Copyright 2. PIAGGIO C. S. p. A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited. SERVICE STATION MANUAL Carnaby 1. This service station manual has been drawn up by Piaggio C. Spa to be used by the workshops of Piaggio Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle repairing techniques and procedures. INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME. Buena Vista Co Rv Parks And Campgrounds. INDEX OF TOPICS CHAR HARACTERISTICS. 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. Carnaby 1. 25 2. Characteristics Vehicle identification The chassis prefix A is located near the right shock absorber connection to the frame. The engine prefix B is stamped near the left shock absorber lower support. VEHICLE IDENTIFICATION 1. Specification Desc. Quantity. Carnaby 1. Characteristics Dimensions and mass WEIGHTS AND DIMENSIONS 1. Specification Desc. Quantity Kerb weight 1. Maximum weight allowed 3. Overall height 1. Width 7. 55 mm Wheelbase 1. Length 2,0. 25 mm WEIGHTS AND DIMENSIONS 2. Specification Desc. Quantity. Carnaby 1. Characteristics Specification Desc. Quantity Lubrication Engine lubrication with lobe pump inside crankcase controlled by a chain with double filter mesh and paper. Lubrication pressure 4 bar Minimum lubrication pressure 1. C 0. 8 bar Fuel supply KEIHIN CVEK 3. Carnaby 1. 25 2. Characteristics Specification Desc. Quantity Spark plug CHAMPION RG4. HC Alternative spark plug NGK CR8. EB Battery Sealed, 1. V 1. 0 Ah ELECTRICAL SYSTEM 2. Specification Desc. Quantity Start up Electric Ignition Capacitive discharge ignition, with variable advance and sep arate HV coil. Carnaby 1. 25 2. Characteristics instead of entering through the muffler as for 2. T engine, the secondary air enters directly in the discharge pipe on the head. The 2. T reed valve has a diaphragm. The unit, indicated by an arrow in the figure, has a cut off connected to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions in the muffler. Carnaby 1. 25 2. Characteristics The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reac tion of the catalytic converter. Carnaby 1. 25 2. Characteristics Specification Desc. Quantity Tapered pin stamping 3. D CUT OFF device Not present Diffuser 2. Maximum jet Minimum jet Max. Minimum air jet Throttle valve spring 1. Minimum mixture set screw initial opening Tapered pin. Carnaby 1. 25 2. Characteristics FRONT SUSPENSION Name Torque in Nm Fixing screw for pumping elements to lower fork plate 2. Front wheel axle 4. Fork leg screw 6 7 front mudguard to plate fixing screw 4. Carnaby 1. 25 2. Characteristics CYLINDER HEAD Name Torque in Nm Spark plug 1. Nuts fixing head to cylinder 1 9 1. Head fixing side screws 1. Starter ground screw 7 8. M5 side screw locking washers on camshaft 7. Carnaby 1. 25 2. Characteristics Assembly clearances Cylinder piston assy. COUPLING CATEGORIES WITH ALUMINIUM CYLINDER Name Initials Cylinder Piston Play on fitting Cylinder piston 7. Cylinder piston 7. Carnaby 1. 25 2. Characteristics COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 5. Cylinder 5. 7. 0. Piston 5. 7. 0. 11 5. Carnaby 1. 25 2. Characteristics ENGINE SEALING RINGS Name Description Dimensions Initials Quantity Compression ring 5. Oil scraper ring 5. Oil scraper ring 5. ENGINE SEALING RINGS 1. ST OVERSIZECarnaby 1. Characteristics ENGINE SEALING RINGS Name Description Dimensions Initials Quantity Compression ring 7. Oil scraper ring 7. Oil scraper ring 7. Crankcase crankshaft connecting rod. Carnaby 1. 25 2. Characteristics Fitting clearances Crankshaftcrankcase axial clearance H 0. CHAR 2. 1. Carnaby 1. Characteristics CRANKSHAFT CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half shaft, transmission 1. D 0. 2. 0 0. 5. Flywheel side half shaft 1. D 0. 2. 0 0. 5. Connecting rod 1. D 0. 2. 0 0. 5. Spacer tool 5. Carnaby 1. 25 2. Characteristics Name Measure A Thickness Shimming Cylinder 6. Head gasket 1. 1 2. Base gasket 0. 6 Characteristic Compression ratio 1. Measurement A to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. Carnaby 1. 25 2. Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 8. W 9. 0 Rear hub oil SAE 8. W9. 0 Oil that exceeds the re quirements of API GL3 specifications AGIP CITY HI TEC 4. T Oil to lubricate flexible transmissions. INDEX OF TOPICS TOOL OOLING. Carnaby 1. 25 2. Tooling APPROPRIATE TOOLS Stores code Description 0. Y Air heater 0. 20. Y Digital multimeter 0. Y Single battery charger 0. Y Multiple battery charger 0. Y0. 14 Pliers to extract 1. TOOL 2. 6. Carnaby 1. Tooling Stores code Description 0. Y 1. 5 mm guide 0. Y Magnetic support for dial gauge 0. Y Flywheel lock calliper spanner 0. Y 1. 7 mm guide 0. Y 4. 2x. 47 mm adaptor TOOL 2. Carnaby 1. 25 2. Tooling Stores code Description 0. Y 2. 0 mm guide 0. Y Punch for fitting bearing on steering tube 0. Y Puller for lower bearing on steering tube 0. Y Engine support 0. Y Flywheel extractor 0. Y Oil pressure control fitting TOOL 2. Carnaby 1. 25 2. Tooling Stores code Description 0. Y0. 11 adapter for valve removal tool 0. Y Driven pulley roller casing fitting punch 0. Y Valve oil seal extractor 0. Y Oil pressure gauge 0. Y Punch for assembling valve seal rings 0. Y Adaptor 5. 2 x 5. Carnaby 1. 25 2. Tooling Stores code Description 0. Y 2. 5 mm guide 0. Y Adaptor 2. 8 x 3. Y Adaptor handle 0. Y Tool for fitting removing the driven pulley clutch 0. Y Stroboscopic light to check timing 0. Y0. 35 Belle for OD 4. Carnaby 1. 25 2. Tooling Stores code Description 0. Y driving pulley lock wrench 0. Y Immobilizer check tester 0. Y Clamp to assemble piston on cylinder 0. Y Sheath for driven pulley fitting 0. Y Crankcase splitting strip 0. Y Pin lock fitting tool TOOL 3. Carnaby 1. 25 2. Tooling Stores code Description 0. Y Piston position check support 0. Y Piston fitting fork 0. Y Punch for flywheel side oil seal 0. Y driven pulley lock wrench 0. Y 2. 8 mm guide 0. Y Piston fitting band TOOL 3. Carnaby 1. 25 2. Tooling Stores code Description 0. Y Valve cotters equipped with part 0. Y 1. 0 mm guide 0. Y Pulley lock wrench 0. Y Water pump service tool 0. Y Mity. Vac vacuum operated pump 0. Y 3. 2 x 3. 5 mm adaptor. Carnaby 1. 25 2. Tooling Stores code Description 0.