandard opening: 0.15 to 0.30 mm

Middle piston ringStandard opening: 0.20 ÷ 0.40 mm

scraper ringStandard opening: 0.20 ÷ 0.40 mm

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

- With opening in the position indicated on the tool

S = left

D= right

- Place the wrist pin retainer ring into position using

a punch

- Fit the pin retainer ring using the plug as shown

in the figureN.B.


ENG - 114

THE TOOL FOR INSTALLING THE RETAINER RINGS MUSTBE USED MANUALLY.CAUTIONUSING A HAMMER MIGHT DAMAGE THE STOPS' HOUS-ING.

Specific tooling020454Y Tool for fitting piston pin stops (200 -250)

Choosing the gasket

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

- Assemble a dial gauge on the specific tool.

Specific tooling020428Y Piston position check mounting

- Using an abutment plane, reset the dial gauge

with a preload of a few millimetres.

- Finally fix the dial gauge.

- Check the perfect sliding of the feeler pin.

- Install the tool on the cylinder without changing

the dial gauge position.

- Lock the tool using the original head fixing nuts.

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

sion point of the dial gauge rotation)

- Measure the deviation from the reset value.

- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to

be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-

sion ratio.

- Remove the special tool and the cylinder.N.B.

IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORYARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEATTHE TOOL INSTALLATION BY INVERTING ITS POSITION.

See alsoSlot packing system


ENG - 115

Refitting the piston rings

Fitting the sealing 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

chamfered side of the oil scraper ring should al-

ways be facing 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.

- The top piston ring on the 250 engine has an L

cross section.N.B.THE TWO PISTON RINGS ARE MADE WITH A TAPEREDCYLINDRICAL CONTACT CROSS-SECTION. THIS IS TOACHIEVE A BETTER BEDDING.

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 CYLINDERLINER.

Specific tooling020426Y Piston fitting fork


ENG - 116

020393Y Piston assembly band

Inspecting the cylinder head

- Using a trued bar and a feeler gauge check that

the cylinder head surface is not worn or distorted.

Maximum allowable run-out: 0.05 mm

- Check that the camshaft and the rocking lever pin

capacities exhibit no wear.

- Check that the cylinder head cover surface, the

intake manifold and the exhaust manifold are not

worn.

Characteristicbearing «A»Ø 12.000 - 12.018 mm

bearing «B»Ø 20.000 ÷ 20.021 mm

bearing «C»Ø 37.000 - 37.025 mm

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.

- Ensure that the camshaft control pulley chain as-

sembly and the sprocket wheel are not worn.

- If you detect wear, replace the parts or, if the

chain, sprocket wheel and pulley are worn, replace

the whole unit.

- Remove the centre screw with the washer 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.


ENG - 117

Inspecting the valve sealings

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust

valves.

- 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 valve housings

- Check the width of the imprint on the valve

seat«V» wear limit max. 1.6 mm.

- 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.

- 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.

CharacteristicValve seat wear Intake guidelimit accepted: 5.022

Valve seat wear Intake guideStandard diameter: 5.000 ÷ 5.012 mm

Valve seat wear Exhaust guideAccepted limit 5.022

Valve seat wear Exhaust guideStandard diameter: 5.000 ÷ 5.012 mm


ENG - 118

Inspecting the valves

- Measure the width of the sealing surface on the

valve seats and on the valves.

Sealing surface width: After use: Intake and ex-

haust: 1.6 mm

- If any of the sealing surfaces on the valves is

wider than the specified limit or is damaged in one

or more points, or curved, replace the valve with a

new one.CAUTIONDO NOT REVERSE THE FITTING POSITIONS OF THEVALVES (RIGHT - LEFT).

CharacteristicValve wear check Standard: Intake and ex-haust:0.99 - 1.27 mm

- Measure the diameter of the valve stems in the three positions indicated in the diagram.

- Calculate the clearance between valve and valve guide.

- Check that there are no signs of wear on the faying surface with the articulated set screw terminal.

- If no anomalies are found during the above checks, you can use the same valves. For best sealing

results, it is advisable to grind the valves. Grind the valves gently with a fine-grained lapping compound.

During the grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent

the lapping compound residues from penetrating between the valve stem and the guide (see figure).CAUTIONTO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NOLAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVESWITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.N.B.DO NOT CHANGE THE POSITIONS THE VALVES ARE FITTED IN

CharacteristicValve check Standard lengthExhaust: 94.4 mm

Valve check Standard lengthIntake: 94.6 mm

Valve check Maximum admissible clearanceExhaust: 0.072 mm

Valve check Maximum admissible clearanceIntake: 0.062 mm

Valve check standard clearanceExhaust: 0.025 to 0.052 mm


ENG - 119

Valve check standard clearance

Intake: 0.013 ÷ 0.040 mm

Valve check Minimum admissible diameter:

Exhaust: 4.95 mm

Valve check Minimum admissible diameter:

Intake: 4.96 mm

Valve check Standard diameter:

Intake: 4.972 ÷ 4.987 mm

Valve check Standard diameter:

Exhaust: 4.96 ÷ 4.975 mm


ENG - 120

Inspecting the springs and half-cones

- Check that the upper spring caps and the cotter

halves show no signs of abnormal wear.

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.

- Using the special punch, fit the four valve seal

rings.

- Fit the valves, the springs and the caps. Using

the appropriate tool with adapter, compress the

springs and insert the cotters in their seats.N.B.DO NOT CHANGE THE VALVE FITTING POSITION. FIT THEVALVE SPRINGS WITH THE REFERENCE COLOUR ONCOTTER SIDE (TURNS WITH GREATER PITCH).

Specific tooling020306Y Punch for assembling valve sealrings

020382Y Valve cotters equipped with part 012removal tool

020382Y011 adapter for valve removal tool


ENG - 121

Inspecting the cam shaft

- Inspect the camshaft for signs of abnormal wear

on the cams.

- Check the cam height.

- 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.

- 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 the rocking lever pins do not show signs

of wear or scoring.

- Measure the internal diameter of each rocking

lever.

Check there are no signs of wear on the pad from

contact with the cam and on the jointed adjustment

plate.

CharacteristicRocking lever inside diameter: Standard diam-eterDiameter 12.000 - 12.011 mm

Rocking lever pin diameter: Standard diameter


ENG - 122

Diameter 11.977 - 11.985 mm

Camshaft check: Maximum admissible axialclearance0.42 mm

Camshaft check: Standard axial clearance:0.11 - 0.41 mm

Camshaft check: Standard heightExhaust: 29.209 mm

Camshaft check: Standard heightIntake: 30.285 mm

Camshaft check: Minimum admissible diame-terBearing B diameter: 19.950 mm

Camshaft check: Minimum admissible diame-terBearing A Ø: 36.94 mm

Camshaft check: Standard diameterBearing B diameter: 19.959 ÷ 19.98 mm

Camshaft check: Standard diameterBearing A Ø: 36.95 ÷ 36.975 mm

Refitting the head and timing system components

- Refit the lower timing chain sprocket wheel on the

crankshaft, with the chamfer facing the insertion

side.

- Loop the timing chain around the sprocket on the

crankshaft.

- Fit the chain tensioner slider from the cylinder

head side.

- Fit the spacer and the screw fastener.

- Tighten the screws to the prescribed torque.

- Fit the pins and rocking levers.

- Lubricate the two rocking levers through the

holes at the top.

- Lubricate the 2 bearings and insert the camshaft

in the cylinder head with the cams corresponding

to the rocking levers.


ENG - 123

- Insert the retention plate and tighten the two

screws shown in the figure to the prescribed tor-

que.

- Refit the spacer on the camshaft.

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

centre, using the reference marks on the flywheel

and the crankcase.

- Holding this position insert the chain on the cam-

shaft control pulley.

- Insert the pulley on the camshaft while keeping

the reference 4V in correspondence with the ref-

erence mark on the head.

- Fit the counterweight and tighten the clamping

screw to the prescribed torque.

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

cam and fit the automatic valve-lifter cam to the

camshaft.

- Fit the automatic valve lifter return spring.

- During this operation the spring must be loaded

by approximately 180°.

- Fit the automatic valve-lifter retaining dish, using

the counterweight screw fastener as a reference.

- Tighten the clamping screw to the prescribed tor-

que.

- Set the tensioner cursor in the rest position.

- Fit the chain tensioner on the cylinder, using a

new gasket, and tight the two screws to the pre-

scribed torque.

- Insert the chain tensioning screw, together with

the spring and washer, tightening it to the prescri-

bed torque.

- Adjust the valve clearance.

- Fit the spark plug.

Electrode distance 0.8 mmN.B.GREASE THE END STOP RING TO PREVENT IT COMINGOUT AND FALLING INTO THE ENGINE.

Locking torques (N*m)Timing chain tensioner support screw 11 to 13Spark plug 12 to 14 Starter ground screw 7 to 8.5


ENG - 124

Timing chain tensioner slider screw 10 to 14Starter counterweight support screw 11 to 15Timing chain tensioner central screw 5 to 6Camshaft retention plate screw 4 to 6

- Refit the lower timing chain sprocket wheel on the

crankshaft, with the chamfer facing the insertion

side.

- Loop the timing chain around the sprocket on the

crankshaft.

- Fit the chain tensioner slider from the cylinder

head side.

- Fit the spacer and the screw fastener.


- Fit the pins and rocking levers.

- Lubricate the two rocking levers through the

holes at the top.


ENG - 125

- Lubricate the 2 bearings and insert the camshaft

in the cylinder head with the cams corresponding

to the rocking levers.

- Insert the retention plate and tighten the two

screws shown in the figure to the prescribed tor-

que.

- Refit the spacer on the camshaft.

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

centre, using the reference marks on the flywheel

and the crankcase.

- Holding this position insert the chain on the cam-

shaft control pulley.

- Insert the pulley on the camshaft while keeping

the reference 4V in correspondence with the ref-

erence mark on the head.

- Fit the counterweight and tighten the clamping

screw to the prescribed torque.

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

cam and fit the automatic valve-lifter cam to the

camshaft.

- Fit the automatic valve lifter return spring.

- During this operation the spring must be loaded

by approximately 180°.

- Fit the automatic valve-lifter retaining dish, using

the counterweight screw fastener as a reference.

- Tighten the clamping screw to the prescribed tor-

que.

- Set the tensioner cursor in the rest position.

- Fit the chain tensioner on the cylinder, using a

new gasket, and tight the two screws to the pre-

scribed torque.

- Insert the chain tensioning screw, together with

the spring and washer, tightening it to the prescri-

bed torque.

- Adjust the valve clearance.

- Fit the spark plug.

Electrode distance 0.8 mmN.B.


ENG - 126

GREASE THE END STOP RING TO PREVENT IT COMINGOUT AND FALLING INTO THE ENGINE.

Locking torques (N*m)Timing chain tensioner support screw 11 to 13Spark plug 12 to 14 Starter ground screw 7 to 8.5Timing chain tensioner slider screw 10 to 14Starter counterweight support screw 11 to 15Timing chain tensioner central screw 5 to 6Camshaft retention plate screw 4 to 6


ENG - 127

Refitting the rocker-arms cover

- Refit the cylinder head cover and tighten the 5

clamping screws to the prescribed torque.

- Make sure the gasket is positioned properly.

Locking torques (N*m)Tappet cover screws 6 - 7 Nm

Refitting the intake manifold

- Fit the intake manifold and do up the three

screws.

Locking torques (N*m)Intake manifold screws 11 to 13

Crankcase - crankshaft

Splitting the crankcase halves

- 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 appropriate tool

dial gauge.

- Upper clearances are an indication of wear on

the surfaces of the crankshaft casing support.

