Piaggio Liberty 125 - 150 MY 2009 (en))

SERVICE STATION MANUAL *******

Liberty 125 - 150 (2009)

SERVICE STATION MANUAL

Liberty 125 - 150 (2009)

The The descr escrip ipttion ions and and illu illust stra rattion ions given iven in this publica licattion ion are are not bind inding ing. Whil While e the basic asic spec specif ific icat atio ion ns as described and illustrat illustrated ed in this manual manual remain remain unchanged, unchanged, PIAG P IAGGI GIO-G O-GIL ILE ERA reserves reserves the right, 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 manufacturing or construct construction ion reasons. 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 P iaggio sales network. network. "©Copyright "©Copyright 200 2008 8 - P IAGG IAGGIO IO & C. S.p.A. P onteder ontedera. a. All All rights rights reserved. Reprod R eproduct uction ion of this publicat publication ion 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 This serv servic ice e stat statio ion n manu anual has has bee been n draw rawn up by Piaggi Piaggio o & C. SpA SpA to to be used used by the works orksho hops ps of Piagg Piaggio-Gi io-Gile lera ra deal dealer ers. s. It is assumed assumed that that the the user of this manual manual for maintaining maintaining and repairing Piaggio P iaggio vehicles vehicles has a basic basic knowledge of mechanica mechanicall 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.

key information information to make make the procedure easier easier to understand and carry out. N.B. P rovides key

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 S ections marked wit with h this sym symbol bol 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 TIME

PRE DE TIME

INDEX OF TOPICS

CHARACTERISTICS

CHAR

Characteristics

Liberty 125 - 150 (2009)

Rules This This sect sectio ion n descr escrib ibes es gener eneral al saf safety ety rules les for for any any main aintenan enance ce oper operat atio ions ns per perform ormed on the vehic ehicle le..

Safety rules - If If work can only be done on the vehicle with the engine running, make make sure that the premises 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.

CHAR - 6

Liberty 125 - 150 (2009)

Characteristics

Vehicle identification The The chas chassi sis s pr prefix efix «A» is stamped on the right strut.

The The eng engine ine pref refix «B» is stam s tamped ped near the rear left shock absorber lower support.

VEHICLE IDENTIFICATION (125) Specification

Desc./Quantity

Chassis prefix Engine prefix

M67100 M671M

VEHICLE IDENTIFICATION (150) Specification

Desc./Quantity

Chassis prefix Engine prefix

M67200 M672M

CHAR - 7

Liberty 125 - 150 (2009)

Characteristics

Dimensions and mass

WEIGHTS AND DIMENSIONS Specification

Desc./Quantity

Kerb weight Wheelbase Length Width Height

114±5 kg 1325 mm 1935 mm 760 mm 1120 mm

Engine SPECIFICATIONS - 125 ENGINES Specification

Desc./Quantity

Typ Type Engine capacity Bore x stroke Compression ratio Engine idle speed Timing ing syst system em Valve clearance Max. power MAX. torque Tran Transm smiss issio ion n

Singl Singlee-cy cyli lind nder er,, 4-st 4-stro roke ke 124 cm³ 57.0 x 48.6 mm 10.6 ±0.5: 1 1650 ±100 rpm 2 valv valves es,, sin singl gle e over overhe head ad cam camshaf shaftt, cha chain in-d -dri rive ven. n. Intake: 0.10 mm Exhaust: 0.15 mm 7.7 kW at 8,250 rpm 9.6 Nm at 7,250 rpm Aut Automatic atic expa expan ndabl dable e pulle ulley y varia ariattor with ith torqu orque e serv server er,, VVbelt, self-ventilating dry automatic centrifugal clutch and transmission issi on housing with forced-circulation air cooling. Gear reduction unit in oil bath.

F inal reduction gear

CHAR - 8

Liberty 125 - 150 (2009)

Characteristics

Specification

Desc./Quantity

Lubrication

E ng ngine lubrication with lobe pump (inside crankcase), chaindriven, with double filter: mesh and paper. F orced-air circulation cooling. starter Capacitive discharge ignition, with variable advance and separate HV coil. Three-dimensional map managed by control unit CHAMP ION RG 6 Y C NGK CR7E B KEIHIN CVK 27 carburettor and vacuum-operated fuel pump. Unleaded petrol (95 RON) Absorption-type exhaust muffler with catalytic converter. E URO 3

Cooling Starter Ignition Ignition advance Spark plug Alternative spark plug F uel system F uel Exh Exhaust silencer Emissions compliance

