DSR Ex 125

WORKSHOP MANUAL
ENGINE 125 4T / 4V 6M EURO 4

INTRODUCTION
This manual has been produced by UM Motorcycles for use by UM dealer and sub-agency workshops.
It is assumed that those using this publication for training purposes and for repairing UM vehicles, have
a basic knowledge of mechanics and of the methods inherent in the technique of vehicle repair. Significant
variations in the characteristics of the machines or in the specific repair operations will be communicated by
means of updates to this manual.
Completely satisfactory work cannot however be carried out without the availability of suitable facilities
and tools, which is why we ask you to consult the pages of this manual referring to special tools and imple-
ments.
Particularly important items of information in this manual are distinguished by the following an N.B.:tions:
N.B.
KEY INFORMATION FOR PERFORMING THE PROCEDURE IN AN EASIER AND CLEARER WAY, OR ANY
ESSENTIAL OPERATION.
UM MOTORCYCLES
The UM logo is the registered trademark and property of UM.

The total or partial reproduction of any photograph, graphical image or text inserted in this ma-
nual is prohibited.© 2017 UM
1 WORKSHOP MANUAL
INDEX
GENERAL INFORMATION Pag. 4

ENGINE SPECIF ICATIONS Pag. 12
TIGHTENING TORQUES Pag. 13
IDENTIFICATION OF SETS Pag. 15
ELECTRICAL SYSTEM SPECIFICATIONS Pag. 19
LUBRICATION CIRCUIT Pag. 21
COOLANT CIRCUIT Pag. 23
PERIODICAL INSPECTIONS AND ADJUSTMENTS Pag. 34
DISMANTLING THE ENGINE Pag. 33
Camshaft Pag. 33
Timing chain Pag. 34
Cylinder head, cylinder and piston Pag. 36
Flyweel magneto Pag. 40
Clutch Pag. 41
Oil pump Pag. 43
Crankshaft Pag. 44
Crankcases Pag. 45
Transmission, gear selector, gearchange shaft and selector distributor Pag. 46
INSPECTION AND REPAIR Pag. 48
ASSEMBLING AND ADJUSTING THE ENGINE Pag. 58
Transmission, gear selector, gearchange shaft and selector distributor Pag. 59
Crankshaft Pag. 63
Crankcases Pag. 66
Oil pump Pag. 68
Clutch Pag. 70
Flyweel magneto Pag. 75
Camshaft Pag. 78
Timing chain Pag. 81
Installing the piston rings Pag. 84
Cylinder head, cylinder and piston Pag. 85
Diagram
FUEL wiring
SUPPLY Pag. 91
APPENDIX :
MAGNETI MARELLI DONGLE INSRUCTION
3 WORKSHOP MANUAL
GENERAL INFORMATION
REGULATIONS
This section describes the machine’s general safety and maintenance work rules.
SAFETY REGULATIONS
- In the event of having to carry out work on the engine while this is running, ensure that the area is well
ventilated, where possible using extractor fans. Never leave engines running in closed spaces. Exhaust gases
are poisonous.
- Petrol is extremely inflammable and in certain conditions may explode. Smoking must not be allowed in the
work area, nor should there be naked flames or sparks.
MAINTENANCE REGULATIONS
Use genuine UM spare parts and lubricants recommended by UM. Non-genuine or unauthorised parts
may damage the machine.
Only use the specific tools intended for this machine.
During assembly, always use new gaskets, oil seals, piston rings and keys.
After dismantling, clean the components with solvents that are non-inflammable or with a high flammability
point. Grease all working surfaces before assembling, excluding tapered joints.
After assembly, check that all components have been correctly fitted and that they are functioning perfectly.
For dismantling, checking and assembly operations use only tools with metric measurements. Metric screws,
nuts and bolts are not interchangeable with imperial measurement joining devices. Using unsuitable tools
and joining devices may damage the machine.
In the case of work on the machine’s electrical circuitry, check that electrical connections have been correctly
fitted, especially the earth connections.
4 WORKSHOP MANUAL
GENERAL INFORMATION
IDENTIFICATION
MODEL CHASSIS CODE ENGINE CODE
DSR EX 125
DSR SM 125 M6FDS0001Hxxxxxxx
RENEGADE SCRAMBLER CLASSIC 125 UXPI 125

RENEGADE SCRAMBLER SPORT 125 M6FSC0001Hxxxxxxx xxxxxxx
DSR ADVENTURE 125 M6FDA0001Hxxxxxxx

DSR ADVENTURE TT 125
ENGINE CODE
The engine code can be found at the back of the engine,
in front of the rear wheel.
5 WORKSHOP MANUAL
GENERAL INFORMATION
P REPARATION FOR REMOVAL AND DISMANTLING
Remove all the dirt, grime, dust and other foreign material
before removing and dismantling.
Use properly cleaned tools and equipment.

See “ SPECIAL TOOLS ”.
On dismantling parts, always keep related items together.

This includes gears, cylinders, pistons and other parts sub-
mitted to natural wear together. Related parts must always
be reassembled or replaced together.
While dismantling the motorcycle, clean all the parts and lay
them out on trays in the order dismantled. This speeds up re-
assembly and ensures the correct fitting of all the parts.
Keep all parts away from any contact with fire.
6 WORKSHOP MANUAL
GENERAL INFORMATION
SPARE PARTS
Use only genuine UMspare parts. For all lubrication tasks,

use oils and greases recommended by UM. Other makes
make seem similar in their function and appearance, but are
inferior in quality.
SEALS, RETAINING RINGS AND O - RINGS
Renew all seals, retaining rings and O-rings when servicing

the engine.
All surfaces receiving seals, retaining ring edges and O-rings
must be cleaned.
Apply oil to all paired parts and bearing during reassembly.

Apply grease to the retaining ring edges.
TAB/ SPACER WASHERS AND SPLIT PINS

T
After removing them, renew all tab/spacer washers (1) and

split pins. Bend the tabs to fit the flat surfaces of the bolt or
nut once they have been tightened to the specified torque.
B EARINGS AND RETAINING RINGS
Fit bearings and retaining rings in such a way that the ma-
nufacturers marks remain visible. On fitting retaining rings,
applying a thin film of light lithium soap based grease to
their edges. Where required, apply oil generously when fit-
ting bearings.
WARNING
DO NOT USE COMPRESSED AIR TO DRY BEARINGS. THIS
DAMAGES THE BEARING SURFACES.
7 WORKSHOP MANUAL
GENERAL INFORMATION
TDC measuring tool.
LOCKING RINGS
Examine all the locking rings carefully before fitting. Always

replace the gudgeon pin circlips after every use. Replace dis-
torted locking rings. On fitting a locking ring (1), ensure that
the sharp edge (2) is on the opposite side to the force (3) to
be applied to it.
See the figure on the side, (4) Shaft.
SPECIAL TOOLS
The following special tools are needed for assembly and for
complete and exact adjustments. Only use the proper special
tools; thereby avoiding damage caused by the use of unsui-
table tools or improvised techniques.
Ref.
Ref. 865260
T01010047
The camshaft sprocket locking tool.
Ref.
Ref. 865259
T01010046
Magneto flywheel locking tool.
8 WORKSHOP MANUAL
GENERAL INFORMATION
Ref. 864592
Ref. T01010045
TDC measuring tool.
Ref. 00H05300041
Ref. T01010042
Clutch bell housing fitting tool.
Ref. 864486
Ref. T01010043
Balance shaft locking tool.
Ref. 864567
Ref. T01010044
Set of camshaft locking keys.
9 WORKSHOP MANUAL
GENERAL INFORMATION
Ref.
Ref. 864487
T01010050
Crankshaft sprocket locking tool.
Ref. 864868
Ref. T01010051
Magneto flywheel extractor tool.
Ref.
Ref. 865261
T01010049
Piston fitting clamp.
Ref.
Ref. 865207
xxxxxxxx
Set of tools for 125cc 4-stroke 4 valve engine.
10 WORKSHOP MANUAL
GENERAL INFORMATION
Engine EURO 4 single cylinder 4-stroke
Diameter x stroke 58x47 mm

Cubic capacity 124.2 cm 3
Cooling Water
Starter Electric
Compression ratio 12:1
Maximum nominal power Cv: 15,5 Kw:11,4 a 9250 at the crankshaft

Cv: 14,0 Kw:10,3 a 9250 at the rear wheel
Fuel Lead-free petrol
Lubrication system Semi-wet crankcase
Ignition C.D.I type electronic ignition
Primary transmission Gearing
Type of oil
Engine oil AGIP CITY 4T
Viscosity SAE 10W-40
Total capacity 1150 ml
Oil filter Paper cartridge

Reference 874081
Air filter Laminated paper

Reference 861130
Power Supply MAGNETI MARELLI

EFI CM128218
Spark Plug
Type NGK CR8EB
Gap between electrodes 0,7 ÷ 0,8 mm
Clutch 6 driving disks and 5 driven disks
11 WORKSHOP MANUAL
ENGINE SPECIFICATIONS
TRANSMISSION
Primary transmission ratio - 2,38
First gear ratio - 3
Second gear ratio - 2
Third gear ratio - 1,5
Fourth gear ratio - 1,2
Fifth gear ratio - 1,08
Sixth gear ratio - 0,96
Secondary transmission ratio - 14/51 = 3,64
12 WORKSHOP MANUAL
TIGHTENING TORQUES
THREAD TIGHTENING TORQUE

PARTS TO BE TIGHTENED DESCRIPTION QTY. Obs.
MEASUREMENT Kgf.m N·m
Spark plug - M10 1 1,2-1,4 12-14
Rocker cover Bolt M6 4 1-1,2 10-12
Camshaft bridge Bolt M6 8 1-1,2 10-12
Timing crown wheel 1 Bolt M8 1 2,5-2,7 25-27
Timing crown wheel 2 Bolt M8 1 2,5-2,7 25-27
Cylinder head Bolt M8 4 2,7+90° 27+90°
Cylinder head Bolt M6 2 1,1-1,3 11-13
Inlet pipe Bolt M6 3 1,1-1,3 11-13
Thermostat cover Bolt M6 2 1-1,2 10-12
Coolant temperature sensor - M10 1 0,8-1,0 8-10
Timing chain tensioner Bolt M6 2 1,1-1,3 11-13
Timing chain tensioner spring Cover - 1 0,8-1 8-10
Water pump cover Bolt M5 3 0,5-0,6 5-6
Water pump turbine - M5 1 0,4-0,6 4-6
Clutch control cam Bolt M6 1 0,8-1,0 8-10
Oil filter cover - M56x1,5 1 2,4-2,6 24-26
Oil pressure sensor - M10 1 1,2-1,4 12-14
Clutch cover Bolt M6 10 1,1-1,3 11-13
Clutch spring Bolt M5 5 0,35-0,45 3,5-4,5
Clutch bell housing-ram Nut M12 1 3,5-4,5 35-45
Balance shaft Nut M10 1 3,5-4,5 35-45
Crankshaft-clutch bell housing gear Nut M12 1 7,5-8,3 75-83
Timing chain roller. Bolt M6 1 1-1,2 10-12
Oil pump Bolt M5 3 0,5-0,6 5-6
Selector drum flor. Bolt M5 1 0,35-0,45 3,5-4,5
Selector drum flor. locking cam Bolt M6 1 0,8-1,0 8-10
Starter motor Bolt M6 2 1,1-1,3 11-13
Phase inspection cover - M18X1,5 1 0,35-0,45 3,5-4,5
Magneto side oil filter cover - M28X1 1 2,4-3,0 24-30
13 WORKSHOP MANUAL
TIGHTENING TORQUES
PIEZAS A APRETAR DESCRIPCIÓN

MEDIDA DE CANT. TORQUE DE APRIETE Obs.
LA ROSCA Kgf.m N·m
Magneto cover Bolt M6 10 1,1-1,3 11-13

Oil sensor cable securing device Bolt M4 1 0,3-0,5 3-5
Neutral sensor indicator - M10x1,25 1 0,8-1,0 8-10
Oil dipstick - M12x1,5 1 0,4-0,6 4-6
Magneto stator Bolt M5 2 0,5-0,7 5-7
Pick-up. ( R.P.M. sensor) Bolt M5 2 0,3-0,4 3-4
Starter crown wheel clamp Bolt M6 1 0,5-0,6 5-6
Magneto rotor Nut M14x1,5 1 8,3-9,0 83-90
Magneto rotor- starting clutch Bolt M6 6 1,1-1,3 11-13
Semi crankcases joint Bolt M6 12 1,1-1,3 11-13
14 WORKSHOP MANUAL
SETS IDENTIFICATION
CRANKCASE LOCATION
½ CRANKSHAFT DIAMETER 2
2
2 T
S/T BALANCE SHAFT GEARINGENGRANAJES T T Y
Y
PRIMARY SHAFT GEARING Y
CRANKSHAFT DIAMETER
MIN MAX REFERENCE
CLASS 1 32.480 32.485 Go to8711475001
spare parts catalogs
CLASS 2 32.485 32.490 Go to8711475002

