Piaggio Carnaby 125 - 200 Workshop Service Repair Manual

SERVICE STATION MANUAL 633986 IT-633987 EN-633988 FR-633989 DE-633990 ES-633991 PT-633992 OL-633993 EL Carnaby 125 - 200 Downloaded from www.Manualslib.com manuals search engine

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. "© 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) Downloaded from www.Manualslib.com manuals search engine

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 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. Downloaded from www.Manualslib.com manuals search engine

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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 Downloaded from www.Manualslib.com manuals search engine

INDEX OF TOPICS CHARACTERISTICS CHAR Downloaded from www.Manualslib.com manuals search engine

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. Carnaby 125 - 200 Characteristics CHAR - 7 Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

Specification Desc./Quantity Lubrication Engine lubrication with lobe pump (inside crankcase) 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 Engine lubrication with lobe pump (inside crankcase) 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 T RANSMISSION Specification Desc./Quantity Transmission Automatic expandable pulley variator with torque server, V- belt, self-ventilating dry automatic centrifugal clutch and transmission 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 Downloaded from www.Manualslib.com manuals search engine

Piaggio Carnaby 125 - 200 Workshop Service Repair Manual

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