- Remove the 10 crankshaft coupling screws.

- Separate the crankcase while keeping the crank-

shaft in one of the two halves of the crankcase.

- Remove the crankshaft.

- Remove the half crankcase coupling gasket.


ENG - 128

- Remove the two screws and the internal shield


- 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.

- Check the radial clearance on the connecting rod.

-Check the surfaces that limit the axial free-play

are not scored and measure the width of the crank-

shaft between these surfaces, as shown in the

diagram.

- 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.

- Check the diameters of both the bearings of the

crankshaft in accordance with the axes and surfa-

ces shown in the figure. The half-shafts are clas-

sified in two categories Cat. 1 and Cat. 2 as shown

the chart below.CAUTIONTHE CRANKSHAFT CAN BE REUSED WHEN THE WIDTHIS WITHIN THE STANDARD VALUES AND THE SURFACESSHOW NO SIGNS OF SCORING.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.CAUTIONKEEP THE CRANKSHAFT IN ONE OF THE TWO HALVESOF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAILTO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLYFALL.N.B.WHEN MEASURING THE WIDTH OF THE CRANKSHAFT,MAKE SURE THAT THE MEASUREMENTS ARE NOTMODIFIED BY THE RADIUSES OF FITTINGS WITH THECRANKSHAFT BEARINGS.

Specific tooling020262Y Crankcase splitting plate


CharacteristicAxial crankshaft/crankcase clearance: Stand-ard clearance


ENG - 129

0.15 - 0.40 mm (when cold)

Axial connecting rod - crankshaft clearanceStandard clearance0.20 to 0.50 mm

Radial connecting rod - crankshaft clearanceStandard clearance0.036 to 0.054 mm

Width of crankshaft with integral washers:standard measurements55.67 to 55.85 mm

Crankshaft bearings: Standard diameter: Cat.128.994 ÷ 29.000

Crankshaft bearings: Standard diameter: Cat.229.000 ÷ 29.006

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


ENG - 130

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

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 when handling the oil pump com-

partment and the oil ducts, the by-pass duct, the

main bushings and the cooling jet on the trans-

mission 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.

- 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.


ENG - 131

- Inspect the coupling surfaces on the crankcase

halves for scratches or deformation, taking partic-

ular care with the cylinder/crankcase surfaces and

the crankcase halves surfaces.

- Defects in the crankcase coupling gasket be-

tween the crankcase halves or the mating surfaces

shown in the diagram, could cause a drop in the

oil pressure lubricating the main bushings and

connecting rod.

- 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.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.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.

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure 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 lubrication

whereas the other is solid.

CharacteristicLubrication pressure

3.5 to 4 bar


ENG - 132

- 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

shown in the figure.

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

See alsoCrankcase - crankshaft - connecting rod

Refitting the crankcase halves

- Fit the internal shield by locking the two screws

to the prescribed torque.

- Fit the oil filter fitting and tighten it to the prescri-

bed torque.

- Position the oil pre-filter element as shown in the

picture.

- Place a new gasket on one of the crankcase

halves, preferably on the transmission side, to-

gether with the alignment dowels.

- Lubricate the main bushings and insert the crank-

shaft in the transmission side crankcase half.

- Reassemble both crankcase halves.

- Fit the 10 screws and tighten them to the speci-

fied torque.

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

- Insert the filter on the engine with the relative cap.

Tighten to the prescribed torque.

Locking torques (N*m)Internal engine crankcase bulkhead (transmis-sion-side half shaft) screws 4 to 6 Engine-crank-case coupling screws 11 to 13 Oil filter oncrankcase fitting 27 to 33 Engine oil drainageplug/ mesh filter 24 to 30


ENG - 133

Studs

Check that the stud bolts have not worked loose

from their seat in the crankcase.

Check the depth of stud bolt driving with a gauge,

as indicated in the picture. If it varies significantly

from the driving depth indicated, it means that the

stud bolt has yielded.

In this case, replace it.


ENG - 134

By working on two fitted cylinder head fixing nuts,

nut and lock nut, as shown in the picture, remove

the stud bolt from its seat.

Clean the threaded seat on the carter thoroughly.

Refit a new stud bolt and apply the special product

on the threading crankcase side.

Tighten up to the depth of the driving indicated.

Recommended productsLoctite Quick Set Loctite 270 high strengththreadlockLoctite 270 high strength threadlock

Lubrication

Conceptual diagrams

LUBRICATION CIRCUIT


ENG - 135


ENG - 136

Oil pressure check

- Disconnect the electrical minimum oil pressure

connection and remove the switch.

- Check that the oil pressure reading is between

0.5 and 1.2 atm with the engine idling at 1650 rpm

and the oil at the required temperature (wait for at

least one electric ventilation).

- Check that the oil pressure is between 3.2 and

4.2 atm with the engine running at 6000 rpm and

the oil at the required temperature.

- Remove the appropriate tools once the meas-

urement is complete, refit the oil pressure switch

and washer, tightening it to the specified 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.

CharacteristicOil pressureMinimum pressure admitted at 6000 rpm: 3.2 atm.

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

Crankshaft oil seals


ENG - 137

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.

Specific tooling020622Y Transmission-side oil seal punch

- Screw the threaded bar onto the base of the tool

and extract the oil seal.


Refitting

- Always use a new oil seal upon refitting

- Prepare the new oil seal by lubricating the sealing

lip.

- Preassemble the oil seal with the appropriate tool

by positioning the screws.

- Insert the sheath over the crankshaft.

- Insert the tool with the oil seal on the crankshaft

until it comes into contact with the crankcase.

- Insert the adaptor bushing of the tool in the hole

on the crankcase.


ENG - 138

- Orientate the oil seal by inserting the bracket

which is part of the appropriate tool.

- Tighten the threaded bar onto the crankshaft as

far as it will go.

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

can see the end of the oil seal driving stroke

- Remove all the tool components following the

procedure but in reverse orderCAUTIONDO NOT LUBRICATE THE KEYING SURFACE ONTO THEENGINE CRANKCASE.CAUTIONORIENT 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.CAUTIONFAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TOTHE WRONG TENSIONING OF THE OIL PUMP CONTROLCHAIN.


Oil pump


ENG - 139

Removal

- Undo the two clamping screws in the figure and

remove the cover over the pump control sprocket.

- Block the rotation of the oil pump control pulley

with a screwdriver inserted through one of its two

holes.

- Remove the central screw with cup washer, as


- Remove the chain with the crown.

- Remove the control sprocket wheel with relative

O-ring.

- Remove the oil pump by undoing the two screws

in the figure.

- Remove the oil pump seal.N.B.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

- Check the clearance between the rotors in the

position shown in the diagram using a feeler

gauge.

Measure the distance between the outer rotor and

the pump body (see figure).

- Check the axial clearance of the rotors using a

trued bar as shown in the figure.

CharacteristicAxial rotor clearanceLimit values admitted: 0.09 mm

Distance between the outer rotor and the pumpbodyAdmissible limit clearance: 0.20 mm

Distance between the rotorsAdmissible limit clearance: 0.12 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 unit.

- Fit the pump cover in the position that permits the

crankcase clamping screws to be aligned.

- Make sure the gasket is positioned properly and

refit the pump on the engine crankcase. The pump

can only be fitted in one position. - Tighten the

screws to the prescribed torque.


ENG - 141

- Fit the sprocket wheel with a new O-ring.

- Fit the chain.

- Fit the central screw and the cup washer. Tighten

to the prescribed torque.

-Fit the oil pump cover, by tightening the two

screws to the prescribed torque.N.B.FIT THE CUP WASHER SO THAT ITS OUTER RIM TOUCH-ES THE PULLEY. MAKE SURE THAT THE PUMP TURNSFREELY.

Locking torques (N*m)Screws fixing oil pump to the crankcase 5 to 6Oil pump command sprocket screw 10 to 14 Oilpump cover screws 0.7 - 0.9

Removing the oil sump

- Remove the oil filler plug, the transmission cover,

the complete driving pulley assembly with belt and

the sprocket wheel, as described in the "Trans-

mission" chapter.

- Drain the oil as described above.

- Remove the 7 screws, shown in the diagram, and

the 2 rear brake fluid pipe fixing brackets.

- Remove the screw, the by-pass piston, the gas-

ket and the centring dowels shown in the figure.


ENG - 142

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

Refitting the oil sump

- Refit the by-pass piston in its housing.

- Insert the pressure-regulating spring.

- Fit a new sump seal.

- Refit the two centring dowels.

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

the appropriate recess machined into the inside of

the sump.

- Refit the rear brake cable brackets and the

screws in the reverse order from which they were

removed.


- 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

chapter "Crankcase and Crankshaft", regard-

ing lubrication of the crankshaft and connect-

ing rod

Locking torques (N*m)Oil sump screws 10 to 14


ENG - 143

INDEX OF TOPICS

INJECTION INJEC

COMPONENT LAYOUTSpecification Desc./Quantity

1 Battery 12V-14Ah2 Fuel injector3 Throttle body and electronic injection control unit (MIU)4 Diagnostics socket connector5 Fuel pump6 Water temperature sensor7 Injection load solenoid8 HV coil9 Speed sensor10 Lambda probe11 Electric fan solenoid

MIU injection system

This vehicle is fitted with an integrated injection and ignition system.

Injection is indirect in the manifold through an electro-injector.

The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the

crankshaft (24-2 teeth) and pick-up sensor.

Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further

corrections are made according to the following parameters:

- Coolant temperature.

- Intake air temperature

- Lambda probe

Carnaby 250ie Injection

INJEC - 145

The system implements an idle feeding correction with cold engine through a Stepper motor on a by-

pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening

time, thereby ensuring the idle steadiness and the proper combustion.

In all conditions of use, mixture preparation is managed by modifying the injector opening time.

The fuel system pressure is kept constant based on the ambient pressure.

The fuel supply circuit consists of:

- Fuel pump

- Fuel filter

- Injector

- Pressure regulator

The pump, the filter and the regulator are placed inside the fuel tank on a single support.

The injector is connected by a pipe with fast-release fitting. The pressure regulator is located at the

beginning of the circuit.

The fuel pump is controlled by the MIU control unit; this ensures safety of the vehicle.

The ignition circuit consists of:

- HV coil

- HV cable

- Shielded cap

- MIU control unit

- Spark plug

The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only

in the compression phase) at the same time.

The MIU injection-ignition system controls engine functions by means of a pre-set program.

Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to

reach a service station.

Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the

control circuits:

- Fuel pump

- HV coil

- Injector

Injection Carnaby 250ie

INJEC - 146

The control unit is provided with a self-diagnosis

system connected to an indicator light in the in-

strument panel.

Failures are detected and restored by the diag-

nostic tester.

In any case, when the fault is no longer present,

the data storage is automatically cleared after 16

cycles of use (cold start, running at regular engine

temperature, stop).

The diagnostic tester is also required to adjust the

idle mixture.


The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide

further safety for the vehicle.

PrecautionsTroubleshooting hints

1 A MIU failure is more likely to be due to the connections than to the components.

Before troubleshooting the MIU system, carry out the following checks:

A: Electrical power supply

a. Battery voltage

b. Blown fuse

c. Remote controls

d. Connectors

B: Chassis ground

C: Fuel system

a. Broken fuel pump

b. Dirty fuel filter

D: Ignition system

a. Faulty spark plug

b. Broken coil

c. Broken shielded cap


INJEC - 147

E: Intake circuit

a. Dirty air filter

b. Dirty by-pass circuit

c. Faulty Stepper motor

F: Other

a. Incorrect distribution timing

b. Wrong idle mixture

c.Incorrect reset of the throttle valve position sensor

2 MIU system faults may be caused by loose connectors. Make sure that all connections have been

correctly made.

