Derbi Rambla 250 User manual

WORKSHOP MANUAL
RAMBLA 250

WORKSHOP MANUAL
RAMBLA 250
This workshop manual has been drawn up by NACIONAL MOTOR, S.A.U.. Spa to be used by the
workshops of DERBI dealers. This manual is addressed to Derbi service mechanics who are sup-
posed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and proce-
dures. Any important changes made to the vehicles or to specific fixing operations will be promptly re-
ported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary
equipment and tools are unavailable. It is therefore advisable to read the sections of this manual rela-
ting to specific tools, along with the specific tool c atalogue.
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 personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage 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

INDEX OF TOPICS
CHARACTERISTICS CHAR

Rules
Safety rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
CAUTION
USEOFNAKEDFLAMESISFORBIDDENDURINGALLTYPESOFOPERATION.BEFORESTART-
ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE
ENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE
COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL
GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM
PARTS.
DO NOT HOLD ANY MECHANICAL OR OTHER SCOOTER PARTS WITH YOUR MOUTH: SCOOT-
ER COMPONENT ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE HARMFUL AND
EVEN TOXIC.
CARBON MONOXIDE
If you need to keep the engine running in order to carry out any procedure, please ensure that you do
so in an open or very well ventilated area.
Never let the engine run in an enclosed area.
If you do work in an enclosed area, make sure to use a smoke-extraction system.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
FUEL
CAUTION
FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EX-
PLOSIVE UNDER SPECIFIC CONDITIONS.
IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PRO-
CEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF.
DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT
WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE
OR EXPLODE.
CAUTION
DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.
CAUTION
KEEP OUT OF THE REACH OF CHILDREN
HIGH-TEMPERATURE COMPONENTS
Characteristics
CHAR - 7

The engine and the components of the exhaust system can get very hot and remain hot for some time
even after the engine has been switched off.
Before handling these components, make sure that you are wearing insulating gloves or wait until the
engine and the exhaust system have cooled down.
TRANSMISSION OIL AND USED FORK OIL
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.
THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR
LONG PERIODS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.
CAUTION
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.
CAUTION
KEEP OUT OF THE REACH OF CHILDREN
BRAKE FLUID
CAUTION
THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING
THE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH.
ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM.
THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES.
IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH
ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
CAUTION
KEEP OUT OF THE REACH OF CHILDREN
HYDROGEN GAS AND BATTERY ELECTROLYTE
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN.
WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO-
TECTIVE APPAREL.
IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT
COOL WATER.
IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS
OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES,
Characteristics
CHAR - 8

RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL-
IST AS SOON AS POSSIBLE.
IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL-
LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE-
LY.
THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGA-
RETTES OR ANY OTHER HEAT SOURCE.
ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
CAUTION
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
THE BATTERY LIQUID IS CORROSIVE.
DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS.
ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTI-
VATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
CAUTION
UNLESS OTHERWISE INDICATED, REFIT THE UNIT FOLLOWING THE REMOVAL STEPS BUT
IN REVERSE ORDER. THE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THE
OTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY, AVOIDING ANY UNNECESSARY RE-
MOVAL OF COMPONENTS. DO NOT POLISH MATT PAINTWORK WITH ABRASIVE PASTES.
NEVER USE FUEL AS SOLVENT FOR CLEANING THE SCOOTER.
DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUBBER AND PLASTIC PARTS
AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP INSTEAD.
DISCONNECT THE NEGATIVE CABLE (-) OF THE BATTERY IF YOU INTEND TO CARRY OUT
ELECTRICAL WELDING WORK.
BEFORE REMOVING COMPONENTS
•Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
•Use the special tools designed for this scooter, as required.
REMOVAL OF COMPONENTS
•Do not loosen and/or tighten screws and nuts using pliers or other tools than the specially
designed wrench.
•Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
•Each component needs to be clearly marked in order to be identified during reassembly.
•Clean and wash the dismantled components carefully using a low-flammability detergent.
Characteristics
CHAR - 9

