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PIAGGIO Carnaby 125 User Manual

PIAGGIO Carnaby 125
310 pages
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Page #144 background imageLoading...
Page #144 background image
bearing «A»
Ø 12.000 - 12.018 mm
bearing «B»
Ø 20.000 ÷ 20.021 mm
bearing «C»
Ø 37.000 - 37.025 mm
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Ensure that the camshaft control pulley chain as-
sembly and the sprocket wheel are not worn.
- If you encounter wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn replace
the whole assembly.
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
Engine Carnaby 125 - 200
ENG - 144

Table of Contents

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PIAGGIO Carnaby 125 Specifications

General IconGeneral
Displacement124 cc
Front SuspensionTelescopic fork
Engine TypeSingle cylinder, 4-stroke
Cooling SystemAir-cooled
TransmissionCVT
Front BrakeDisc brake

Summary

Rules and Guidelines

Safety Rules for Maintenance

General safety guidelines applicable to all maintenance operations performed on the vehicle.

Maintenance Rules and Best Practices

Guidelines for using genuine parts, specific tools, and proper refitting procedures.

Vehicle Identification and Specifications

Chassis and Engine Prefixes

Locating and identifying chassis and engine prefixes for models 125 and 200.

Dimensions and Mass Specifications

Weights and overall dimensions for both the 125 and 200 models.

Engine Specifications Overview

Technical details for the 125cc and 200cc engines, including type, capacity, and power.

Transmission, Capacities, and Electrical System

Information on transmission, fluid capacities, and electrical system components for 125cc models.

Electrical, Chassis, Suspension, and Brake Specs

Details on electrical systems, chassis, suspensions, brakes, wheels, and tyres.

Carburettor and Tightening Torques

Carburettor Details and Identification

Specifications and identification for the Keihin carburettor used in 125cc and 200cc versions.

Tightening Torques - Steering and Frame

Specified torque values for steering components and frame assembly fasteners.

Component Tightening Torques

Torque specifications for suspension, brake, muffler, and lubrication system components.

Engine Component Tightening Torques

Torque values for cylinder head, transmission, flywheel, and cooling system parts.

Engine Assembly and Clearances

Cylinder-Piston Coupling Categories

Categories and clearances for cylinder-piston assembly with different cylinder materials.

Piston Rings Specifications

Dimensions and quantities for engine sealing rings for various piston oversizes.

Crankcase-Crankshaft-Connecting Rod Data

Specifications for crankshaft bearings, couplings, and crankcase dimensions.

Fitting Clearances and Slot Packing System

Axial clearance for crankshaft and piston protrusion measurement for gasket selection.

Recommended Products and Tooling

Recommended Products Table

Table listing recommended products for engine oil, brake fluid, and other maintenance fluids.

Appropriate Tools Catalog

A catalog of essential tools required for vehicle maintenance and repair procedures.

Maintenance Procedures

Maintenance Chart Overview

Schedule of recommended maintenance tasks based on time intervals or mileage.

Carburettor and Ignition System Service

Procedures for carburettor service and checking spark advance and ignition timing.

Engine Component Maintenance

Procedures for spark plug, hub oil, air filter, and engine oil/filter service.

System Checks and Adjustments

Checking oil pressure, ignition timing, valve clearance, coolant level, and brake fluid levels.

Troubleshooting Guide

Engine Performance and Starting Issues

Diagnosing and resolving poor engine performance, starting difficulties, and overheating.

Transmission, Brake, and Suspension Issues

Troubleshooting clutch, braking system, and suspension problems.

Electrical System and Steering Issues

Diagnosing and resolving battery, turn signal, and steering/suspension issues.

Suspension Oil Leakage Troubleshooting

Identifying and addressing suspension oil leakage problems.

Electrical System Details

Electrical System Diagrams and Keys

Wiring diagrams, component keys, and legends for the vehicle's electrical system.

Electrical Component Locations

Visual guide to the location of key electrical components on the scooter.

Ignition and Charging System Checks

Procedures for checking ignition circuit, Pick-Up, HV coil, stator, and voltage regulator.

Battery Service and Pump Electrics

Instructions for battery charging, servicing, and electric fuel pump checks.

Engine Service Procedures

Exhaust Assembly and Engine Removal

Steps for removing the exhaust system and the engine from the vehicle frame.

Automatic Transmission Service

Procedures for removing, inspecting, and refitting the automatic transmission cover and components.

Clutch and Driven Pulley Service

Steps for removing, inspecting, and refitting the clutch assembly and driven pulley components.