Check the connections as follows:

A check that the terminals are not bent.

B check that the connectors have been properly connected.

C check whether the malfunction can be fixed by shaking the connector slightly.

3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,

install the original control unit again and check if the fault occurs again.

4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instru-

ments that are not suitable might damage the MIU central control unit. Use instruments with definitions

over 0.1V and 0.5 W , the precision must be greater than 2%.

Troubleshooting hints

1 A MIU failure is more likely to be due to the connections than to the components.

Before troubleshooting the MIU system, carry out the following checks:

A: Electrical power supply

a. Battery voltage

b. Blown fuse

c. Remote controls

d. Connectors

B: Chassis ground

C: Fuel system

a. Broken fuel pump

b. Dirty fuel filter

D: Ignition system

a. Faulty spark plug

b. Broken coil

c. Broken shielded cap

E: Intake circuit

a. Dirty air filter


INJEC - 148

b. Dirty by-pass circuit

c. Faulty Stepper motor

F: Other

a. Incorrect distribution timing

b. Wrong idle mixture

c.Incorrect reset of the throttle valve position sensor

2 MIU system faults may be caused by loose connectors. Make sure that all connections have been

correctly made.

Check the connections as follows:

A check that the terminals are not bent.

B check that the connectors have been properly connected.

C check whether the malfunction can be fixed by shaking the connector slightly.

3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,

install the original control unit again and check if the fault occurs again.

4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instru-

ments that are not suitable might damage the MIU central control unit. Use instruments with definitions

over 0.1V and 0.5 W , the precision must be greater than 2%.

Terminals setup


INJEC - 149

TERMINAL LAYOUTSpecification Desc./Quantity

1 Injection telltale light2 -3 -4 Lambda probe negative5 Live supply6 Battery-powered7 -8 Electric fan solenoid9 Water temperature sensor10 -11 Lambda probe positive12 engine stop switch13 Engine speed sensor (+)14 Fuel injector15 Engine speed sensor (-)16 Diagnostics socket output17 -18 Side stand19 Headlight solenoid20 Injection load solenoid21 -22 HV coil23 -24 Start up enabling25 -26 Ground lead

EMS circuit diagram

SYSTEM DIAGRAMSpecification Desc./Quantity

1 Injection ECU


INJEC - 150

Specification Desc./Quantity2 Diagnostics socket connector3 Water temperature sensor4 engine stop switch5 Fuel pump6 Fuel injector7 Lambda probe8 HV coil9 Speed sensor10 Electric fan11 Electric fan solenoid12 Fuse 15A13 Fuse 15A14 Injection load solenoid15 Start-up solenoid16 Battery 12V-14Ah17 Fuse 15A18 Ignition switch contacts19 Headlight solenoid20 Fuse 3 A21 Fuse 7.5 A22 Water temperature gauge23 "WARNING" light

Troubleshooting procedure

Engine does not start

ENGINE DOES NOT START IF ONLY PULLEDPossible Cause Operation

Presence of faults detected by the self diagnosis Pump relayHV coilInjector

Revolution timing sensorFuel system Fuel in the tank

Fuel pump activationFuel pressure (low)

Injector capacity (low)Power to the spark plug Shielded spark plug cap HV coil (secondary insulation)

Parameter reliability Coolant temperatureDistribution timing - injection ignition

Intake air temperatureEnd of compression pressure End of compression pressure

Starting difficulties

ENGINE START-UP PROBLEMSPossible Cause Operation


Revolution timing sensorAir temperature

Coolant temperatureStart-up speed Starter motor and solenoid

BatteryGround connections

End of compression pressure End of compression pressurePower to the spark plug Spark plug

Shielded capHV coil


INJEC - 151

Possible Cause OperationSpeed-timing sensor

Ignition advanceFuel system Fuel pressure (low)

Injector capacity (low)Injector sealing (poor)

Correctness of the parameters Coolant temperatureStepper throttle valve position intake air temperature (steps

and actual opening)Cleaning of the auxiliary air pipe and throttle valve; air filter ef-

ficiency

Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOWPossible Cause Operation



Coolant temperatureIgnition efficiency Spark plug

Ignition timingCorrectness of the parameters Throttle valve position sensor

StepperCoolant temperature sensor

Intake air temperature sensorIntake system cleaning Air filter

Diffuser and throttle valveAdditional air pipe and Stepper

Intake system sealing (infiltrations) Intake manifold - headThrottle body - manifold

Intake sleeveFilter box

Fuel system (low pressure) Fuel pumpPressure regulator

Fuel filterInjector capacity

Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGHPossible Cause Operation



Coolant temperatureIgnition efficiency Ignition timing

Correctness of the parameters Throttle valve position sensorStepper

Coolant temperature sensorIntake air temperature sensor






INJEC - 152

Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATINGPossible Cause Operation



Coolant temperatureLambda probe

Correctness of the parameters Throttle valve position sensorStepper

Coolant temperature sensorIntake air temperature sensor





Exhaust system sealing (infiltrations) Manifold - headManifold - silencersilencer welding

Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPENPossible Cause Operation

Intake system cleaning Air filterDiffuser and throttle valve

Additional air pipe and StepperIntake system sealing Intake sleeve

Filter boxIgnition system Spark plug wear check

Parameter reliability Throttle valve position signalCoolant temperature indicator

Intake air temperature indicatorIgnition advance

TPS reset successful TPS reset successfulPresence of faults detected by the self diagnosis Pump relay

HV coilInjector



Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-ANCE ON PICKUP

Possible Cause OperationPresence of faults detected by the self diagnosis Pump relay

HV coilInjector

Revolution timing sensor


INJEC - 153

Possible Cause OperationAir temperature


Spark plug power supply Spark plugShielded cap

HV cableHV coil

Intake system Air filterFilter box (sealing)

Intake sleeve (sealing)Parameter reliability Throttle valve position signal

Coolant temperature indicatorIntake air temperature indicator

Ignition advanceFuel system Fuel level in the tank

Fuel pressureFuel filter

Injector capacity

Engine knocking

PRESENCE OF KNOCKING (COMBUSTION SHOCKS)Possible Cause Operation




Ignition efficiency Spark plugParameter reliability Throttle valve position signal

Coolant temperature indicatorIntake air temperature indicator

Ignition advanceIntake system sealing Intake sleeve

Filter boxTPS reset successful TPS reset successful

Fuel system Fuel pressureFuel filter

Injector capacityFuel quality

Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness

Fuel supply system

The fuel system circuit includes the electric pump, the filter, the pressure regulator, the electro-injector

and the fuel delivery pipes.

The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through

the filter.

The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.


INJEC - 154

Removing the butterfly valve

Remove the fuel piping clamping screw indicated

in the figure.

Remove the fast-release fitting from the injector

support.


INJEC - 155

Remove the injector connector.

Remove the three screws fixing the manifold to the

cylinder head and the clip fixing the throttle body

to the manifold.

Remove the MIU ECU connector.

Remove the clip fixing the throttle body to the air

cleaner bellows.


INJEC - 156

Remove the gas command fitting as indicated in

the picture

Refitting the butterfly valve

To refit, perform the operations in the reverse or-

der from the removal operations being careful to

position the clip fixing the throttle body to the air

filter bellows at 45° as shown in the photograph.


INJEC - 157

Pump supply circuit

INJECTION LOADSSpecification Desc./Quantity

1 Battery 12V-14Ah2 Fuse 15A3 Fuse 15A4 Ignition switch contacts5 Fuse 7.5 A6 Injection load solenoid7 Fuel pump8 HV coil9 Fuel injector10 Lambda probe


INJEC - 158

Specification Desc./Quantity11 Electric fan solenoid

When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine

starts, in the presence of rpm timing signal the pump is continuously supplied.

ELECTRICAL DATA

• Pump winding resistance ~ 1.5 Ohm

• Input current during normal functioning 1.4 to 1.8 A

• Input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel

pressure control, choking the circuit on the return pipe)

Check that 15A fuse N° 10 for injection load oper-

ates properly.

Check that the 7.5A fuse No. 2 for live control unit

power works properly.

Check the efficiency of the injection load solenoid.

Check the resistance of the energising coil be-

tween pins 86 and 85: 40 to 80 Ohm

Apply a voltage of 12V to pins 86 and 85; make

sure that there is continuity between pins 30 and

87 of the solenoid.


INJEC - 159

Check the power supply line of the injection load

solenoid energising coil: after switching to «ON »,

make sure there is battery voltage, for 2 seconds,

between the Red-Green cable and the Black-Pur-

ple cable of the solenoid base. If there is not, check

the continuity of the Red-Green cable between the

fuse box and the solenoid base and of the Black-

Purple cable between pin 20 of the control unit and

the solenoid base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (SOLENOIDS, CON-TROL UNIT, FUSES ETC.).

Check if there is steady voltage between the Or-

ange-Blue cable of the solenoid base and the

ground lead. If there is not, check the continuity of

the Orange-Blue cable between the fuse box (15A

fuse No. 10) and the solenoid base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (SOLENOIDS, CON-TROL UNIT, FUSES ETC.).

After switching to «ON», check that there is battery

voltage, for about 2 seconds, between the Black-

Green cable of the pump connector and the

ground lead with the pump connector disconnec-

ted. Otherwise, check the continuity of the Black-

Green cable between the pump connector and the

solenoid base.

Check the efficiency of the ground line of the fuel

pump by measuring the continuity between the


INJEC - 160

pump connector black cable, system side, and the

ground.

If, when switching to «ON», the pump continues to

turn after 2 seconds of activation, check, with the

control unit disconnected and the injection load

solenoid disconnected, that the Black-Purple ca-

ble (pin 20 on the interface wiring) is insulated from

the ground.

Specific tooling020331Y Digital multimeter

Circuit leak test

Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.

Check during regular operation by placing the ap-

propriate tool between the pump and the injector.

With the battery voltage> 12 V check that the fuel

pressure is 2.5 BAR and that the input current is

1.4 to 1.8 A

With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe

equipped with the pressure gauge of the appropriate tool. Get a graded burette with a flow rate of

approximately 1 L. Rotate the pump using the active diagnoses of the palm top computer. Using a pair

of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5 BAR.

Check that within 15 seconds the pump has a flow rate of approx. 110 cm³.

Specific tooling020480Y Petrol pressure check kit


INJEC - 161

Fuel filter check

Disconnect the terminals from the electric pump

Remove the screw shown in the picture

Remove the clip fixing the piping to the filter shown

in the picture

Separate the lower part of the pump mounting as



INJEC - 162

Remove the filter from the pump mounting


INJEC - 163

Inspecting the injector circuit




INJEC - 164


Check the resistance at the injector ends: 14.5 ± 5% Ohm


ates properly.








87 of the solenoid.


INJEC - 165















With the control unit and the injector disconnected,

check the continuity of the Red-Yellow cable be-

tween pin 14 of the interface wiring and the injector

connector

Switch to «ON» and check if there is voltage, with

injector disconnected and control unit connected,

between the Black-Green cable of the injector con-

nector and the ground lead


INJEC - 166

With injector disconnected and the injector load

solenoid disconnected, check the continuity of the

Black-Green cable between the injector connector

and solenoid base.

Inspecting the injector hydraulics

To carry out the injector check, remove the intake

manifold by removing the three clamping screws

at the head and the clip connecting the control unit

to the manifold.

Install the appropriate tool for checking fuel pres-

sure and position the manifold over a container

graduated by at least 100 cm³. Connect the injec-

tor with the cable making up part of the supply for

the injection tester. Connect the clamps of the ca-

ble to an auxiliary battery. Activate the fuel pump

with the active diagnosis. Check that, within fifteen

seconds, approximately 40 cm³ of fuel is dis-

pensed with an adjustment pressure of approxi-

mately 2.5 BAR.