•Keep coupled parts together since they have "adjusted" to each other due to normal wear
and tear.
•Some components must be used together or replaced altogether.
•Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH
A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED
MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT.
AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS
SEAT.
DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS.
NOTE
BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH-
ERWISE THEY NEED REPLACING.
•Use only ORIGINAL Derbi SPARE PARTS.
•Comply with lubricant and consumables usage guidelines.
•Lubricate parts (whenever possible) before refitting them.
•When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and
screws with new ones if their tread is damaged.
•When fitting bearings, make sure to lubricate them well.
•Check that each component is fitted correctly.
•After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-
hicle on private grounds or in an area with low traffic density.
•Clean all coupling surfaces, oil guard rims and washers before refitting them. Apply a light
layer of lithium-based grease on the oil guard rims. Reassemble the oil guards and the
bearings with the brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below as non-compliance with the procedure
so described causes irreparable damage to both the connector and the cable harness: Press the rele-
vant safety hooks, if any.
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.
•Grip the two connectors and disconnect them by pulling them in opposite directions.
Characteristics
CHAR - 10

•In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a
pressurised air jet.
•Make sure that the cables are correctly linked to the connector's internal terminal ends.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY
ROUND.
•Then fit the two connectors making sure that they couple correctly (if the relevant hooks are
provided, you will hear them "click" into place).
TIGHTENING TORQUE
CAUTION
DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS,
BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN
ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS.
IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH, ONE OF THE COMPONENTS MAY
BECOME LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COM-
PROMISING THE VEHICLE'S MANOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISK
OF SERIOUS INJURY OR DEATH.
BRAKE FLUID
CAUTION
DO NOT USE FLUIDS OTHER THAN THOSE PRESCRIBED AND DO NOT MIX DIFFERENT LIQ-
UIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM.
DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THAT
HAVE BEEN OPEN FOR A PROLONGED TIME.
SUDDEN CHANGES IN THE PLAY OR ELASTIC RESISTANCE IN THE BRAKE LEVERS ARE DUE
TO FAULTS IN THE HYDRAULIC CIRCUIT.
MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOT
SMEARED OR GREASY, PARTICULARLY AFTER CARRYING OUT MAINTENANCE AND IN-
SPECTION OPERATIONS.
CHECK THAT BRAKE WIRES ARE NOT TWISTED OR WORN.
ENSURE THAT WATER OR DUST DO NOT INGRESS INADVERTENTLY INTO THE CIRCUIT.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT.
DISC BRAKE
CAUTION
ANY OIL OR OTHER LIQUIDS ON A DISC WILL SOIL THE BRAKE PADS.
SOILED PADS MUST BE REMOVED AND REPLACED. A SOILED DISC OR A DISC WITH TRACES
OF OIL MUST BE CLEANED WITH A TOP QUALITY DEGREASING AGENT.
IF THE SCOOTER IS USED CLOSE TO WATER OR ON DUSTY OR UNSURFACED ROADS, OR
IF IT IS USED FOR SPORTS APPLICATION, HALVE THE SERVICE INTERVALS.
COOLANT
Coolant liquid solution is 50% water and 50% antifreeze. This is the ideal mixture for most operating
temperatures and provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce
the need for top-ups.
Characteristics
CHAR - 11

