PIAGGIO Liberty 125 Workshop Manual
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PIAGGIO Liberty 125 Workshop Manual

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WORKSHOP MANUAL
633120
Liberty 125 - 200 4tempi

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  • Page 1 WORKSHOP MANUAL 633120 Liberty 125 - 200 4tempi...
  • Page 2 Not all versions shown in this publication are available in all countries. The availability of single models should be checked at the official Piaggio sales network. "© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 Liberty 125 - 200 4tempi This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    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.

  • Page 8: Vehicle Identification

    Liberty 125 - 200 4tempi Characteristics Vehicle identification VEHICLE IDENTIFICATION (125) Specification Desc./Quantity Chassis prefix (125) ZAPM38100 ÷ 1001 Engine prefix (125) M381M ÷ 1001 VEHICLE IDENTIFICATION (200) Specification Desc./Quantity Chassis prefix (200) ZAPM38400 ÷ 1001 Engine prefix(200) M384M ÷ 1001...
  • Page 9 Liberty 125 - 200 4tempi Characteristics Engine ENGINE Specification Desc./Quantity Engine Single-cylinder, 4-stroke Piaggio LEADER Timing system Single overhead camshaft (SOHC) with 2 valves Valve clearance intake 0.10 outlet 0.15 Bore x stroke (125) 57 x 48.6 mm Bore x stroke (200) 72 x 48.6 mm...
  • Page 10 Liberty 125 - 200 4tempi Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling. Capacities CAPACITIES Specification Desc./Quantity Engine oil 61 in³...
  • Page 11 To ensure the best functioning of the SAS system, every 12,000 km the scooter should be taken to an Authorised Piaggio Service Centre to have the filter cleaned (Scheduled maintenance operations section). The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air.

  • Page 12: Tightening Torques

    Liberty 125 - 200 4tempi Characteristics Kehin CARBURETTOR SETTING Specification Desc./Quantity Type CVEK26 Throttle valve diameter Ø 26.5 Diffuser diameter Ø 26.4 Setting stamping 262A Maximum jet Maximum air jet (on the body) Tapered pin stamping NELA Throttle valve spring 130 ÷...
  • Page 13 Liberty 125 - 200 4tempi Characteristics Name Torque in Nm Alternator flywheel nut 40 ÷ 44 Nm Stator screws 3 ÷ 4 Pick-up screws 3 ÷ 4 Oil pump bulkhead screw 4 ÷ 5 Timing chain/oil pump compartment cover screws 4 ÷...

  • Page 14: Assembly Clearances

    Liberty 125 - 200 4tempi Characteristics Assembly clearances Cylinder - piston assy. COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER (125) Name Initials Cylinder Piston Play on fitting Coupling 56.980 ÷ 56.987 56.933 ÷ 56.940 0.040 - 0.054 Coupling 56.987 ÷...
  • Page 15 Liberty 125 - 200 4tempi Characteristics Name Description Dimensions Initials Quantity Oil scraper ring 1st 57.2x1 0.10 ÷ 0.30 oversize Oil scraper ring 1st 57.2x2.5 0.10 ÷ 0.35 oversize Compression ring 2nd 57.4x1 0.15 ÷ 0.30 oversize Oil scraper ring 2nd 57.4x1...
  • Page 16 Liberty 125 - 200 4tempi Characteristics Name Description Dimensions Initials Quantity Crankshaft category 2 - C - C Crankcase category 1 Crankshaft category 2 - B - B Crankcase category 2 Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40 AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (200)
  • Page 17 Liberty 125 - 200 4tempi Characteristics Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions...
  • Page 18 INDEX OF TOPICS TOOL OOLING...
  • Page 19 Liberty 125 - 200 4tempi Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42-mm bearings 001467Y013 Pliers to extract ø 15-mm bearings 002465Y Pliers for circlips 005095Y Engine support 008564Y Flywheel extractor TOOL - 19...
  • Page 20 Liberty 125 - 200 4tempi Tooling Stores code Description 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge...
  • Page 21 Liberty 125 - 200 4tempi Tooling Stores code Description 020262Y Crankcase splitting strip 020263Y Driven pulley assembly sheath 020287Y Clamp to assemble piston on cylinder 020306Y Punch for assembling valve sealing rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing...
  • Page 22 Liberty 125 - 200 4tempi Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 22...
  • Page 23 Liberty 125 - 200 4tempi Tooling Stores code Description 020335Y Magnetic support for dial gauge 020357Y 32x35-mm Adaptor 020359Y 42x47-mm Adaptor 020360Y 52x55-mm Adaptor 020363Y 20 mm guide 020364Y 25-mm guide TOOL - 23...
  • Page 24 Liberty 125 - 200 4tempi Tooling Stores code Description 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y011 adapter for valve removal tool 020409Y Multimeter adaptor - Peak voltage detec- tion TOOL - 24...
  • Page 25 Liberty 125 - 200 4tempi Tooling Stores code Description 020412Y 15 mm guide 020414Y 28-mm guide 020423Y Driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel-side oil seal 020426Y Piston fitting fork TOOL - 25...
  • Page 26 Liberty 125 - 200 4tempi Tooling Stores code Description 020427Y Piston fitting band 020428Y Piston position check support 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driven pulley...
  • Page 27 Liberty 125 - 200 4tempi Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020622Y Transmission-side oil guard punch 494929Y Exhaust fumes analyser 020625Y Kit for sampling gas from the exhaust manifold TOOL - 27...
  • Page 28 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 29: Maintenance Chart

