Derbi Manuals for mechanics

This manual has been prepared by DERBI Nacional Motor, S.A. Sociedad Unipersonal for use by concessionaires and DERBI sub-agency workshops. It is assumed that persons using this work for the maintenance and repair of DERBI vehicles will have a basic grounding in the principles of mechanics and the necessary technical methods used in the repair of such vehicles. Major variations in the technical specifications of the vehicles or in specific repair operations will be communicated by means of updates to this manual. Nevertheless, completely satisfactory work cannot be performed without the necessary installations and tools: for this reason we strongly recommend that you consult the pages in this manual which refer to specific tools and equipment. Information in this manual which is of particular importance is indicated by the following notes: N.B. This indicates a note which gives key information for performing the procedure more easily and clearly. This indicates specific procedures which should be followed to avoid causing damage to the vehicle. This indicates procedures which should be followed to avoid possible injury to the person carrying out the repairs to the vehicle. Caution! Warning !!! All data may be changed without prior notice. Derbi declines all responsibility for the use of non-original parts and accessories which have not been tested and approved. 1  DERBI - NACIONAL MOTOR Sociedad Unipersonal / 2002 • Dep. Leg. GI-1302-2000 • N.º 80881158407 fourth edition - May 2002

3 INDEX Predator-LC / O2 Atlantis-LC / O2 / 100 Models Hunter - Paddock - Vamos Models Technical specifications of the engine _4 Special tools_____________________5 Regular maintenance table _________6 Torque settings___________________7 Front forks - HUNTER _____________8 Front forks - PADDOCK ____________9 Front forks - VAMOS ______________9 Withdrawing the engine from the frame ________________10 Stripping the engine ______________11 Assembly of the engine ___________16 Crankshaft inspection_____________18 Assembly of right hand crankcase bearing ______________________19 Water pump ____________________20 Assembly of sliding weight hub _____22 Clutch assembly_________________23 Reduction gear__________________24 Left hand crankcase cover _________24 Cylinder head, cylinder, and piston ____________________27 Carburettor _____________________30 Cylinder sleeve cover, radiator and filter box ___________33 Fitting the engine in the frame ______35 Electrical system ________________36 Electrical wiring diagrams _________45 Regular Maintenance Table ________50 Torque settings__________________51 Front forks _____________________52 Rear suspension ________________54 Removing the engine from the frame ________________56 Magneto _______________________57 Cylinder head, cylinder and piston ___58 Crankshaft - Variable speed unit ____60 Carburettor _____________________61 Electrical system ________________62 Electrical wiring diagrams _________65 Engine Piaggio Models Special tools_________________________74 Regular Maintenance Table __________77 Torque settings ______________________78 Paioli front forks _____________________79 Engine ______________________________80 Magneto_____________________________81 Electronic ignition ____________________83 Transmission - mixer_________________84 Cylinder head - cylinder - piston (Liquid cooled models) ____________95 Crankcase halves - crankshaft _______98 Secondary air system_______________102 Cylinder head - cylinder - piston (Air cooled models) ______________104 Vehicle service data ________________107 Carburettors ________________________110 Electrical system____________________111 Electrical wiring diagrams ___________113 1 2 3

4 Engine Number of cylinders .................1 Cycle ........................................2-stroke Stroke and Bore .......................41 x 37.4 mm Cubic capacity..........................49cc Fuel admission .........................reed valve direct to crankcase Compression ratio ....................11.5 : 1 Starter system ..........................electric start Engine cooling system .............fan-driven pressurised air LC: liquid cooling Fuel ..........................................Unleaded fuel Lubrication system ...................petrol-oil mixture, using constant flow pump driven lubrication Atlantis 100: Stroke and Bore .......................50 x 43 mm Cubic capacity..........................85cc Compression ratio ....................9.5 : 1 Carburettor Type .........................................DELL’ORTO PHVA 10.GD / PHVA12 DD / PHVA 14 DD / PHVA 17.5 WEBER 14 OM 1 AA / WEBER 14 OM 1 BA / WEBER 12 OM 1 QA WEBER 12 OM 1 SA / WEBER 14 OM 1 FA Primary drive...............................automatic variable speed unit through trapezoidal belt drive Clutch ..........................................automatic centrifugal dry clutch Ignition System .....................................magneto 12V 80W. Ignition advance .......................18º before T.D.C. Spark plug ................................NGK B8 HS / CHAMPION L.78 C. NGK B9 ES / CHAMPION N.2.C / NGK B8 ES / CHAMPION N3C Battery......................................12V 4Ah TECHNICAL SPECIFICATIONS OF THE ENGINE

