Gilera Runner 125-200 Service & Repair Manual

SERVICE STATION MANUAL 633616 - 633623 Runner RST 125 - 200

SERVICE STATION MANUAL Runner RST 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. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication 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 Runner RST 125 - 200 This service station manual has been drawn up by Piaggio & C. Spa 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, completely satisfactory work cannot be carried out without the necessary equipment and tools. It is therefore advisable to read the sections of this manual relating to appropriate tools, along with the appropriate 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 Sections marked with this symbol indicate the correct use of the vehicle 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

This section describes the general specifications of the vehicle. 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 sure the electric connections have been made properly, particularly the ground and battery connections. Runner RST 125 - 200 Characteristics CHAR - 7

Vehicle identification Vehicle 125 Chassis prefix: ZAPM46100 ÷ 1001 Engine prefix: M461M Vehicle 200 Chassis prefix: ZAPM46200 ÷ 1001 Engine prefix: M462M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity dry weight 134 kg Maximum load Driver + passenger + baggage (180 Kg) Wheelbase 1340 mm Saddle height 810 mm Overall length 1890 mm Overall width 750 mm Characteristics Runner RST 125 - 200 CHAR - 8

Engine TECHNICAL DATA 125 Specification Desc./Quantity Engine single-cylinder, four-stroke Bore x stroke 57 x 48.6 mm Cubic capacity 124 cm³ Compression ratio 11÷12 :1 ignition advance (before TDC) 10° at 2000 rpm - 34° at 6000 rpm Kehin Carburettor CVEK-30 Spark plug Champion RG 4 HC Max. speed 105 km/h Timing system Single overhead camshaft, chain-driven on the left-hand side, three-arm rocking levers with set screw. intake valve clearance 0.10 mm Valve clearance: discharge 0.15 mm Air filter Sponge impregnated with fuel mixture (50% SELENIA air filter oil and 50% unleaded petrol). Starting system Electric starter with Bendix gear Lubrication With lobe pump (inside the crankcase) operated by a double filter chain: mesh and paper filters Fuel supply Petrol (unleaded, with minimum octane rating of 95) through carburettor Engine - wheel ratio long: 1/9.1 Engine - wheel ratio Short: 1/30.36 TECHNICAL DATA 200 Specification Desc./Quantity Engine single-cylinder, four-stroke Bore x stroke 72 x 48.6 mm Cubic capacity 198 cm³ Compression ratio 11.5 :1 ignition advance (before TDC) 10° ± 1° at 2000 rpm - 32° ± 1° at 6500 rpm Kehin Carburettor CVEK-30 Runner RST 125 - 200 Characteristics CHAR - 9

Specification Desc./Quantity Spark plug CHAMPION RG 6 YC Max. speed 120 km/h Timing system Single overhead camshaft, chain-driven on the left-hand side, three-arm rocking levers with set screw. intake valve clearance 0.10 mm Valve clearance: discharge 0.15 mm Air filter Sponge impregnated with fuel mixture (50% SELENIA air filter oil and 50% unleaded petrol). Starting system Electric starter with Bendix gear Lubrication With lobe pump (inside the crankcase) operated by a double filter chain: mesh and paper filters Fuel supply Petrol (unleaded, with minimum octane rating of 95) through carburettor Engine - wheel ratio long: 1/9.1 Engine - wheel ratio Short: 1/30.36 Transmission T RANSMISSIONS Specification Desc./Quantity Transmission With automatic expandable pulley variator, V belt, automatic clutch, gear reduction unit and transmission housing with forced-circulation air cooling. Capacities C APACITY Specification Desc./Quantity Engine oil ~ 1000 cc (recommended oil: Selenia HI Scooter 4 Tech) Fuel tank (including a ~ 1.7 l reserve) 7 l Rear hub 150 cc (recommended oil: TUTELA ZC 90) Cooling system fluid approx. 2.100 ÷ 2.150 l PARAFLU 11FE (Diluted) Electrical system E LECTRICAL COMPONENTS 125 Specification Desc./Quantity Generator 125 Three-phase alternating current Battery 125 12V-12Ah Spark plug 125 Champion RG 4 HC Ignition type 125 Electronic capacitive discharge ignition (CDI) and variable advance, with separate HV coil. variable ignition advance (before T.D.C.) 125 10°±1° at 2000 rpm - 34°±1° at 6000 rpm E LECTRICAL COMPONENTS 200 Specification Desc./Quantity Generator Three-phase alternating current Battery 12V-12Ah Spark plug 200 Champion RG6YC Ignition type Electronic capacitive discharge ignition (CDI) and variable advance, with separate HV coil. variable ignition advance (before T.D.C.) 200 10°±1 at 2000 rpm - 32°±1 at 6500 rpm Characteristics Runner RST 125 - 200 CHAR - 10

Gilera Runner 125-200 Service & Repair Manual

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