Specific tooling020480Y Petrol pressure check kit


INJEC - 167

Proceed with the injector seal test.

Dry the injector outlet with a blast of compressed

air. Activate the fuel pump. Wait for one minute,

making sure there are no leaks coming from the

injector. Slight oozing is normal.

Value limit = 1 drop per minute

Components location

COMPONENT LAYOUTSpecification Desc./Quantity

1 Battery 12V-14Ah2 Fuel injector3 Throttle body and electronic injection control unit (MIU)4 Diagnostics socket connector5 Fuel pump6 Water temperature sensor7 Injection load solenoid8 HV coil9 Speed sensor10 Lambda probe11 Electric fan solenoid


INJEC - 168

Tachometer

With wiring disconnected from the control unit and

connected to the system, check that the sensor

resistance between pins 13 - 15 is between 100

and 150 Ohm at an engine temperature of approx-

imately 20°

Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring connected

to the control unit and system try to start up the engine and check that the voltage between pins 13 and

15 is around 2.8 V

With the interface cable harness disconnected

from the control unit, check continuity between pin

13 and the red cable of the engine speed sensor

connector and between pin 15 and the brown ca-

ble of the engine speed sensor connector


INJEC - 169

With the interface wiring and rpm sensor connec-

tor disconnected from the control unit, check that

the Red and Brown cables (pin 13 - 15) are isola-

ted from each other and insulated from the ground.

Specific tooling020481Y Control unit interface wiring



INJEC - 170

HT coil




INJEC - 171


The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.

The control unit manages two important parameters:

- Ignition advance

This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure

With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'.

- Magnetisation time

The coil magnetisation time is controlled by the control unit. The ignition power is increased during the

engine start-up phase.

The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during

compression.



ates properly.








87 of the solenoid.


INJEC - 172















Check there is voltage between pins 22 and 26 of

the interface wiring for around two seconds when

switching to «ON».


INJEC - 173

Check the resistance of the primary coil between

pin 22 of the interface wiring and the green black

cable of the injection load solenoid base with the

control unit disconnected and the solenoid discon-

nected.

Electric characteristicHV coil resistance primary value:~ 0.9 Ω

Coolant temperature sensor

TEMPERATURE SENSORSpecification Desc./Quantity

1 Instrument panel2 Electronic control unit


INJEC - 174

Specification Desc./Quantity3 Water temperature sensor

With the connector on the control unit side discon-

nected and the coolant temperature sensor con-

nector connected, check that the resistance val-

ues between pin 9 and the ground lead correspond

with the engine temperature.

20° = 2500 ± 100 Ω

80° = 308 ± 6 Ω



nector disconnected, check the insulation be-

tween the Yellow-Red cable and the ground

connection.



nector disconnected, check the continuity be-

tween pin 9 of the interface cable harness and the

Yellow-Pink cable of the connector.

Specific tooling020481Y Control unit interface wiring


Zeroing the throttle

Resetting the throttle valve position signal (TPS reset)

The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.

Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of

air under pre-set reference conditions.

Pre-calibration ensures optimal air flow to control idling.

This regulation must not be tampered with in any way whatsoever.

The injection system will complete the management of the idling through the Stepper motor and the

variation of the ignition advance.

The throttle body after the pre-calibration has an opened valve with an angle that can vary depending

on the tolerances of the machining of the pipe and the valve itself.

The valve position sensor can also assume various fitting positions. For these reasons the mV of the

sensor with the valve at idle can vary from one throttle body to another.

To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to

match the throttle body with the control unit following the procedure known as TPS resetting.


INJEC - 175

With this operation we inform the control unit, as the starting point, of the mV value corresponding to

the pre-calibrated position.

To reset, proceed as follows.

Connect the diagnostic tester.

Switch to «ON».

Select the functions of the diagnostic tester on

«TPS RESET».


Make sure that the throttle valve with the control is

supporting the stop screw.

Guaranteeing that this position will be kept, send

a confirmation for the TPS reset procedure.


INJEC - 176

Reset should be performed in the following cases:

- on first fitting.

- if the injection control unit is replaced.N.B.

THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODYBECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THEAIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.

Given that the TPS resetting is also done when the

control unit is replaced, place the control unit - filter

box bellows at 45° during the refitting operation as


Lambda probeSIGNAL CONTROL

Install the electronic control unit interface wiring.

Start the engine and warm up until the electric fan

switches on.

Use an analogue multimeter with a direct voltage

scale measuring down to 2 V.

Place the tips of the multimeter between pins 4 (-)

and 11 (+)


INJEC - 177

With the engine running at idle speed, check that

the voltage oscillates between 0V and 1V

With the throttle valve completely open, the volt-

age is approx. 1V.

During the closing phase, the voltage is approx.

0V.

If the voltage remains constant, the sensor may be

damaged. Remove the sensor and check that

there are no oil or carbon deposits inside it..


INJEC - 178

INDEX OF TOPICS

SUSPENSIONS SUSP

Front

Removing the front wheel

- Remove the front brake calliper.

- Loosen the wheel axle lock-nut.

- Loosen the two wheel axle safety screws on the

fork leg, on the brake calliper side.

- Pull out the wheel axle.

Suspensions Carnaby 250ie

SUSP - 180

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 plastic cover on the tone wheel side

to avoid damage by loosening the 5 fixing screws.

- Remove the two bearings on the odometer drive

side using the pliers 14 or 34 and the bell detail 9.

- Remove the internal spacer.

* Either tool can be used.

- 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,

15 mm adaptor and guide) from the odometer drive

side to permit the removal of the brake disc side

bearing and the spacer bushing.



020412Y 15-mm guide

Carnaby 250ie Suspensions

SUSP - 181

- Heat the bearing seat on the side the brake disc

with the heat gun.

- 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

- Turn over the wheel and insert the internal spacer

with the part fitted with the Seeger ring facing the

bearing on the brake disc side installed previously.


SUSP - 182

- Heat the bearing seat on the odometer drive side

with the heat gun.

- Insert the two bearings using the punch consist-

ing of adaptor handle, 32x35 mm adaptor and 15

mm guide, and drive it up to the stop.



020412Y 15-mm guide

- Refit the cap and tighten the five fixing screws.

Refitting the front wheel

- Grease the wheel axle, then install it from the

tone wheel side and install the tone wheel proper-

ly.

- Tighten the wheel axle nut to the prescribed tor-

que.N.B.TAKE CARE NOT TO DAMAGE THE ODOMETER DRIVE.FOR THE SAKE OF SAFETY, OFFSET THE INTERNALSTOP FROM THE STOP OF THE TONE WHEEL BY 90°.


SUSP - 183

- Tighten the two safety screw on the leg to the

prescribed torque.

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

Handlebar

Removal

- Remove the front handlebar cover.

- Remove the rear handlebar cover.

- Remove the fixing pin.

- Remove the handlebar resting it on the shield

back plate.

If you want to remove the fork, proceed as follows:


- Remove the rear handlebar cover by disconnect-

ing the odometer cable and the instrument panel

connectors.

- Remove the brake pumps.

- Release the throttle control.

- Remove the fixing pin.

- Remove the handlebar.


SUSP - 184

Refitting

- Install the handlebar 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 steer-

ing tube to the prescribed torque.

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

(*) Lubricate the nuts with engine oil before installation

Front fork

Removal

- With the 10 mm hexagonal wrench for internal

parts loosen the upper stem closing cap.

- Loosen the stem support clamp and remove fork

leg and stem.


SUSP - 185

- Remove the first spring featuring 15 turns.

- Remove the spring support plate.

- Remove the second spring featuring 21 turns.

- Drain the oil.

- Separate the stem from the leg by removing the

screws with copper washer shown in the figure. To

prevent the rotation of the pumping insert a 12 mm

hexagonal wrench for internal parts in the stem.

- Remove the dust gaiter ring using a screwdriver


- Remove the oil seal safety lock using a screw-

driver.

- Using the appropriate special tool, remove the oil

seal.

- Insert the tie rod complete with cable into the oil

seal.

- Insert in sequence the two half-rings per Ø 35-

mm stems.

- Keeping the tie rod in vertical position, insert the

bell for the Ø 35 mm stems.

- Insert the nut in the thread and take out the oil

seal

Specific tooling020487Y Fork oil seal extractor

Overhaul

SPRING LENGTH CHECKSpecification Desc./Quantity

Standard length 15-turn spring: 116.3 + 2-1 mm


SUSP - 186

Specification Desc./QuantityStandard length 21-turn spring: 175.7 + 2-1 mm

Allowable limit after use: 15-turn spring: 114.3 mmAllowable limit after use: 21-turn spring: 173.7 mm

Check there are no signs of wear or seizing up between the stem and the leg. Otherwise, replace the

damaged parts.

CharacteristicMaximum fork leg diameter

35.10 mm

Minimum stem diameter

34.90 mm

Check that the oil holes on the pumping element

are not clogged. - Check that the circlip shows no

sign of damage.

Refitting

- Insert a new oil seal with the special adaptor han-

dle and take it to the stop.

- Insert the safety clip.

- Insert a new dust gaiter.


SUSP - 187

- Insert the contrast spring into the pumping mem-

ber.

- Insert the pumping element inside the stem.

- Insert the pumping element guide bushing at the

lower stem end.

- Insert the stem in the leg being careful not to let

the stem guide bushing come out.

- Inset and screw up the copper washer to the pre-

scribed torque. To prevent the pumping member

from rotating, insert a 12-mm Allen key into the

stem.

- Pour 133 ± 3 cm³ of oil into the stem.

Recommended productsAGIP FORK 7.5 W Fork oilGrade 7.5 W

- Fit the 21-turn spring, the support plate with the

chamfer facing upwards and afterwards the 15-

turn spring.

- Insert the stem into the fork clamp.

- Do up the clamp once to allow the stem closure

upper cap to be tightened.

- Check that the seal ring on the cap is in good

working order, then tighten the cap on the stem to

the prescribed torque.


SUSP - 188

- Loosen the fork clamp screws and ensure the

stem closure cap is fitted properly on the clamp.

- Tighten the clamp screws to the prescribed tor-

que.



Locking torques (N*m)Fork clamp screws 20 to 25 Stem upper cap 15 ÷30 Lower screw with copper washer 25 - 35

Steering column

Removal

- Remove the front wheel.

- Remove the front mudguard

- Remove the front brake calliper

- Remove the front and rear handlebar covers.

- Remove the pin mounting the handlebar to the

steering tube.

- Remove the handlebar and rest it on the shield

back plate.

Using the special tool, loosen and remove the up-

per ring nut, the spacer washer and the counter-

lock ring.

- Extract the fork.N.B.TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENTIT FROM COMING OFF ABRUPTLY

Specific tooling020055Y Wrench for steering tube ring nut


SUSP - 189

Refitting

- Fit the lower steering bearing on the steering

tube.

- Fit the fork together with the lower steering bear-

ing on the headstock and hold it so that it does not

fall.N.B.LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITHRECOMMENDED GREASE BEFORE USE.

Recommended productsAGIP GREASE PV2 Grease for steering bear-ings, bolt seatings for swinging arms and fay-ing surface of driven pulley spring (only pulleyside)Soap-based lithium and zinc oxide grease con-

taining NLGI 2; ISO-L-XBCIB2

- Fit the upper steering bearing.CAUTIONINSERT THE UPPER STEERING BEARING WITH THECAGE FACING UPWARDS.

- Fit the steering bearing upper seat.


SUSP - 190

- Fit the cover plate.

- Insert the lower tightening ring nut, screw until it

stops and, with the specific tool, tighten to the pre-

scribed torque.


