PIAGGIO Carnaby 125 Guide

SERVICE STATION MANUAL
633986 IT-633987 EN-633988 FR-633989 DE-633990
ES-633991 PT-633992 OL-633993 EL
Carnaby 125 - 200

SERVICE STATION
MANUAL
Carnaby 125 - 200
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/models shown in this publication are available in all countries. The availability of single
versions should be checked at the official Piaggio sales network.
"©Copyright2007-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL
Carnaby 125 - 200
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to
have 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 be
promptly communicated by updates to this manual. Nevertheless, no work can be satisfactory if the
necessary equipment and tools are not available. It is therefore advisable to read the sections of this
manual 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 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
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 sizes. Using unsuitable coupling
members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.
Carnaby 125 - 200 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 IDENTIFICATION 125
Specification Desc./Quantity
Frame prefix ZAPM 60200
Engine prefix M28FM
VEHICLE IDENTIFICATION 200
Specification Desc./Quantity
Frame prefix ZAPM 60100
Engine prefix M601M
Characteristics Carnaby 125 - 200
CHAR - 8

Dimensions and mass
WEIGHTS AND DIMENSIONS 125
Specification Desc./Quantity
Kerb weight 154 ± 5 kg
Maximum weight allowed 350 kg
Overall height 1.175 mm
Width 755 mm
Wheelbase 1.370 mm
Length 2,025 mm
WEIGHTS AND DIMENSIONS 200
Specification Desc./Quantity
Kerb weight 154 ± 5 kg
Maximum weight allowed 350 kg
Overall height 1.175 mm
Width 755 mm
Wheelbase 1.370 mm
Length 2,025 mm
Engine
ENGINE 125
Specification Desc./Quantity
Type Single-cylinder, 4-stroke
Cubic capacity 124 cm³
Bore x stroke 57.0 x 48.6 mm
Compression ratio 12 ± 0.5: 1
Engine idle speed 1650 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm
Max. Power 11 kW at 9,750 rpm
MAX. torque 12 Nm at 8,000 rpm
Carnaby 125 - 200 Characteristics
CHAR - 9

Specification Desc./Quantity
Lubrication Enginelubricationwithlobepump(insidecrankcase)controlled
by a chain with double filter: mesh and paper.
Lubrication pressure 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel supply KEIHIN CVEK 30 carburettor and electrical fuel pump.
Cooling Forced-circulation coolant system.
Fuel Unleaded petrol (95 RON)
Exhaust muffler absorption-type exhaust muffler with catalytic converter.
Emission regulations EURO 3
ENGINE 200
Specification Desc./Quantity
Type Single-cylinder, 4-stroke
Cubic capacity 198 cm³
Bore x stroke 72 x 48.6 mm
Compression ratio 11 ± 0.5 : 1
Engine idle speed 1650 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm
MAX. power 14.5 kW at 9,000 rpm
MAX torque 16.5 Nm at 7.250 rpm
Lubrication Enginelubricationwithlobepump(insidecrankcase)controlled
by a chain with double filter: mesh and paper.
Lubrication pressure 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel supply KEIHIN CVEK 30 carburettor and electrical fuel pump.
Cooling Forced-circulation coolant system.
Fuel Unleaded petrol (95 RON)
Exhaust muffler absorption-type exhaust muffler with catalytic converter.
Emission regulations EURO 3
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque server, V-
belt, self-ventilating dry automatic centrifugal clutch and trans-
mission housing with forced-circulation air cooling.
Final reduction Gear reduction unit in oil bath.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil 1.10 l
Transmission oil 250 cm³
Cooling system fluid ~ 2 l
Fuel tank (reserve) ~ 10 l (2 l)
Electrical system
ELECTRICAL SYSTEM 125
Specification Desc./Quantity
Start-up Electric
Ignition Capacitive discharge ignition, with variable advance and sep-
arate HV coil.
Ignition advance 10° at 2.000 rpm - 29° at 6.750 rpm
Characteristics Carnaby 125 - 200
CHAR - 10