BALANCE SHAFT – GEAR SET
CRANKSHAFT GEAR BALANCE GEAR

REFERENCE REFERENCE
S SET Go to8714465001
spare parts catalogs Go to8711565001
T SET Go to8714465002
spare parts catalogs Go to8711565002
N.B.: The crankcases available as spare parts are always of the S kind.
MIN MAX
S CLASS 64.00 64.03
T CLASS 63.97 64.00
N.B.: The distances between the balance shaft and the crankshaft are the following.
15 WORKSHOP MANUAL
SETS IDENTIFICATION
PRIMARY SHAFT- GEAR SET
CRANKSHAFT GEAR BALANCE GEAR

REFERENCE REFERENCE
X CLASS 8714475001
Go to spare parts catalogs Go to8714605001
Y CLASS 8714475002
Go to spare parts catalogs Go to8714605002
N.B.: The crankcases available as spare parts are always of the X kind.
MIN MAX
X CLASS 86.00 86.04
Y CLASS 85.96 86.00
N.B.: the distances between the primary shaft and the crankshaft are the following.
Distances between gears
With the aim of minimising noise and friction, the cranks-

haft, primary shaft and balance shaft gears exist as joint
assemblies.
X or Y S or T
16 WORKSHOP MANUAL
SETS IDENTIFICATION
VALVE GUIDES
REFERENCE THICKNESS
1 Go to CM222701
spare parts catalogs 2,20
2 CM222702 2,25
3 CM222703 2,30
4 CM222704 2,35
5 CM222705 2,40
6 CM222706 2,45
7 CM222707 2,50
8 CM222708 2,55
THICKNESS
9 CM222709 2,60
10 CM222710 2,65
11 CM222711 2,70
12 CM222712 2,75
N.B.: In the markings on the inside of the valve, you will find for example:
20, corresponding to 2.20 in the table.
IRON CYLINDER AND PISTON SETS
CATEGORY
CATEGORY CYLINDERPISTON
MIN MAX MIN MAX PISTON REFERENCE
M 58.010 58.017 57.953 57.960 Go to8745340001
N 58.017 59.024 57.960 57.967 Go to8745340002

O 58.024 58.031 57.967 57.974 Go to8745340003

P 58.031 58.038 57.974 57.981 Go to8745340004

N.B.: Clearance on assembling 0.050 - 0.064

The cylinder is only available as a spare part in a kit with the piston. Reference 874533
17 WORKSHOP MANUAL
SETS IDENTIFICATION
CRANKSHAFT
RANKCASE
HALF-BEARING
HALF-BEARING
D1
CRANKCASE MACHINED DIAMETER (D1)
MIN MAX
CLASS A 36.500 36.508
CLASS B 36.508 36.516
CRANKSHAFT DIAMETER
MIN MAX REFERENCE
CLASS 1 32.480 32.485 8711475001
Go to spare parts catalogs
CLASS 2 32.485 32.490 8711475002

HALF-BEARING THICKNESS
MIN MAX Lower Ref. Upper Ref.
RED 2.005 2.010 864591 864589
BLUE 2.010 2.015 864590 864588

CRANKCASE
CLASS A CLASS B
CRANKSHAFT
CLASE 1 RED+BLUE BLUE+BLUE
CLASE 2 RED+RED RED+BLUE
Example:
Based on an engine comprising a Class A crankcase (diameter between 36.500 and 36.508 mm), and a Class
2 crankshaft (diameter between 32.485 and 32.490 mm), two RED type bearings should be fitted, Ref. 864591
Spare Parts
and 864589.
Spare Parts
If the crankcases have mixed bearings, they can be fitted regardless of their initial location.
18 WORKSHOP MANUAL
ELECTRICAL SYSTEM SPECIFICATIONS
IGNITION
DESCRIPTION OF THE SYSTEM
System logic
- The fundamental parameter is the rpm reading from the

pick-up
- Based on the information from this sensor the ECU calcula
tes the moment in which the spark plug should fire.
Components
- Engine rpm sensor (pick-up)
Sensor resistance: 105 -124 _ at 20º C

(magneto side connector between R and B cable).
Red (R)
Black (B)
- Ignition coil
Resistance of primary winding

0,21 +/- 0,025 at 25+/-5º C
Resistance of secondary winding

3,1 K +/- 0,31 K at 25 +/-5º C
Primary winding Secondary winding Resistance of spark plug cap

5 K at 20 ° C
19 WORKSHOP MANUAL
ELECTRICAL SYSTEM SPECIFICATIONS
CHARGING SYSTEM
COMPONENTS
- Three-phase system with a power rating of 200w.
- Voltage produced at regulator output:

13 – 15 v at 8000 rpm
- Current produced at regulator output:

around 14A at 8000 rpm
Resistance of stator between phases:

0,4 +/- 10%.
Check at the magneto side connector between 1, 2 and 3 (3 measurements).
1
2
Current leakage
- With the ignition key in the ‘OFF’ position, connect the ammeter in series between the negative battery
terminal and the negative battery cable.
- The readout value must be less than 1mA = 0,001A.
20 WORKSHOP MANUAL
LUBRICATION CIRCUIT
- (1) Crankshaft breather. 3 1 2 4
- (2) To the gearbox.

- (4) To the filter, lubrication of technical part.
N.B.
THE OIL PUMP IS A DOUBLE ROTOR PUMP THAT
PUMPS SEPARATELY.
- The lubrication is the semi-wet crankcase type.

- The gearbox is used as an oil tank.
- The pump is driven by the clutch and fitted with two rotors made of sintered material:
- One 13mm thick rotor, for oil suction.
- One 8.5 mm thick rotor, for pumping.
- The maximum pressure is 4.2 bars, and at the top of the engine the pressure is 1 bar.
- The circuit consists of a pre-filter, filter, pressure overload by-pass valve and oil pressure sensor.
- The suction is from:
- The front of the crankcase (crankshaft housing).
- The rear of the crankcase (gearbox).
- Pumping is:
- To the oil filter (classic circuit).
- To the gearbox.
ATTENTION
DO NOT DAMAGE THE CRANKCASE COVER SURFACES, AS THIS WILL LEAD TO OIL LEAKAGES.
21 WORKSHOP MANUAL
LUBRICATION CIRCUIT
To bottom of cylinder
Oil input to filter
Oil to supports
Rises for
Oil to filter By-pass camshafts
Oil input
Oil input
Rises for
camshafts
Oil to supports
Rises for
camshafts
22 WORKSHOP MANUAL
LUBRICATION CIRCUIT
GEAR BOX CIRCUIT LUBRICATION
Gear Box lubrication circuit
THIS PIPE HAVE SEVEN HOLE
7ALWAYS
holes pipe
REPLACE PIPE OR
Lubricate the CONDITION
CHECK IF THE gear shaft OF
before
PIPE assembly
IS GOOD
Always replace pipe OR
BEFORE ASSEMBLY THE ENGINE LUBRICATE SHAFT AND GEAR VERY WELL
Oil input to filter
OIL TO PIPE LUBRICATION

PIPE
Oil to supports
Rises for
Oil to filter By-pass camshafts
Oil input
Oil input
Rises for
camshafts
REPLACE OR
Oil to supports
OUTPUT SHAFT LUBRICATION HOLE

Rises for
camshafts
CHECK THE PIPE CONDITION
CHECK THE SIX HOLE ARE FREE
bis 22
22 WORKSHOP MANUAL
COOLANT CIRCUIT
- There is a small by-pass to heat up the carburettor.

- The pump oil seal is the metal type.
- The thermostat opens at between 80ºC and 85ºC.
- The radiator is fitted with an electric fan.
- Resistance value of the temperature sensor (NTC):

- At 60ºC = 600-470
- At 90ºC = 215-175
- At 120ºC = 93-73
NTC
23 WORKSHOP MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
I NTRODUCTION
This chapter contains all the necessary information for carrying out recommended inspections and adjust-
ments. If followed correctly, these preventative maintenance procedures will ensure a reliable operation
of the machine and a longer operating life. The need for costly servicing will be significantly reduced. This
information applies not only to machines already
in service but also new machines being prepared for sale. All technical assistance staff should familiarise
themselves with the whole of this chapter.
P ERIODICAL MAINTENANCE PLAN
ADVICE NOTES NOTE

Note 1 Carry out checks more frequently when the machine is used intensively at full thro-
ttle or in dusty and/or damp areas.
Note 2 TRANSMISSION SPROCKET, WHEEL SPROCKET AND CHAIN: If any of these com-
ponents reaches the end of its useful life, all 3 must be changed together.
SYSTEM BEFORE EVERY START-UP NOTE

Engine/trans. ENGINE OIL: Check the level - Top up if necessary
DRIVE CHAIN: Check the tension - Adjust if necessary
Cycle COOLANT: Check the level - Top up if necessary
BRAKE PADS: Check the wear – Renew if necessary
TYRES: Check condition and pressure
BRAKES: Check the correct operation
FUEL PIPES: Check for possible cracks
Electrical Check for possible fluid leaks (petrol, oil, coolant, brake fluid)
CONTROL ELEMENTS: Check the correct operation
LIGHTS: Check the operation of the mechanisms and the correct functioning of
the bulbs/LEDs
HORN: Check that it is working correctly
SYSTEM AFTER EVERY WASHING NOTE

Engine/trans. DRIVE CHAIN: Clean and lubricate
Cycle BRAKE AND CLUTCH LEVERS: Lubricate
BRAKES: Check the correct operation
Electrical LOCKS AND LIGHT SWITCHES: Apply anti-damp spray
SYSTEM EVERY 2 YEARS NOTE

Engine/trans. COOLANT: Change
Cycle BRAKE FLUID: Change
SYSTEM EVERY 500 KM NOTE

Cycle DRIVE CHAIN: Clean and lubricate Note 1
24 WORKSHOP MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
SYSTEM 1ST SERVICE/RUNNING IN NOTE

Engine/trans. ENGINE OIL: Change (warm up the engine before draining)
OIL FILTER: Change
Cycle WHEELS: Check the correct tension of the spokes

Electrical FINAL CHECK: Carry out an on-road test drive, paying attention to the general
operation of the brakes, steering, clutch, suspensions, engine, lights and instru-
ment panel indicator lights.
SYSTEM INSPECTION TYPE 1 NOTE

Engine/trans. ENGINE OIL: Change (warm up the engine before draining)
OIL FILTER: Change
SPARK PLUG: Check the gap between the electrodes - Adjust if necessary
SECONDARY TRANSMISSION: Check the chain tension - Adjust if necessary Note 2
SECONDARY TRANSMISSION: Check the wear of the sprocket and plate Note 2
SECONDARY TRANSMISSION: Check the wear on the roller and chain guides -
Change if necessary
COOLANT: Check the level – Top up if necessary
Cycle BRAKE PADS: Check the wear – Renew if necessary

BRAKE LEVER CABLES: Check condition
BRAKE LEVERS AND THROTTLE TWIST GRIP: Check the correct operation
and free play
WHEELS: Check the correct tension of the spokes
BRAKE FLUID: Check the level – Top up if necessary
FUEL PIPES: Check for possible cracks
Check for possible fluid leaks (petrol, oil, coolant, brake fluid)
Electrical ELECTRIC FAN: Check operation
FRONT HEADLIGHT: Adjust the beam height
BATTERY: Check state of charge – Charge if necessary
CONTROL ELEMENTS: Check the correct operation
LIGHTS: Check the operation of the mechanisms and the correct functioning of the
bulbs/LEDs
HORN: Check its correct operation
General FINAL CHECK: Carry out an on-road test drive, paying attention to the general
ment panel lights.
25 WORKSHOP MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
SYSTEM INSPECTION TYPE 2 NOTA

Engine/trans. SPARK PLUG: Change
EXHAUST SYSTEM: Check the correct tightness of the bolts and clamps
ENGINE SUPPORT BOLTS: Check nominal torque tightness
SECONDARY TRANSMISSION: Check the condition of the chain, sprocket and Note 2
plate - Renew if they have reached the end of their useful life
AIR FILTER: Renew Note 1
Cycle BRAKE CALLIPERS: Check nominal torque tightness
SWINGING ARM SHAFT: Check for absence of play and nominal torque tightness
WHEELS: Check bearing play and the nominal torque tightness of the shaft
STEERING SHAFT: Check for absence of play – Adjust if necessary
PROP STAND AND/OR CENTRE STAND: Grease
General FINAL CHECK: Carry out an on road test drive, paying attention to the general
ment panel lights
SYSTEM INSPECCIÓN TIPO 3 NOTE

Engine/trans. RADIATOR: Check external appearance – Clean if necessary
Cycle FRONT SUSPENSION: Change fork oil
MILOMETER TAKE-OFF: Grease
General FINAL CHECK: Carry out an on-road test drive, paying attention to the general
operation of the brakes, steering, clutch, suspensions, engines, lights and instru-
ment panel indicator lights.
1 ST SERVICE INSPECTION INSPECTION INSPECTION VALVE

SERVICE NO. KM
RUNNING IN TYPE 1 TYPE 2 TYPE 3 PLAY
1 1000 X X
2 6000 X
3 12000 X X X
4 18000 X
5 24000 X X X X
6 30000 X
7 36000 X X X
8 42000 X
9 48000 X X X X
10 54000 X
11 60000 X X X
12 66000 X
13 72000 X X X X
14 78000 X
15 84000 X X X
26 WORKSHOP MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
ADJUSTING THE THROTTLE CABLE
N.B:
BEFORE ADJUSTING THE THROTTLE CABLE, THE IDLE
SPEED MUST BE ADJUSTED.
1. Check:
- Throttle cable play (1).
Outside that specified => Adjust .