Piston, Cylinder, and Head Service

Procedures for removing, inspecting, and refitting the cylinder, piston, head, and valves.

Camshaft, Timing System, and Carburettor Service

Inspecting and refitting camshaft, timing system, and carburettor components.

Engine Idle Adjustment

Procedure for warming up the engine and adjusting idle speed and carburetion.

Suspension System Service

Front Wheel Service

Procedures for removing, overhauling, and refitting the front wheel and its hub bearings.

Handlebar and Front Fork Service

Steps for removing and overhauling the handlebar and front fork assemblies.

Steering Bearing Service

Procedures for refitting and servicing steering column bearings and headstock components.

Rear Wheel and Swing-arm Service

Steps for removing and refitting the rear wheel, brake disc, and swing-arm.

Shock Absorber and Exhaust Bracket Service

Procedures for removing and refitting shock absorbers and the exhaust bracket.

Centre-stand Service

Procedures for refitting and lubricating centre-stand components.

Braking System Service

Braking System Intervention Rules

General rules and warnings regarding brake fluid handling and system maintenance.

Rear Brake Calliper and Disc Service

Procedures for removing, overhauling, and refitting the rear brake calliper and disc.

Front Brake Calliper and Disc Service

Steps for removing, overhauling, and refitting the front brake calliper and disc.

Brake Pad Service

Procedures for replacing front and rear brake pads, including thickness checks.

Brake System Bleeding Procedures

Procedures for bleeding air from the rear and front brake systems.

Brake Pump Service

Steps for removing, overhauling, and refitting the front and rear brake master cylinders.

Cooling System Service

Cooling Circuit Diagram and Fan Check

Diagram of the cooling system and procedure for checking the electric fan.

Thermoswitch and Coolant Replacement

Testing the thermoswitch and procedures for replacing engine coolant.

Thermostat Service

Steps for removing, checking, and refitting the engine thermostat.

Chassis Components Service

Seat, Rack, and Handlebar Cover Removal

Procedures for removing the seat, rear rack, and handlebar covers.

Instrument Panel and Front Handlebar Cover Removal

Steps for removing the instrument panel and front handlebar fairing.

Headlight, Legshield, and Knee-guard Removal

Procedures for removing headlight, legshield panels, and knee guards.

Ignition Key-Switch and Front Wheel Housing Removal

Steps for removing ignition key switch and front wheel housing components.

Taillight, Footrest, and Side Fairing Removal

Procedures for removing taillight, footrests, and side fairings.

Rear Mudguard and Helmet Bay Removal

Steps for removing rear mudguard and underseat helmet compartment.

Fuel Tank and Front Mudguard Removal

Procedures for removing fuel tank and front mudguard components.

Radiator Fan and Expansion Tank Removal

Steps for removing radiator fan, expansion tank, and related hoses.

Pre-Delivery Checks

Aesthetic and Torque Inspection

Visual checks for appearance and proper tightening of critical fasteners.

Electrical System and Battery Checks

Verification of electrical system functionality and battery condition.

Fluid Levels and Road Test

Checking fluid levels and performing a road test to assess vehicle performance.

Static and Functional Inspection

Post-road test checks on starting, steering, and overall system functionality.

Time Intervals (Maintenance Schedule)

Engine Component Time Intervals

Recommended time intervals for engine part service and replacement.

Crankcase and Crankshaft Time Intervals

Recommended time intervals for crankcase and crankshaft component service.

Cylinder Assembly Time Intervals

Recommended time intervals for cylinder-piston and related components.

Cylinder Head Assembly Time Intervals

Recommended time intervals for cylinder head, valves, and gasket service.

Camshaft and Timing System Time Intervals

Recommended time intervals for camshaft and timing system component service.

Transmission Components Time Intervals

Recommended time intervals for driven pulley, clutch, and related parts service.

Oil Pump and Sump Unit Time Intervals

Recommended time intervals for oil pump and sump unit service and replacement.

Final Drive and Driving Pulley Time Intervals

Recommended time intervals for final gear and driving pulley component service.

Carburettor and Exhaust Pipe Time Intervals

Recommended intervals for carburettor and exhaust system maintenance.

Air Cleaner and Frame Time Intervals

Recommended intervals for air cleaner and chassis component replacement.

Electrical Components Time Intervals

Recommended intervals for electrical device and fuse replacement.

Secondary Air Box Time Intervals

Recommended intervals for secondary air filter, housing, and valve replacement.

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