2009 Piaggio Liberty 125-250 OEM Service & Repair Manual

SERVICE STATION MANUAL ******* Liberty 125 - 150 (2009)

SERVICE STATION MANUAL Liberty 125 - 150 (2009) 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 Liberty 125 - 150 (2009) 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 SUSPENSIONS SUSP CHASSIS CHAS PRE-DELIVERY PRE DE TIME TIME

INDEX OF TOPICS CHARACTERISTICS CHAR

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. Characteristics Liberty 125 - 150 (2009) CHAR - 6

Vehicle identification The chassis prefix «A» is stamped on the right strut. The engine prefix «B» is stamped near the rear left shock absorber lower support. VEHICLE IDENTIFICATION (125) Specification Desc./Quantity Chassis prefix M67100 Engine prefix M671M VEHICLE IDENTIFICATION (150) Specification Desc./Quantity Chassis prefix M67200 Engine prefix M672M Liberty 125 - 150 (2009) Characteristics CHAR - 7

Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 114±5 kg Wheelbase 1325 mm Length 1935 mm Width 760 mm Height 1120 mm Engine SPECIFICATIONS - 125 ENGINES Specification Desc./Quantity Type Single-cylinder, 4-stroke Engine capacity 124 cm³ Bore x stroke 57.0 x 48.6 mm Compression ratio 10.6 ± 0.5: 1 Engine idle speed 1650 ± 100 rpm Timing system 2 valves, single overhead camshaft, chain-driven. Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm Max. power 7.7 kW at 8,250 rpm MAX. torque 9.6 Nm at 7,250 rpm 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. Characteristics Liberty 125 - 150 (2009) CHAR - 8

Specification Desc./Quantity Lubrication Engine lubrication with lobe pump (inside crankcase), chain- driven, with double filter: mesh and paper. Cooling Forced-air circulation cooling. Starter starter Ignition Capacitive discharge ignition, with variable advance and sep- arate HV coil. Ignition advance Three-dimensional map managed by control unit Spark plug CHAMPION RG 6 YC Alternative spark plug NGK CR7EB Fuel system KEIHIN CVK 27 carburettor and vacuum-operated fuel pump. Fuel Unleaded petrol (95 RON) Exhaust silencer Absorption-type exhaust muffler with catalytic converter. Emissions compliance EURO 3 SPECIFICATIONS - 150 ENGINES Specification Desc./Quantity Type Single-cylinder, 4-stroke Engine capacity 151 cm³ Bore x stroke 62.8 x 48.6 mm Compression ratio 10.6 ± 0.5 : 1 Engine idle speed 1,650±100 rpm Timing system 2 valves, single overhead camshaft, chain-driven. Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm Max. power 8.9 kW at 7,750 rpm MAX. torque 11.8 Nm at 6,500 rpm 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. Lubrication Engine lubrication with lobe pump (inside crankcase), chain- driven, with double filter: mesh and paper. Cooling Forced-air circulation cooling. Starter starter Ignition Capacitive discharge ignition, with variable advance and sep- arate HV coil. Ignition advance Three-dimensional map managed by control unit Spark plug CHAMPION RG 6 YC Alternative spark plug NGK CR7EB Fuel system KEIHIN CVK 27 carburettor and vacuum-operated fuel pump. Fuel Unleaded petrol (95 RON) Exhaust silencer Absorption-type exhaust muffler with catalytic converter. Emissions compliance EURO 3 Transmission TRANSMISSION Specification Desc./Quantity Main drive Automatic expandable pulley variator with torque server, V- belt, automatic self-ventilating centrifugal dry clutch Final reduction gear Gear reduction unit in oil bath. Capacities CAPACITIES Specification Desc./Quantity Engine oil 1.10 l Transmission oil 200 cm3 Fuel tank capacity about 7 litres (1.5 l of which is reserve) Liberty 125 - 150 (2009) Characteristics CHAR - 9

Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Starter starter Ignition Capacitive discharge ignition, with variable advance and sep- arate HV coil. Ignition advance Three-dimensional map managed by control unit Spark plug CHAMPION RG 6 YC Alternative spark plug NGK CR7EB Battery Sealed, 12 V / 10 Ah Alternator alternating current Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc./Quantity Chassis Tubular steel frame FRONT SUSPENSION Ø 32 Hydraulic telescopic fork - travel: 76 mm Rear suspension Hydraulic single shock absorber and spring adjustable to 4 po- sitions at preloading; travel: 85.5 mm. Brakes BRAKES Specification Desc./Quantity Front brake Ø 240mm drum brake with twin-plunger floating calliper. Rear brake Ø 140-mm drum brake with mechanical control activated by the handlebar left-side lever. Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Wheel rim type Light alloy wheel rims. Front wheel rim 16'' x 2.15 Rear wheel rim 14'' x 2.75 Front tyre Tubeless, 90/80 - 16" 51J Rear tyre Tubeless, 110/80 - 14" 59J Front tyre pressure (with passenger) 2 bar (- bar) Rear tyre pressure (with passenger) 2.2 bar (2.5 bar) Secondary air In order to reduce polluting emissions, the vehicle is furnished with a catalytic converter in the muffler. To favour the catalytic process, an extra amount of oxygen is added to the exhaust through a secondary air system (SAS). Characteristics Liberty 125 - 150 (2009) CHAR - 10

2009 Piaggio Liberty 125-250 OEM Service & Repair Manual

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