1
Clearance:
2÷6 mm.
In the throttle twist-grip plate.
2. Adjust:
- Throttle cable play.
Checking steps:
N.B:
NEVER ACCELERATE WHILE THE ENGINE IS STOPPING.
- Loosen the throttle cable locknut (2).
- Turn the adjuster (3) inwards or outwards until the speci-

fied play is obtained (1).
Turning inwards => Increasing the clearance.

Turning outwards => Reducing the clearance.
- Tighten the lock nut.
N.B.:
IF THE PLAY IS STILL INCORRECT, ADJUST IT USING THE
ADJUSTER (3) BELOW THE TWIST GRIP.
WARNING:
AFTER MAKING THE ADJUSTMENT, TURN THE HANDLE-
BARS BOTH WAYS TO ENSURE THAT THERE IS NO VARIA-
TION IN THE IDLE SPEED.
27 WORKSHOP
27 MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
INSPECTING THE SPARK PLUG
1. Extract:
- Spark plug connector.
- Spark plug.
ATTENTION
BEFORE REMOVING THE SPARK PLUG, BLOW AROUND IT
WITH COMPRESSED AIR TO REMOVE ANY DIRT, THEREBY
PREVENTING THIS FROM FALLING INTO THE ENGINE.
2. Check:
- Spark plug type
Incorrect => Renew.
Standard spark plug:

NGK CR8EB
3. Inspect:
- Electrode (1).
Damage/warping/wear => Renew.
- Insulator (2).
Abnormal colour => Renew.

The normal colour is a light brown.
4. Clean:
- Spark plug.
(Clean the spark plug with a spark plug cleaner or a wire
brush)
5. Measurement:
- Gap between the electrodes (a).
(using a feeler gauge)
Distance between electrodes:

0,7 mm - 0,8 mm
6. Fit:
- Spark plug.
Spark plug.
1,2-1,4 kgf.m (12-14 N.m)
N.B.:
- BEFORE FITTING THE SPARK PLUG, CLEAN ITS SEATING
AND GASKET.
- IF NO TORQUE WRENCH IS AVAILABLE, A GOOD WAY
OF JUDGING THE CORRECT TORQUE IS TO TIGHTEN (1)
THE SPARK PLUG BY HAND AND THEN TIGHTEN IT FROM
¼ TO ½ A TURN (2).
- ALWAYS USE A NEW GASKET.
28 WORKSHOP MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
ADJUSTING THE COMPRESSION PRESSURE
N.B.:
INSUFFICIENT COMPRESSION PRESSURE LEADS TO A LOSS
OF POWER.
Check:
- Valve clearance.
See “ VALVE CLEARANCE ADJUSTMENT ” section.
Start the engine and leave to warm up for a few minutes.
Stop the engine.
Extract:
- Spark plug.
ATTENTION
BEFORE REMOVING THE SPARK PLUG, BLOW AROUND IT
WITH COMPRESSED AIR TO REMOVE ANY DIRT, THEREBY
PREVENTING THIS FROM FALLING INTO THE ENGINE.
Fit:
q$PNQSFTTJPONFUFS
Measurement:
- Compression pressure.
If it exceeds the permitted maximum pressure => Inspect

the cyulinder head, valve surfaces and piston head for
carbonisation.
If below the minimum pressure=> Inject a few drops of

oil into the cylinder and measure again.
Follow the table below:
$0.13&44*0/13&4463& 8*5)0*-*/+&$5&%*/505)&$:-*/%&3
READING DIAGNOSTIC
More than without oil Piston worn or damaged

Possibility of defect in the rings, valves or seals of
The same as without oil
the cylinder head or piston => Repair.
24 WORKSHOP MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
Compression pressure (at sea level):

Standard:
1200 kPa (12 kg/cm 2 )
Minimum:
1040 kPa (10,4 kg/cm 2 )
Steps for removal:

- Start the engine with the throttle completely open, until the
comprerssion reading stabilises.
WARNING:
BEFORE STARTING THE ENGINE CONNECT THE SPARK
PLUG WITH HANDLE TO PREVENT SPARKS.
Fit:
- Spark plug.
30 WORKSHOP MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
I NSPECT THE ENGINE OIL LEVEL
Position the motorcycle on a flat surface.
N.B.:
ENSURE THAT THE MOTORCYCLE IS PARALLEL TO THE
GROUND IN ORDER TO BE ABLE TO CHECK THE OIL LEVEL
CORRECTLY.
Stop the engine.
4. Remove the dipstick (1). Clean it with a cloth then replace

it in the oil filler hole without screwing in. Remove it again
immediately.
Check:
- The engine oil level.
The oil level should be between the MAXIMUM and MINI- 1
MUM marks.
Oil below the minimum level => Add oil up to the correct
level.
RECOMMENDED OIL FOR THE ENGINE
Recommended oil for the engine:

AGIP CITY 4T (4-STROKE) or equivalent.
Stop the engine.

MAX
N.B.:
WAIT A FEW MINUTES FOR THE OIL TO PERCOLATE DOWN MIN
BEFORE RE-CHECKING THE OIL LEVEL
31 WORKSHOP MANUAL
REGULAR INSPECTION
AND ADJUSTMENTS
1
CHANGING THE ENGINE OIL
Stop the engine and place a container under the engine.
Extract:
- Dipstick.
- Drain plug (1).
- The prefilter.
Drain the oil from the crankcase.
Fit:
- El prefiltro.
- Drain plug (1).
- Dipstick.
Pre-filter cap:
2,4-3,0 Kgf.m (24-30 N.m)
Replenish:
Oil in the crankcase.
Quantity of oil:
1.150 ml
Type of oil: AGIP CITY 4T (4-STROKE)
Check:
- The engine oil level.
See “ INSPECT THE ENGINE OIL LEVEL ” section
I NSPECTING THE EXHAUST SYSTEM
Inspect:
- Bolts (1) (exhaust pipe)
Loose/damaged => Tighten/renew.
- Gasket (exhaust pipe).

Leaking exhaust fumes => Tighten/renew.
Bolts:
1,7-1,9 kgf.m (17-19 N.m)
1
32 WORKSHOP MANUAL
DISMANTLING THE ENGINE
3 1
CAMSHAFT
Extract:
- The spark plug (1).
- The four bolts (2) from the cylinder head.
- The cylinder head (3).
Extract: 4
- Bolts (timing chain tensioner):
Fit:
- The camshaft sprocket locking tool (5).
The camshaft sprocket locking tool:

Ref. 865260 9
Ref. T01010047 5
8
N.B.:
TIE A PIECE OF WIRE TO THE TIMING CHAIN TO STOP IT
FROM FALLING INTO THE CRANKCASE (9).
Extract: 6 7
- The 2 bolts (6) and 2 washers (7) from the camshaft
crown wheels:
- The camshaft distribution crown wheels (8).
10
11
Extract:
- The 8 bolts (10) from the bridge of the camshafts.
- The bridge (11) from the camshafts.
- The inlet camshaft (12) ref.(0906).
13
- The inlet camshaft (13) ref.(0906).
12
33 WORKSHOP MANUAL
AMSHAFT
3 1
TIMING CHAIN
Extract:
- The 4 bolts(2) from the cylinder head cover.
- The cylinder head cover (3).
Extract:
- The 4 bolts (4) from the bridge of the camshafts. 4
- The bridge (5) of the camshafts.
Extract:
7
- The 2 bolts (6) securing the starter motor.
- The starter motor (7).
N.B.:
REMOVE THE STARTER MOTOR TO ENABLE EASY EXTRAC-
TION OF THE TIMING CHAIN TENSIONER .
6
Extract:
-The 2 timing chain bolts, the tensioner and the seal (8).
N.B.:
PLACE A CONTAINER UNDER THE ENGINE AND DRAIN 10
THE OIL FROM THE CRANKCASE.
Extract:
- The oil plug and filter (9).
- The coolant pipe (10).
- The 3 water pump bolts (11) and cover(12). 12
11
34 WORKSHOP MANUAL
14 13 13
Extract:
- The 10 bolts (13) from the clutch cover.
- The clutch cover (14).
- The clutch cover gasket. (Renew when refitting).
Remove the clutch assembly (see the chapter). 13 13 13
Extract:
- The fixed timing chain roller (15).
15
Fit:
- The crankshaft sprocket locking tool (16).
16
Crankshaft sprocket locking tool:
Ref. 864487
Ref. T01010050
Extract:
- The nut (17).
- The crankshaft sprocket (18).
17 18
Extract:
- The timing chain sprocket (19).
- The timing chain from the top (20).
20
19
35 WORKSHOP MANUAL
C YLINDER HEAD, CYLINDER AND PISTON
1
Extract:
- The inlet manifold, by removing the 3 bolts (1).
2
Remove:
- The TDC (top dead centre) checking plug (2).
- The central plug (3).
Align:
Use an Allen key (b) to turn the crankshaft in an anti-cloc-
kwise direction until the mark (a) is aligned with the statio-
nary point.
b
N.B.:
GIRE EL CIGÜEÑAL EN SENTIDO ANTIHORARIO.
N.B.: 5
REMOVE THE STARTER MOTOR TO ENABLE EASY EXTRAC-
TION OF THE TIMING CHAIN TENSIONER .
Extract:
- The starter motor (5). 4
36 WORKSHOP MANUAL
7
Extract:
- The 2 bolts (6) securing the timing chain tensioner.
- Bolts (timing chain tensioner):
- The tensioner seal.
Extract:
- The 2 bolts and the thermostat cover (8).
Extract:
-The thermostat (9).
Extract: 12 10
- The 4 cylinder head cover bolts(11).
- Cylinder head side cover (12).
11
37 WORKSHOP MANUAL
Extract:
- The two cylinder head cover gaskets(13). 14
- The 8 bolts (14) from the camshafts cover.

- The bridge (15) from the camshafts.
15
N.B.:
TIE A PIECE OF WIRE TO THE TIMING CHAIN TO STOP IT 13
FROM FALLING INTO THE ENGINE.
Extract:
- The camshaft (see chapter).
Extract: 17 16
- The 6 bolts (16) securing the cylinder head to the cylinder.
- The cylinder head (17).
16
16
Extract: 18
- The top cylinder gasket (18). (Renew when refitting).
- The timing chain mobile roller(19).
- Coolant pipe (20).
- The cylinder (21). 19
- The bottom cylinder gasket.(Renew when refitting).
20 21
38 WORKSHOP MANUAL
Fit:
- The fork tool for fitting the piston (22).
Piston fitting clamp.