SPECIFICATIONS - 150 ENGINES Specification

Desc./Quantity

Typ Type Engine capacity Bore x stroke Compression ratio Engine idle speed Timing ing syst system em Valve clearance Max. power MAX. torque Trans Transm missio ission n

Sing Single-c le-cy ylind linder er,, 4-st 4-stro rok ke 151 cm³ 62.8 x 48.6 mm 10.6 ±0.5 : 1 1,650±100 rpm 2 valv alves, es, sin singl gle e over overh head ead cam camshaf shaftt, cha chain in-d -dri riv ven. en. Intake: 0.10 mm Exhaust: 0.15 mm 8.9 kW at 7,750 rpm 11.8 Nm at 6,500 rpm Aut Automatic atic expa expan ndab dable pull pulley ey varia ariattor with ith torq orque serv server er,, VVbelt, self-ventilating dry automatic centrifugal clutch and transmission housing with forced-circulation air cooling. Gear reduction unit in oil bath. E ng ngine lubrication with lobe pump (inside crankcase), chaindriven, with double filter: mesh and paper. F orced-air circulation cooling. starter Capacitive discharge ignition, with variable advance and separate HV coil. Three-dimensional map managed by control unit CHAMP ION RG 6 Y C NGK CR7E B KEIHIN CVK 27 carburettor and vacuum-operated fuel pump. Unleaded petrol (95 RON) Absorption-type exhaust muffler with catalytic converter. E URO 3

F inal reduction gear Lubrication Cooling Starter Ignition Ignition advance Spark plug Alternative spark plug F uel system F uel Exh Exhaust silencer Emissions compliance

Transmission TRANSMISSION Specification

Desc./Quantity

Main drive

Automatic expandable pulley variator with torque server, Vbelt, automatic self-ventilating centrifugal dry clutch Gear reduction unit in oil bath.

F inal reduction gear

Capacities CAPACITIES Specification

Desc./Quantity

E ngine oil Tran Transm smiss issio ion n oil oil F uel tank capacity

1.10 l 200 200 cm3 about 7 litres (1.5 l of which is reserve)

CHAR - 9

Liberty 125 - 150 (2009)

Characteristics

Electrical system ELECTRICAL SYSTEM Specification

Desc./Quantity

Starter Ignition

starter Capacitive discharge ignition, with variable advance and separate HV coil. Three-dimensional map managed by control unit CHAMP ION RG 6 Y C NGK CR7EB S ealed, 12 V / 10 Ah alternating current

Ignition advance Spark plug Alternative spark plug Battery Alternator

Frame and suspensions CHASSIS AND SUSPENSIONS Specification

Desc./Quantity

Chassis F RONT SUS P ENS ION Rea Rear su suspension

Tubular steel frame Ø 32 Hydraulic telescopic fork - travel: 76 mm Hydraulic single shock absorber and spring adjustable to 4 positions at preloading; travel: 85.5 mm.

Brakes BRAKES Specification

Desc./Quantity

F ront brake Rear brake

Ø 240mm drum brake with twin-plunger floating calliper. Ø 140-mm drum brake with mechanical control activated by the handlebar handlebar left-side left-si de lever.

Wheels and tyres WHEELS AND TYRES Specification

Desc./Quantity

Wheel rim type F ront wheel rim Rear wheel rim F ront tyre Rear tyre F ront tyre pressure (with passenger) Rear tyre pressure (with passenger)

Light alloy wheel rims. 16'' x 2.15 14'' x 2.75 Tubeless, 90/80 - 16" 51J Tubeless, 110/80 - 14" 59J 2 bar (- bar) 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 fav favour our the cat cataly alytic proce rocess, ss, an ext extra amou amoun nt of oxygen is added to the exhaust through a secondary air system (SAS).

CHAR - 10

Liberty 125 - 150 (2009)

Characteristics

This This syst system em allo allow ws more ore oxy oxygen to be add added to the unburned gases before they reach the converter, thus improving the action of the catalytic converter. The The air air ent enters ers the exh exhaust aust duct uct from rom the head ead, and and is purified by a black filter. The The syst system em is fitt itted with ith a cont contrrol valv alve that disaisables operation while decelerating to to avoid unwanted noise. To ensu ensurre the best est functio ction ning ing of the SAS syst system em clean the filter as indicated in the scheduled maintenance table. The The filt ilter spon spong ge shou should ld be clea cleane ned d with ith water ater and and mild soap, then it should be dried with a cloth and slight blows of compressed air.