Specification Desc./Quantity
Spark plug CHAMPION RG4HC
Alternative spark plug NGK CR8EB
Battery Sealed, 12 V / 10 Ah
ELECTRICAL SYSTEM 200
Specification Desc./Quantity
Start-up Electric
Ignition Capacitive discharge ignition, with variable advance and sep-
arate HV coil.
Ignition advance 10° at 2,000 rpm - 26° at 6,750 rpm
Spark plug CHAMPION RG4HC
Alternative spark plug NGK CR8EB
Battery SEALED 12V / 12Ah BATTERY
Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification Desc./Quantity
Chassis Tubular and sheet steel.
Front suspension Hydraulic telescopic fork with Ø 35-mm stem
Front suspension travel 104 mm
Rear suspension Two double-acting shock absorbers with preloading adjust-
ment in 4 positions.
Rear suspension travel - mm
Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 260-mm disc brake with hydraulic control activated by han-
dlebar right lever.
Rear brake Ø 260-mm disc brake with hydraulic control activated by han-
dlebar left lever.
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Wheel rim type Light alloy rims.
Front rim 16'' x 3.00
Rear rim 16'' x 3.00
Front tyre Tubeless, 110/70 - 16'' 52P
Rear tyre Tubeless, 130/70 - 16'' 61P
Front tyre pressure (with passenger) 2 bar (2 bar)
Rear tyre pressure (with passenger) 2.2 bar (2.3 bar)
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
Secondary air
The SAS for LEADER engines operates in a similar manner to the SAS for 2T engines.
The differences are the following:
Carnaby 125 - 200 Characteristics
CHAR - 11

insteadofenteringthroughthemufflerasfor2Tengine,thesecondaryairentersdirectlyinthedischarge
pipe on the head.
The2Treed valvehasadiaphragm.Theunit,indicated byanarrowinthefigure,hasacut-off connected
to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions
in the muffler.
Air is drawn through the opening «A», goes through the first filter and is channelled through the opening
«B».
Air gets to the second filter «B» through the opening shown in the figure. Now, the filtered air enters
the diaphragm device, and then is channelled to the head.
Characteristics Carnaby 125 - 200
CHAR - 12

The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to
supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reac-
tion of the catalytic converter.
Carburettor
125cc Version
Kehin
CARBURETTOR KEIHIN
Specification Desc./Quantity
Type Depression carburettor
Model CVK 30
Body stamping CVK
Carnaby 125 - 200 Characteristics
CHAR - 13

Specification Desc./Quantity
Tapered pin stamping 306D
CUT-OFF device Not present
Diffuser Ø 29
Maximum jet 98
Minimum jet 35
Max. air jet 70
Minimum air jet 130
Throttle valve spring 100 ÷ 160 g
Minimum mixture set screw initial opening 2
Tapered pin Ø 2.45
Diffuser nozzle Ø 2.8
Starter air jet Ø 1.5
Starter jet 42
Starter device resistance ~ 20 Ω
Starter pin travel 10
200cc Version
Kehin
CARBURETTOR KEIHIN
Specification Desc./Quantity
Type Depression carburettor
Model CVK 30
Body stamping CVK
Tapered pin stamping 309D
CUT-OFF device Present
Diffuser Ø 29
Maximum jet 90
Minimum jet 35
Max. air jet 70
Minimum air jet 115
Throttle valve spring 150 ÷ 250 g
Minimum mixture set screw initial opening 2 ½
Tapered pin Ø 2.49
Diffuser nozzle Ø 2.8
Starter air jet Ø 1.5
Starter jet 42
Starter device resistance ~ 20 Ω
Starter pin travel 10
Tightening Torques
STEERING
Name Torque in Nm
Upper steering ring nut 30 ÷ 36
Steering lower ring nut 10 ÷ 13 then loosen by 90°
Handlebar fixing screw (*) 45 ÷ 50
Fixing screws for handlebar control assembly U-bolts 7 ÷ 10
FRAME ASSEMBLY
Name Torque in Nm
Bolt of the Silent block support plate 54
Frame arm-engine arm coupling pin nut 61
Frame-swinging arm pin nut 60
Engine-swinging arm bolt 40
Centre stand bolt 25 ÷ 30
Characteristics Carnaby 125 - 200
CHAR - 14

