Name: PIAGGIO Liberty 125
Brand: PIAGGIO
Rating: 4 (1 reviews)

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WORKSHOP MANUAL

633120

Liberty 125 - 200 4tempi

Index of Topics5
Characteristics6
Safety Rules7
Maintenance Rules7
Vehicle Identification8
Dimensions and Mass8
Weight and Dimensions8
Engine9
Secondary Air11
Carburettor11
125Cc Version11
200Cc Version12
Tightening Torques12
Carburettor Setting12
Overhaul Data13
Assembly Clearances14
Cylinder - Piston Assy.14
Piston Rings14
Crankcase - Crankshaft - Connecting Rod15
Sealing Rings (200)15
Axial Clearance between Crankshaft and Connecting Rod (125)15
Axial Clearance between Crankshaft and Crankshaft Half-Bearings15
Table of Recommended Products17
Tooling18
Tools19
Maintenance28
Maintenance Chart29
Every 2 Years29
Every 3000 Km29
After 1000 Km29
After 24000 Km, 48000 Km30
After 30000 Km, 42000 Km, 66000 Km30
After 36000 Km31
After 72,000 Km31
CO Check32
Specific Tooling33
Troubleshooting34
Engine Poor Performance35
Rear Wheel Spins at Idle35
Starting Difficulties35
Difficulty Starting up35
Troubleshooting35
Excessive Oil Consumption/Exhaust Smoke36
Insufficient Lubrication Pressure36
Engine Tends to Cut-Off at Full Throttle36
Engine Tends to Cut-Off at Idle36
High Fuel Consumption37
Transmission and Brakes37
Clutch Grabbing or Performing Inadequately37
Insufficient Braking37
Excessive Fuel Consumption37
Electrical System38
Battery38
Turn Signal Lights Malfunction38
Heavy Steering38
Noisy Suspension39
Suspension Oil Leakage39
Oil Leakage from Suspension39
Conceptual Diagrams43
Ignition43
Headlights and Automatic Starter Section44
Battery Recharge and Starting45
Level Indicators and Enable Signals Section46
Start Permissive Buttons and Level Indicators46
Turn Signal Lights47
Turn Indicators and Horn47
Instruments and Warning Lights Control Board48
Checks and Inspections48
4-Pin Connector48
6-Pin Connector48
Immobiliser49
Virgin Circuit50
Diagnostic Codes51
Diagnostic Code - 2 Flashes51
Diagnostic Code - 3 Flashes52
Ignition Circuit52
No Spark Plug53
Pick-Up Inspection53
H.T. Coil Primary Circuit Inspection53
HV Coil Secondary Check53
Pick-Up54
Multimeter Adaptor - Peak Voltage Detection54
Battery Recharge Circuit55
Stator Check55
Voltage Regulator Check56
Recharge System Voltage Check56
Choke Inspection56
Turn Signals System Check57
Sealed Battery58
Dry-Charge Battery58
Voltage Check up58
Constant Voltage Battery Charge Mode58
Commissioning Dry-Charged Batteries59
Battery Maintenance59
Electrolyte Level Check59
Load Status Check59
Recharging the Battery60
Battery Cleaning60
Engine from Vehicle61
Exhaust Assy. Removal62
Removal of the Engine from the Vehicle62
Automatic Transmission65
Transmission Cover65
Air Duct65
Air Duct Filter66
Removing the Driven Pulley Shaft Bearing66
Refitting the Driven Pulley Shaft Bearing67
Removing the Driven Pulley67
Inspecting the Clutch Drum67
Removing the Clutch68
Inspecting the Clutch69
Pin Retaining Collar70
Removing the Driven Half-Pulley Bearing70
Inspecting the Driven Fixed Half-Pulley71
Inspecting the Driven Sliding Half-Pulley71
Refitting the Driven Half-Pulley Bearing71
Refitting the Driven Pulley72
Inspecting the Clutch Spring73
Refitting the Clutch73
Drive-Belt75
Removing the Driving Pulley76
Inspecting the Rollers Case77
Bushing Roller Container77
Bush Slide Pulley77
Variable Speed Rollers77
Refitting the Driving Pulley79
Refitting the Transmission Cover80
End Gear80
Removing the Hub Cover81
Removing the Wheel Axle81
Removing the Hub Bearings81
Removing the Wheel Axle Bearings82
Inspecting the Hub Shaft83
Inspecting the Hub Cover83
Refitting the Hub Cover Bearings84
Refitting the Hub Bearings85
Refitting the Ub Cover85
Flywheel Cover85
Cooling Hood85
Cooling Fan86
Removing the Stator87
Refitting the Stator87
Flywheel and Starting87
Removing the Flywheel Magneto88