Carburettor 125cc Version Kehin CARBURETTOR SETTING Specification

Desc./Quantity

Typ Type Thro Throtttle valv alve diam diameter eter Diffuser diameter Setting stamping Maximum jet Maximum air jet (on the body) Taper Tapered ed pin pin stam stamping ping Thro Throtttle valve alve spri spring ng Minimum jet Idle air jet (on the body) Idle mixture adjustment screw initial opening Starter nozzle S tarter air jet (on the body) S tarter pin travel S tarter resistance

CVEK27 Ø 26. 26.5 5 Ø 26.4 2701A 82 85 NJ HA 130 130 ÷18 ÷180 gr. gr. 42 150 2½ 42 Ø 1.5 10 mm (at 24°) 20 Ohm (at 24°)

150cc Version

CHAR - 11

Liberty 125 - 150 (2009)

Characteristics

Kehin CARBURETTOR CARBURETTOR SETTING Specification

Desc./Quantity

Typ Type Thro Throtttle valve alve diam diameter eter Diffuser diameter S etting stamping Maximum jet Maximum air jet (on the body) Maximum air jet (on the body) MAJ 2 Tape Tapere red d pin pin stam stamping ping Thro Throtttle valv valve e spri spring ng Minimum jet Idle air jet (on the body) Idle mixture adjustment screw initial opening Starter nozzle S tarter air jet (on the body) S tarter pin travel S tarter resistance

CVEK27 Ø 26. 26.5 5 Ø 26.4 2702B 80 130 80 NELA 130 130 ÷180 ÷180 gr. gr. 35 150 2 42 Ø 1.5 10 mm (at 24°) 20 Ohm (at 24°)

Tightening Torques MOTORE Name

Torque in Nm

Ignition spark plug Head cover screws Head-cylinder stud bolt nuts S crews fixing head and cylinder to crankcase Chain tensioner pad screw Timing ing chai chain n tensio ensione nerr scre screw ws Timing ing chai chain n tensi ension oner er cen central ral screw screw Camshaft pulley screw Rocking lever axle and camshaft bearing screw Valve clearance adjustment lock nuts E ngine oil pre-filter cover: Engine oil drainage cap Alternator flywheel nut S tator screws P ick-up screws Oil pump bulkhead screw Timing ing chai chain/ n/oi oill pum pump com compart partm ment ent cove coverr screw screws s Oil decantation labyrinth sheet screws Oil pump crown screw Screws fixing oil pump to the crankcase Oil pump coupling screws Oil sump screws Inlet manifold screw Carburettor/manifold clamp screw S crews fixing cables to starter motor S tarter screws Trans Transm missio ission n cov cover scre screw ws Crankcase cooling cover screw Nut locking clutch unit on pulley Crankshaft pulley nut Driven pulley shaft nut Hub oil drainage screw Rear hub cap screws Wheel axle nut Crankcase half union screw

10 to 15 Nm 8 ÷10 6 to 7 +90° +90° * 8 to 10 5 to 7 Nm 8 ÷10 ÷10 Nm 5 to 6 12 to 14 3 to 4 Nm 7 ÷9 Nm 25 to 28 Nm 25 to 28 40 ÷44 Nm 3 to 4 3 to 4 4 to 5 4 to 5 Nm 7 to 8 8 to 10 5 to 6 7 ÷9 Nm 8 to 10 Nm 7- 9 1.2 ÷1.5 Nm 1.5 to 2.5 11 to 13 11 ÷13 ÷13 Nm 2 to 2.5 55 to 60 Nm 18 to 20 +90° Nm 40 ÷44 Nm 3 to 5 Nm 24 ÷26 Nm 115 ÷125 8 to 10

Per assicurare una corretta coppia di bloccaggio lubrificare i dadi prima del montaggio.

CHAR - 12

Liberty 125 - 150 (2009)

Characteristics

* Montando dei nuovi prigionieri, l'operazione di serraggio dei dadi comprende l'effettuazione di 3 rotazioni di 90° dopo il primo bloccaggio a 6÷7 Nm, pertanto: 6÷7 Nm + 90° + 90° + 90° a passaggi incrociati.