Thus, mineral salt deposits formed in the radiator by evaporated water are also minimised and the
efficiency of the cooling system is not affected.
When the temperature drops below zero degrees centigrade, check the cooling system frequently and
add more antifreeze if needed (up to 60% max.).
Use distilled water in the coolant mixture to avoid damaging the engine.
Depending on the freezing temperature of the coolant mixture you wish to achieve, add the percentage
of coolant indicated in the following table to the water:
FREEZING POINT C° (-°F)
Specification Desc./Quantity
-20° (-4) Coolant 35% by volume
-30° (-22) Coolant 45% by volume
-40° (-40) Coolant 55% by volume
NOTE
THE DIFFERENT ANTIFREEZE LIQUIDS HAVE DIFFERENT CHARACTERISTICS. THE DEGREE
OF PROTECTION GUARANTEED CAN BE FOUND ON THE LABEL OF THE PRODUCT.
CAUTION
USE ONLY ANTIFREEZE AND CORROSION INHIBITORS WITHOUT NITRITE THAT ENSURE A
PROTECTION OF AT LEAST -35°C (-31°F).
TYRES
CAUTION
CHANGING, REPAIR, MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT
ARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS.
THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COATING THAT IS
SLIPPERY. DRIVE CAREFULLY FOR THE FIRST FEW KILOMETRES (MILES).
NEVER USE RUBBER TREATMENT AGENTS OF ANY KIND ON THE TYRES.
IN PARTICULAR ENSURE THAT THE TYRES DO NOT COME INTO CONTACT WITH LIQUID FUEL
THAT WOULD CAUSE A RAPID DETERIORATION OF THE RUBBER.
A TYRE THAT HAS BEEN IN CONTACT WITH OIL OR PETROL MUST BE REPLACED AND NOT
SIMPLY CLEANED.
DO NOT FIT TYRES WITH INNER TUBES ON RIMS FOR TUBELESS TYRES AND VICE VERSA.
Vehicle identification
Chassis number
The chassis number is stamped on the chassis
central bar. Remove the indicated cap placed in-
side the front glove-box in order to read this num-
ber.
Characteristics
CHAR - 12

Engine number
The engine number is stamped near the rear
shock absorber lower support.
CAUTION
ALTERING IDENTIFICATION NUMBERS CAN BE SERI-
OUSLY PUNISHED BY LAW, PARTICULARLY MODIFYING
THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE
THE WARRANTY.
Dimensions and mass
DIMENSIONS
Specification Desc./Quantity
Max. length 1965 mm (77.36 in)
Max. width 730 mm (28.74 in)
Max. height (to windshield) 1130 mm (44.49 in)
Saddle height 790 mm (31.10 in)
Wheelbase 1360 mm (53.54 in)
Minimum ground clearance 130 mm (5.11 in)
Kerb weight 148 kg (328.28 lb)
Engine
ENGINE TECHNICAL DATA
Specification Desc./Quantity
Engine model M288M
Engine type Single-cylinder, 4-stroke, 4 valves, wet sump forced lubrication
system, overhead camshaft.
Overall engine capacity 244.29 cm³
Bore / stroke 72 mm / 60 mm
Compression ratio 11.0 ± 0.5 : 1
Start-up Electric
Engine revs at idle speed 1600 ± 100 rpm
Clutch Automatic centrifugal dry clutch
Transmission Automatic
Cooling forced-circulation air cooling driven by a centrifugal pump
Valve clearance Inlet: 0.10
Outlet: 0.15
Throttle body diffuser (throttle body Ø) Electronic injection Ø 32 mm
Supply Vacuum pump
Fuel Use premium unleaded petrol only, with minimum octane rating
of 95 (NORM) and 85 (NOMM).
IGNITION Capacitive discharge ignition, variable advance
Spark plug CHAMPION RG4 - PHP
Transmission
TRANSMISSION
Specification Desc./Quantity
Gear continuous and automatic variator
Main transmission V-belt
Secondary transmission Gear reduction unit
Engine/wheel total ratio - minimum: 1:2.3
Characteristics
CHAR - 13