Locking torques (N*m)Steering tube lower ring nut 14 ÷ 17

- Fit the spacer between the two ring nuts on the

steering tube in the position indicated.

- Insert the upper tightening ring nut, screw until it

stops and, with the specific tool, tighten to the in-

dicated torque.


Locking torques (N*m)Steering tube upper ring nut 40 ÷ 45


SUSP - 191

- Fit the front wheel.

Steering bearing

Removal

- Clean thoroughly and visually inspect if the com-

ponents are in good conditions.

- Check the upper steering bearing for wear.

- Check the lower steering bearing for wear.


SUSP - 192

- Visually inspect that the steering fifth wheel

tracks, the headstock and the steering tube exhibit

no scores or abnormal wear. Otherwise, replace

them.

STEERING FIFTH WHEEL TRACK REMOVAL

- Remove the steering fifth wheel tracks on the

chassis with the specific tool, following the indica-

ted procedure.

- Fit the specific tool from the lower part of the

headstock until it makes contact with the upper

track.

- Hit with force the specific tool, placing it at differ-

ent points diametrically opposed so as to remove

the upper track.

Specific tooling020004Y Punch for removing steering bearingsfrom headstock

- Repeat the procedure for the lower steering bearing track.


SUSP - 193

- Remove the lower steering bearing seat on the

steering tube using the specific tool.

Specific tooling020004Y Punch for removing steering bearingsfrom headstock

Refitting

STEERING FIFTH WHEEL TRACK FITTING

- Thoroughly clean the track seats on the head-

stock and the steering tube.

- Fit the new tracks of the headstock with the spe-

cific tool.

- Screw the nut until the tracks are fully inserted.N.B.LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITHRECOMMENDED GREASE BEFORE USE.

Specific tooling001330Y Tool for fitting steering seats

001330Y014 Tool for fitting steering seats

001330Y015 Tool for fitting steering seats




SUSP - 194

- Fit the lower steering bearing seat on the steering

tube.

- With a tube of the indicated sizes, fit the lower

seat until it stops. Inside Ø: 35.5 mm; Outside Ø:

38 mm; Length: 350 mm.N.B.LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITHRECOMMENDED GREASE BEFORE USE.



Rear

Removing the rear wheel

- Remove the exhaust silencer.

- Unscrew the shock absorber lower clamp and

rotate the shock absorber towards the vehicle rear

part.

- Remove the cotter pin and the cap.


SUSP - 195

- Loosen the nut and collect the spacer.

- Remove the two screws fixing the right shock ab-

sorber support bracket and remove the bracket.

- Remove the five screws fixing the wheel to the

hub.

- Remove the wheel and collect the conical spacer.

Refitting the rear wheel

- Carry out the removal operations but in reverse order, observing the prescribed tightening torques.

Locking torques (N*m)Fixing screw for wheel rim to hub 34 ÷ 38

Swing-arm

RemovalWARNING

IT IS NOT NECESSARY TO REMOVE THE SWINGING ARM TO SERVICE IT.


SUSP - 196

- Rest the vehicle on its centre stand.

- Remove the side spoilers.

- Remove the footrest.

- Support the engine adequately.

- Unscrew the pin connecting the swinging arm to

the engine and collect the spacer.

- Operating from both sides of the vehicle, loosen

the nut from the inside and collect the washer.

- Remove the pin from the silent bloc.

- Once the swinging arm on the engine side is re-

leased, release the swinging arm on the frame

side, operating on both sides.

- Loosen the nut and collect the washer.


SUSP - 197

- Remove the pin connecting the swinging arm to

the frame.

- Remove the swinging arm by pulling it forwards.

OverhaulWARNING

THE SWINGING ARM CLEARANCE MUST BE CHECKED WITH THE ARM MOUNTED IN RIDINGCONDITIONS.

- Remove the side spoilers.


- Check the axial clearance between the two

swinging arms using a feeler gauge.

- If non-conforming values are detected, remove

the swinging arm and replace the Teflon spacer

bushings.

CharacteristicAxial clearance between the two swingingarmsMin 0.6 Max 1.2 mm


SUSP - 198

- Check clearances between the arm on the frame

side and the frame using a feeler gauge.

- If non-conforming values are detected, remove

the swinging arm and replace the Teflon spacer

bushings.

CharacteristicClearance between the bushing and the platesMin 0.6 Max 1.2 mm

- To check the silent bloc, loosen the nut from the

inside, undo the screw and remove the silent bloc.

- Make sure it is not broken. If it does, replace it.

- To remove the roller casings, take out the Teflon spacer bushing and the internal spacer «A».

- Using an appropriate pin, remove the roller casings «B».

- Using an appropriate tool, set new roller casings, being careful to place the bearings with the O-rings

facing outwards.

- Once fitted, lubricate the ball cages with the recommended product.

Specific tooling020115Y Ø 18 punch

020244Y 15-mm diameter punch

Recommended productsAGIP GREASE PV2 Grease for control levers on the engine

White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °C

and +120 °C; NLGI 2; ISO-L-XBCIB2


SUSP - 199

Refitting

- Carry out removal operations in reverse order.

- Tighten to the prescribed torques.

SWINGING ARM FITTINGName Torque in Nm

Swinging arm on engine side - Engine 40Silent bloc - Frame 54

Swinging arm on frame side - Frame 60Swinging arm on engine side - Swinging arm on frame side 61

Shock absorbers

Removal

Proceed as follows:

- Place the vehicle on its centre stand;

- Lift the engine using a jack so as to free both

shock absorbers.

- Remove the silencer.

- Undo the screws fixing the shock absorber spring

unit from the support fixed to the engine on one

side.


SUSP - 200

- Loosen the nut fixed to the silencer support on

the other side.

- Undo the two upper nuts (one on each side) fixing

the shock absorber spring unit to the frame and

remove the shock absorbers themselves.

Refitting

Carry out the previous operations but in reverse order.

Locking torques (N*m)Shock absorber lower clamping 33 to 41 Shock absorber upper clamp 33 to 41

Exhaust bracket

Removal

- Remove the silencer.

- Loosen and remove the lower retaining bolt of the

right-hand shock absorber at the supporting arm.

- Undo the two screws fixing the arm to the engine.


SUSP - 201

- Remove the split pin and safety cover;

- Unscrew the wheel axle nut; to prevent the wheel

from rotating, use the rear brake and collect the

spacer.

- Remove the supporting arm.

See alsoExhaust assy. Removal

Overhaul

- Remove the circlip shown in the picture

- Support the silencer support bracket sufficiently

- Using the special punch, remove the bearing

from its seat as shown in the picture




SUSP - 202

- Heat the bearing seat using the heat gun

- Using the special punch, install a new bearing in

the seat as shown in the picture


020151Y Air heater

Refitting

To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.

Locking torques (N*m)Rear wheel axle nut 104 to 126 Silencer supporting arm to engine screws (*) 20 to 25 Shockabsorber lower clamping 33 to 41

Centre-stand

- Remove the silencer

- Remove the two stand return springs.

- Detach the rear brake pipe from the clamps, un-

screw the fixing nut and collect the washer.

- Slide off the pin and remove the stand.

- To refit, carry out these operations in reverse order.

- Tighten the nut to the prescribed tightening torque.CAUTION

LUBRICATE THE FOLLOWING PARTS WITH GREASE: SPRING COUPLING PINS, BUSHINGS ONSTAND FIXING BRACKETS.


SUSP - 203

Recommended productsAGIP GREASE PV2 Grease for control levers on the engine

White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °C

and +120 °C; NLGI 2; ISO-L-XBCIB2

Locking torques (N*m)Bolt fixing the centre stand to the frame 25 ÷ 30


SUSP - 204

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Interventions rulesWARNING

BRAKING SYSTEM FLUID IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THEEVENT OF ACCIDENTAL CONTACT WITH YOUR EYES, RINSE THE CONTACT AREA WELLWITH ABUNDANT WATER.THE BRAKE FLUID DRAINED FROM THE SYSTEM IS HARMFUL TO THE ENVIRONMENT. COL-LECTION AND DISPOSAL MUST BE CARRIED OUT IN COMPLIANCE WITH THE REGULATIONSIN FORCE. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGETHE FLUID EVERY TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CON-DITIONS, CHANGE THE FLUID MORE FREQUENTLY.DURING INSTALLATION, THE PARTS TO BE REUSED MUST BE ABSOLUTELY CLEAN ANDFREE FROM ANY TRACES OF OIL, FUEL AND GREASE: IT IS THEREFORE NECESSARY TOCLEAN THEM THOROUGH WITH DENATURED ALCOHOL.N.B.

FOR TOPPING UP AND CHANGE, USE ONLY BRAKE FLUID DOT4 - NHTSA 116.OBSERVE THE MAXIMUM DEGREE OF CLEANLINESS. HYDRAULIC FLUID IS EXTREMELYCORROSIVE FOR PAINTED SURFACES.BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-ING AIR.IF THE MOISTURE CONTENT IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, IT WILL RE-SULT IN POOR BRAKING EFFICIENCY DUE TO A LOW BOILING POINT OF THE FLUID.N.B.

ALWAYS USE FLUID FROM SEALED CONTAINERS.N.B.

RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL LONGER THAN 20 SECONDS. AFTERWASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEANCLOTH.THE SEAL RINGS MUST BE IMMERSED IN THE OPERATING FLUID; THE USE OF PRF1 PRO-TECTIVE DEVICE IS ALLOWED.WARNING

THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES BRAKING EFFI-CIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITYSOLVENT.

Rear brake calliper

Removal

- Make sure the brake pipes and the joint are in

good conditions. Remove and repair the calliper in

the event of fluid leaks.

- Disconnect the brake fluid pipe from the calliper,

pouring the fluid inside a container.

Braking system Carnaby 250ie

BRAK SYS - 206

- Undo the screws fixing the calliper support to the

engine.

Refitting

- Fix the brake calliper support plate to the crank-

case and the brake calliper to the bracket, tight-

ening the screws to the prescribed torque.

- Apply the recommended product to the fixing

screws of the brake calliper to the bracket.

- Purge the system.N.B.WHILE REFITTING, REPLACE THE COPPER GASKETS ONTHEIR FITTINGS.

Recommended productsLoctite 243 Medium strength threadlockMedium Loctite 243 threadlock

Locking torques (N*m)Oil bleed screw 12 - 16 Screw tightening calliperto support 23 ÷ 25 Screw fixing rear brake cal-liper support to engine 20 to 25 Brake fluid tube-calliper fitting 16 - 20

See alsoRear - combined

Front brake calliper

Carnaby 250ie Braking system

BRAK SYS - 207

Removal

- Make sure the brake pipes and the joint are in

good conditions. Remove and repair the calliper in

the event of fluid leaks.

- Disconnect the brake fluid pipe from the calliper,

pouring the fluid inside a container.

- Undo the screws fixing the brake calliper support

to the fork.

Overhaul

Proceed as follows:

1) remove the two male hexagonal screws (1) and

take out the two pads (10);

2) remove the two male hexagonal screws (2) and

remove the reaction plate (3);

3) take out the fixed plate (4) from the guide;

4) remove the internal elements from the floating

body (5) with the help of short blows of com-

pressed air through the brake fluid pipe in order to

facilitate the expulsion of pistons (6).

5) Check:

- that the plates and the body are whole and in

good condition;

- that the cylinder and the floating body of the cal-

liper do not show signs of scratches or erosion,

otherwise replace the entire calliper;


BRAK SYS - 208

- that the guides of the fixed plate are not scratched

or eroded, otherwise replace the entire plate;

- that the brake pad check spring works properly.