STEERING ASSEMBLY Name

Torque in Nm

Upper steering ring nut Lower steering ring nut handlebar fixing screw

35 ÷40 12 ÷14 45 ÷55

FRAME ASSEMBLY Name

Torque in Nm

Engine-swinging arm pin F rame-swinging arm bolt Shock absorber - chassis nut Shock absorber/engine pin Rear wheel axle S tand bolt F ront mudguard fixing screw

33 to 41 64 - 72 20 to 25 33 - 41 N.m 104 ÷126 20 ÷25 4 ÷6

FRONT SUSPENSION Name

Torque in Nm

F ork bottom screw F ront wheel axle Odometer drive screw

20 ÷25 45 to 50 6 ÷7

FRONT BRAKE Name

Torque in Nm

Brake fluid pump-hose fitting Brake fluid pipe-calliper fitting Calliper tightening screw Disc tightening screw (Apply LOCTITE 243 medium-strength threadlocker) Oil bleeding valve

20 ÷25 20 ÷22 20 ÷25 8 ÷12 Nm 8 ÷12

Overhaul data Assembly clearances Cylinder - piston assy. PISTON TO CAST IRON CYLINDER COUPLING (125) Name

Initials

Cylinder

P is t o n

Play on fitting

Coupling Coupling Coupling Coupling Coupling 1st oversize Coupling 1st oversize Coupling 1st oversize Coupling 1st oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize

M N O P M1 N1 O1 P1 M2 N2 O2 P2 M3 N3 O3 P3

56.997 to 57.004 57.004 to 57.011 57.011 to 57.018 57.018 to 57.025 57.197 to 57.204 57.204 to 57.211 57.211 to 57.218 57.218 to 57.225 57.397 to 57.404 57.404 to 57.411 57.411 to 57.418 57.418 to 57.425 57.597 to 57.604 57.604 to 57.611 57.611 to 57.618 57.618 to 57.625



CHAR - 13

Liberty 125 - 150 (2009)

Characteristics

COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER (125) Name

Initials

Cylinder

Piston

Play on fitting


A B D C A1 B1 D1 C1 A2 B2 C2 D2 A3 B3 C3 D3

56.980 ÷56.987 56.987 ÷56.994 57.001 ÷57.008 56.994 ÷57.001 57.180 ÷57.187 57.187 ÷57.194 57.201 ÷57.208 57.194 ÷57.201 57.380 ÷57.387 57.387 ÷57.394 57.394 ÷57.401 57.401 ÷57.408 57.580 ÷57.587 57.587 ÷57.594 57.594 ÷57.601 57.601 ÷57.608

56.933 ÷56.940 56.940 ÷56.947 56.954 ÷56.961 56.947 ÷56.954 57.133 ÷57.140 57.140 ÷57.147 57.154 ÷57.161 57.147 ÷57.154 57.333 ÷57.340 57.340 ÷57.347 57.347 ÷57.354 57.354 ÷57.361 57.533 ÷57.540 57.540 ÷57.547 57.547 ÷57.554 57.554 ÷57.561

0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054 0.040 ÷0.054

COUPLING BETWEEN (ASSO-WERKE) PISTON AND CYLINDER (150) Name

Initials

Cylinder

Piston

Play on fitting


A B C D A1 B1 C1 D1 A2 B2 C2 D2 A3 B3 C3 D3




COUPLING BETWEEN (RIGHT WAY) PISTON AND CYLINDER (150) Name

Initials

Cylinder

Piston

Play on fitting

Coupling Coupling Coupling Coupling

A B C D

62.580 to 62.587 62.587 to 62.594 62.594 to 62.601 62.601 to 62.608

62.541 to 62.548 62.548 to 62.555 62.555 to 62.562 62.562 to 62.569

0.032 to 0.046 0.032 to 0.046 0.032 to 0.046 0.032 to 0.046

Piston rings

CHAR - 14

Liberty 125 - 150 (2009)

Characteristics

SEALING RINGS (125) Name

Description

Compression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize Oil scraper ring 1st oversize Oil scraper ring 1st oversize Compression ring 2nd oversize Oil scraper ring 2nd oversize Oil scraper ring 2nd oversize Compression ring 3rd oversize Oil scraper ring 3rd oversize Oil scraper ring 3rd oversize