Specification Desc./Quantity
- maximum: 1:0.815
Capacities
CAPACITY
Specification Desc./Quantity
Fuel (reserve included) 9 l
Fuel reserve 1.5 l
Engine oil change to service engine 1150 cm³ (70.18 cu.in3)
Engine oil and engine oil filter change 1100 cm³ (67.12 cu.in)
Transmission oil 250 cm³ ( 15.25 cu.in)
Fork oil 135
± 1 cm³ ( 8.24 ± 0.06 cu.in) for each stem
Coolant 1.5 litres (0.39 gal) (50% water + 50% ethylene glycol anti-
freeze solution)
Seats 2
Vehicle max. load (rider + passenger + luggage) 210 kg (463 lb)
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuses 20- 15- 7.5 A
3 (Permanent magnet) Generator 12V - 300W
4 Low-/ high-beam light 12 V - 55 W - H7
5 Tail light 12V - 3 W
6 Turn indicator lights 12V - 10W
7 Rear tail light /stop light 12V - 5W / 21W
8 License plate light 12V - 5W
9 Instrument panel lighting LED
10 Turn indicator warning light LED
11 High-beam warning light LED
12 Low fuel warning light LED
13 Spark plug CHAMPION RG4 PHP
14 Spark plug electrode gap 0.7 ± 0.8 mm ( 0.027 in - 0.031 in)
15 Ignition type Capacitive discharge ignition, variable advance
16 Ignition advance Variable managed by control unit. 5th minimum . 15°>
6000/8000 rpm.
Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification Desc./Quantity
Chassis type High-strength steel tubular chassis, single spar at the front, su-
perimposed double cradle at the rear.
Steering inclination angle 25.5°
Front suspension Hydraulic action telescopic fork
Front suspension - travel 100 mm (3.94 in)
Rear suspension hydraulic action double-acting shock absorber, adjustable pre-
loading
Rear suspension - travel 80 mm ( 3.15 in)
Characteristics
CHAR - 14

Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 260 mm (10.236 in) disc brake with hydraulic transmission
Rear brake Ø 220 mm (8.6 in) disc brake with hydraulic transmission
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Wheel rims Made of light alloy
Front wheel rim 2.75 x 15"
Rear wheel rim 3.00 x 15"
Tyres Without inner tube (Tubeless)
Front tyre 120/70 - 15'' 56P
Rear tyre 130/80 - 15'' 63P
Rear tyre standard inflation pressure 200 kPa (2.0 bar)
Front tyre standard inflation pressure 200 kPa (2.0 bar)
Front tyre standard inflation pressure with passenger 200 kPa (2.0 bar)
Rear tyre standard inflation pressure with passenger 230 kPa (2.3 bar)
Tightening Torques
LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15÷17 (11.1 ÷ 12.5 ftlb)
Oil filter fitting on crankcase 27÷33 (19.9÷24.4 ftlb)
engine oil drainage plug/mesh filter 24÷30 (17.7÷22.1 ftlb)
Oil filter 4÷6 (3÷4.4 ftlb)
Oil pump cover screws 7÷9 (5.2÷6.6 ftlb)
Screws fixing oil pump to crankcase 5÷6 (3.7÷4.4 ftlb)
oil pump driving crown gear screw 10÷14 (7.4÷10.3 ftlb)
Oil pump cover plate screws 4÷6 (3÷4.4 ftlb)
Oil sump screws 10÷14 (7.4÷10.3 ftlb)
Minimum oil pressure sensor 12÷14 (8.9÷10.3 ftlb)
CYLINDER HEAD
Name Torque in Nm
Spark plug 12÷14 (8.9÷10.3 ftlb)
Cylinder head cover screws 6÷7 (4.4÷5.2 ftlb)
Head to cylinder retaining nuts 7±1 + 10±1 + 270° (5.2±0.7 + 7.4±0.7 ftlb + 270°)
Head side fixing screws 11÷12 (8.1÷8.9 ftlb)
Starter ground screw 7÷8.5 (5.2÷6.3 ftlb)
Tappet set screw lock nut 6÷8 (4.4÷5.9 ftlb)
Inlet manifold screws 11÷13 (8.1÷9.6 ftlb)
Timing chain tensioner pad screw 10÷14 (7.4÷10.3 ftlb)
Starter ground bell screw 11÷15 (8.1÷11.1 ftlb)
Timing chain tensioner support screw 11÷13 (8.1÷9.6 ftlb)
Timing chain tensioner central screw 5÷6 (3.7÷4.4 ftlb)
Camshaft retention plate screw 4÷6 (3÷4.4 ftlb)
TRANSMISSION
Name Torque in Nm
Belt support roller screw 11÷13 (8.1÷9.6 ftlb)
Clutch assembly nut on driven pulley 45÷50 (33.2÷36.9 ftlb)
Driving pulley nut 75÷83 (55.4÷61.3 ftlb)
Transmission cover screws 11÷13 (8.1÷9.6 ftlb)
Characteristics
CHAR - 15