Refitting

1) insert the pistons (6) and the sealing rings (7) in

the body;

2) place the guide rubbers (8) and refit the fixed

plate (4);

3) assemble the reaction plate (3) tightening the

screws (2), insert the brake pad check spring (9)

and then the pads, fixing them with the corre-

sponding screws (1);

5) place the calliper on the disc and lock it to the

strut by tightening the fixing screws;

6) fix the pipe joint on the calliper at the prescribed

torque.

Functioning

This is a floating type calliper.

It takes advantage of the action and reaction prin-

ciple to obtain the thrust for both pads.

The body and the reaction plate body work inte-

grally and can move axially with respect of the

fixed plate that is integral to the strut.

The pistons, forced by pressure to push the pad to

the disc, cause the reaction plate to push in turn

the other pad towards the disc.

The brake pad lock spring

1. Pad fixing screws

2. Reaction plate fixing screws

3. Reaction plate

4. Fixed plate

5. Floating body

6. Piston

7. Piston sealing rings

8. Guide protection rubbers

9. Brake pad check spring

10. Brake padsCAUTION


BRAK SYS - 209

ALL THE SEALS AND GASKETS MUST BE REPLACED EV-ERY TIME THE CALLIPER IS SERVICED.

Locking torques (N*m)Brake fluid tube-calliper fitting 20 to 25 Pad fas-tening pin 19.6 ÷ 24.5

Refitting

- When refitting, tighten the nuts to the prescribed

torque.

- Reconnect the brake pipe.

- Purge the system.N.B.WHILE REFITTING, REPLACE THE COPPER GASKETS ONTHEIR FITTINGS.

Locking torques (N*m)Oil bleed screw 12 - 16 Screw tightening calliperto support 20 to 25 Brake fluid tube-calliper fit-ting 16 - 20

Rear brake disc

Removal


- Remove the brake calliper.

- Remove the hub and the brake disc.

- Carry out the same procedure with the front brake

disc.

See also


BRAK SYS - 210

Removing the rear wheel

Refitting

- For the installation, position the disc correctly using the arrow stamped on it as reference.

- Tighten the screws to the prescribed torque and apply the recommended product.N.B.

THE SURFACE OF THE DISC WITH THE STAMPED ARROW FOR THE DIRECTION OF ROTATIONMUST FACE TOWARDS THE OUTSIDE OF THE VEHICLE.



Locking torques (N*m)Brake disc fixing screws 11 to 13

Disc Inspection

Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or any oth-

er dirt, and must show no signs of deep scoring.

CharacteristicNew rear disc thickness4.0 mm

Disc thickness at wear limit (rear)3.5 mm

- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake

surface is within the prescribed limits.

- If this is not the case, replace the disc and repeat

the test.WHEN INSTALLING, THOROUGHLY CLEAN THE DISCAND ITS SEAT ON THE HUB.

CharacteristicMax. axial run-out0.1 mm

Front brake disc


BRAK SYS - 211

Removal

Proceed as follows:

- Remove the front wheel.

- Loosen the five disc fixing screws.

- Thoroughly clean the seats on the front wheel

hub and on the disc.

See alsoRemoving the front wheel

Refitting

For fitting, position the disc correctly using the arrow stamped on it as reference.

- Do up the screws to the prescribed torque and apply the recommended productN.B.

THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTEDTOWARDS THE OUTSIDE OF THE VEHICLE.



Locking torques (N*m)Brake disc fixing screw 5 to 6.5

Disc Inspection

Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or any oth-

er dirt, and must show no signs of deep scoring.

CharacteristicThickness of a new front disc4.0 mm

Disc thickness at wear limit (front)3.5 mm


BRAK SYS - 212

- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake

surface is within the prescribed limits.

- If this is not the case, replace the disc and repeat

the test.WHEN INSTALLING, THOROUGHLY CLEAN THE DISCAND ITS SEAT ON THE HUB.

CharacteristicMax. axial run-out0.1 mm

Front brake pads

Removal

Proceed as follows:

- Remove the front brake calliper.

- Loosen the two pins shown in the figure that lock

the two pads.

- Remove the pads, being careful with the pad

spring clamp.

- Check the thickness of the pads.

CharacteristicMinimum value1.5 mm

See alsoFrontbrake calliper

Refitting

To fit, proceed as follows:

- Insert the two pads in the callipers.

- Screw the two pad lock pins to the correct torque, and apply the recommended product.

- Fit the calliper on its support, tightening the two screws to the prescribed torque.N.B.IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-TING, GENTLY EXPAND THE PADS.

Recommended productsLoctite 243 Medium strength threadlockMedium Loctite 243 threadlock


BRAK SYS - 213

Locking torques (N*m)Screw tightening calliper to support 20 to 25 Pad fastening pin 19.6 ÷ 24.5

Rear brake pads

Removal

Proceed as follows:

- Remove the rear brake calliper

- Remove the two pins holding the brake pads.

- Remove the pads, paying attention to the pad re-

taining spring.

- Check the thickness of the pads.

If the thickness is less than the minimum value,

replace the pads with new pads.

CharacteristicMinimum value1.5 mm

See alsoRemoval

Refitting

Carry out the installation by analogy with the procedure described for the installation of the rear brake

calliper.

- Tighten the two calliper fixing screws to the prescribed tightening torque.

Locking torques (N*m)Pad fastening pin 19.6 ÷ 24.5 Screw tightening calliper to support 20 to 25 Fixing screws for thecalliper support on the engine 20 to 25

Fill


BRAK SYS - 214

Rear - combined

Proceed as follows:

- Position the vehicle on a flat surface and on the

stand

- Loosen the two screws shown in the figure and

open the front brake fluid reservoir.

- Through the bleed screw on the brake calliper,

bleed the system using a hose of adequate diam-

eter.

- Collect the used fluid in a container.

- Pump on the brake lever to completely drain the system of all used fluid.

- Tighten the bleed valve.

- Refill the brake system tank up to the maximum level with the prescribed fluid.

- Attach the tube of the special tool to the bleed fitting.

- Actuate the tool at the bleed fitting, at the same time constantly topping up the brake system tank to

prevent air being drawn into the system, until no more air escapes at the bleed fitting. The operation is

finished when only brake fluid comes out of the bleed screw.

- Close the bleed screw and tighten to the prescribed torque.

- Close the brake pump tank.N.B.

IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FIT-TINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUTAMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUTTHE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER ANDON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKEDISC.

Specific tooling020329Y Mity-Vac vacuum-operated pump

Locking torques (N*m)Oil bleed screw 12 - 16


BRAK SYS - 215

Front

Proceed as follows:

- Position the vehicle on a flat surface and on the

stand

- Loosen the two screws shown in the figure and

open the front brake fluid reservoir.

- Through the bleed screw on the brake calliper,

bleed the system using a hose of adequate diam-

eter.

- Collect the used fluid in a container.

- Pump on the brake lever to completely drain the system of all used fluid.

- Tighten the bleed valve.

- Refill the brake system tank up to the maximum level with the prescribed fluid.

- Attach the tube of the special tool to the bleed fitting.

- Actuate the tool at the bleed fitting, at the same time constantly topping up the brake system tank to

prevent air being drawn into the system, until no more air escapes at the bleed fitting. The operation is

finished when only brake fluid comes out of the bleed screw.

- Close the bleed screw and tighten to the prescribed torque.

- Close the brake pump tank.N.B.

IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FIT-TINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUTAMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUTTHE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER ANDON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKEDISC.

Specific tooling020329Y Mity-Vac vacuum-operated pump

Locking torques (N*m)Oil bleed screw 12 - 16


BRAK SYS - 216

Front brake pump

Removal



- Drain the braking system.

- Disconnect the brake fluid pipe from the pump,

paying attention to a possible escape of remaining

brake fluid.

- Remove the front brake stop button from the lev-

er.

- Loosen the two fixing screws of the stand and

remove together with the rear view mirror.

- Remove the front brake pump together with the

lever.

See alsoRear handlebar coverFront

Refitting

- Upon refitting, perform the operation but in reverse order.

- Tighten the hydraulic line to the prescribed torque and purge the system.

- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.WARNINGBRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILLBE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDERNORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERYTWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGETHE FLUID MORE FREQUENTLY.CAUTIONWHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THEBLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.

Locking torques (N*m)Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 - 20 Fixing screws for the handlebar controlunit U-bolts 7 to 10


BRAK SYS - 217

See alsoFront

Rear brake pump - combined

Removal



- Drain the braking system.

- Disconnect the brake oil pipe from the pump,

paying attention to a possible escape of remaining

oil.

- Remove the rear brake stop button from the lev-

er.

- Loosen the two fixing screws of the stand and

remove together with the rear view mirror.

- Remove the front brake pump together with the

lever.

See alsoRear - combinedRear handlebar cover

Refitting

- Upon refitting, perform the operation but in reverse order.

- Tighten the hydraulic line to the prescribed torque and purge the system.

- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.WARNING

BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILLBE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDERNORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERYTWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGETHE FLUID MORE FREQUENTLY.CAUTION

WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THEBLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.


BRAK SYS - 218

Locking torques (N*m)Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 - 20 Fixing screws for the handlebar controlunit U-bolts 7 to 10

See alsoFront


BRAK SYS - 219

INDEX OF TOPICS

COOLING SYSTEM COOL SYS

Circuit diagram

KEY

A = Expansion tank

B = Radiator

C = Radiator intake pipe

D = Water pump

E = Delivery pipe to cylinder

F = By-Pass pipe

G = Thermostat

H = Radiator delivery pipe

Electric fan check- Check and, if necessary, restore the correct battery voltage.

Carnaby 250ie Cooling system

COOL SYS - 221

CharacteristicBattery voltage

12V

- Check that the electric ventilation relay is working

properly.

- If the relay is not working, replace it.

- If the relay is working, remove it and jump the red

- red black (85 - 86) wires. The electric ventilation

starts if the ignition switch is set to «ON» and all

components are working.

- In order to check the coolant temperature sensor, see the «Injection» chapter.

See alsoRemote controls check

System bleed

- Start up the engine until the operating tempera-

ture is reached.

- Remove the rubber hood over the bleed valve

- Obtain a rubber tube that is of the right length to

connect the valve to the expansion tank

- Place one end of the pipe on the bleed valve and

the other in the expansion tank

- Loosen the screw by two turns until the commu-

nication hole is revealed with the head as shown

in the picture

- Wait until only coolant comes out of the rubber

pipe so as to eliminate any air bubbles inside the

circuit.

Cooling system Carnaby 250ie

COOL SYS - 222

- Tighten the bleed valve respecting the maximum

torque.

- Bring the coolant up to the correct level inside the

expansion tank

Locking torques (N*m)Bleed screw 3

Thermostat

Removal

- Loosen the two screws indicated in the figure and

remove the thermostat cover.

- Remove the thermostat with its gasket.

Check

- Visually check that the thermostat is not dam-

aged.

- Prepare a metal container with approx. 1 litre of

water.

- Immerse the thermostat, keeping it in the centre

of the container.

- Immerse the multimeter temperature probe, near

the thermostat.

- Warm up the container using the heat gun.

- Check the temperature when the thermostat

starts to open:

- Warm up until the thermostat opens completely.

- Replace the thermostat if it does not work prop-

erly.CAUTION

Carnaby 250ie Cooling system

COOL SYS - 223

TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-THER THE THERMOSTAT NOR THE THERMOMETERTOUCHES THE CONTAINER.


020151Y Air heater

CharacteristicThermostat check: Opening start temperature85 ± 1.5°C

Refitting

- Place the thermostat with the bleeding hole at the

highest point.

- Make sure that the rubber gasket is positioned

properly.

- Fit the thermostat cover with the connection for

the carburettor heating pipe facing the flywheel.