Dimensions

Initials

Quantity

57 x 1 57x1 57x2.5 57.2 x 1

A A A A

0.15 to 0.30 0.10 to 0.30 0.10 to 0.35 0.15 to 0.30

57.2x1

A

0.10 to 0.30

57.2x2.5

A

0.10 to 0.35

57.4x1

A

0.15 to 0.30

57.4x1

A

0.10 to 0.30

57.4x2.5

A

0.10 to 0.35

57.6x1

A

0.15 to 0.30

57.6x1

A

0.10 to 0.30

57.6x2.5

A

0.10 to 0.35

Dimensions

Initials

Quantity

62.6x1 62.6x1 62.6x2.5 62.8x1

A A A A

0.15 to 0.30 0.20 to 0.40 0.20 to 0.40 0.15 to 0.30

62.8x1

A

0.20 to 0.40

62.8x2.5

A

0.20 to 0.40

63.0 x 1

A

0.15 to 0.30

63.0 x 1

A

0.20 to 0.40

63.0 x 2.5

A

0.20 to 0.40

63.2 x 1

A

0.15 to 0.30

63.2 x 1

A

0.20 to 0.40

63.2 x 2.5

A

0.20 to 0.40

Maximum clearance after use: 1 mm

SEALING RINGS (150) Name

Description

Compression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize Oil scraper ring 1st oversize Oil scraper ring 1st oversize Compression ring 2nd oversize Oil scraper ring 2nd oversize Oil scraper ring 2nd oversize Compression ring 3rd oversize Oil scraper ring 3rd oversize Oil scraper ring 3rd oversize

Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (125) Name

Trans Transm missio issions nsid ide e half alfshaft F lywheel-side halfshaft Connecting rod with P P Crank pin width

Description

Dimensions

Initials

Quantity

16.6 +0-0.05

A

D =0.20 to 0.50

16.6 +0-0.05 18 -0.10 -0.15 51.400

B C E

D =0.20 to 0.50 0.20 to 0.50

CHAR - 15

Liberty 125 - 150 (2009)

Characteristics

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS (125) Name

Description

Dimensions

Crankshaft Crankshaft Crankcase Crankcase Crankshaft half-bearing Crankshaft half-bearing Crankshaft half-bearing Crankshaft category 1 Crankcase category 1 Crankshaft category 1 Crankcase category 2 Crankshaft category 2 Crankcase category 1 Crankshaft category 2 Crankcase category 2

Initials

Quantity

Category 1 Category 2 Category 1 Category 2 Category B - blue Category C - yellow Category E - green E-E

28.998 to 29.004 29.004 to 29.010 32.953 to 32.959 32.959 to 32.965 1.973 to 1.976 1.976 to 1.979 1.979 to 1.982

C-C C-C B -B

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (150) Name

Description

Tran Transm smiss issio ions nsid ide e half half-shaft F lywheel-side halfshaft Connecting rod with P P Crank pin width

Dimensions

Initials

Quantity

16.6 +0-0.05

A

D =0.20 to 0.50

16.6 +0-0.05 18 -0.10 -0.15

B C E

D =0.20 to 0.50 0.20 to 0.50 51.4 +0.050

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS (150) Name

Crankshaft Crankshaft Crankcase Crankcase Crankshaft half-bearing Crankshaft half-bearing Crankshaft half-bearing Crankshaft category 1 Crankcase category 1 Crankshaft category 1 Crankcase category 2 Crankshaft category 2 Crankcase category 1 Crankshaft category 2 Crankcase category 2

CHAR - 16

Description

Dimensions

Initials

Quantity

Category 1 Category 2 Category 1 Category 2 Category B - blue Category C - yellow Category E - green E-E

28.998 to 29.004 29.004 to 29.010 32.959 ÷32.965 32.953 ÷32.959 1.973 to 1.976 1.976 to 1.979 1.979 to 1.982

C-C C-C B -B

Liberty 125 - 150 (2009)

Characteristics

Characteristic Crankshaft/crankcase axial clearance «A»:

0.15 ÷0.40

Slot packing system SHIMMING SYSTEM Value measured

0 ÷0.1 0.1 ÷0.3 0.3 - 0.4

Gasket thickness

0.8 ±0.05 0.6 ±0.05 0.4 ±0.05

Characteristic Compression ratio

10.6 ±0.5: 1

CHAR - 17

Liberty 125 - 150 (2009)

Characteristics

Products RECOMMENDED PRODUCTS TABLE Product

Description

Specifications

AGIP ROTRA 80W-90

Rear hub oil

AGIP GIP CITY CITY HI HI TEC TEC 4T 4T

Oil Oil to lubricate flexible transmissi ssions (brakes, throttle control and odometer) Oil for air filter sponge

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Oil for 4-stroke engines

AGIP F ILTER OIL AGIP AGIP GP GP 33 330 AGIP CITY HI TEC 4T AGIP AGIP GREA GREASE SE MU3 MU3

Mineral oil with specific additives for increased adhesiveness Gre Grease for brake levers, th throttle, st stand White calcium complex soap-ba -based spray grease grease with with NLGI 2; ISO-L-X ISO -L-XBCI BCIB2 B2 Engine oil S AE 5W-40, AP I SL, ACEA A3, J ASO MA Synthetic Synthetic oil Gre Grease for odometer transmission gear Soap-based lithium grease with NLGI 3; case ISO-L-XBCHA3, DIN K3K-20

UNIT OF MEASURE - CONVERSION - ENGLISH S YSTEM TO INTERNATIONAL S YSTEM (IS).