Name Torque in Nm
Driven pulley shaft nut 54÷60 (39.9÷44.3 ftlb)
Rear hub cover screws 24÷27 (17.7÷19.9 ftlb)
FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11÷13 (8.1÷9.6 ftlb)
Stator unit screws 3÷4 (2.2÷3 ftlb) (Apply LOCTITE 242 medium-strength thread-
lock)
Flywheel nut 94÷102 (69.4÷75.3 ftlb)
Pick-Up fixing screws 3÷4 (2.2÷3 ftlb)
Screws fixing freewheel to flywheel 13÷15 (9.6÷11.1 ftlb)
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Screws for engine crankcase internal bulkhead (transmission-
side half shaft)
4÷6 (3÷4.4 ftlb)
Engine crankcase coupling screws 11÷13 (8.1÷9.6 ftlb)
Starter motor screws 11÷13 (8.1÷9.6 ftlb)
Crankcase timing system cover screw 3.5÷4.5 (2.6÷3.3 ftlb) (Apply LOCTITE 242 medium-strength
threadlocker)
HANDLEBAR
Name Torque in Nm
Handlebar to fork retainer 48±20% (35.52 ftlb)
Safety screw 20±20% (14.8 ftlb)
Steering set nut 15±20% (11.1 ftlb)
Steering series fixing lock nut 110±20% (81.4 ftlb)
CHASSIS
Name Torque in Nm
License plate holder support to chassis retainer 25±20% (18.5 ftlb)
Passenger grab handle to chassis retainer 25±20% (18.5 ftlb)
Horn to chassis retainer 10±20% (7.4 ftlb)
Regulator to chassis retainer 10±20% (7.4 ftlb)
Switch to chassis retainer 10±20% (7.4 ftlb)
Control unit to chassis retainer 10±20% (7.4 ftlb)
Fuel tank to chassis retainer 10±20% (7.4 ftlb)
Helmet compartment to chassis retainer 5±20% (3.7 ftlb)
Air deflector to chassis retainer 5±20% (3.7 ftlb)
Coil to chassis retainer 5±20% (3.7 ftlb)
ELECTRICAL SYSTEM
Name Torque in Nm
Starter motor cable retainer 5±20% (3.7 ftlb)
Battery to relay retainer 4±20% (2.96 ftlb)
Starter motor on relay retainer 4±20% (2.96 ftlb)
Battery cable harness ground lead retainer 10±20% (7.4 ftlb)
SADDLE
Name Torque in Nm
Hinge on saddle retainer 7±20% (5.18 ftlb)
LOCKS
Name Torque in Nm
Glove-box lock on cover retainer 4±20% (2.96 ftlb)
Saddle lock on right and left half-tail sections retainer 3±20% (2.22 ftlb)
Saddle lock on helmet compartment retainer 5±20% (3.7 ftlb)
Characteristics
CHAR - 16