- Tighten the two screw to the torque indicated be-

low.

Locking torques (N*m)Thermostat cover screws 3 to 4

Cooling system Carnaby 250ie

COOL SYS - 224

INDEX OF TOPICS

CHASSIS CHAS

Seat

- Remove the cover by undoing the two screws.

- Operating on both sides, undo the four screws

and remove the spark plug inspection cover pulling

it upwards.

- With the saddle opened, remove the cotter pin.

- Take out the pin with a punch.

Chassis Carnaby 250ie

CHAS - 226

Rear rack

- Undo the five fixing screws.

Rear handlebar cover


- Remove the rear-view mirrors.

- Remove the four frame fixing screws from both

sides, as shown in the figure.

Instrument panel


- Disconnect the connectors.

- Remove the odometer cable.

- Remove the three screws shown in the figure.

- Remove the instrument panel

Carnaby 250ie Chassis

CHAS - 227

Front handlebar cover

- Undo the four screws indicated and remove the

windshield.

- Operating on both sides of the vehicle, remove

the two inspection covers of the brake calliper res-

ervoir «A».

- Undo the two screws «B».

- Remove the five screws «C».


CHAS - 228

- Remove the right and left controls assembly.

- Undo the two screws «D» and remove the front

handlebar cover.CAUTIONOPERATE VERY CAREFULLY TO AVOID DAMAGING THEPLASTIC PARTS

Headlight assy.

- Undo the four screws «A» and remove the front

case «B».

- Undo the screw «C» and remove the cover to

reach the expansion tank cap.


CHAS - 229


eight screws «D».


six screws «E».

- Undo the two screws «F» connecting the head-

light assembly to the turn indicators.

- Undo the six screws «G» connecting the headlight assembly to the legshield and remove the headlight

assembly.

LegshieldWARNING

CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD.WARNING

DETACH THE BATTERY POLES.


CHAS - 230

- Undo the four screws «A» and remove the radi-

ator cover «B».

- Undo the screws fixing the legshield to the frame

above the bag hook.

- Undo the screw «C» and remove the cover to

reach the expansion tank cap.

- Unscrew the expansion tank cap.


eight screws «D».


CHAS - 231


six screws «E» and remove the front shield.

Knee-guard



- Undo the screws of the cover of the expansion

tank compartment and remove the cap.

- Undo the screw of the bag hook.

- Operating from both sides, undo the eight fixing

screws.

- Slide off the shield back plate from the bottom.

Removing the ignition key-switch when on *off*

- Remove the leg shield back plate.

- Detach the electrical wiring.

- Remove the ignition ignition switch, by removing

the retaining spring as shown in the figure.


CHAS - 232

- Lightly push the master-cylinder and extract the

lock from the notch shown in the figure.

- Hence extract the master-cylinder complete with

the key-switch.

- To refit, proceed in the reverse order.

Removing the ignition key-switch when on *lock*

In position "Lock", it is not possible to access the

cylinder retaining spring. The spring must then be

removed as shown in the figure, allowing the lock

spring to be pressed out.N.B.TO REFIT THIS ITEM, THE VEHICLE STEERING LOCKMUST BE RELEASED WITH THE LOCK BODY (INTERNALAND EXTERNAL PART) IN POSITION "OFF". PROCEED ASDESCRIBED IN THE PREVIOUS PARAGRAPH.

See alsoRemoving the ignition key-switch when on *off*

Front wheel housing

- The front wheel housing is divided in two parts.

Two different procedures must be carried out to

remove it.

- Lower part:


- Remove the lower spoilers.

- Remove the four screws connecting the lower

part to the legshield.

- Upper part:

- Remove the lower part.

- Remove the legshield.

- Remove the fork

- Remove the two screws fixing the upper part to the frame.


CHAS - 233

Taillight assy.

The rear light unit has two parts that can be re-

moved separately. The operations described refer

to one part but apply to both.

- Lift the saddle and remove the three screws

«A» fixing the tail light fairing B».

- Operating on both sides, undo the screw inside

the rear wheel housing «C» and disconnect the

connector.

- Undo the two screws «D».


CHAS - 234

Footrest

- Remove the side fairings.


- Remove the cover and take out the battery.

- Remove the fuse box by pulling it upwards.

- Remove the battery lower support.

- Undo the two screws connecting the battery to

the frame.

- Undo the four centre screws.

- Operating on both sides, undo the two screws on

the lower part.


Side fairings

- Remove the cover by undoing the two screws.


CHAS - 235

- Operating on both sides, undo the four screws

and remove the spark plug inspection cover pulling

it upwards.

- Remove the luggage rack.

- Remove the upper fairing of the rear light unit by

undoing the three screws indicated.

- Undo the two screws indicated.

- Unfold the passenger footrest and undo the two

screws.


CHAS - 236

- Undo the screw indicated, inside the spark plug

inspection compartment.

- Remove the side fairing.

Rear mudguard

- Undo the two screws « A» under the air filter.

- Undo the two screws «B».

- Unscrew the shock absorber lower clamp and

rotate the shock absorber towards the vehicle rear

part.

- Remove the mudguard.


CHAS - 237

Helmet bay

- Remove the side fairings.

- Remove the luggage rack.

- Remove the upper fairing of the rear light assem-

bly.

- Operating on both sides, undo the screws indi-

cated connecting the helmet compartment to the

tank.

- Undo the screws fixing the helmet compartment

to the frame.

- Undo the screws fixing the saddle lock.

- Undo the fuel tank cap, remove the rubber fuel

recovery tank and disconnect the bleed pipe.

- Remove the helmet compartment by pulling it upwards.


CHAS - 238

spoiler

- The lower spoiler is divided into two parts that can

be removed separately. The operations described

refer to one part but apply to both.


- Remove the lower centre screw and the external

screw.

- Remove the external screw and the spoiler.

Fuel tank

- Remove the helmet compartment.N.B.

THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY.

- Undo the two screws, on the rear wheel housing,

connecting the tank to the frame and collect the

washer.


CHAS - 239

- Disconnect the fuel hose.

- Disconnect the power connector from the fuel

pump.

- Disconnect the connector of the probe checking

fuel level.

- Disconnect the overflow pipe.

Front mudguard

- Undo the three screws fixing the front mudguard

to the fork plate inside the mudguard.

- Remove the mudguard.


CHAS - 240

Radiator fan


- Remove the radiator cover and disconnect the

headlight assembly connectors.


- Prepare a container to collect the coolant.

- Disconnect the delivery and return hoses of the

expansion tank.

- Disconnect the delivery and return hoses from

the radiator.

- Disconnect the connectors of the water temper-

ature sensor and the electric fan.

- Undo the screw fixing the radiator to the frame.

- Detach the radiator and the electric fan.

- Once refitted, bleed the cooling system.

Expansion tank


- Remove the radiator cover and disconnect the

headlight assembly connectors.


- Prepare a container to collect the coolant.

- Disconnect the delivery and return hoses of the

expansion tank.

- Undo the two screws and remove the expansion

tank.


CHAS - 241

Radiator cover

- Undo the four screws «A» and remove the radi-

ator cover «B».


CHAS - 242

INDEX OF TOPICS

PRE-DELIVERY PRE DE

Carry out the listed tests before delivering the vehicle.

Warning - Handle fuel with care.

Aesthetic inspection

Appearance check:

- Paintwork

- Fitting of plastics

- Scratches

- Dirt

Tightening torques inspection

Lock check

- Safety fasteners

- Fixing screws

Safety fasteners:

Rear shock absorber upper fixing

Rear shock absorber lower fixing

Front wheel axle nut

Wheel hub nut

Swinging arm - chassis pin

Engine-swinging arm pin

Engine arm pin - Chassis arm

Handlebar lock nut

Lower steering ring nut

Upper steering ring nut

Electrical system

Electrical system:

- Main switch

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

- Adjusting the headlights according to the regulations currently in force

- Rear light, parking light, stop light

- Front and rear stop light switches

- Turn indicators and their warning lights

- Instrument panel lights

- Instrument panel: fuel and temperature indicator

- Instrument panel warning lights

Pre-delivery Carnaby 250ie

PRE DE - 244

- Horn

- StarterCAUTION

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 THAT RECOMMENDED. USING A FUSEOF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

Levels check

Level check:

- Hydraulic braking system fluid level.

- Rear hub oil level

- Engine coolant level.

Road test

Test ride

- Cold start

- Instrument operations

- Response to the throttle control

- Stability on acceleration and braking

- Rear and front brake efficiency

- Rear and front suspension efficiency

- Abnormal noise

Carnaby 250ie Pre-delivery

PRE DE - 245

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

Pre-delivery Carnaby 250ie

PRE DE - 246

INDEX OF TOPICS

TIME TIME

Engine

ENGINECode Action Duration

1 001001 Engine from chassis - Removal andrefit.

2 003064 Engine oil - change3 001127 Engine - Complete service4 003057 Engine retainer - Tighten nuts

Time Carnaby 250ie

TIME - 248

Crankcase

CRANKCASECode Action Duration

1 001153 Crankcase halves gasket - Replace-ment

2 001133 Engine crankcase - Replacement

Carnaby 250ie Time

TIME - 249

Crankshaft

CRANKSHAFTCode Action Duration

1 001117 Crankshaft - Replacement

Time Carnaby 250ie

TIME - 250

Cylinder assy.

CYLINDER - PISTONCode Action Duration

1 001002 Cylinder / Piston - Replacement2 001154 Pistonsrings-pin assembly - Service3 001176 Rings / Pin - Replacement

Carnaby 250ie Time

TIME - 251

Cylinder head assy.

VALVE HEADCode Action Duration

1 001126 Head - Replacement2 001045 Valves - Replacement3 001049 Valves - adjust4 001056 Head gasket - change5 000235 Coolant temperature sensor - Repl.6 001057 Thermostat - Replacement7 007012 Coolant bleed valve - Replacement

Time Carnaby 250ie

TIME - 252

Rocker arms support assy.

CAMSHAFTCode Action Duration

1 001148 Rockers valves - Replacement2 001044 Camshaft - Replacement3 001169 Pressure reducer - Replacement

Carnaby 250ie Time

TIME - 253

Cylinder head cover

HEAD COVERCode Action Duration

1 001093 Spark plug - Replacement2 001089 Head cover - Replacement3 001088 Head cover gasket - Replacement4 001074 Oil vapour recovery pipe - Replace-

ment

Time Carnaby 250ie

TIME - 254

Oil filter

OIL FILTERCode Action Duration

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

Carnaby 250ie Time

TIME - 255

Flywheel cover

FLYWHEEL COVERCode Action Duration

1 001087 Flywheel cover - Replacement2 001150 Flywheel cover gasket - change3 007007 Water pump rotor - Replacement4 001113 Water pump / Pump rotor - Replace-

ment5 001099 Flywheel-side oil seal - Replacement

Time Carnaby 250ie

TIME - 256

Driven pulley

DRIVEN PULLEYCode Action Duration

1 001022 Clutch - Replacement2 001012 Driven pulley - overhaul3 001110 Driven pulley- Replacement4 001155 Clutch housing - Replacement

Carnaby 250ie Time

TIME - 257

Oil pump

OIL PUMPCode Action Duration

1 001125 Chain guide pads - Replacement2 001051 Distribution belt - Timing chain - Re-

placement3 001042 Oil pump - overhaul4 001112 Oil pump - change5 001122 Oil pump chain - Replacement6 001172 Chain cover flap - change7 001130 Oil sump - change8 001129 Chain tensioner - Service and Re-

placement9 888133 Chain cover flap - Check / replace-

ment

Time Carnaby 250ie

TIME - 258

Final gear assy.

