Derbi GPR 125 4-stroke Motorcycle Service & Repair Manual

WORKSHOP MANUAL GPR 125 4-stroke

INTRODUCTION ................................................................... SAFETY REGULATIONS ...................................................... MAINTENANCE REGULATIONS ....................................... SPECIAL TOOLS FOR THE ENGINE .................................. SPECIAL TOOLS - CHASSIS .............................................. TECHNICAL DATA ............................................................... TIGHTENING TORQUES ..................................................... PDI (Pre-delivery inspection) ................................................. LOCATION OF ELEMENTS ................................................. REMOVING BODYWORK ELEMENTS ................................ PERIODICAL MAINTENANCE TABLE ................................. LUBRICATION POINTS ....................................................... INSPECTION AND MAINTENANCE .................................. INSPECTION AND MAINTENANCE ................................. IDENTIFICATION OF SETS ................................................... REMOVING THE ENGINE FROM THE FRAME ................... DISMANTLING THE ENGINE ............................................... INSPECTING THE ENGINE ELEMENTS ............................... ASSEMBLING THE ENGINE .................................................. FITTING THE ENGINE INTO THE FRAME ........................... DISMANTLING THE CARBURETTOR ................................... ASSEMBLING THE CARBURETTOR ...................................... CHECKING LEVEL OF THE FLOAT CHAMBER ................... CHECKING THE VACUM VALVE AND TAPERED NEEDLE ........... CHECKING THE AUTOMATIC CHOKE .............................. ENGINE 4 9 10 13 16 17 26 31 34 36 48 51 52 83 85 89 91 104 119 150 155 160 164 164 166 FUEL SYSTEM CONTENTS 4 5 MAINTENANCE 3 1 GENERAL INFORMATION 0 2

COOLING SYSTEM CHASSIS BRAKE SYSTEM CONTENTS DIAGRAM OF THE SYSTEM .................................................. DESCRIPTION OF THE SYSTEM AND CHECKING OF ELEM .... RENEWING THE WATER PUMP OIL SEAL .......................... DIAGRAM OF THE SYSTEM .................................................. DESCRIPCIÓN OF THE LUBRICATION SYSTEM ................ INSPECTING THE WHEELS ................................................... FRONT WHEEL ....................................................................... FRONT SUSPENSION ........................................................... STEERING ................................................................................ REAR WHEEL ........................................................................... REAR SUSPENSION ............................................................... FRONT BRAKE ........................................................................ REAR BRAKE ............................................................................ GENERAL INDICATIONS ...................................................... LOCATING ELECTRICAL COMPONENTS .......................... WIRING DIAGRAM ................................................................ CHARGING SYSTEM ............................................................. IGNITION SYSTEM ................................................................ STARTER MOTOR SYSTEM .................................................... INSTRUMENT PANEL ............................................................. LIGHTING AND INDICATING ............................................. FITTING NEW COMPONENTS ............................................ INSPECTING THE BATTERY AND FUSES ............................ 6 7 8 9 10 169 171 175 179 181 185 187 189 195 198 200 203 211 221 223 224 225 226 227 228 235 241 245 LUBRICATING SYSTEM ELECTRICAL SYSTEM

4 0 - INTRODUCTION Particularly important items of information in this manual are distinguished by the following annota- tions: Indicates a serious possibility of suffering SEVERE PERSONAL INJURIES OR DEATH if the instructions are not followed. Indicates the possibility that the ELEMENT WILL BE DAMAGED if the instructions are not followed. Presents USEFUL INFORMATION. This manual has been produced by Nacional Motor, S.A.U. for use by DERBI dealer and sub-agency works- hops. It is assumed that those using this publication for training purposes and for repairing DERBI machines have a basic knowledge of mechanics and of the methods inherent in the technique of vehicle repair. Signifi- cant variations in the characteristics of the machines or in the specific repair operations will be communicated by means of updates to this manual. Completely satisfactory work cannot however be carried out without the availability of suitable facilities and tools, which is why we ask you to consult the pages of this manual referring to special tools and imple- ments. NACIONAL MOTOR, S.A.U. CAUTION The DERBI logo is the registered trademark and property of DERBI - Nacional Motor, S.A.U. The total or partial reproduction of any photograph, graphical image or text inserted in this manual is prohibited. © 2009 DERBI - Nacional Motor, S.A.U. Created by: www.ciandisseny.com WARNING N.B.