INSTRUMENT PANEL
Name Torque in Nm
Right handlebar cover to left handlebar cover retainer 1±20% (0.74 ftlb)
Windshield on handlebar cover retainer 1±20% (0.74 ftlb)
Instrument panel on instrument panel support retainer 2±20% (1.48 ftlb)
Instrument panel support on internal handlebar cover retainer 1±20% (0.74 ftlb)
Internal handlebar cover on handlebar retainer 3±20% (2.22 ftlb)
External handlebar cover on windshield retainer 3±20% (2.22 ftlb)
REAR BODYWORK
Name Torque in Nm
Retroreflector to license plate holder retainer 1.5±20% (1.11 ftlb)
License plate to license plate holder retainer 1±20% (0.74 ftlb)
Rear taillight to right and left half-tail sections retainer 1±20% (0.74 ftlb)
Right and left half-tail sections on helmet compartment retainer 4±20% (2.96 ftlb)
Rear light cover on license plate holder retainer 1±20% (0.74 ftlb)
License plate holder on right and left half-tail sections retainer 3±20% (2.22 ftlb)
License plate holder on rear mudguard chassis retainer 5±20% (3.7 ftlb)
Luggage carrier cover on luggage carrier retainer 1±20% (0.74 ftlb)
Right and left half-tail sections on helmet compartment retainer 1±20% (0.74 ftlb)
Fuel probe lid on helmet compartment retainer 1±20% (0.74 ftlb)
Retainer for lower lock of right and left half-tail sections on right
and left half-tail sections
3±20% (2.22 ftlb)
CENTRAL BODYWORK
Name Torque in Nm
Central inspection cover on helmet compartment retainer 1±20% (0.74 ftlb)
Central inspection cover on right and left fairings retainer 3±20% (2.22 ftlb)
Left side inspection cover retainer 3±20% (2.22 ftlb)
Right side inspection cover retainer 3±20% (2.22 ftlb)
Battery cover retainer 3±20% (2.22 ftlb)
Footrest retainer 3±20% (2.22 ftlb)
Right and left lower shield retainer 3±20% (2.22 ftlb)
Glove-box lid on front internal shield retainer 1±20% (0.74 ftlb)
Front internal shield to front external shield retainer 1±20% (0.74 ftlb)
Glove-box net on front internal shield retainer 1±20% (0.74 ftlb)
Glove-box lid reinforcing retainer 1±20% (0.74 ftlb)
Bag hook retainer 1±20% (0.74 ftlb)
Air intake on front internal shield retainer 1±20% (0.74 ftlb)
FRONT AND REAR BRAKE
Name Torque in Nm
Calliper on fork retainer 25±20% (18.5 ftlb)
Calliper on muffler plate retainer 25±20% (18.5 ftlb)
Pipe cable guide on link rod retainer 10±20% (7.4 ftlb)
Pipe cable guide on air deflector retainer 5±20% (3.7 ftlb)
Right and left pump on handlebar retainer 10±20% (7.4 ftlb)
Rear calliper support to muffler plate retainer 25±20% (18.5 ftlb)
Rear calliper support on muffler plate retainer 25±20% (18.5 ftlb)
Front pipe cable guide on fork retainer 10±20% (7.4 ftlb)
FRONT BODYWORK
Name Torque in Nm
Right and left air intake on front internal shield retainer 1±20% (0.74 ftlb)
Right and left turn indicators on front external shield retainer 1±20% (0.74 ftlb)
Front headlamp on front external shield retainer 1±20% (0.74 ftlb)
Front external shield on cover retainer 1±20% (0.74 ftlb)
Front external shield on lower shield retainer 1±20% (0.74 ftlb)
Front mudguard clamp on fork retainer 1±20% (0.74 ftlb)
Front external shield on under-footrest retainer 3±20% (2.22 ftlb)
Front mudguard on clamps retainer 5±20% (3.7 ftlb)
Case on front internal shield retainer 2±20% (1.48 ftlb)
Characteristics
CHAR - 17