FINAL DRIVECode Action Duration

1 001010 Geared reduction unit - Service2 001156 Gear reduction unit cover - Replace-

ment3 003065 Gear box oil - Replacement4 004125 Rear wheel axle - Replacement

Carnaby 250ie Time

TIME - 259

Driving pulley

DRIVING PULLEYCode Action Duration

1 001086 Driving half-pulley - Replacement2 001011 Drive belt - Replacement3 001066 Driving pulley - Removal and refitting4 001177 CVT rollers / sliders - Replacement5 001141 Belt anti-flapping roller - Replace-

ment6 001006 Driving pulley - Service7 001175 Anti-flapping roller/ Belt - Service

Time Carnaby 250ie

TIME - 260

Transmission cover

TRANSMISSION COVERCode Action Duration

1 001135 Transmission cover bearing - Re-placement

2 001096 Transmission crankcase cover - Re-placement

3 001131 Transmission air intake - Replace-ment

Carnaby 250ie Time

TIME - 261

Water pump

WATER PUMPCode Action Duration

1 007017 Water pump cover - Replacement2 007003 Coolant delivery and return pipe -

change

Time Carnaby 250ie

TIME - 262

Starter motor

ELECTRIC STARTERCode Action Duration

1 001020 Starter motor - Replacement2 001151 Starter driven gearing - Replacement3 001017 Start-up pinion - Replacement

Carnaby 250ie Time

TIME - 263

Flywheel magneto

MAGNETO FLYWHEELCode Action Duration

1 001067 Stator - Removal and Refitting2 001173 Rotor - Replacement3 001058 Complete flywheel - change4 001104 Start-up freewheel - Replacement

Time Carnaby 250ie

TIME - 264

Butterfly valve

THROTTLE BODYCode Action Duration

1 001166 Throttle body - Replacement2 001047 Injector - Replacement3 001013 Intake manifold - change

Carnaby 250ie Time

TIME - 265

Exhaust pipe

SILENCERCode Action Duration

1 001009 Silencer - Replacement2 001092 Exhaust manifold - Replacement3 001095 Silencer heatshield - Replacement4 005138 Lambda probe - Replacement

Time Carnaby 250ie

TIME - 266

Air cleaner

AIR CLEANERCode Action Duration

1 001014 Air filter - Replacement/Cleaning2 001015 Air filter box - Replacement3 004122 Carburettor air cleaner attachment -

Replacement

Carnaby 250ie Time

TIME - 267

Frame

CHASSISCode Action Duration

1 004001 Chassis - Replacement2 004079 Passenger footrest (1) - Replace-

ment

Time Carnaby 250ie

TIME - 268

Centre-stand

STANDCode Action Duration

1 004004 Stand - Replacement2 001053 Stand pin - Replacement3 004179 Stand bumper - Replacement

Carnaby 250ie Time

TIME - 269

Legshield spoiler

LEGSHIELD - SPOILERCode Action Duration

1 004064 Legshield - Replacement2 004167 Grill / radiator cover - replace

Time Carnaby 250ie

TIME - 270

Side fairings

SPOILER SIDE COVERSCode Action Duration

1 004053 Spoiler - Replacement2 004085 Fairing (1) - Replacement3 003087 Wheel housing - Replacement

Carnaby 250ie Time

TIME - 271

Rear cover

REAR SHIELDCode Action Duration

1 004065 Legshield rear section - Remov. andRefit.

Time Carnaby 250ie

TIME - 272

Central cover

CENTRAL COVERCode Action Duration

1 004011 Frame central cover - Replacement2 004015 Footrests - Remov. and Refit.3 005046 Battery cover - change

Carnaby 250ie Time

TIME - 273

Underseat compartment

HELMET COMPARTMENTCode Action Duration

1 004016 Helmet compartment - Remov. andRefit.

2 004145 Glove box - Replacement

Time Carnaby 250ie

TIME - 274

Mudguard

FRONT AND REAR MUDGUARDSCode Action Duration

1 004002 Front mudguard - change2 004022 Shield lower section - Replacement3 004009 Rear mudguard - Replacement

Carnaby 250ie Time

TIME - 275

Fuel tank

FUEL TANKCode Action Duration

1 005010 Tank float - Replacement2 004005 Fuel tank - Replacement3 004109 Fuel tank breather - change4 004073 Fuel pump - Replacement5 004137 Carburettor pump hose - Replace-

ment

Time Carnaby 250ie

TIME - 276

Rear shock-absorber

REAR SHOCK ABSORBERCode Action Duration

1 003007 Rear shock absorber - Remov. andRefit.

2 003077 Silencer/rear shock absorber sup-port arm - Service

Carnaby 250ie Time

TIME - 277

Steering column bearings

STEERING BEARINGCode Action Duration

1 003051 Fork unit - Replacement2 003079 Fork stem - Replacement3 003048 Fork oil seal - Replacement4 004119 Bearing/upper steering bearing - Re-

placement5 003002 Steering bearing - Replacement6 003073 Steering clearance - Adjustment7 003010 Front suspension - Service8 003050 Fork lower plate - Replacement9 003076 Fork sleeve - Replacement

Time Carnaby 250ie

TIME - 278

Handlebar covers

HANDLEBAR COVERCode Action Duration

1 004018 Handlebar front section - Replace-ment

2 004019 Handlebar rear section - Replace-ment

Carnaby 250ie Time

TIME - 279

Handlebar components

HANDLEBAR COMPONENTSCode Action Duration

1 002037 Brake or clutch lever - Replacement2 002059 Right-hand knob - Replacement3 002060 Throttle grip - Replacement4 002024 Front brake pump - Removal and Re-

fitting5 003001 Handlebar - Replacement6 002067 Rear brake pump - Replacement7 002071 Left knob - Replacement8 002063 Complete throttle grip transmission -

Replacement9 003061 Accelerator transmission - adjust

Time Carnaby 250ie

TIME - 280

Swing-arm

SWINGING ARMCode Action Duration

1 001072 Engine-chassis connection swingingarm - Replacement

2 004058 Silent block - Replacement

Carnaby 250ie Time

TIME - 281

Brake hoses

BRAKE PIPINGCode Action Duration

1 002039 Front brake calliper - Replacement2 002040 Front brake calliper - Service3 002021 Front brake piping - Replacement4 002047 Front brake fluid and system bleed-

ing plug - Repl.5 003070 Front brake pads/shoes - Check for

wear6 003071 Rear brake pads/shoes - Check for

wear7 002002 Rear brake pads/shoes - Repl.8 002007 Front Shoe/brake pad - Removal and

Refitting9 002048 Rear brake calliper - Replacement10 002020 Rear brake hose - Remov. and Refit.11 002080 Rear brake oil bleed system -

Change12 002081 Rear brake rigid pipes - Replacement

Time Carnaby 250ie

TIME - 282

Seat

SADDLECode Action Duration

1 004003 Saddle - Replacement

Carnaby 250ie Time

TIME - 283

Instrument panel

INSTRUMENT PANELCode Action Duration

1 005014 Odometer - Replacement

Time Carnaby 250ie

TIME - 284

Rear rack

LUGGAGE RACKCode Action Duration

1 004008 Luggage rack - Replacement

Carnaby 250ie Time

TIME - 285

Locks

LOCKSCode Action Duration

1 005016 Key switch - Replacement2 004010 Anti-theft lock - Replacement3 004054 Saddle lock catch - Replacement

Time Carnaby 250ie

TIME - 286

Turn signal lights

FRONT HEADLIGHT ASSEMBLYCode Action Duration

1 005002 Front headlamp - Replacement2 005008 Headlight bulbs - Replacement3 005067 Front direction indicator bulb - Re-

placement4 005139 Tail light bulb - Replacement

Carnaby 250ie Time

TIME - 287

REAR LIGHT UNITCode Action Duration

1 005031 number plate light bulb - Replace-ment

2 005005 Taillight - change3 005066 Rear light bulbs - Replacement

Time Carnaby 250ie

TIME - 288

Front wheel

FRONT WHEELCode Action Duration

1 002041 Brake disc - Replacement2 003037 Front wheel rim - Remov. and Refit.3 003038 Front wheel axle - Remov. and Refit.4 003040 Front wheel bearings - Replacement5 003047 Front tyre - Replacement6 004123 Front wheel - Replacement7 002011 Odometer drive - Replacement

Carnaby 250ie Time

TIME - 289

Rear wheel

REAR WHEELCode Action Duration

1 001016 Rear wheel - Replacement2 001071 Rear wheel rim - Removal and Refit-

ting3 002070 Rear brake disc - Replacement4 004126 Rear wheel tyre - Replacement

Time Carnaby 250ie

TIME - 290

Electric devices

SOLENOIDS - BATTERIES - HORNCode Action Duration

1 005007 Battery - change2 005003 Horn - Replacement3 280211 Solenoid - Replac.4 005011 Starter relay - Replacement

Carnaby 250ie Time

TIME - 291

VOLTAGE REGULATOR - ELECTRONIC CONTROL UNIT - H.V. COILCode Action Duration

1 005009 Voltage regulator - Replacement2 001094 Spark plug hood - Replacement3 001069 HV coil - Replacement

CABLE ASSEMBLYCode Action Duration

1 005001 Electrical system - Replacement

Time Carnaby 250ie

TIME - 292

Electronic controls

ELECTRIC CONTROLSCode Action Duration

1 005040 Horn button - Replacement2 005006 Light or turning indicator switch - Re-

placement3 005039 Lights switch - Replacement4 005017 Stop switch - Replacement5 005077 Emergency stop switch - Replace-

ment6 005041 Starter button - Replacement

Carnaby 250ie Time

TIME - 293

Transmissions

TRANSMISSIONCode Action Duration

1 002051 Odometer transmission assembly -Replacement

2 002083 Saddle opening transmission - Re-placement Saddle opening transmis-

sion - Replacement

Time Carnaby 250ie

TIME - 294

Rear side fairings

REAR COVERSCode Action Duration

1 004136 License plate holder mounting - Re-placement

2 005048 number plate holder - Replacement

Carnaby 250ie Time

TIME - 295

Cooling system

COOLING SYSTEMCode Action Duration

1 007001 Expansion tank - Replacement2 001052 Coolant and air bleeding - Replace-

ment3 007013 Radiator expansion tank connection

pipe - change4 007016 Complete fan with support - Replace-

ment5 007003 Coolant delivery and return pipe - Re-

placement6 007002 Radiator water - Replacement

Time Carnaby 250ie

TIME - 296

Stickers

TRANSFERSCode Action Duration

1 004159 Plates / Stickers - Replacement

Carnaby 250ie Time

TIME - 297

REAR-VIEW MIRRORSCode Action Duration

1 004066 Driving mirror - Replacement2 004162 Mirror mounting and/or brake pump

fitting U-bolt - Replacement

Time Carnaby 250ie

TIME - 298

AAir filter: 35

BBattery: 64, 65Brake: 206, 207, 210, 211, 213, 214, 217, 218, 282Bulbs:

CChecks: 52Coolant: 174

EElectric: 221, 291Engine oil: 35

FFuel: 154, 162, 239, 276Fuses: 63

HHeadlight: 42, 229Headlight assembly: Horn: 58Hub oil: 33

IIdentification: 8Instrument panel: 227, 284

LLuggage rack:

MMaintenance: 7, 30Mirrors:

OOil filter: 36, 37, 255

RRecommended products:

SSaddle:

Shock absorbers: 200Spark plug: 32, 53Stand: Start-up: Suspension: 46

TTank: 239, 241, 276Transmission: 10, 45, 81, 95, 261Tyres: 11

VVehicle: 8, 75

Date post:	27-Apr-2015
Category:	Documents
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Piaggio Carnaby 250ie (EN)

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