Ref. 865261
Ref. T01010049
22
N.B.:
BEFORE REMOVING THE CIRCLIP FROM THE GUDGEON
PIN, COVER THE BASE OF THE CYLINDER WITH A CLOTH
TO PREVENT OBJECTS FROM FALLING INTO THE ENGINE.
Extract:
- The 2 circlips (23), one on each side, securing the piston 23
gudgeon pin.
26
Extract:
- The piston gudgeon pin (24).
- The piston (25).
24
39 WORKSHOP MANUAL
Fit:
2 2
F LYWEEL MAGNETO
N.B.:
PLACE A CONTAINER UNDER THE ENGINE AND DRAIN
THE OIL FROM THE CRANKCASE. 2
Extract:
- The engine oil pre-filter cap (1). 3
- The engine oil pre-filter.
- The 10 bolts (2) from the magneto flywheel cover. 2 2 1
- The cover gasket. (Renew when refitting).
Fit:
- The magneto flywheel (4) locking tool.
Magneto flywheel locking tool:

Ref. 865259
Ref. T01010046
4
Fit:
- The magneto flywheel extractor (5).
Magneto flywheel extractor tool:

Ref. 864868
Ref. T01010051
Extract:
- The nut.
- The washer.
7
Extract:
- The safety roller(6).
- The 2 starter system sprockets (7).
7 6
40 WORKSHOP MANUAL
C LUTCH
Extract: 1
- The 3 bolts (2) from the water pump cover (3).
3
Extract:
- The water pump turbine (4).
N.B.:
PLACE A CONTAINER UNDER THE ENGINE AND DRAIN
THE OIL FROM THE CRANKCASE.
Extract:
- The engine oil plug (5).
- The spring (6).
- The oil filter (7). 7 6 5
9 8 8
Extract:
- The 10 bolts (8) from the clutch cover.
- The cover gasket. (Renew when refitting).
8 8 8
41 WORKSHOP MANUAL
Extract: 11
- The 5 bolts (10) with washer and spring from the clutch
closing cover.
- The clutch closing cover (11).
10
12
Extract:
- The clutch disks and separators (12).
Abrir:
- The seal tab (13).
Extract:
- The nut(15).
- The seal (13).
13 14
Extract:
- Use the clutch housing extraction tool (15) to remove it. 15
Clutch housing extraction tool:

Ref. 00H05300041
Ref. T01010042
Extract:
- The clutch bell housing (16).
16
42 WORKSHOP MANUAL
OIL PUMP
Remove the clutch assembly (see the chapter).
Extract:
- The intermediate starter gear clip and washer(1).
- The intermediate starter gear (2).
2 1
Extract:
- The oil pump gear clip (3).
- The oil pump gear (4).
3 4
Extract:
- The 3 oil pump bolts (5).
- The oil pump (6).
Extract:
- The oil pump gasket (7).
43 WORKSHOP MANUAL
3 2
CRANKSHAFT
Removing the cylinder head, piston and clutch (see

chapter).
Fit:
- The balance shaft locking tool (1).
Balance shaft locking tool:

Ref. 864486 1
Ref. xxxxxxxx
Extract:
- The nut balance shaft nut (2).
- The balance gear (3).
Fit:
- Fit the crankshaft sprocket using the locking tool (4).
5
Ref. 864487 6
Ref. T01010050
Extract:
- The nut (5).
- The fitting tool (4).
7
Extract:
- The timing chain (7) from the top.
- The timing chain sprocket(8).
8 9
Remove crankcase (see chapter). 10
Extract:
- The crankshaft (10) by pulling it upwards.
44 WORKSHOP MANUAL
CRANKCASES
Remove the cylinder head, cylinder and piston (see the

chapter).
Remove the magneto (see the chapter).
Remove the crankshaft (see the chapter).
Extract: 1
- The balance shaft (1).
3 2
Extract:
- The 6 outer bolts (2) from the left-hand crankcase.
- The outer bolt (3) from the left-hand crankcase (longer).
- The 6 inner bolts (4) from the left-hand crankcase.
4
2
4
2
Extract: 5
- Tilt the engine and remove the left-hand crankcase (5)
upwards.
Extract:
- The gasket from the crankcases (6).
45 WORKSHOP MANUAL
1
T RANSMISSION, GEAR SELECTOR, GEARCHANGE
SHAFT AND SELECTOR DISTRIBUTOR
3
2
Remove the cylinder head, cylinder and piston (see the
chapter).
Remove the magneto (see the chapter).
Remove the crankshaft (see the chapter).
Remove the crankcases (see the chapter). 3
Extract:
- The 2 gear selector fork rods.
Long rod (1).
Short rod (2).
- The 3 gear selector forks (3).
Extract:
- The gear selector shaft (4) by pulling it out.
4
N.B.:
THE INTERMEDIATE GEAR MUST BE REMOVED TO BE ABLE
TO EXTRACT THE GEAR LEVER.
5
Extract:
- The gear change spring bolt (5).
- The gear lever (6).
N.B.:
TAP THE ALLEN KEY WITH A PLASTIC HAMMER
TO RELEASE IT (TAPERED BOLT).
Extract:
- The gear selector bolt (7) situated on the other side of
the right-hand crankcase. 7
Gear change shaft assembly (8).
46 WORKSHOP MANUAL
Extract:
- The gear selector (9) by pulling it upwards.
Extract: 11
- The main shaft (10). 10
- The intermediate shaft (11).
N.B.
LENGTH OF SECONDARY SHAFT
92’2mm (+010 -0,18mm).
47 WORKSHOP MANUAL
INSPECTION AND REPAIR
CYLINDER HEAD
1. Eliminate:
- Carbon sediments (from the combustion chamber) Use a
rounded spatula.
N.B.:
AVOID USING ANY SHARP EDGED INSTRUMENT THAT CAN
CAUSE DAMAGE AND SCRATCHING.
- IN THE SPARK PLUG THREADS
- ON THE VALVE SEATS.
2. Inspect:
- Cylinder head
Wear/damage => Renew.
Steps for measuring distortion and for rectification:

Place a ruler (1) and a thickness calliper (2) on the head
cylinder surface, as in the figure to the side.
- Place a 400 ~ 600 emery paper on a flat surface and rec-

tify the surface of the cylinder head by making figure eight
movements.
N.B.:
TURN THE CYLINDER HEAD SEVERAL TIMES TO PREVENT
EXCESSIVE MATERIAL FROM BEING REMOVED FROM ONE
SIDE ONLY.
48 WORKSHOP MANUAL
ADJUSTING THE VALVES
Remove the camshaft (see chapter)
Valve clearance:
Inlet: 0,10 – 0,15mm para 0,15 – 0,20mm
Outlet: cambiar de 0,15 – 0,20 para 0,20 – 0,25mm
1
Extract:
Remove the tappet and check the numbering of the pad fitted (1).
In the event of the clearance being incorrect, continue by

calculating the appropriate pad(s) in accordance with the fo-
llowing calculation:
Thickness of new pad = (A – B) + C (mm)
Where
A= Clearance indicated (inlet or exhaust)
B= Value measured with the feeler gauge
C= Thickness of pad fitted
Example (exhaust valve):

A= 0,20
B= 0,15
C= 2,00
Thickness of new pad = (0,20-0,15)+2,00 = 2,05 mm
49 WORKSHOP MANUAL
VALVE SEATS
V
1. Eliminate:
- Carbon sediments.
(from the valve face and seat).
2. Inspect:
- Valve seats.
Grooves/wear => Grind the valve.
Steps for removal:

- Apply blue mechanical dye (Dykem) (b) to the valve face.
- Fit the valve into the cylinder head.
- Press the valve against the guide and against the seat to
make a visible mark.
- Measure the width of the valve seat.

Where there was contact between the seat and the valve
face, the dye will be removed.
- If the valve seat width is large or small, or if the seat is not

centred, it has to be redone
3. Grind:
- Valve face.
- Valve seat.
N.B.:
AFTER RECTIFYING THE VALVE SEAT OR REPLACING THE
VALVE AND ITS GUIDE, THE SEAT AND FACE MUST BE
GROUND.
50 WORKSHOP MANUAL
Steps for seating valves:
- Apply a coarse abrasive paste to the valve face.
ATTENTION
DO NOT ALLOW THE PASTE TO PENETRATE IN THE SPACE
BETWEEN THE VALVE STEM AND THE VALVE GUIDE.
- Apply acid with molybdenum disulphate to the valve stem.
-Twist the valve until its face and its seat are uniformly
ground, then remove the paste immediately.
N.B.:
TO OBTAIN THE BEST VALVE SEATING RESULTS, SHAKE
SOFTLY IN THE VALVE SEAT WHILE TWISTING BACKWARDS
AND FORWARDS BY HAND.
- Apply a coarse abrasive paste to the valve face and repeat

the above steps.
N.B.:
MAKE SURE THAT ALL TRACES OF GRINDING PASTE ARE
REMOVED FROM THE FACE OF THE VALVE SEAT AFTER
EVERY VALVE SEATING OPERATION.
- Apply blue mechanical dye (Dykem) to the valve face (b) .
- Press the valve through the valve guide and against its seat
to obtain a good contact.
- Measure the width of the valve seating (c) once again. If it is

outside that specified, rectify and grind the valve seat.
51 WORKSHOP MANUAL
V ALVES AND VALVE SPRINGS
1. Measurement:
- Free length (a) of spring.
Outside that specified => Renew .
Valve spring free length:

44,90 mm
2. Measurement:
- Spring contact face.
Wear/damage/scratches => Renew.
I NSPECTING THE CAMSHAFT
1. Check:
- Cam salients.
Grooves/scratches/blue colouring => Renew.
2. Inspect:
- Oil passage in the camshaft.
Obstructions => Blow through with compressed air.
52 WORKSHOP MANUAL
TIMING CHAIN, SPROCKET AND GUIDES
1. Inspect:
- Timing chain.
Rigidity/damage => Renew chain and sprockets.
2. Inspect:
- Drive sprockets
Damage/wear => Renew the sprockets and the timing

chain.
(1) 1/4 of the tooth

(2) Correct
(3) Roller
(4) Sprocket
3. Inspect:
- Timing chain guide (exhaust) (1).
- Timing chain guide (inlet) (2).
Damage/wear => Renew.
53 WORKSHOP MANUAL
C YLINDER AND PISTON
1. Inspect:
- Cylinder and piston walls.
Vertical scratches => Rectify or replace the cylinder and

the piston.
2. Measurement:
- Cylinder-Piston clearance.
Steps for removal:

Step 1:
- Measure cylinder diameter “C” with an internal calliper.
N.B.:
MEASURE THE DIAMETER “C” OF THE CYLINDER ACROSS
AND AT A RIGHT ANGLE TO THE CRANKSHAFT. NEXT, CAL-
CULATE THE AVERAGE OF THE MEASUREMENTS.
Cylinder and piston:

0,050 - 0,064mm
54 WORKSHOP MANUAL
1
I NSPECTING THE CLUTCH BELL HOUSING
1. Inspect:
- Primary sprocket teeth (1) .
- Bell housing sprocket teeth (2) .
Wear/damage => Renew both sprockets.
Excessive noise when functioning => Renew both spro-

ckets.
2
I NSPECTING THE CLUTCH
1. Inspect:
- Friction disks
Wear/damage => Renew the friction disks assembly.
2. Inspect:
- Separators
Damage => Renew the separators assembly.
3. Inspections:
- Clutch springs.
Damage=> Renew the springs assembly.
4. Inspect:
- Claws (of the bell housing) (1).
Rough edges/wear/damage => Eliminate the rough ed-

ges or renew the bell housing.
- Clutch assembly slots (2).
Rough edges/wear/damage => Renew the clutch assembly.
N.B.:
ROUGH EDGES ON THE BELL HOUSING CLAWS AND ON
THE CLUTCH HUB SLOTS LEAD TO UNEVEN FUNCTIO-
NING.
55 WORKSHOP MANUAL
I NSPECTION OF THE FORKS AND GEAR SELECTOR
1. Inspect:
- Fork follower (1).
- Ends of the gear change forks (2).
Scoring/warping/wear/damage => Renew.
2. Inspect:
Wear/damage/scratches => Renew.
- Gear change selector follower.
3. Inspect:
- Gear change fork 1 centre right (1).
- Gear change fork 2 top left (2).
- Gear change fork 3 bottom left (3).
- Guide bar (4).
- Gear change selector (5).
- Guide pin (6).
Roll the guide bar on a flat surface.
Warping => Renew.
WARNING:
DO NOT TRY AND STRAIGHTEN A WARPED BAR.
4. Check:
- Movement of the gear change forks (in the guide bar)
Uneven movement => Renew the fork and the bar.
N.B.:
IF THE GEAR CHANGE FORK AND THE DRIVE SPROCKETS
ARE DAMAGED, RENEW THE SPROCKETS TO EITHER SIDE
ALL TOGETHER.
5. Measurement:
- Warping of the shafts (drive and driven)
Use a support between points and a comparison meter (1).
Outside that specified => Renew the warped shaft.
56 WORKSHOP MANUAL
6. Inspect:
- Gear teeth
Blue colouring/grooves/wear => Renew.
- Gear claws
Rounded edges/cracks/pieces missing => Renew.
7. Inspect:
- Gear change shaft (1).
Damage/warping/wear => Renew.
- Return spring (gear change shaft) (2).
- Return spring (limiter rod) (3).
I NSPECTING THE OIL PUMP
1. Inspect:
- Rotary filter
Cracks/damage => Renew.