FILTER HOUSING
Name Torque in Nm
Sleeve on carburettor retainer 2±20% (1.48 ftlb)
Sleeve on filter housing retainer 2±20% (1.48 ftlb)
Filter housing on engine retainer 8±20% (5.92 ftlb)
COOLING UNIT
Name Torque in Nm
Thermal switch retainer 20±20% (14.8 ftlb)
Head pipe on radiator retainer 2±20% (1.48 ftlb)
Pump pipe on radiator retainer 2±20% (1.48 ftlb)
Radiator on bulkhead retainer 7±20% (5.18 ftlb)
Electric fan on radiator retainer 1±20% (0.74 ftlb)
Expansion tank on air deflector retainer 4±20% (2.96 ftlb)
FRONT WHEEL
Name Torque in Nm
Pin retainer 50±20% (37 ftlb)
Safety screw retainer 10±20% (7.4 ftlb)
LINK ROD
Name Torque in Nm
Connecting rod to chassis retainer 60±20% (44.4 ftlb)
Connecting rod to engine retainer 40±20% (29.6 ftlb)
Chassis connecting rod on engine connecting rod retainer 60±20% (44.4 ftlb)
Silent-block on chassis retainer 50±20% (37 ftlb)
EXHAUST
Name Torque in Nm
Manifold to engine retainer 15±20% (11.1 ftlb)
Muffler to manifold retainer 16±20% (11.84 ftlb)
Muffler on plate retainer 25±20% (18.5 ftlb)
Protection on muffler retainer 7±20% (5.18 ftlb)
REAR WHEEL
Name Torque in Nm
Rear wheel retainer 110±20% (81.4 ftlb)
Speed sensor screw retainer 10±20% (7.4 ftlb)
Speed sensor on muffler plate retainer 10±20% (7.4 ftlb)
STAND
Name Torque in Nm
Stand to engine retainer 27±20% (19.98 ftlb)
ENGINE
Name Torque in Nm
Muffler plate on engine 25±20% (18.5 ftlb)
Fuel breather pipe cable guide on crankcase 10±20% (7.4 ftlb)
REAR SUSPENSION
Name Torque in Nm
Right and left shock absorber to chassis retainer 40±20% (29.6 ftlb)
Shock absorber on engine bracket retainer 40±20% (29.6 ftlb)
Shock absorber on muffler plate retainer 40±20% (29.6 ftlb)
Shock absorber bracket on engine retainer 25±20% (18.5 ftlb)
FUEL SUPPLY SYSTEM
Name Torque in Nm
Probe to tank retainer 1.5±20% (1.11 ftlb)
Characteristics
CHAR - 18

Name Torque in Nm
Fuel coupling clamp retainer 1±20% (0.74 ftlb)
Tank to helmet compartment retainer 2±20% (0.74 ftlb)
Petrol pump on helmet compartment retainer 2±20% (1.48 ftlb)
Overhaul data
Assembly clearances
Cylinder - piston assy.
Piston: the category marking is on the piston crown.
Cylinder: the category marking is on the external side of the cylinder.
CYLINDER - PISTON COUPLING CATEGORY
Name Initials Cylinder Piston Play on fitting
Cylinder - Piston M = 1 72.01 ÷ 72.017 71.953 ÷ 71. 960 0.050 ÷ 0. 064
Cylinder - Piston N = 2 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 ÷ 0.064
Cylinder - Piston O = 3 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 ÷ 0.064
Cylinder - Piston P = 4 72.031 ÷ 72.038 71.974 ÷ 71.981 0.050 ÷ 0.064
If only the piston is replaced, check the cylinder category taking into account the CYLINDER - PISTON
COUPLING CATEGORY table.
CAUTION
THERE IS ONLY ONE CYLINDER CODE IN THE SPARE PART CATALOGUE AND IT IS SUPPLIED
TOGETHER WITH THE PISTON.
Characteristics
CHAR - 19

Crankcase - crankshaft - connecting rod
CRANKSHAFT / CRANKCASE AXIAL CLEARANCE
Name Description Dimensions Initials Quantity
Half shaft, transmission
side
16.6 +0-0.05 A D = 0.20 ÷ 0.50
Half shaft, flywheel side 16.6 +0-0.05 B D = 0.20 ÷ 0.50
Connecting 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
Characteristic
Compression ratio
10.5 ÷ 11.5 : 1
Characteristics
CHAR - 20