Piaggio Carnaby Cruiser 300 ie Full Service & Repair Manual

SERVICE STATION MANUAL xxxxxx (IT) - xxxxxx (EN) - xxxxxx (FR) - xxxxxx (DE) - xxxxxx (ES) - xxxxxx (PT) -xxxxxx (NL) - xxxxxx (EL) Carnaby Cruiser 300 ie

SERVICE STATION MANUAL Carnaby Cruiser 300 ie 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 each model should be checked at the official Piaggio sales network. "© Copyright 2008 - 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 Carnaby Cruiser 300 ie 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, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special 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 INJECTION INJEC 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. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections. Carnaby Cruiser 300 ie Characteristics CHAR - 7

Vehicle identification The chassis prefix «A» is stamped near the right shock absorber upper connection to the chassis. The engine prefix «B» is stamped near the rear left shock absorber lower support. VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix M60400 Engine prefix M604M Characteristics Carnaby Cruiser 300 ie CHAR - 8

Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Length 2050 mm Width to handlebar 780 mm Wheelbase 1400 mm Height 1200 mm Kerb weight 163 kg ± 5 kg Maximum weight allowed 350 kg Engine ENGINE Specification Desc./Quantity Type Single-cylinder, 4-stroke Engine capacity 278 cm³ Bore x Stroke 75x63 mm Compression ratio 11 ± 0.5 : 1 Engine idle speed 1,700 ± 100 rpm Timing system 4 valves, single overhead camshaft, chain-driven. Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm Max. power 16.1 kW at 7,250 rpm MAX. torque 23 Nm at 6,000 rpm Lubrication Engine lubrication with lobe pump (inside crankcase), chain- driven, with double filter: mesh and paper. Lubrication pressure 4 bar Minimum lubrication pressure (100° C) 0.8 bar Fuel system Electronic injection with Ø 32-mm throttle body and electric fuel pump. Cooling Forced coolant circulation system. Fuel Unleaded petrol (95 RON) Carnaby Cruiser 300 ie Characteristics CHAR - 9

Specification Desc./Quantity Exhaust silencer Absorption-type exhaust silencer with a 3-way catalytic con- verter and lambda probe. Emissions compliance EURO 3 Transmission TRANSMISSION 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 Gear reduction unit in oil bath. Capacities CAPACITY Specification Desc./Quantity Engine oil 1.3 l Transmission oil 250 cm³ Cooling system fluid 1.75 l Fuel tank (reserve) ~ 10 l (2 l) Fork oil (quantity per stem) 133 cm³ Electrical system ELECTRICAL COMPONENTS Specification Desc./Quantity Starter starter Ignition Electronic inductive discharge ignition, high efficiency, with separate HV coil. Ignition advance α/N three-dimensional map managed by control unit Spark plug NGK CR8EKB Battery Sealed, 12 V / 10 Ah Fuses 2+1 3A - 5+1 7.5A - 4+1 15A - 1+1 30A Alternator alternating current CHECKING REMOTE CONTROLS «A» OPER- ATING AS CIRCUIT BREAKERS 1) Check that, given regular conditions, there is no continuity between terminals 30 and 87. 2) Apply 12V voltage to power terminals 85 and 86 of the remote control. 3) With the remote control powered, check that there is continuity between terminals 30 and 87. 4) If these conditions are not fulfilled, the remote control is damaged and must be replaced. To check buttons and switches, check that, according to their position, the continuity of contacts is correct as indicated in the following charts. Characteristics Carnaby Cruiser 300 ie CHAR - 10

Piaggio Carnaby Cruiser 300 ie Full Service & Repair Manual

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