Contamination => Clean.
2. Inspect:
- Oil suction device

Contamination => Clean.
57 WORKSHOP MANUAL
I NSPECTING THE OIL PASSAGES

( RIGHT HAND SIDE CASING COVER)
1. Inspect:
- Oil passage
Obstructions => Blow through with compressed air.
C ASING
1. Wash the casings well with petrol.
2. Clean the seal-bearing surfaces and the casing contact

surfaces well.
3. Inspect:
- Casings
- Oil passages
Obstructions => Blow through the passages with com-

pressed air.
B EARINGS AND RETAINING RINGS
1. Inspect:
- Bearings
Clean and lubricate, then turn the inner ring by hand.
Roughness => Renew
2. Inspect:
- Retaining rings.
Damage/wear => Renew.
L OCKING RINGS AND WASHERS
1. Inspect:
- Circlips
- Washers
Damage/loose/distorted => Renew.
58 WORKSHOP MANUAL
ASSEMBLING THE ENGINE
AND ADJUSTMENTS
2
T RANSMISSION, GEAR SELECTOR, GEAR CHANGE
1
SHAFT AND SELECTOR DISTRIBUTOR
Fit:
- The main shaft (1).
- The intermediate shaft (2).
Fit:
- Gear change shaft assembly (3).
Fit:
- Gear change shaft assembly (4).
- The gear change selector bolt (5) situated on the other
side of the right-hand crankcase.
Fit: 6
- The 2 gear change forks rods.

Long rod (6).
Short rod (7). 8
7
- The 3 gear change forks (8).
59 WORKSHOP MANUAL
AND ADJUSTMENTS
Fit:
10
- The gear selector lever (9) and the spring, using the
bolt (10).
Fit:
- The gear change selector shaft (11).
N.B.:
FIT THE GEAR CHANGE SELECTOR SHAFT, BY ALIGNING
THE ENDS OF THE RETURN SPRING WITH THE POSITIO-
NING BRACKET (12) ON THE CRANKCASE.
N.B.:
THE INTERMEDIATE GEAR REMOVED IN DISMANTLING 12 11
MUST BE REFITTED.
60 WORKSHOP MANUAL
AND ADJUSTMENTS
T RANSMISSION PARTS
1 Distributor drum 26 Gear change greasing tube

2 Roller 27 O-ring
3 Washer 28 Z14 gear change output gear
4 Primary fork shaft 29 Output gear seal
5 Cat. 1 gear change fork. 30 5M80x10 Allen bolt
6 Secondary fork shaft 31 Int. star washer
7 Cat. 2 gear change fork
8 Secondary shaft
9 1st secondary gear 1º
10 5th secondary gear 5ª
11 3rd secondary gear 3ª
14 2nd secondary gear 2ª
15 Adjustment washer
16 Needle bearing assy.
18 Safety ring
20 Washer
21 Bush
22 Washer
23 Primary shaft assy.
24 Secondary shaft assembly
61 WORKSHOP MANUAL
AND ADJUSTMENTS
G EAR CHANGE SELECTOR PARTS
1 Clutch push rod

2 Selector spring stud
3 Clutch lever
4 Bolt
5 Clutch cable securing plate
6 Gear selection lever
7 Selector shaft assembly
8 Spring
9 D12 safety ring
10 Washer
11 Bolt
12 Washer
13 Drum control head
14 Gear selection spring
15 Special bolt
16 Gear lever assy.
17 6M100x25 bolt
18 D6 washer
62 WORKSHOP MANUAL
AND ADJUSTMENTS
1
C RANKSHAFT
Fit:
- Crankshaft (1). A
Fit crankcases (see chapter)
ATTENTION
TO PREVENT SCRATCHES TO THE CRANKSHAFT AND TO
HELP ITS FITTING, APPLY GREASE TO THE RETAINING RING
EDGES AND ENGINE OIL TO THE BEARINGS.
GREASE THE CRANKSHAFT USING THE GREASING HOLES

(A).
N.B.:
COVER THE BASE OF THE CYLINDER WITH A CLOTH TO PRE-
VENT OBJECT FROM FALLING INTO THE ENGINE.
Fit:
- The crankshaft key.
- The balance shaft gear (2).
- The crankshaft gear (3).
3 2
N.B.:
ALIGN THE CRANKSHAFT AND BALANCER GEARS USING
THE GUIDE POINTS.
5
Fit:
- The balance shaft locking tool (4).
Balance shaft locking tool:

Ref. 864486
Ref. xxxxxxxx
-The balance shaft nut (5).
Balance shaft nut.

4
3,5-4,5 kgf.m (35-45 N.m)
N.B.:
FIT THE TIMING CHAIN SPROCKET WITH THE GUIDE POINT
FACING FORWARDS.
Fit:
63 WORKSHOP MANUAL
AND ADJUSTMENTS
Fit:
- The timing chain (7).
N.B.:
FIT IT ON THE CENTRAL TEETH.
Fit:
9
- The fitting tool (9).

Ref. 864487
Ref. T01010050
Fit:
-The crankshaft gear nut (10). 10 8
Crankshaft gear nut:

7,5-8,3 kgf.m (75-83 N.m)
N.B.:
THERE ARE SETS OF BALANCER SHAFTS.
- CRANKSHAFT GEARING
N.B.
See chapter (identification of sets).
64 WORKSHOP MANUAL
AND ADJUSTMENTS
CRANKSHAFT PARTS
1 Crankshaft-connecting rod assy.

2 Counterweight shaft
3 Key
4 Intermediate gear counterweight
5 Counterweight gear
6 Nut
65 WORKSHOP MANUAL
AND ADJUSTMENTS
CRANKCASES
Fit:
- The engine crankcase gasket (1) (new gasket).
Fit:
2
- The left-hand crankcase (2) onto the right-hand crankcase
(3), being guided by the centring studs (4).
ATTENTION
MAKE SURE THAT THE GASKET REMAINS IN THE CORRECT
POSITION. 4
N.B.:
TAP THE CRANKCASE LIGHTLY WITH A PLASTIC HAMMER. 3
IMPORTANT
TIGHTEN THE BOLTS ON THE BLOCK IN SUCCESSION 6 5
CROSSWISE, GOING FROM ONE TO ANOTHER TWO OR
THREE TIMES.
Fit:
- The 6 outer bolts (5) on the left-hand crankcase.
- The (longer) outer bolt (6) on the left-hand crankcase.
- The 6 inner bolts (7) on the left-hand crankcase.
7
5
7
5
Bolts (crankcases):
1,1-1,3 kgf.m (11-13 N.m)
66 WORKSHOP MANUAL
AND ADJUSTMENTS
C RANKCASE PARTS
1 Crankcases assy. 24 M5x14 bolt

2 Counterweight bearing 25 Top mounting blue semi-bearing
3 Crankcase gasket 26 Bottom mounting blue semi-bearing
4 Crankshaft oil seal
5 Secondary shaft bearing
6 Primary shaft needle bearing assy.
7 Neutral switch
8 Gasket
9 Counterweight shaft needle bearing assy.
10 Bolt
11 Key
12 M6x75 hex. bolt
13 Key
14 m6x60 bolt
15 Clamp
16 Selector lever shaft oil seal
17 Centring stud
18 Secondary shaft needle bearing assy.
19 Primary shaft bearing
20 5.2x15x1.5 washer
21 M5x14 bolt
22 Centring stud
23 5.2x15x1.5 washer
67 WORKSHOP MANUAL
AND ADJUSTMENTS
3 1 2 4
O IL PUMP
- (1) Crankshaft breather.

- (4) To the filter, lubrication technical part.
N.B.:
THE OIL PUMP IS A DOUBLE ROTOR PUMP WHICH PUMPS
5
SEPARATELY.
One 13mm thick rotor, for suction. One 8.5 mm thick ro-
tor, for pumping.
Fit:
- The oil pump gear (5). 7
Fit:
- The oil pump (6).
- The 3 oil pump bolts (7).
The oil pump bolts: 6
0,5-0,6 kgf.m (5-6 N.m)
Fit:
- The oil pump gear (8).
- The oil pump gear clip (9).
9 8
Fit:
- The intermediate starter gear (10).
- The intermediate starter gear clip and washer (11).
N.B.
10 11
68 WORKSHOP MANUAL
AND ADJUSTMENTS
O IL PUMP ASSEMBLY PARTS
1 Rubber ring.
2 Flat washer
3 Intermediate oil pump gear
4 Bolt
5 Circlip
6 Oil pump gear
7 Oil pump gear
8 Crankcase / oil pump gasket
9 Oil pressure valve spring
10 Oil by-pass valve
11 Oil filter
12 Oil filter gasket
13 Plug gasket
14 Oil filter plug
69 WORKSHOP MANUAL
AND ADJUSTMENTS
I NSTALLING THE CLUTCH
Fit:
- The washer (2).
1 2
Fit:
- The seal (4).
3
- The nut (5).
The clutch housing nut:

3,5-4,5 kgf.m (35-45 N.m)
Closing: 4 5
- The seal tab (4).
6
- Use the clutch housing (7) fitting key (6) .
Bell housing extraction tool:

Ref. 00H05300041
Ref. T01010042
N.B.
70 WORKSHOP MANUAL
AND ADJUSTMENTS
8
Fit:
- The clutch disks and separators (8).
N.B.:
- FIT THE DISKS (BLADES TO THE RIGHT) AND THE SEPARA-
TORS (ROUNDED PROFILE INWARDS) ALTERNATELY ONTO
THE CLUTCH HUB, BEGINNING WITH A FRICTION DISK
AND ENDING WITH A FRICTION DISK.
- LUBRICATE ALL THE DISKS AND SEPARATORS WITH ENGI-

NE OIL BEFORE FITTING.
Fit:
9
- The clutch closing cover (9).
Fit:
- The 5 clutch closing cover bolts (10) with washer and
spring.
The clutch closing cover bolts:

0,35-0,45 kgf.m (3,5-4,5 N.m)
10
Fit:
- The cover gasket (11) (new gasket).
Fit:
- The 10 clutch cover bolts (13).
- The clutch cable support (14).
11
The clutch cover bolts:
1,1-1,3 kgf.m (11-13 N.m)
12 13 14 13
N.B.:
TO HELP THE COVER TO FIT, THE WATER PUMP SHOULD BE
TURNED UNTIL THE 2 GEARS COINCIDE.
IMPORTANT
TIGHTEN THE BOLTS ON THE BLOCK IN SUCCESSION
CROSSWISE, GOING FROM ONE TO ANOTHER TWO OR
THREE TIMES.
13 13 13
71 WORKSHOP MANUAL
AND ADJUSTMENTS
Fit:
- The oil filter (15).
- The spring (16).
- The oil filter plug (17)
The oil filter plug: 15 16 17

2,4-2,6 kgf.m (24-26 N.m)
Fit:
- The water pump turbine (18).
18
The water pump turbine:

0,4-0,6 kgf.m (4-6 N.m)
Fit:
- The water pump cover (19) and the 3 bolts (20). 21
19
The water pump cover:

20
0,5-0,6 kgf.m (5-6 N.m)
72 WORKSHOP MANUAL
AND ADJUSTMENTS
C LUTCH BELL HOUSING PARTS
1 Clutch bell housing

2 Clutch casing
3 HZ driving disk
4 HZ driven disk
5 Clutch closing cover
6 Clutch spring
7 Bolt with washer
8 Washer
9 M6 hexagonal nut
10 Clutch bolt
11 Separator
12 Washer
13 Nut with tapered spring
14 Engine gear
15 Key
16 Seeger ring
17 Washer
18 Needle bearing assy.
19 Separator bush
73 WORKSHOP MANUAL
AND ADJUSTMENTS
C LUTCH COVER PARTS
1 Clutch cover assy.

