Mode d'emploi PIAGGIO SKIPPER

[. . . ] WORKSHOP MANUAL 633225 Fly 125 - 150 4T WORKSHOP MANUAL Fly 125 - 150 4T The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this booklet 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 shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. [. . . ] - Remove the rocking levers and the elastic washer. N. B. MARK THE ROCKING LEVERS ASSEMBLE POSITION, SO AS TO AVOID THE INVERSION OF INLET WITH THE OUTLET. Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two centring dowels and the gasket. N. B. IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REENG - 107 Engine Fly 125 - 150 4T MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool - Remove the oil seals with the appropriate tool. - Remove the lower spring supports. Specific tooling 020431Y Valve oil seal extractor Removing the cylinder - piston assy. - Remove the chain guide pad. - Remove the cylinder base gasket. CAUTION TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER. ENG - 108 Fly 125 - 150 4T Engine - Remove the two stop rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston. N. B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL. Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N. B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER". Characteristic Rod small end check-up: Maximum diameter 15. 030 mm Rod small end check-up: Standard diameter 15 +0. 015+0. 025 mm Inspecting the wrist pin - Check the outer diameter of the gudgeon pin. Characteristic Standard pin diameter 14. 996 ÷ 15 mm Minimum diameter permitted Ø 14. 994 mm ENG - 109 Engine Fly 125 - 150 4T - Calculate the piston pin coupling clearance. N. B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON. Characteristic Piston pin bore - standard diameter Ø 15+0. 001 +0. 006 - Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis. - Measure 36. 5 mm from the piston crown's shown in the figure. N. B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON. - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D). Characteristic Maximum allowable run-out: 0. 05 mm - The cylinder rectifying operation should be carried out with a surfacing that respects the original angle. - The cylinder surface roughness should be 0. 9 micron. - This is indispensable for a good seating of the sealing rings, which in turn minimises oil consumption and guarantees optimum performance. ENG - 110 Fly 125 - 150 4T Engine - The pistons are oversized due to cylinder rectification and are subdivided into three categories 1st, 2nd, 3rd with 0. 2-0. 4-0. 6 mm oversize. They are also classified into 4 categories A-A, B-B, CC, D-D. Inspecting the piston - Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston. STANDARD COUPLING CLEARANCE Name Top piston ring Middle piston ring oil scraper Description Dimensions 0. 025 ÷ 0. 070 0. 015 ÷ 0. 060 0. 015 ÷ 0. 060 Initials Quantity MAXIMUM ADMITTED CLEARANCE AFTER USE Name Top piston ring Middle piston ring oil scraper Description Dimensions 0. 080 mm 0. 070 mm 0. 070 mm Initials Quantity Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Fit the pin stop ring onto the appropriate tool. Specific tooling 020430Y Pin lock fitting tool ENG - 111 Engine Fly 125 - 150 4T - With the opening in position indicated on the tool, take stop ring in the closed position using the punch. - Fit the wrist pin stop using the plug as shown in the figure N. B. THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING. Refitting the piston rings - Place the oil scraper spring on the piston. [. . . ] Refit the new shoes giving a few taps with the mallet. Attach the spring using the specific pliers. Specific tooling 020325Y Brake-shoe spring calliper BRAK SYS - 173 INDEX OF TOPICS CHASSIS CHAS Fly 125 - 150 4T Chassis Removing the ignition key-switch when on *off* • Remove the shield back plate • Push the lock body until the stop spring does not show grooves. • Keep the lock body blocked with a screwdriver and remove the spring with a pair of pliers. • Take out the lock block. Removing the ignition key-switch when on *lock* Remove the shield. [. . . ]