CHAR - 18

Specification

Desc./Quantity

1 Inch (in) 1 F oot (ft) 1 Mile (mi) 1 US Gallon (USgal) 1 P ound (lb) 1 Cubic inch (in³) 1 F oot pound (ft lb) 1 Mile per hour (mi/h) 1 P ound per square inch (P SI) 1 F ahrenheit (°F )

25.4 Millimetres (mm) 0.305 Meter (m) 1.609 Kilometre (km) 3.785 Litre (l) 0.454 Kilogram (kg) 16.4 Cubic centimetres (cm³) 1,356 Newton meter (Nm) 1,602 Kilometres per hour (km/h) 0.069 (bar) 32+(9/5) Celsius (°C)

INDEX OF TOPICS

TOOLING

TOOL

Liberty 125 - 150 (2009)

Tool Toolin ing g

APPROPRIATE TOOLS

TOOL - 20 20

Stores code

Description

001330Y

Tool for fitting steering seats

001467Y 009

Driver for OD 42-mm bearings

001467Y 01 013

Calliper to extract ø 15-mm bearings

002465Y

Calliper for circlips

005095Y

E ngine support

008564Y

F lywheel extractor

Liberty 125 - 150 (2009)

Tooli Toolin ng

Stores code

Description

020004Y

P un unch for removing steering bearings from headstock

020055Y

Wrench for steering tube ring nut

020074Y

Support base for checking crankshaft alignment

020150Y

Air heater mounting

020151Y

Air heater

020193Y

Oil pressure check gauge

TOOL - 21 21

Liberty 125 - 150 (2009)

Tool Toolin ing g

TOOL - 22 22

Stores code

Description

020262Y

Crankcase splitting plate

020263Y

Driven pulley assembly sheath

020287Y

Clamp to fit piston on cylinder

020306Y

P un unch for assembling valve seal rings

020329Y

Mity-Vac vacuum-operated pump

020330Y

S troboscopic light to check timing

Liberty 125 - 150 (2009)

Tooli Toolin ng

Stores code

Description

020331Y

Digital multimeter

020332Y

Digital rpm indicator

020648Y

S ingle battery charger

020335Y

Magnetic mounting for dial gauge

020357Y 020359Y

32x35-mm Adaptor 42x47-mm Adaptor

TOOL - 23 23

Liberty 125 - 150 (2009)

Tool Toolin ing g

TOOL - 24 24

Stores code

Description

020360Y

52x55-mm Adaptor

020363Y

20-mm guide

020364Y

25-mm guide

020368Y

driving pulley lock wrench

020375Y

28 x 30 mm adaptor

020376Y

Adaptor handle

Liberty 125 - 150 (2009)

Tooli Toolin ng

Stores code

Description

020382Y 011

adapter for valve removal tool

020409Y

Multimeter adaptor - P ea eak voltage detection

020412Y

15-mm guide

020414Y

28-mm guide

020423Y

Driven pulley lock wrench

TOOL - 25 25

Liberty 125 - 150 (2009)

Tool Toolin ing g

TOOL - 26 26

Stores code

Description

020424Y

Driven pulley roller casing fitting punch

020425Y

P unch for flywheel-side oil seal

020426Y

P iston fitting fork

020427Y

P iston assembly band

020428Y

P iston position check mounting

020430Y

P in lock fitting tool

Liberty 125 - 150 (2009)

Tooli Toolin ng

Stores code

Description

020431Y

Valve oil seal extractor

020434Y

Oil pressure check fitting

020444Y

Tool for fitting/ removing the driven pulley clutch

020565Y

F lywheel lock calliper spanner

020622Y

Transmission-side oil seal punch

494929Y

E xhaust fumes analyser

TOOL - 27 27

Liberty 125 - 150 (2009)