2 Clutch cover – crankcase gasket
3 Oil filter cover
4 O-ring
5 Oil filter cartridge spring
6 Oil filter cartridge
7 M5x14 bolt
8 Water pump cover
9 O-ring
10 Complete drive shaft
11 Water pump oil seal
12 Clamp
13 M6x35 bolt
14 Oil seal
15 Pump-cylinder head pipe
16 Oil pressure sensor
17 Washer
18 Water pump shaft assy.
19 20x30x5 oil seal
20 Water pump gear
74 WORKSHOP MANUAL
AND ADJUSTMENTS
2 1
M AGNETO
Fit:
- The 2 starter system gears (1).
- The key (2).
- The safety roller (3).
1 3
Fit:
- The rotor (4)
- The washer (5).
4 5
Fit:
- The rotor nut (6).
Fifar:
6
- The rotor onto the magneto flywheel, using the magne-
to fl ywheel locking tool (7).
Magneto flywheel locking tool:

Ref. 865259
Ref. T01010046
Magneto flywheel rotor nut:
8,3-9,0 kgf.m (83-90 N.m)
N.B.
POSITION A RUBBER PAD BETWEEN THE TOOL FIXING
POINT AND THE MAGNETO FLYWHEEL TO PREVENT THIS
FROM BEING DAMAGED.
7
76 WORKSHOP MANUAL
AND ADJUSTMENTS
Fit:
- The cover gasket (8) (new gasket).
10 10
Fit:
- The 10 bolts (10) on the left-hand crankcase cover.
10
The crankcase cover bolts:
1,1-1,3 kgf.m (11-13 N.m)
IMPORTANT 9
TIGHTEN THE BOLTS ON THE BLOCK IN SUCCESSION
CROSSWISE, GOING FROM ONE TO ANOTHER TWO OR 10 10 11
THREE TIMES.
Fit:
- The engine oil pre-filter.
- The pre-filter plug (11)
The pre-filter plug:

2,4-3,0 kgf.m (24-30 N.m)
76 WORKSHOP MANUAL
AND ADJUSTMENTS
M AGNETO PARTS
1 Magneto side cover 22 Starter crown wheel retaining plate

2 Magneto cover-crankcase gasket 23 M6x14 bolt
3 O-ring 24 Key
4 Ignition cover 25 6M100 hexagonal nut with clamp
5 M6x35 bolt
6 O-ring
7 Oil dipstick
8 Nut
9 Flat washer
10 Stator
11 M 5x25 bolt
12 M 5x16 bolt
13 Bolt
14 Washer
15 Rotor
16 Free wheel inner ring
17 Free wheel
18 Electric start crown wheel
19 Starter motor takeoff gear
20 Starter motor
21 M6x25 bolt
77 WORKSHOP MANUAL
AND ADJUSTMENTS
a
C AMSHAFT
Remove:
- The TDC (top dead centre) checking plug.
- The central plug.
Align:
b
Turn the crankshaft in an anticlockwise direction with an
Allen key (b) until the mark (a) is lined up with the point on
the nut, as shown in the photograph.
ATTENTION
DO NOT TURN THE CRANKSHAFT DURING THE FITTING
OF THE CAMSHAFT. TO DO SO MAY CAUSE DAMAGE OR
THE ENGINE TIMING TO BE INCORRECT.
Fit:
- The inlet camshaft (1) ref.(0906) (A).
1
- The inlet camshaft (2) ref.(0906) (S).
N.B.:
POSITION THE CAMSHAFT LOCKING HOLES FACING
UPWARDS.
Lubricate:
- The camshaft (3) with engine oil.
5 4
Fit:
- The camshaft bridge (4).
- The 8 camshaft bridge bolts (5).
The bolts (camshaft bridge):

1-1,2 kgf.m (10-12 N.m)
78 WORKSHOP MANUAL
AND ADJUSTMENTS
Position: 6
- Set of camshaft locking keys (6).
Set of camshaft locking keys:

Ref. 864567
8
Fit:
7
- The camshaft crown wheels (7).
- The timing chain (8).
- Apply Loctite before fitting the 2 volts.
- The camshaft crown wheels washer (9) and bolts (10).
N.B.:
DO NOT TIGHTEN THE CROWN WHEEL BOLTS UNTIL THE TIMING 10 9
CHAIN TENSION HAS FIRSTLY BEEN SET.
Adjust:
- Press the tab (11).
- Push the timing chain tensioner (12).
- Release the tab (11). 11
12
Fit:
- The tensioner seal. 13
- The timing chain tensioner (13).
The timing chain tensioner bolts.

1,1-1,3 kgf.m (11-13 N.m)
- The spring (14), by pressing until the bolt is in position. 14
The timing chain tensioner spring.

0,8-1 kgf.m (8-10 N.m)
79 WORKSHOP MANUAL
AND ADJUSTMENTS
Fit: 16

- The starter motor (16).
- The 2 bolts (apply Loctite before fitting ).
15
The starter motor bolts:
1,1-1,3 kgf.m (11-13 N.m)
17
Fit:
- The camshaft sprocket locking tool (17).
The camshaft sprocket locking tool.

Ref. 865260
Ref. T01010047
Fifar:
- Fit the 2 bolts onto the camshaft crown wheels.
The camshaft sprocket bolts:

2,3-2,7 kgf.m (23-27 N.m)
18 20
Fit:
- The cylinder head cover (18).
- The 4 rocker cover bolts (19).
(Rocker cover) bolts:

1-1,2 kgf.m (10-12 N.m)
19
80 WORKSHOP MANUAL
AND ADJUSTMENTS
T IMING CHAIN
N.B.:
FIT THE TIMING CHAIN SPROCKET WITH THE GUIDE POINT
FACING FORWARDS.
Fit:
1
N.B.
N.B.:
TIE A PIECE OF WIRE TO THE TIMING CHAIN TO PREVENT
IT FROM DETACHING FROM THE SPROCKET.
2
Fit:
- The timing chain (2) from the top.
Fit:
- The fixed roller (3).
Timing chain fixed roller:

1-1,2 kgf.m (10-12 N.m)
Fit:
- The crankshaft sprocket locking tool (4).

Ref. 864487
Ref. T01010050 3
Fit:
-The crankshaft gear nut (6).
The crankshaft gear nut. 4

7,5-8,3 kgf.m (75-83 N.m)
Fit:
The clutch assembly (see chapter).
6 5
81 WORKSHOP MANUAL
AND ADJUSTMENTS
7 9 8 9
Fit:
- The clutch cable support (8).
- The 10 clutch cover bolts (9).
The clutch cover bolts:

1,1-1,3 kgf.m (11-13 N.m)
N.B.:
TO HELP THE COVER TO FIT, THE WATER PUMP SHOULD 9 9
9
BE TURNED UNTIL THE 2 GEARS COINCIDE.
Fit:
- The water pump cover (10) and the 3 bolts (11).
12
The water pump cover bolts.

0,5-0,6 kgf.m (5-6 N.m) 10
11
Fit:
82 WORKSHOP MANUAL
AND ADJUSTMENTS
V ALVES AND CAMSHAFT PARTS
1 Cylinder head assy. 25 Gasket

2 12x13 centring bush 26 Chain guide fixed roller
3 M8x20x1 bolt 27 Chain tensioner mobile roller
4 8x13 centring bush 28 M6 bolt
5 M8x166 bolt 29 Timing chain
6 8.5x16x1.5 washer 30 Crown wheel
7 M6x130 bolt 31 8.25x23x4 washer
8 Distribution gear
9 125cc exhaust valve
10 125cc inlet valve
11 Oil seal
12 Valve spring
13 Valve semi-cone
14 Valve top casing
15 Exhaust camshaft
16 Intake camshaft
17 Seal washer
18 Camshaft cover
19 M6x40 bolt
20 Rocker cover gasket
21 Rocker cover
22 Rocker cover bolt
23 Valve cover rubber washer
24 NGK CR8EB spark plug
83 WORKSHOP MANUAL
AND ADJUSTMENTS
I NSTALLING THE PISTON RINGS
N.B.:
COVER THE BASE OF THE CYLINDER WITH A CLOTH TO PRE-
VENT OBJECT FROM FALLING INTO THE ENGINE.
Fit in accordance with the following sequence:

- Expansion ring (oil ring) (1).
- Secondary ring (scraper) (2).
- Top ring (compression) (3).
N.B.:
- FIT THE RINGS IN SUCH A WAY THAT THE MANUFACTURER’S
MARK IS TOWARDS THE TOP.
- LUBRICATE THE PISTON AND THE RINGS WELL WITH EN-

GINE OIL.
Position:
- Rings (1).
N.B.:
POSITION THE ENDS OF THE RINGS AS IN THE FIGURE.
Lubricate:
- External surface of the piston
- Rings
- Inner surface of the cylinder
84 WORKSHOP MANUAL
AND ADJUSTMENTS
C YLINDER HEAD, CYLINDER AND PISTON
Fit:
- The piston fitting clamp (1).
Piston fitting clamp:

Ref. 865261
Ref. T01010049
N.B.:
BEFORE REMOVING THE CIRCLIP FROM THE GUDGEON
2
PIN, COVER THE BASE OF THE CYLINDER WITH A CLOTH
TO PREVENT OBJECTS FROM FALLING INTO THE ENGINE.
N.B.:
- APPLY ENGINE OIL TO THE GUDGEON PIN.
- THE ( ) MARK MUST FACE TOWARDS THE EXHAUST

SIDE.
3
Fit:
- The piston (2).
- The piston gudgeon pin (3).
Fit:
- The piston gudgeon pin securing circlip (4).
Fit: 5
- The cylinder (5).
85 WORKSHOP MANUAL
AND ADJUSTMENTS
6
Fit:
- The comparer (6) onto the TDC measuring tool (7).
N.B.:
PLACE THE COMPARER ON A FLAT SURFACE AND ADJUST
CORRECTLY (0). 7
7
Fit:
- The TDC measuring tool (7), using 2 cylinder head bolts.
TDC measuring tool:

Ref. 864592
Position:
- The piston at TDC.
- Take a reading of the measurement on the comparer.
- Choose the cylinder gasket (see table).
N.B.:
THE CYLINDER GASKET THICKNESS MUST BE CALCULATED TO
ESTABLISH THE APPROPRIATE COMPRESSION RATIO.
THERE ARE THREE THICKNESSES OF GASKET AVAILABLE: 0.3

0.4 AND 0.5 MM.
PERFORM THE CALCULATION WITH THE COMPARER WITHOUT

FITTING ANY GASKET.
TDC measurement Thickness of Gasket Reference
0.95 / 1.09 0.3 ± 0.05 Go toCM22801

1.1 / 1.25 0.4 ± 0.05 Go toCM222802

1.26 /1.45 0.5 ± 0.05 Go toCM222803

86 WORKSHOP MANUAL
AND ADJUSTMENTS
Fit: 9
- The front timing chain roller (8).

- The top gasket (9) (new gasket).
8
10
Fit: 12 11
- The cylinder head.
N.B.:
APPLY OIL TO THE WASHERS OF THE 4 BOLTS JOINING THE
CYLINDER HEAD TO THE CRANKCASE.
Fit:
- The 6 bolts (11) and the 4 washers (12) securing the
cylinder head to the cylinder.
The bolts securing the cylinder head to the cylinder.