5 0 - I NTRODUCTION The aim of this manual is to provide the mechanic with a handy and easy to use reference source. It contains comprehensive explanations of all the installation, extraction, dismantling, assembly, repair and checking procedures organized step by step in sequence. Each chapter is divided into sections whose titles appear at the top of each page. The titles of the subsections appear in a smaller format than the section titles. Each operation is accompanied by photographs or illustrations. Numbering corresponding to the chapter. 1 2 3 4 4 3 1 2

6 0 - INTRODUCTION LEFT-HAND SIDE (facing forwards) RIGHT-HAND SIDE (facing forwards) VIEWS OF THE MACHINE Whenever Right-hand or Left-hand Side are specified in this manual, it is understood as meaning facing forward (i.e. in the riding direction). N.B.

7 0 - I NTRODUCTION IDENTIFICATION OF THE MACHINE FRAME SERIAL NUMBER VTHRG1A1Axxxxxxxx The frame serial number is located to the right of the steering column. MANUFACTURER’S PLATE The manufacturer’s plate is located to the right of the steering column. It includes information about the exhaust system’s noise emissions (useful in MOT inspec- tions). ENGINE SERIAL NUMBER * xxxx * The frame serial number is on the rear of the chassis.

8 1 - GENERAL INFORMATION SAFETY REGULATIONS ............................................................ MAINTENANCE REGULATIONS ............................................. SPECIAL TOOLS FOR THE ENGINE ....................................... SPECIAL TOOLS FOR THE CHASSIS ....................................... TECHNICAL DATA .................................................................... TORQUE TIGHTENING VALUES ............................................. 9 10 13 16 17 26 1.1 - 1.2 - 1.3 - 1.4 - 1.5 - 1.6 -

1 - G ENERAL INF ORMATI ON 9 1.1 - SAFETY REGULATIONS - In the event of having to carry out work on the machine while the engine is running, ensure that the work area is well ventilated, where possible using suitable extractor fans. Never leave engines running in closed spaces. The exhaust gases produced contain CO (carbon monoxide) which can cause loss of consciousness and can lead to death when inhaled. - The battery electrolyte contains sulphuric acid. Protect eyes, clothing and skin. Sulphuric acid is highly co- rrosive; in the event of contact with the eyes or skin, wash with copious amounts of water and seek medical attention immediately. If electrolyte is swallowed accidentally, drink copious amounts of water or milk and seek medical attention immediately. - The battery produces hydrogen, a gas that can be highly explosive. Do not smoke, and avoid flames or sparks close to the battery, especially during battery charging operations. - Avoid prolonged contact of used engine oil with the skin. Either wear gloves or wash your hands on finishing handling used oil. - Petrol is extremely inflammable, and in certain conditions can be explosive. Do not smoke, and avoid sparks or other points of ignition in the work area. - Clean brake pads in a well-ventilated place. DO NOT use compressed air to clean brake pads or brake calli- pers. Although the dust does not contain asbestos, its inhalation can cause respiratory illnesses. - Brake liquid attacks painted surfaces very aggressively. Protect painted elements with a clean cloth when performing operations with brake fluid. Wear gloves if possible, since contact of brake fluid with the skin is not advisable. - Prevent coolant from spilling onto hot elements, since it produces an “invisible flame” which may lead to a person receiving burns as a result of not seeing the flame. - Do not remove the radiator cap when the engine is hot, since the coolant is under pressure and at a high temperature, and may cause severe burning. - If coolant enters the eyes, they must be washed immediately with cold water and medical attention sought. - During normal functioning, the exhaust system and the engine are at a high temperature. If work has to be carried out on these, either wait until they have cooled down or wear suitable gloves to avoid being burnt. WARNING

1 - G ENERAL INF ORMATI ON 10 1.2 - MAINTENANCE REGULATIONS - Use genuine DERBI spare parts and lubricants recommended by DERBI. Non-genuine or unauthorised parts may damage the machine. - Only use the specific tools intended for this machine. - During re-assembly, always use new oil seals, gaskets, piston rings and grommets. - After dismantling, clean the components with solvents that are non-inflammable or that have a high flam- mability point. Grease all working surfaces before assembling, excluding tapered joints. - After assembly, check that all components have been correctly fitted and that they are functioning perfectly. - For dismantling, checking and re-assembly operations use only tools with metric measurements. Metric screws, nuts and bolts are not interchangeable with imperial measurement joining devices. Using unsuitable tools and joining devices may damage the machine. - In the case of work on the machine’s electrical circuitry, check that electrical connections have been correctly fitted, especially the earth connections. Use only genuine DERBI spare parts. For all lubrication tasks use oils and greases recommended by DERBI. Other makes make seem similar in their function and appearance, but are inferior in quality. Examine all the locking rings carefully before fitting. Always replace the gudgeon pin circlips after every use. Replace distorted locking rings. On fitting a locking ring (1), ensure that the sharp edge (2) is on the opposite side to the force (3) to be applied to it. See the figure on the side, (4) Axle. CAUTION N.B.

Derbi GPR 125 4-stroke Motorcycle Service & Repair Manual

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