Tool Toolin ing g

TOOL - 28 28

Stores code

Description

020625Y

Kit for sampling gas from the exhaust manifold

020481Y 005

EF I Technology interface wiring

020680Y

Diagnosis Tool

020469Y

Rep Reprogramming kit for vehicle diagnostic tester

020641Y

E F I Technology software upgrade

INDEX OF TOPICS

MAINTENANCE

MAIN

Liberty 125 - 150 (2009)

Maintenance

Maintenance chart MAINTENANCE TABLE Replacement Check * Check level every 3,000 km ** Replace every 2 years Clean the external filter of the Secondary Air System (SAS) every 2 years

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Km x 1,000

Safety locks Ignition spark plug Centre stand s tand (lubrication) (lubrication) Driving belt Thro Throtttle cont contro roll (ad (adju just stm ment ent) Air filter SAS filter Oil net filter (cleaning) Oil filter Valve clearance Electrical system and battery Cylinder ventilation ventilation system Brake control lever (greasing) Brake fluid level ** Engine oil * Hub oil Headlight aiming adjustment Brake pads Sliding blocks / variable speed rollers Tyre Tyre pres pressu sure re and and wear ear Vehicle test ride Idle speed Odometer gear (greasing) Suspension Steering Tran Transm smiss issio ion n Operation time

Hub oil Check

MAIN - 30

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48

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66

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54

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150' 160' 150' 175'

95'

270'

95'

175' 150' 160'

95'

270'

INDEX OF TOPICS

TROUBLESHOOTING

TROUBL

Liberty 125 - 150 (2009)

Trou Troub blesh leshoo ootting ing

Engine Poor performance POOR PERFORMANCE PERFORMANCE Possible Cause

Operation

Air Air filter blocked or dirty.

Rem Remove the spo sponge, wash with water and car sha shampoo, then soak it in a mixture of 50% petrol and 50% specific oil. Press with your hand without squeezing, allow it to drip dry and refit. Dism Disman anttle, le, was wash h with ith sol solv vent and and dr dry with ith com compresse essed d air air Check Check the filt filter er on the coc cock, k, rem remove ove the the pet petrol rol and and wash ash the the tank, if necessary. Replace the cock as a last resource. Check the the elect electric rical al wirin wiring g and and mechani echanical cal movem ovemen ent, t, replac replace e if necessary. Check it and replace, if necessary Rep Replace the worn parts Che Check for causes and fill to reach the correct level Desca Descale le the the cyli cylind nder er,, the the pist piston on,, the the head ead and and the valv valves es Time the the syst system em agai again n or repl replac ace e th the wor worn n part parts s Replace Chec Check k th the ro roller llers s and and th the pu pulle lley mov movem ement ent, rep replace lace the da damaged parts and lubricate the movable guide of the driven pulley with grease. Adjust the valve clearance properly Rem Remove the head and the valves, grind or replace the valves Replace the head unit Replac Replace e the the pist piston on cylin cylinde derr assem assembly bly or or just just the pist piston on ring rings s

Fuel Fuel noz nozzl zles es or cock cock clog clogg ged or dirt irty Dirt Dirty y or faul faultty vacuu acuum m-ope -opera ratted cock cock Failing Failing aut autom omat atic ic start starter er on the carbu carburet retto torr Excessive drive belt wear Lack of compression: parts, cylinder and valves worn Oil level exceeds maximum Exces Excess s of scale scales s in the the com combust ustion ion cha cham mber ber Inco Incorr rrec ectt timing ing or worn orn timing ing sy system stem elem element ents S ilencer obstructed Inef Ineffficie icien nt au automatic atic tran ransmis smissi sion on

Wrong valve adjustment Overheated valves Valve seat distorted Worn Worn cylin cylinde der, r, Wor Worn n or or bro broke ken n pist piston on ring rings s

Rear wheel spins at idle REAR WHEEL ROTATES WITH ENGINE AT IDLE Possible Cause

Operation

Idling rpm too high Clutch fault

Adjust the engine idle speed. Check the springs / clutch masses

Starting difficulties START-UP PROBLEMS Possible Cause

Operation

F la lat battery

Check the state of the battery. If it shows signs of sulphation replace it and bring the new battery into service charging it for eight hours at a current of 1/10 of the capacity of the battery itself Replace Replace the the spark sparkplug plug or or che check ck the ignit ignition ion circui circuitt componen ponents ts Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it and before refitting, make the motor turn so as to expel the fuel excess taking care to connect the cap to the spark plug, and a nd this in turn to the ground. If the fuel tank is empty, refuel and start up. Insp Inspec ectt the head head and/ and/or or rest restor ore e the corr correc ectt clea cleara ranc nce e Check the starter motor and the kick-starter unit