Inspecting the Flywheel Components88
Refitting the Flywheel Magneto88
Refitting the Starter Motor89
Cylinder Assy. and Timing System89
Removing the Timing System Drive89
Removing the Cam Shaft90
Removing the Cylinder Head91
Removing the Valves91
Removing the Cylinder - Piston Assy.92
Inspecting the Small End92
Inspecting the Wrist Pin93
Inspecting the Piston94
Standard Coupling Clearance94
Maximum Admitted Clearance after Use94
Inspecting the Piston Rings95
Removing the Piston96
Choosing the Gasket96
Cylinder Base Gasket Thickness97
Refitting the Piston Rings98
Refitting the Cylinder98
Inspecting the Cylinder Head99
Inspecting the Timing System Components99
Inspecting the Valve Sealings100
Inspecting the Valve Housings100
Inspecting the Valves101
Inspecting the Springs and Half-Cones102
Refitting the Valves103
Inspecting the Cam Shaft103
Refitting the Head and Timing System Components104
Crankcase - Crankshaft108
Splitting the Crankcase Halves109
Standard Diameter110
Inspecting the Crankshaft Alignment111
Inspecting the Crankcase Halves112
Inspecting the Crankshaft Plain Bearings113
Refitting the Crankcase Halves114
Main Bearings114
Oil Pressure Check117
Crankshaft Oil Seals117
Oil Pump Removal120
Oil Pump Inspection121
Oil Pump Refitting122
Removing the Oil Sump123
Inspecting the By-Pass Valve123
Refitting the Oil Sump124
Fuel Supply124
Removing the Carburettor125
Refitting the Carburettor129
Level Check131
Inspecting the Valve and Needle133
Inspecting the Automatic Choke Device134
Adjusting the Idle136
Suspensions138
Front Suspension139
Front Wheel Hub Overhaul139
Handlebar Removal139
Front Fork Overhaul140
Steering Column Refitting140
Steering Bearing140
Steering Bearing Upper Race141
Upper Bearing Washer and Race141
Lower and Upper Races from Frame141
Removing the Rear Wheel142
Refitting the Rear Wheel142
Shock Absorbers Removal142
Centre-Stand142
Changing the Complete Stand143
Expelling Stand Pivot Pin from Bracket143
Braking System144
Rear Brake Calliper Refitting145
Front Brake Calliper Removal146
Front Brake Calliper Overhaul146
Front Brake Calliper Refitting146
Front Brake Disc Removal147
Front Brake Disc Refitting147
Disc Inspection148
Front Brake Pads Removal148
Front Brake Pads Refitting148
Front149
Recommended Products149
Front Brake Pump150
Chassis152
Seat153
Side Fairings153
Rear Rack154
Driving Mirrors154
Rear Handlebar Cover155
Instrument Panel155
Front Handlebar Cover156
Headlight Assy.156
Frame Central Cover157
Legshield157
Knee-Guard158
Removing the Ignition Key-Switch When on *Off*159
Removing the Ignition Key-Switch When on *Lock*159
Taillight Assy.159
Footrest160
License Plate Holder160
Air Filter161
Rear Mudguard161
Helmet Bay162
Spoiler162
Fuel Tank162
Front Mudguard163
Top-Case163
Pre-Delivery165
Aesthetic Inspection166
Tightening Torques Inspection166
Levels Check167
Road Test167
Static Test168
Functional Inspection168
Time169
Crankcase171
Crankshaft172
Cylinder Assy.173
Cylinder Head Assy.174
Rocker Arms Support Assy.175
Cylinder Head Cover176
Chain Tensioner177
Oil Filter178
Driven Pulley180
Oil Pump181
Final Gear Assy.182
Driving Pulley183
Starter Motor184
Flywheel Magneto185
Belt Cooling Duct186
Exhaust Pipe188
Air Cleaner189
Frame190
Legshield Spoiler191
Rear Cover192
Central Cover193
Underseat Compartment194
Plate Holder195
Mudguard196
Rear Shock-Absorber198
Steering Column Bearings199
Handlebar Covers200
Handlebar Components201
Swing-Arm202
Brake Hoses203
Front Wheel206
Grease Tone Wheel or Drive206
Rear Wheel207
Electric Devices208
Electronic Controls209
Transmissions210
Index212

Brand	PIAGGIO
Model	Liberty 125
Category	Scooter
Language	English

PIAGGIO Liberty 125 User Manual

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PIAGGIO Liberty 125 Specifications

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