FRONT SUSPENSION
Name Torque in Nm
Fixing screw for pumping elements to lower fork plate 20 ÷ 25
Front wheel axle 45 ÷ 50
Fork leg screw 6 ÷ 7
front mudguard to plate fixing screw 4.5 ÷ 7
Fixing screw for mudguard plate to fork 9 ÷ 11
FRONT BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 16 ÷ 20
Brake fluid pipe-calliper fitting 16 ÷ 20
Calliper to fork tightening screw 20 ÷ 25
Disc tightening screw (°) 5 - 6
Oil bleed screw 12 - 16
Pad fastening pin 19.6 ÷ 24.5
REAR SUSPENSION
Name Torque in Nm
Left lower shock absorber support bolt 20 ÷ 25
Upper shock absorber clamp 33 ÷ 41
Lower shock absorber clamp 33 ÷ 41
Rear wheel axle 104 ÷ 126
Fixing screw for wheel rim to hub 34 ÷ 38
Muffler support arm to engine screws (*) 20 ÷ 25
REAR BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 16 ÷ 20
Brake fluid pipe-calliper fitting 16 ÷ 20
Flexible/ rigid oil pipe coupling 9 ÷ 11
Rear disc tightening bolt 11 ÷ 13
Oil bleed screw 12 - 16
Screw tightening calliper to the support 20 ÷ 25
Screw fixing rear brake calliper support to engine 20 ÷ 25
Pad fastening pin 20 ÷ 25
MUFFLER
Name Torque in Nm
Screw fixing manifold to muffler 15.5 ÷ 18.5
Muffler heat guard fixing screw 5 - 6
Exhaust fumes inlet screw 22 ÷ 26
Screw fixing muffler support arm to crankcase 33 ÷ 41
Nuts fixing muffler to support arm 27 ÷ 30
Nut fixing muffler to cylinder head 16 ÷ 18
LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 ÷ 17
Oil filter on crankcase fitting 27 ÷ 33
Engine oil drainage plug/mesh filter 24 ÷ 30
Oil filter 4 ÷ 6
Oil pump cover screws 0.7 ÷ 0.9
Screws fixing oil pump to crankcase 5 - 6
Oil pump control crown screw 10 ÷ 14
Oil pump cover plate screws 4 ÷ 6
Oil sump screws 10 ÷ 14
Minimum oil pressure sensor 12 ÷ 14
Carnaby 125 - 200 Characteristics
CHAR - 15

CYLINDER HEAD
Name Torque in Nm
Spark plug 12 ÷ 14
Nuts fixing head to cylinder (1) (^) 9 ÷ 11 + 180°
Head fixing side screws 11 ÷ 12
Starter ground screw 7 ÷ 8.5
M5 side screw locking washers on camshaft 7 ÷ 8.5
Tappet set screw lock nut 6 ÷ 8
Timing chain tensioner slider screw 10 ÷ 14
Starter ground support screw 11 ÷ 15
M6 central screw locking washers on camshaft 11 ÷ 15
Timing chain tensioner support screw 11 ÷ 13
Timing chain tensioner central screw 5 - 6
Camshaft retention plate screw 4 ÷ 6
TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 ÷ 13
Clutch unit nut on driven pulley 45 ÷ 50
Drive pulley nut 75 ÷ 83
Transmission cover screws 11 ÷ 13
Driven pulley shaft nut 54 ÷ 60
Rear hub cover screws 24 ÷ 27
FLYWHEEL
Name Torque in Nm
Flywheel cover fixing screws 5 - 6
Stator assembly screws (°) 3 ÷ 4
Flywheel nut 52 ÷ 58
Pick-Up clamping screws 3 ÷ 4
Screw fixing freewheel to flywheel 13 ÷ 15
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half
shaft) screws 4 ÷ 6
Engine-crankcase coupling screws 11 ÷ 13
Starter motor screws 11 ÷ 13
Crankcase timing system cover screws (°) 3.5 ÷ 4.5
COOLING
Name Torque in Nm
Water pump rotor cover 3 ÷ 4
Screws for water pump rotor driving link 3 ÷ 4
Thermostat cover screws 3 ÷ 4
Bleed 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
Characteristics Carnaby 125 - 200
CHAR - 16