Faulty Faulty spark spark plug plug or or incorr incorrect ect ignit ignition ion adv advanc ance e Eng Engine flooded

Inco Incorr rrec ectt valv alve seal sealin ing g or valv alve adju adjust stm ment ent Rpm too low at start-up or engine and start-up system damaged Alt Altered fuel characteristics Vacu Vacuu um oper operat ated ed cock cock failu ailurre Failing Failing aut autom omat atic ic start starter er on the carbu carburet retto torr

TROUBL - 32 32

Drain off the fuel no longer up to standard; then, refill Chec Check k that fuel is ade adequately ely sup supplied lied throug ough the pipe ipe by apapplying a vacuum to the vacuum pipe Check the the elect electric rical al wirin wiring g and and mechani echanical cal movem ovemen ent, t, replac replace e if necessary.

Liberty 125 - 150 (2009)

Trou Troubl bles esh hoot ooting ing

Possible Cause

Operation

Star Startt-up -up en enabli ablin ng bu buttons ons fail failu ure

Chec Check k con continu inuity ity usin sing an an Oh Ohm meter, er, wit with h th the sw switch itch presse essed d; replace if necessary Dism Disma antle, le, wa wash with ith sol solv vent and dr dry wit with h com compresse ressed d air air Rem Remove the spo sponge, wash with ith water and car sha shampoo, th then soak it in a mixture mixture of 50% petrol petrol and 50% specific oil. P ress with your hand without squeezing, allow it to drip dry and refit. Check the pump control device

Car Carburettor nozzles zzles clog clogg ged or dirt irty Air Air filt ilter obstr structed or dirty.

F uel pump fault

Excessive oil consumption/Exhaust smoke EXCESSIVE OIL CONSUMPTION/SMO CONSUMPTION/SMOKEY KEY EXHAUST Possible Cause

Operation

Worn valve guides Worn valve oil seal Oil leak leaks s from from the the coup couplin lings gs or or from from the gaske gaskets ts Worn or broken piston rings or piston rings that have not been fitted properly

Check and replace the head unit if required Replace the valve oil seal Check and and rep replace lace the the gask gasket ets s or restore restore the the cou coupli pling ng seal Replace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure LOW LUBRICATION PRESSURE Possible Cause

Operation

By-Pa -Pass re remains op open

Che Check the ByBy-Pass Pass and replace if required. Car Carefully clean the By-Pass area. Perf Perform orm the dim dimensi ension ona al ch checks cks on the oil oil pump co componen onentts Replace the cartridge filter Restore the level adding the recommended oil type

Oil Oil pu pump wit with h ex excess cessiv ive e cle clear aran ance ce Oil filter too dirty Oil level too low

Engine tends to cut-off at full throttle THE ENGINE TENDS TO STOP AT MAXIMUM THROTTLE Possible Cause

Operation

Maximum jet clogged

Rem Remove the carburettor, wash with sol solvent and dry with compressed air Remove Remove the the tank tank,, wash wash with with solvent solvent and dry with with com compressed air air Rest Resto ore the level in the chamber by bending on the float the thrusting reed of the petrol intake rod so as to have the float parallel to the chamber level with the carburettor inverted.

Water Water or or conden condensatio sation n in the the carbur carburett ettor or cham chamber ber Lev Level in chamber too low

Engine tends to cut-off at idle THE ENGINE TENDS TO STOP AT IDLE SPEED Possible Cause

Operation

Incorrect idle adjustment Incorrect timing The The star startter rem remains ains on

Adjust using the rpm indicator Time the system and check the timing system components Check Check:: elec electtric ric wirin iring g, cir circu cuit it not not int interru errupt pted ed,, mecha echan nical ical movement and power supply; replace if necessary Replace Replace the spark spark plug plug or check check the the ign ignit ition ion circui circuitt component ponents s Check Check the therm hermal gro group up seals seals and and repl replac ace e wor worn n com compone ponent nts s Wash the nozzle with solvent and dry with compressed air

Faulty Faulty spark spark plug plug or or incorr incorrect ect ignit ignition ion adv advanc ance e Pressure Pressure too low low at at the end end of of com compressi pression on Minimum nozzle dirty

TROUBL - 33 33

Piaggio Liberty 125 - 150 MY 2009 (en))

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