5 Part Name Reference Number 1.- Magneto disassembly tool unit ..............................................................0.0G.053.0.001.1 2.- Connecting rod blocking tool .................................................................0.0G.056.0.037.1 3.- Water pump shaft extractor tool ............................................................0.0G.056.0.042.1 4.- Crankshaft assembly tool (use for water pump shaft) ...........................0.0G.056.0.036.1 5.- Crankshaft seal guide bush ...................................................................0.0F .053.0.084.1 6.- Crankshaft seal assembly punch ..........................................................0.0F .054.0.045.1 7.- Gudgeon pin circlip assembly tool ........................................................0.0G.056.0.041.1 8.- Water pump pinion blocking tool ...........................................................0.0G.053.0.098.1 9.- Engine splitting tool ...............................................................................0.0G.053.0.015.1 SPECIAL TOOLS 1 8 6 4 5 3 9 7 2

6 REGULAR MAINTENANCE TABLE Período: este período puede Km 1000 2500 5000 10000 15000 20000 25000 valorarse según los kilómetros Months 2 6 12 24 36 recorridos o el tiempo en meses Reduction gear or crankcase oil Replace Check Check Replace Check Replace Check Suspensions Check Check Check Check Check Tighten all fastenings Check Check Check Check Check Check Check Electrical connections Check Check Check Check Check Check Check Spark plug Clean Adjust Replace Replace Replace Replace Replace Carburettor Adjust Adjust Adjust Adjust Adjust Adjust Clean Clean Clean Clean Clean Clean Water pump drive belt Replace Variable speed drive rollers Check drive belt transmission Replace Oil filter Check Replace Check Replace Check Air filter Clean Clean Clean Clean Clean Brakes / hose / pads Check Check Check Check Check Brake equipment Check Check Brake fluid EVERY 2 YEARS EVERY 2 YEARS Tyres Check Check Check Check Check Tyres pressures Check Check Check Check Check Check Check Fuel or oil hoses Check Replace Check Replace Check Transmission Lubricate Lubricate Lubricate Lubricate Lubricate Cylinder head nuts Tighten up Tighten up Inlet valve reeds Check Check Period: the period may be calcu- lated by kilometres run or by time in months

7 PART NAME TORQUE SETTING (Nw x m.) BRAKE SHOE ROTATION SHAFT 8M125 17 - 19 LOCTITE CYLINDER STUD 6M100 STUD 10 - 12 CRANKCASE HALVES 6M100 SCREW 9 - 10 LOCTITE CYLINDER HEAD 6M100 NUT 10 - 12 INLET MANIFOLD VALVE BRACKET 4M70 SCREW 1 - 2 LOCTITE CRANKCASE INLET MANIFOLD 6M100 SCREW 9 - 10 LOCTITE OIL PUMP 5M80 SCREW 4 - 5 LOCTITE COIL TO BASE PLATE 6M100 SCREW 8 - 10 LOCTITE BASE PLATE TO CRANKCASE 6M100 SCREW 8 - 10 LOCTITE MAGNETO 10M100 NUT 35 - 40 LOCTITE STARTER MOTOR 6M100 SCREW 9 - 10 LOCTITE FAN TO MAGNETO 6M100 SCREW 8 - 10 LOCTITE ENGINE BRACKET PLATE A.E. 6M100 SCREW 9 - 10 LOCTITE LEFT HAND SIDE CRANKSHAFT 10M100 NUT 35 - 40 LOCTITE REDUCTION GEAR COVER 6M100 SCREW 9 - 10 LOCTITE PULLEY SHAFT 10M100 NUT 35 - 40 LOCTITE PLASTIC OIL FILLER CAP 14M150 CAP HAND TIGHT LEFT HAND CRANKCASE COVER 6M100 SCREW 9 - 10 LOCTITE OIL DRAIN PLUG 8M125 SCREW 17 - 19 CYLINDER SLEEVE 6M100 SCREW 9 - 10 FRONT WHEEL 12M150 NUT 50 - 60 REAR WHEEL 16M150 NUT 100 - 105 SWINGING ARM 10M150 NUT 40 - 45 SHOCK ABSORBER UPPER/LOWER 10M150 NUT 40 - 45 HANDLEBAR 8M125 SCREW 20 - 25 EXHAUST PIPE TO CYLINDER 6M100 SCREW 8 - 12 EXHAUST PIPE - INTERMEDIATE 6M100 NUT 8 - 12 EXHAUST PIPE TO CRANKCASE 10M150 SCREW 40 - 45 FORK LEG CLOSURE 6M100 NUT 8 - 12 STEERING 25M100 NUT 70 - 90 FRONT BRAKE 8M125 SCREW 20 - 25 KICK START PEDAL 6M100 SCREW 08 - 12 LOCTITE SILENCER PROTECTOR 4M70 SCREW 1 - 2 LOCTITE TORQUE SETTINGS