Assembly clearances
Cylinder - piston assy.
200 cm³ version
COUPLING CATEGORIES (WITH ALUMINIUM CYLINDER)
Name Initials Cylinder Piston Play on fitting
Cylinder / piston A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044
Cylinder / piston B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044
Cylinder / piston C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044
Cylinder / piston D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044
COUPLING CATEGORIES (WITH CAST IRON CYLINDER)
Name Initials Cylinder Piston Play on fitting
Cylinder / piston M 72 ÷ 72.007 71.953 ÷ 71.960 0.040 - 0.054
Cylinder / piston N 72.007 ÷ 72.014 71.960 ÷ 71.967 0.040 - 0.054
Cylinder / piston O 72.014 ÷ 72.021 71.967 ÷ 71.974 0.040 - 0.054
Cylinder / piston P 72.021 ÷ 72.026 71.974 ÷ 71.981 0.040 - 0.054
125 cm³ version
Carnaby 125 - 200 Characteristics
CHAR - 17

COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059
Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059
Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059
Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059
Cylinder 1st Oversize A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059
Cylinder 1st Oversize B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059
Piston 1st Oversize C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059
Piston 1st Oversize D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059
Cylinder 2nd Oversize A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059
Cylinder 2nd Oversize B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059
Piston 2nd Oversize C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059
Piston 2nd Oversize D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059
Cylinder 3rd Oversize A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059
Cylinder 3rd Oversize B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059
Piston 3rd Oversize C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059
Piston 3rd Oversize D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059
Piston rings
125 cm³ version
Characteristics Carnaby 125 - 200
CHAR - 18

ENGINE SEALING RINGS
Name Description Dimensions Initials Quantity
Compression ring 57 x 1 A 0.15 ÷ 0.30
Oil scraper ring 57 x 1 A 0.10 ÷ 0.30
Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35
ENGINE SEALING RINGS (1ST OVERSIZE)
Name Description Dimensions Initials Quantity
Compression ring 1st
oversize 57.2 x 1 A 0.15 ÷ 0.30
Oil scraper ring 1st
Oversize 57.2 x 1 A 0.10 ÷ 0.30
Oil scraper ring 1st
Oversize 57.2 x 2.5 A 0.15 ÷ 0.35
ENGINE SEALING RINGS (2ND OVERSIZE)
Name Description Dimensions Initials Quantity
Compression ring 2nd
Oversize 57.4 x 1 A 0.15 ÷ 0.30
Oil scraper ring 2nd
Oversize 57.4 x 1 A 0.10 ÷ 0.30
Oil scraper ring 2nd
Oversize 57.4 x 2.5 A 0.15 ÷ 0.35
ENGINE SEALING RINGS (3RD OVERSIZE)
Name Description Dimensions Initials Quantity
Compression ring 3rd
Oversize 57.6 x 1 A 0.15 ÷ 0.30
Oil scraper ring 3rd
Oversize 57.6 x 1 A
Oil scraper ring 3rd
Oversize 57.6 x 2.5 A 0.15 ÷ 0.35
200 cm³ version
Carnaby 125 - 200 Characteristics
CHAR - 19

ENGINE SEALING RINGS
Name Description Dimensions Initials Quantity
Compression ring 72x1.5 A 0.15 ÷ 0.30
Oil scraper ring 72 x 1 A 0.10 ÷ 0.40
Oil scraper ring 72 x 2.5 A 0.20 ÷ 0.40
Crankcase - crankshaft - connecting rod
CRANKSHAFT HALF-BEARINGS
Name Description Dimensions Initials Quantity
Crankshaft half-bearing Category B - blue 1.973 ÷ 1.976
Crankshaft half-bearing Type C - yellow 1.976 ÷ 1.979
Crankshaft half-bearing Category E - green 1.979 ÷ 1.982
CRANKCASE - CRANKSHAFT COUPLINGS
Name Description Dimensions Initials Quantity
Crankshaft category 1 -
Crankcase category 1 E - E
Crankshaft category 1 -
Crankcase category 2 C - C
Crankshaft class 2 -
Crankcase class 1 C - C
Crankshaft category 2 -
Crankcase category 2 B - B
CRANKSHAFT - CRANKCASE
Name Description Dimensions Initials Quantity
Crankshaft Category 1 28.998 ÷ 29.004
Crankshaft Class 2 29.004 ÷ 29.010
Crankcase Category 1 32.959 ÷ 32.965
Crankcase Class 2 32.953 ÷ 32.959
Characteristics Carnaby 125 - 200
CHAR - 20