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

ENGINE-VEHICLE
Name Torque in Nm
Shock absorber to chassis upper attachment 30-40
Shock absorber to chassis lower attachment 55-65
Lower arm to shock absorber chassis clamp 55-65
Arm to chassis clamp 55-65
Arm to suspension clamp 55-65
Oscillating fork 70-80
Engine to chassis front attachment 35-40
Engine to chassis lower attachment 25-28
Fork to steering tube clamping 90-130
Fork leg cap 17-19
Muffler to cylinder 9-12
muffler to chassis clamp 17-19
Muffler silencer to chassis 17-19
Steering arm - fork bar clamp 20-24
Handlebar to steering arm 20-24
Front wheel shaft 70-80
Front brake calliper 17-19
Rear wheel axle 70-80
Rear brake calliper 17-19
Rear brake disc 17-19
Front brake disc 11-12
Rear wheel gear 17-19
Head-cylinder stud bolts 10-12
Head-cylinder fixing nuts 19-22
Flywheel to shaft 35-45
Stator to crankcase 8-10
Clutch cover 8-10
Crankshaft pinion 8-10
Crankcase halves fixing screws 8-10
Starter motor to crankcase 32-38
Cylinder head thermistor 32-38
Cylinder head thermostat nut 25-40
Clutch seat 35-45
Crankcase oil drainage cap 10-15
Pinion counterweight 3.5-4.5
Main shaft bearing unit 3.5-4.5
Gearbox sprocket tightening 3.5-4.5
Products
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions
(brake, throttle control and mixer, odom-
eter)
Oil for 2-stroke engines: SAE 5W-40, API
SL, ACEA A3, JASO MA
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based
spraygreasewithNLGI 2;ISO-L-XBCIB2
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
AGIP GREASE PV2 Grease for the steering bearings, pin
seats and swinging arm White anhydrous-calcium based grease to protect roller bearings; temperature
range between -20 C and +120 C; NLGI
2; ISO-L-XBCIB2.
AGIP GREASE SM 2 Grease for odometer transmission gear
case Lithium grease with NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
SMT RCR Characteristics
CHAR - 11

Product Description Specifications
PARAFLU MOTO RIDER coolant Ready to use monoethylene glycol anti-
freeze fluid, CUNA NC 956-16
AGIP GEAR 80W-90 gearbox oil SAE 80W-90 oil complying with API GL4
specifications
Characteristics SMT RCR
CHAR - 12

INDEX OF TOPICS
TOOLING TOOL

TOOLS
Stores code Description
00H0530004.1 Clutch locking tool
00H0530015.1 Engine opening tool
00H0560032.1 Crankshaft gear extractor
001330Y Tool for fitting steering seats
002465Y Pliers for circlips
020004Y Punch for removing fifth wheels from
headstock
020074Y Support base for checking crankshaft
alignment
020150Y Air heater support
020151Y Air heater
020329Y MityVac vacuum-operated pump
Tooling SMT RCR
TOOL - 14

Stores code Description
020330Y Stroboscopic light to check timing
020331Y Digital multimeter
020332Y Digital rev counter
020333Y Single battery charger
020334Y Multiple battery charger
020357Y 32 x 35 mm adaptor
020358Y 37x40-mm adaptor
SMT RCR Tooling
TOOL - 15

Stores code Description
020363Y 20 mm guide
020376Y Adaptor handle
020412Y 15 mm guide
020425Y Punch for flywheel-side oil seal
020439Y 17 mm guide
020441Y 26 x 28 mm adaptor
Tooling SMT RCR
TOOL - 16

Stores code Description
020455Y 10-mm guide
020456Y Ø 24 mm adaptor
020544y Pliers for clamps
020565Y Flywheel lock calliper spanner
020581Y Flywheel extractor
SMT RCR Tooling
TOOL - 17

INDEX OF TOPICS
MAINTENANCE MAIN

Maintenance chart
AFTER 1000 KM
Action
Coolant- Change
Air filter - cleaning
Odometer gear - greasing
Steering - Check
Brake control levers - greasing
Brake pads - check
Transmission chain - greasing
Tension transmission chain - check
Safety locks - check
Front fork- Check
Electrical system and battery - check
Wheel - Check
Tyres pressure - Check
Fuel and oil hoses - Check
Vehicle and brake test - road test
Engine oil - change
Spark plug / electrode gap - check
Carburettor - Adjustment
Clutch control lever - Adjustment
AT5,000; 25,000; 35,000; 55,000 KM
Action
Coolant level - check
Air filter - cleaning
Brake control levers - greasing
Brake pads - check
Brake fluid level - check
Transmission chain - greasing
Tension transmission chain - check
Front fork- Check
Electrical system and battery - check
Tyre condition and wear - Check
Tyres pressure - Check
Fuel and oil hoses - Check
Vehicle and brake test - road test
Engine oil - Check
Spark plug/electrode gap - replacement
Carburettor - Adjustment
Clutch control lever - Adjustment
AT10,000; 20,000; 40,000; 50,000 KM
Action
Coolant- Change
Air filter - cleaning
Radiator - Cleaning
Odometer gear - greasing
Steering - Check
Brake control levers - greasing
Brake pads - check
Brakes hoses- Check
Transmission chain - greasing
Tension transmission chain - Replacement
Safety locks - check
Front fork - Replacement
Rear shock absorber - Check
Electrical system and battery - check
Headlight - adjustment
Tyre condition and wear - Check
Wheel - Check
SMT RCR Maintenance
MAIN - 19

Action
Tyres pressure - Check
Oil filter -Replacement
Fuel and oil hoses - Replacement
Vehicle and brake test - road test
Engine oil - change
Spark plug/electrode gap - replacement
Carburettor - Adjustment
Clutch control lever - Adjustment
AT15,000; 30,000; 45,000; 60,000 KM
Action
Coolant level - check
Air filter - cleaning
Brake control levers - greasing
Brake pads - check
Brake fluid level - check
Transmission chain - greasing
Tension transmission chain - check
Front fork- Check
Electrical system and battery - check
Tyre condition and wear - Check
Tyres pressure - Check
Fuel and oil hoses - Check
Vehicle and brake test - road test
Engine oil - Check
Spark plug/electrode gap - replacement
Carburettor - Adjustment
Clutch control lever - Adjustment
Cylinder head and cylinder - Cleaning
Complete piston - Replacement
EVERY 2 YEARS
Action
Brake fluid - Change
Maintenance SMT RCR
MAIN - 20