8 HUNTER MODELS Stripping the fork legs - Withdraw the two screws from the brake caliper. - Withdraw the front wheel axle nut and slacken the lock screw. - Withdraw the front wheel axle, the wheel DIS- TANCE PIECE, and leave the transfer box and the separator hanging free. - Withdraw the fork protection plate screw so as to be able to extract the external fork leg cap. - Loosen the 10 x 25 screw from the fork plate and while pushing upwards on the fork leg, release the fork bar securing clip. - Withdraw the fork leg from the vehicle. Both fork legs are the same. Stripping the left or right hand fork bar - Withdraw the safety circlip. - Undo the fork leg tube cap and seal. - Drain the hydraulic fluid from the bar. - Extract the fork leg spring. - Loosen and extract the fork leg screw. - Withdraw the hydraulic tube and the bar from the fork leg. - Extract the dustguard, the seal securing circlip, and finally the seal. Note: Clean thoroughly all the parts which are to be re-fitted; it is mandatory under all cir- cumstances to replace the O-rings and seals. Re-assembly of the fork leg - Fit the seal into the fork leg size 30-40-7/9. Using special tool 0.0H.054.0.045.1 and insert the seal securing circlip. - Insert the hydraulic tube inside the fork bar. - Insert the bar inside the fork leg, fit the fork spring and tighten the 10 x 25 screw using a copper washer and Loctite to a torque of 35 - 40 Nw x m. - Re-fill using 80 cc of AGIP FORK SAE10W hydraulic oil. FRONT FORKS - Insert the fork leg tube cap with the O- ring seal, the safety circlip and the dustguard. - Assemble the fork leg into the vehicle. - Insert the complete fork leg assembly into the fork plate. - Fit the safety circlip and the exterior fork leg cap. - Tighten the fork plate securing screw. - Tighten the mudguard/fork plate protector securing screw. - Locate the wheel axle, the transfer box, the transfer box bushing, the wheel, and fit the brake caliper onto the brake disc; then the distance piece, the washer, the spring washer and nut, tightening to a torque of 50 - 60 Nw x m. - Tighten the fork leg closure screw to a torque of 8 - 12 Nw x m. - Locate the two brake caliper securing screws (8 x 60) to a torque of 20 - 25 Nw x m. using Loctite. Finally turn the wheel and operate the brake lever.

9 PADDOCK MODELS Stripping the fork legs - Withdraw the four mudguard screws and remove the mudguard. - Slacken off the wheel axle nut, withdraw the washer, loosen the 2 front brake caliper screws, loosen the locking screw, extract the wheel axle, the axle distance piece and leave the transfer box and the separator hanging free. Stripping the left hand fork bar - To disassemble the left hand fork bar without stripping the fork the following procedure should be followed: - Remove the dustguard and extract the safety circlip. - Withdraw the two screws securing the bag carrier hook. - Withdraw the seven screws securing the inner shield and remove the inner shield. - Drill a hole using a 15 mm drill through the fork plate protector so as to be able to insert a tube spanner and loosen the 6 x 100 nut and washer; this way it is possible to withdraw the left hand fork leg, with the hydraulic cartridge with bushing and silentbloc, the boss, the rubber stop spring and the guide washer. If the hydraulic cartridge loses oil it must be replaced, since it cannot be repaired. Right hand fork bar - Remove the dustguard and the safety circlip. - Withdraw the right hand fork leg, the lower spring washer, the rubber stop and the spring. This fork leg should be filled with AGIP GR MU 3 type grease only. Re-fitting the two fork legs is carried out in the reverse order from stripping. VAMOS MODELS Stripping the fork legs - Withdraw the 2 front brake caliper screws (“separate the caliper”). - Remove the wheel axle nut, the spring washer and the washer. - Withdraw the wheel axle, the transfer box bushing and the whole transfer box assembly. - Loosen the end piece screws, and withdraw the end pieces. - Extract the fork leg dustguard and the safety circlip. - Withdraw the fork leg, the stop and the spring. When re-assembling, carry out the same procedures in reverse order. The fork legs should be filled with AGIP GR MU 3 type grease.

10 STRIPPING - Remove the luggage carrier ( 4 screws). - In PADDOCK models separate the electrical connectors on the turn indicators. - The left hand footrest cover (1 screw). - The left hand side panel (2 screws). - The right hand footrest cover (1 screw). - The right hand side panel (2 screws). - Raise the saddle. - Remove the side panels (5 screws). - Remove the oil reservoir cap. - Remove the fuel tank filler cap. - Remove the anti-freeze reservoir cap on PAD- DOCK-LC models. - Remove the helmet carrier box (6 screws). - Remove the rear brake cable nut. - Remove the rear brake guide stop (1 screw). - Remove the engine earth screw. - Remove the throttle cable union. - Disconnect the electrical connectors for the magneto, the stop light, the choke, the starter, the high tension coil and the coil earth cable. - On the LC models, also disconnect the thermo- contact spade connector. - Disconnect the two pipes from the connector on the carburettor: the fuel pipe and the vacuum line. - Disconnect the oil hose at the reservoir outlet. - In PADDOCK-LC models extract the antifreeze drain plug. - Remove the cooling hoses where they connect to the antifreeze reservoir. - Remove the 2 fixing screws which secure the engine to the frame. - Remove the 1 shock absorber screw. - Separate the engine from the frame. WITHDRAWING THE ENGINE FROM THE FRAME

Derbi Manuals for mechanics

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