1,1-1,3 kgf.m (11-13 N.m)
Fit:
Fit:
- The inlet manifold, using the 3 bolts (13).
13
Inlet manifold bolts:

1,1-1,3 kfg.m (11-13 N.m)
87 WORKSHOP MANUAL
AND ADJUSTMENTS
Fit:
- The thermostat (14).
14
Fit:
- The 2 thermostat cover bolts.
- The thermostat cover (15).
The thermostat cover bolts:

1-1,2 kfg.m (10-12 N.m) 15
88 WORKSHOP MANUAL
AND ADJUSTMENTS
C YLINDER HEAD AND CYLINDER PARTS
1 Piston-cylinder assy.
3 1st cat. piston assy.
4 Cylinder – cylinder head gasket
5 Cylinder - crankshaft gasket
6 First piston ring
7 Scraper ring
8 Piston gudgeon pin
9 Piston gudgeon pin circlip
10 Chain tensioner
11 Gasket
12 M6x16 bolt
89 WORKSHOP MANUAL
AND ADJUSTMENTS
THERMOSTAT PARTS
1 Hose joining the EFI to the inlet manifold

2 Bolt
3 Intake connector
4 O-ring
5 Thermistor
6 Thermostat
7 Thermostat cover
8 6.3x8x6.8 bush
9 M6x20 bolt
10 Studs
11 Carburettor clamp
90 WORKSHOP MANUAL
ECU INTERFACES 7, 15 and 23 ARE COMMUNICATED
ECU
NEUTRAL GEAR LIGHT/ALARM LIGHT

NEUTRAL GEAR/DUMPING SWITCH
SPEED RIGHT SWITCHER
FAST ACTING SHIFTING DEVICE

FUEL FRONT
OXYGEN SENSOR HEATER (-)

SENSOR SENSOR FLASHER ENGINE IGNITION IGNITION REAR BRAKE INJECTOR
START HEADLAMP BRAKE
FUSE 1 FUSE 2 COILS
SPEED SENSOR SIGNAL

TEMPERATURE SENSOR
SWITCH STOP SWITCH SWITCH FAN SWITCH RELAY
ENGINE STOP SWITCH

SWITCH FAN RELAY
HEADLIGHT RELAY (-)

SPEED SENSOR (+)
INJECTION SIGNAL
OFF
SIDE STAND OUT
INJECTOR RELAY
START RELAY (-)
RBL
ENGINE SPEED
SIDE STAND IN
30A
20A
IGNITION COIL
Y/G B W/R
ON
MAGNETO (+)
O2 SIGNAL (+)
MAGNETO (-)
O2 SIGNAL (-)
Y/GR
IGNITION (+)
Y/B R/B
BATTERY (+)
FAN RELAY
STARTING
LOCK
B BL BL/R
R 1.5
CLUTH
G W/BL
K-LINE
W/R R/B O G
SPEED
G/Y R/B GR Y/R Y/G R/B
GND
B B B R/O BR/Y B/W B G/Y Y/B
OBD
GND
BL R B G Y/GR
R/B G/B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
R/BL
R/B R/O BR/Y B/W Y/G G BR/W BL/W
BL/W R/Y G/W G YW Y/R GB L/GR BR/Y YR WR G R BL/YR/G
GR/G B/W O/B G/R G/Y B/Y WIRE
W
1
W/BL BL/R
Y/P Y/GR GR/R
GR/B
FRONT LEFT TURN SIGNAL WIRE 2
12V10W BL
G O
G O
SPEED SENSOR (+) R/Y
BATTERY (+) R
BACK BOARD LIGHT
IGNITION (+) W/R
LEFT INDICATOR O
WATER O
TEMPERATURE PU/W
SPEEDOMETER (-) G/W O REAR LEFT INDICATOR
FUEL Y/W G 12V10W
NEUTRAL GEAR G/R G REAR BRAKE LIGHT
G 12V21W
ROTATION SPEED Y/P
GND G YG YG
WR 12V5W
FAULT LIGHT BR/W BR
REAR POSITION LIGHT
SPEED BL/W WR BR
G
HIGH LIGHT BL LICENSE LIGHT
G
x1000
OIL LIGHT BL/B 12V5W

G
LB LB REAR RIGHT INDICATOR
SIDE STAND W/G
12V10W
BL
HEADLIGHT HIGH
12V35W
G
HEADLIGHT LOW
12V35W
W
POSITION LIGHT BR W/R
G G
12V5W
LB LB
FRONT RIGHT INDICATOR LAMP
12V10W G G
RIGHT INDICATOR LB
LG G
HORN G
W O GR LB R/B LG G/Y Y/R
GRB BL B/W B/W B/Y W/G BL/Y YB RG GRG YGR
PU/W
G WIRE 1 YB G
BW BR
L/GR W R G
G B BR Y/B GR/R B/W O/B
RO BL W O GR LB B LG GR G BL/B YY Y R/BL R BW
WATER t° WIRE X2 G PU GR B W
TEMPERATURE W BL
B BLACK SENSOR
0
R
UP
STARTING INJECTOR M OXYGEN SENSOR
K-LINE USB
W WHITE DOWN RELAY M
HIGH/LOW 12V6Ah FUEL PUMP
R RED SWITCH INDICATOR HORN CLUTCH RECTIFIER BATTERY
B
SWITCH SWITCH OIL SENSOR
SWITCH SIDE STAND SWITCH
G GREEN GEAR SENSOR MAGNETO STARTING MOTOR
BR BROWN LEFT SWITCHER
Y YELLOW
BL BLUE
91 WORKSHOP MANUAL
GR GRAY
O ORANGE
LG LIGHT GREEN
LB LIGHT BLUE
P PINK
PU PURPLE
ECU INTERFACES 7, 15, 23 ARE COMMUNICATED
NEUTRAL LIGHT ANTI-TEFTH LIGHT

ECU

RIGHT SWITCHER
NEUTRAL / DUMPING SWITCH

SPEED FUEL
SENSOR FRONT REAR
TEMPERATURE SENSOR
SPEED SENSOR SIGNAL

SENSOR FLASHER START HEADLAMP BRAKE IGNITION BRAKE INJECTOR
HEADLAMP RELAY (-)

FAN COIL
O2 SENSOR HEAT (-)

SWITCH SWITCH ENGINE STOP SWITCH FUSE 1 FUSE 2 IGNITION LOCK SWITCH FAN RELAY
LOW POWER START

RELAY
TURN OFF SWITCH
SPEED SENSOR (+)
INJECTOR SIGNAL
INJECTION RELAY
START RELAY (-)
ENGINE SPEED
IGNITION COILS
R/BL
O2 SIGNAL (+)
O2 SIGNAL (-)
OUTPUT LOW
MAGNETO (+)
30A
20A
MAGNETO (-)
W/R
IGNITION (+)
DIAGNOSYS
Y/GR
FAN RELAY
Y/B R/B
START UP
Y/G B BL/R
BATT (+)
B BL
CLUTCH
SPEED
R W/R R/B O G W/BL
BL/W B/W R/B GR Y/R B B R/O BR/Y B/W B Y/G G Y/B
GND
GND
OBD
1.5
BL R B G Y/GR Y/G RB
R/B G/B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
R/BL
BL/W R/Y G Y/R R/B R/O BR/Y B/W Y/G G/B Y/R GR/B B/W G/R B/W WIRE 1 W/BL G G/W BL/W WIRE
G Y/W
LG/R
W/R
G R BL/Y R/GGR/G O/B G/Y BL/R
Y/GR B/R GR/R
FRONT LEFT INDICATOR LAMP BR/Y W 2
BL
12V10W Y/P
Y/G P
G P
BATTERY (+) R
IGNITION (+) W/R
LEFT INDICATOR P
WATER O
TEMPERATURE PU/W
BACK BOARD LIGHT W/R O REAR LEFT INDICATOR
FUEL Y/W G 12V10W
REAR BRAKE LED
NEUTRAL GEAR G/R G
12V0,9W
G
GND G Y/G Y/G
OBD LINE W/R 12V0,11W
G/W BR
REAR POSITION LED
L
MAX
SPEED BL/W W/R Y

G
HIGH LIGHT BL LICENSE LIGHT
G 12V5W
OIL LIGHT BL/B G
LB REAR RIGHT INDICATOR
LB 12V10W
BL
H
HEADLIGHT HIGH
12V35W
G
HEADLIGHT LOW
12V35W
W
POSITION LIGHT BR W/R
12V5W G G
PU PU
Y/G G
12V10W
RIGHT INDICATOR PU
LG
HORN G R/B LG G/Y Y/R
W P GR PU BL/Y R/G GR/G Y/GR
PU/W GR/B BL B/W B/W R/O Y/B
G B/W W/R LG/R WIRE 1
BL/B W R/BL R G
B BLACK R/O
BL W O GR LB B LG G/R
G B/R B G YY Y Y/B GR/R Y/B G B/W O/B
WATER t° W/B R/O G PU GR B W
B/R
W WHITE TEMPERATURE
W HEADLAMP 0
SENSOR R 10
R RED RELAY UP WIRE STARTING INJECTOR M OXYGEN SENSOR
K-LINE
X2 RELAY M
G GREEN HIGH/LOW DOWN
BL 12V4Ah FUEL PUMP
SWITCH INDICATOR HORN CLUTCH RECTIFIER BATTERY B
BR BROWN SWITCH SWITCH OIL SENSOR
SWITCH SIDE STAND SWITCH
GEAR SENSOR MAGNETO STARTING MOTOR
Y YELLOW LEFT SWITCHER
BL BLUE
92 WORKSHOP MANUAL
GR GRAY
O ORANGE
LG LIGHT GREEN
LB LIGHT BLUE
P PINK
PU PURPLE
ECU INTERFACES 7, 15 and 23 ARE COMMUNICATED
ECU
SIDE STAND ENGINE STOP SWITCH SIGNAL

NEUTRAL GEAR LIGHT/ALARM LIGHT
RIGHT SWITCHER
NEUTRAL GEAR/DUMPING SWITCH

SPEED FUEL FRONT REAR
OXYGEN SENSOR HEATER (-)

SIDE STAND ENGINE STOP (-)
SENSOR SENSOR IGNITION BRAKE
FLASHER START HEADLAMP ENGINE BRAKE INJECTOR FAN
FUSE2 COIL
SPEED SENSOR SIGNAL

TEMPERATURE SENSOR
SWITCH SWITCH STOP SWITCH FUSE1 IGNITION LOCK FAN SWITCH RELAY RELAY
ENGINE STOP SWITCH
HEADLIGHT RELAY (-)

SPEED SENSOR (+)
INJECTION SIGNAL
INJECTOR RELAY
START RELAY (-)
ENGINE SPEED
R/BL W/R
30A
R/B
IGNITION COIL
20A
MAGNETO (+)
Y/GR
O2 SIGNAL (+)
MAGNETO (-)
O2 SIGNAL (-)
Y/G B
IGNITION (+)
BATTERY (+)
FAN RELAY
STARTING
Y/B
R1.5 W/R B BL
CLUTH
K-LINE
O G G
SPEED
B B Y/G R/B BL/R
GND
Y/R R/B Y/B W/BL
OBD
B G/Y
GND
BL/W B/W R/B R/O BR/Y B/W
BL R B GR G Y/GR
R/B G/B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
R/BL
R/B R/O BR/Y B/W G/Y G/B LG/R Y/R G BL/Y GR/G B/W G/R B/Y W/BL G BR/W BL/W
BL/W R/Y G/W G Y/W Y/R W/R R R/G Y/P GR/R
O/B G/Y WIRE 1
FRONT LEFT INDICATOR LAMP BR/Y GR/B W Y/GR
12V10W BL/R WIRE 2
BL
Y/G P
G P
BATTERY (+) R
IGNITION (+) W/R
LEFT INDICATOR P
WATER P
TEMPERATURE PU/W
SPEED SENSOR(-) G/W P REAR LEFT INDICATOR LAMP
Y/G 12V10W
FUEL SENSOR Y/W
,,
NEUTRAL GEAR G/R G

G
ENGINE SPEED Y/P BRAKE LAMP
,
Y/G 12V21W
GND G Y/G
REAR POSITION LAMP
W/R BR 12V5W
OBD LIGHT BR/W
SPEED SIGNAL BL/W W/R Y LICENSE LAMP
Y/G 12V5W
HIGH LIGHT BL G
OIL LIGHT BL/B Y/G REAR RIGHT INDICATOR LAMP
PU PU 12V10W
BL
HEADLAMP(HIGH)
12V35W
G
HEADLAMP(LOW)
12V35W
W
POSITION LAMP BR W/R
12V5W G G
PU PU
12V10W Y/G G
RIGHT INDICATOR PU
LG
HORN G
W P GR PU R/B LG G/Y Y/R Y/B
GR/B BL B/W B/W B/Y R/G GR/G Y/GR O/B
BL/Y
PU/W
G B/W WIRE1
WIRE W R G + +S -S - B/W
BL W O GR LB B G B BL/B LG/R R/BL Y/B GR/R Y/B G
WATER R/O LG G/R G X2 YY Y
TEMPERATURE t° BL
G PU GR B W
SENSOR W 0
B BLACK UP R 10 K-LINE
START INJECTOR M O2 SENSOR
W WHITE DOWN
12V4AH
RELAY M
HIGH/LOW LIGHT RECTIFIER B
R RED SWITCH
INDICATOR HORN CLUTCH SIDE STAND OIL SENSOR BATTERY FUEL PUMP
SWITCH SWITCH SWITCH ENGINE STOP
G GREEN SWITCH
GEAR SENSOR MAGNETO START MOTOR
LEFT SWITCHER
BR BROWN
Y YELLOW
93 WORKSHOP MANUAL
BL BLUE
GR GRAY
O ORANGE
LG LIGHT GREEN
LB LIGHT BLUE
P PINK
PU PURPLE
10 NC NC
EMS Link
NC
11 NC NC NC
EMS Link—Installation and

12 NC NC NC
13 NC NC NC
14 Comm. Line CAN1L CAN Bus low
15 NC NC User Manual
NC
16 Power BAT+ KL30 permanent power
EMS Link
This file is in Glasscubes or ask through e-mail, download in
your computer and via USB cable put the file in your android
phone , If the App doesn't open, go to settings and unlock it.
Now you can start !
The diagnostic cable part. number :
4
10 NC NC NC
Download instruction
11 NC NC NC
12 NC NC NC
13 NC NC NC
15 NC NC NC

10 NC NC NC
11
12
NC
NC
NC
NC
Only for Android Phone
NC
NC
13 NC NC NC
15 NC NC NC
EXEC
EMS Link
EMSLinkMIU This file is in Glasscubes or ask through e-mail, download in
your computer and via USB cable put the file in your android
phone , If the App doesn't open, go to settings and unlock it.
Now you can start !
The diagnostic cable part. number :
1. Download into your computer the Magneti Marelli.apk file.

