Gilera SMT RCR 633800 Guide

SERVICE STATION MANUAL
633793 ÷ 633800
SMT RCR

SERVICE STATION
MANUAL
SMT RCR
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as 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 to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions shown in this publication are available in all countries. The availability of single versions
should be checked at the official Piaggio sales network.
"©Copyright2005-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
www.piaggio.com

SERVICE STATION MANUAL
SMT RCR
This service station manual has been drawn up by Piaggio & C. S.p.A. to be used by the workshops of
Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio
vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any
significant changes to vehicle characteristics or to specific repair operations will be communicated by
updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment
and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special
tools, along with the special tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked with this symbol indicatethe correct use of thevehicle
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
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

Vehicle identification
Chassis prefix
Thechassisregistrationnumberis stampedonthe
right side of the headstock.
RCR: ZAPG11D1A
SMT: ZAPG12D1A
Dimensions and mass
SMT SIZES
Specification Desc./Quantity
Width 805 mm
Length 1972 mm
Max. height 1125 mm
Wheelbase 1,355 mm
SMT RCR Characteristics
CHAR - 7

RCR SIZES
Specification Desc./Quantity
Width 805 mm
Length 2036 mm
Max. height 1222 mm
Wheelbase 1,355 mm
Characteristics SMT RCR
CHAR - 8

Engine
ENGINE
Specification Desc./Quantity
Type single-cylinder, two-stroke
Bore 40 mm
Stroke 39.88 mm
Cubic capacity 49 cm³
Compression ratio 11.5 :1
Carburettor Dell'Orto PHVA-17.5 with manual starter
Engine idle speed 1900 ± 100 rpm
Air filter sponge impregnated with a mixture 50% oil (Selenia Air Filter
Oil) and 50% unleaded petrol.
Start-up With pedal
Transmission Chain
Main ratio: 3.7 (78/21)
RCR final ratio: 4.7 (53/13)
SMT final ratio: 3.78 (53/14)
Gearbox At 6 speeds with selector, fork and distribution drum operated
by external control
Speeds First Speed 11/34
Second Speed 15/30
Third Speed 18/27
Fourth Speed 20/24
Fifth Speed 22/23
Sixth Speed 23/22
Lubrication Separate oiling, mixture oil.
Fuel supply Petrol-oil mixture by carburettor, automatic mixer (variable flow
according to engine speed and throttle valve opening)
Inlet By means of a compression valve on the casing
Cooling system forced coolant circulation system
Capacities
CAPACITY
Specification Desc./Quantity
Fuel Tank Capacity 7 l /
Reserve 1.3 l
Oil mixer tank Capacity 1 l / Reserve 0.25 l
cooling circuit ~ 0.850 l
Transmission oil 0.65 l
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
1 Ignition type Capacitive discharge electronic ignition, with
incorporated HV coil
2 Ignition advance (at TDC) 1.2 mm
3 Spark plug NGK B8 ES
4 Headlight 12 ÷ 35/35 W
5 Rear lights 12V ÷ 21/5W
6 Turn indicators 12V ÷ 10W
7 Battery 12V - 4Ah
8 Fuse 4A
9 Generator Magneto flywheel in alternating current
SMT RCR Characteristics
CHAR - 9

Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification Desc./Quantity
Chassis diagonal twin spar frame.
Front suspension: Hydraulic fork and centred axle.
Rear suspension: Swinging with hydraulic progressive shock absorber.
Brakes
BRAKES
Specification Desc./Quantity
Front wheel brake: Hydraulic disc
Ø 240 mm (RCR)
Ø 260 mm (SMT)
Rear wheel brake: Hydraulic Ø 180 mm disc.
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Front tyre: 80/90 x 21'' (RCR)
100/80 x 17'' (SMT)
Rear tyre: 110/80 x 18'' (RCR)
130/70 x 17'' (SMT)
Tightening Torques
Standard tightening torques
TORQUE IN NMBY TYPE OF TIGHTENED MATERIAL
Name Torque in Nm
M4 Ø 8.8 steel screw on plastic with metallic spacers 2
M4 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 2
M4 Ø 8.8 steel screw Iron, steel 3
M5 Ø 8.8 steel screw on plastic with metallic spacers 4
M5 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 4
M5 Ø 8.8 steel screw Iron, steel 6
M6 Ø 8.8 steel screw on plastic with metallic spacers 6.5
M6 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 6.5
M6 Ø 8.8 steel screw Iron, steel 10.5
M7 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 10.5
M7 Ø 8.8 steel screw Iron, steel 17
M8 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 16
M8 Ø 8.8 steel screw Iron, steel 26
M10 Ø 8.8 steel screw Iron, steel 52
M12 Ø 8.8 steel screw Iron, steel 100
M14 Ø 8.8 steel screw Iron, steel 145
Characteristics SMT RCR
CHAR - 10