2. Save it into a new folder
3. Connect your android smartphone via usb cable into your computer.
4. Paste the Magneti Marelli folder into the phone storage.
5. Restart your android phone and remove the usb cable.
6. Go to settings, other settings, security and privacy, allow unknown sources.
7. Search in the phone storage the Magneti Marelli file, open it.
8. Install the Magneti Marelli EMS link app.
9. It will be ready to go.
4
1 Requirement of your smart phone ............................................................................................ 03
2 Connector information ............................................................................................................. 03
3 Installation and step of use ....................................................................................................... 05
3.1 Installation ........................................................................................................................... 05
3.2 Step of use ........................................................................................................................... 05
3.2.1 Connection between the smart phone and vehicle ........................................................ 05
3.2.2 Operation of vehicle ..................................................................................................... 05
3.2.3 How to use EMS Link APP .......................................................................................... 05
3.3 Note ..................................................................................................................................... 12
4 Feature description ................................................................................................................... 13
4.1 DashBoard ........................................................................................................................... 13
4.2 Trip Meter ........................................................................................................................... 14
4.3 Service Tool ........................................................................................................................ 15
4.4 Reflashing............................................................................................................................ 19
4.5 Scan Tool............................................................................................................................. 21
4.6 Log In/Upload Data/Download ........................................................................................... 21
Contact us...................................................................................................................................... 23
1 Requirement of your smart phone
For android system, the OS of smart phone must be 4.2 and above; for IOS, the OS of
ANDROID PHONE
smart phone must be 7.0 and above
2 Connector information
Figure 1 is Dongle OBDII connector (male).
figure 1
Table 1 is pinout of OBDII connector.
Table 1 OBDII connector pinout
OBD Connector Pin N° I/O Type Signal Name Pin Description
1 NC NC NC
2 NC NC NC
3 NC NC NC
4 GND GND Chassis ground
5 GND GND Signal ground
6 Comm. Line CAN1H CAN Bus high
7 Comm. Line K-line K-line
8 NC NC NC
9 NC NC NC
3
10 NC NC NC
11 NC NC NC
12 NC NC NC
13 NC NC NC
15 NC NC NC
4
3 Installation and step of use
3.1 Installation
Download the APK to your smart phone and click “install”
3.2 Step of use
3.2.1 Connection between the smart phone and vehicle
Please insert the Dongle to the vehicle‟s OBD connector, as shown in figure 2
figure 2
3.2.2 Operation of vehicle
Insert the key to the vehicle, and make sure the vehicle‟s status is “key on”. If you need
to test dynamic data, please crank the vehicle
3.2.3 How to use EMS Link APP
Note: The distance between the smart phone and Dongle must be within 5 meters. Make
sure the smart phone‟s Bluetooth is enabled before using APP.
5
(1) Click the icon “EMS Link” to use the APP, as shown in figure 3
figure 3
(2) After clicking „‟EMS Link”, you will enter the “Take A Look” page, as shown in figure 4. In
this page, you can slip picture to learn how to use APP. Click the “Skip” button, you will enter
the “welcome” page.
figure 4
6
(3) The “welcome” page is shown in figure 5. Click the “Introduction” button, you will open the
user manual; click “Take A Look” button, you will learn how to use app briefly; click the “Go”
button, you will enter the “Main” page.
figure 5
(4) When you are in main interface, the APP will scan the available devices automatically, as
shown in figure 6
figure 6
7
(5) when scanning finished, the APP will list all available devices to user, and the user can click
the name of device to connect, as shown in figure 7
figure 7
(6) If the dongle is connected successfully, the “Connect” will become “Disconnect”, as shown
in figure 8
figure 8
8
(7) Click the “Settings” button to enter the “Settings” page, as shown in figure 9
figure 9
(8) In “Settings” page you can select the language, click “Language” button, you will see the
“Chinese” and “English”, you can select either one, as shown in figure 10
figure 10
9
(9) In “Settings” page, click the “Bluetooth Device” to clear the paired device, as shown in
figure 11
figure 11
(10) In “Setting” page, you can select the “important parameters” which will be shown in
“Dashboard”. Click the “Important Parameters” to select. The “Engine RPM” and “Vehicle
Speed” are mandatory, as shown in figure 12
figure 12
10
(11) In “Setting” page, you can select the “other parameters” which will be shown in
“Dashboard”. Click the “Other Parameters” to select, as shown in figure 13
figure 13
(12) Click the “Back” button on Smart Phone or Tablet, you will go back to the “Main” page, as
shown in figure 14
figure 14
Note: to perform diagnostic features, you have to establish the connection by pushing the
“Connect” button.
11
3.3 Note
1 One dongle only can be connected with one smart phone at the same time
2 If you want to use other smart phone to connect dongle, please kill the running EMS Link APP
in the running smart phone, as shown in figure 15
figure 15
12
4 Feature description
The EMS Link APP includes “Dashboard” function, “Trip meter” function, “Service
Tool” function, “Reflashing” function and “Scan Tool” function, as shown in figure 16
figure 16
4.1 DashBoard
The “DashBoard” function can display real-time parameters such as “RPM”, “SPEED”,
“Manifold Pressure”, “Battery Voltage”, “Gear Position”, “Water Temperature”, “Air
Temperature” and so on, as shown in figure 17
figure 17
13
The “other parameters” which is selected in “Other Parameters” page will be shown in
“Information” page, as shown in figure 18
figure 18
4.2 Trip Meter
The “Trip Meter” function through the GPS to display the “Max Speed”, “Acceleration”,
“Altitude” and the “Speed” on your trip. The “Trip Meter” function need to enable the GPS
function, as shown in figure 19
figure 19
14
4.3 Service Tool
“Service Tool” can do the diagnostic function for your vehicle, it includes several
modules, as shown in figure 20
figure 20
（1）Read Data
The “Read Data” function is used to read the system parameter, as shown in figure 21.
Click “Start” button and “Search” icon to read data.
figure 21
15
The test result of “Read Data” function is shown in figure 22
figure 22
（2）Configure Data
The “Configure Data” function is used to read the configuration information, such as
ECU version. Click “Start” button and “Search” icon to read data, as shown in figure 23
figure 23
16
（3）Actuator Control
The “Actuator Control” function sends the command to test the actuator of the
vehicle, as shown in figure 24
figure 24
The test result of “Actuator Control” is shown in figure 25
figure 25
17
（4）Monitor Mode
The “Monitor Mode” allow the users to edit the command to test the vehicle, as shown in
figure 26
figure 26
You can edit the command in edit box, and click the “Send” button to send the command,
the test result of “Monitor Mode” is shown in figure 27
figure 27
18
（5）DTC Management
The “DTC Management” function is used to read the DTC, and you can clear the DTC by
it, as shown in figure 28. Click the “Start” button to scan DTC, click the “Clear” button to clear
DTC.
figure 28
4.4 Reflashing
The “Reflahing” function permits to update the engine control software code into the
ECU. Click the “Reflashing” button to enter the “Reflashing” page, as shown in figure 29
figure 29
19
The .bin file and .cks file which will be downloaded into ECU should be stored in the
same folder on the smart phone. Click “Select” button to select the .bin file, as shown in figure
30
figure 30
After selecting the correct .bin file, click the “Reflash” button to start, as shown in figure
31
figure 31
20
Figure 32 shows the “Reflashing” is successful.
figure 32
4.5 Scan Tool

The “Scan Tool” function read data and perform diagnostic function for OBD II protocol
4.6 Log In/Upload Data/Download

In “Main” page, click the “Log in” button to sign in (if you have registered before) or sign
up (if have not registered before), as shown in figure 33 and figure 34
By this function you can send/upload diagnostic data to the server or receive/download
new engine control software code for the ECU (need to get the access authorization on the
server)
21
figure 33
figure 34
22
when you log in successfully, you can upload ECU data in “Settings” page, as shown in
figure 35
figure 35
Contact us
Please contact the following email address if you meet any question
Email: ems-link.support@magnetimarelli.com
23
ummotorcycles.eu
umglobal.com

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WORKSHOP MANUAL

ENGINE 125 4T / 4V 6M EURO 4

The UM logo is the registered trademark and property of UM.

GENERAL INFORMATION Pag. 4

Only use the specific tools intended for this machine.

MODEL CHASSIS CODE ENGINE CODE

RENEGADE SCRAMBLER CLASSIC 125 UXPI 125

DSR ADVENTURE 125 M6FDA0001Hxxxxxxx

P REPARATION FOR REMOVAL AND DISMANTLING

Use properly cleaned tools and equipment.

On dismantling parts, always keep related items together.

Keep all parts away from any contact with fire.

Use only genuine UMspare parts. For all lubrication tasks,

SEALS, RETAINING RINGS AND O - RINGS

Renew all seals, retaining rings and O-rings when servicing

Apply oil to all paired parts and bearing during reassembly.

TAB/ SPACER WASHERS AND SPLIT PINS

After removing them, renew all tab/spacer washers (1) and

B EARINGS AND RETAINING RINGS

Examine all the locking rings carefully before fitting. Always

See the figure on the side, (4) Shaft.

Engine EURO 4 single cylinder 4-stroke

Diameter x stroke 58x47 mm

Compression ratio 12:1

Maximum nominal power Cv: 15,5 Kw:11,4 a 9250 at the crankshaft

Primary transmission Gearing

Oil filter Paper cartridge

Air filter Laminated paper

Power Supply MAGNETI MARELLI

Clutch 6 driving disks and 5 driven disks

THREAD TIGHTENING TORQUE

Spark plug - M10 1 1,2-1,4 12-14

Rocker cover Bolt M6 4 1-1,2 10-12

Camshaft bridge Bolt M6 8 1-1,2 10-12

Timing crown wheel 1 Bolt M8 1 2,5-2,7 25-27

Timing crown wheel 2 Bolt M8 1 2,5-2,7 25-27

Cylinder head Bolt M8 4 2,7+90° 27+90°

Cylinder head Bolt M6 2 1,1-1,3 11-13

Inlet pipe Bolt M6 3 1,1-1,3 11-13

Thermostat cover Bolt M6 2 1-1,2 10-12

Coolant temperature sensor - M10 1 0,8-1,0 8-10

Timing chain tensioner Bolt M6 2 1,1-1,3 11-13

Timing chain tensioner spring Cover - 1 0,8-1 8-10

Water pump cover Bolt M5 3 0,5-0,6 5-6

Water pump turbine - M5 1 0,4-0,6 4-6

Clutch control cam Bolt M6 1 0,8-1,0 8-10

Oil filter cover - M56x1,5 1 2,4-2,6 24-26

Oil pressure sensor - M10 1 1,2-1,4 12-14

Clutch cover Bolt M6 10 1,1-1,3 11-13

Clutch spring Bolt M5 5 0,35-0,45 3,5-4,5

Clutch bell housing-ram Nut M12 1 3,5-4,5 35-45

Balance shaft Nut M10 1 3,5-4,5 35-45

Crankshaft-clutch bell housing gear Nut M12 1 7,5-8,3 75-83

Timing chain roller. Bolt M6 1 1-1,2 10-12

Oil pump Bolt M5 3 0,5-0,6 5-6

Selector drum flor. Bolt M5 1 0,35-0,45 3,5-4,5

Selector drum flor. locking cam Bolt M6 1 0,8-1,0 8-10

Starter motor Bolt M6 2 1,1-1,3 11-13

Phase inspection cover - M18X1,5 1 0,35-0,45 3,5-4,5