    Liberty 125 - 200 4tempi Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change EVERY 3000 KM Action Engine oil - level check/ top-up AFTER 1000 KM Action Engine oil - replacement Hub oil - change Oil filter (net filter) - clean...
  • Page 30 Liberty 125 - 200 4tempi Maintenance Action Driving belt - replacement Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check...
  • Page 31 Liberty 125 - 200 4tempi Maintenance AFTER 36000 KM 270' Action Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment...
  • Page 32 Liberty 125 - 200 4tempi Maintenance CO check - Remove the exhaust gases outlet cap on the ex- haust pipe - Using the supplied washer, install the exhaust gases collection kit fitting onto the pipe, as shown in the figure.
  • Page 33 Liberty 125 - 200 4tempi Maintenance CHECK THAT THE RESULT IS OBTAINED WITH THE VALVE GAS IN CLOSED POSITION. N.B. ALSO CHECK THE CARBURETION ADJUSTMENT IS OB- TAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS. N.B. OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN THE TANK AND THE FUEL CIRCUIT.
  • Page 34 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 35: Troubleshooting

    Liberty 125 - 200 4tempi Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.
  • Page 36 Liberty 125 - 200 4tempi Troubleshooting Possible Cause Operation Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace if necessary. Start-up enabling buttons failure Check continuity using an Ohm meter, with the switch pressed; replace if necessary...

  • Page 37: Excessive Fuel Consumption

    Liberty 125 - 200 4tempi Troubleshooting High fuel consumption EXCESSIVE FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty. Clean according to the procedure Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and power supply Loose nozzles Check the maximum and minimum nozzles are adequately...
  • Page 38 Liberty 125 - 200 4tempi Troubleshooting Electrical system Battery BATTERY Possible Cause Operation Battery The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically.
  • Page 39 Liberty 125 - 200 4tempi Troubleshooting Noisy suspension NOISY SUSPENSION Possible Cause Operation Noisy suspension If the front suspension is noisy, check: that the front shock ab- sorber works properly and the ball bearings are good condition. Finally, check the locking torque of the wheel axle nut, the brake calliper and the disc.
  • Page 40 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 41 Liberty 125 - 200 4tempi Electrical system Legend: 1. Front LHS turn signal lights (2 bulbs for each lamp) 2. Immobiliser antenna 3. Electronic ignition device with integrated turn signal and choke controller. 4. Horn button 5. Turn signal switch 6.
  • Page 42 Liberty 125 - 200 4tempi Electrical system 13. Low fuel warning light 14. Turn signal warning light (LHS) 15. Dashboard light bulbs 16. Headlamp warning light 17. Odometer with warning lights and level gauges (7 and 2 light bulbs respectively) 18.
  • Page 43 Liberty 125 - 200 4tempi Electrical system N = Black BV = White-Green GN = Yellow-Black Gr = Grey Rs = Pink R = Red Vi = Purple V = Green VN = Green-Black BN = White-Black BBl = White-Blue...
  • Page 44 Liberty 125 - 200 4tempi Electrical system IGNITION Specification Desc./Quantity electronic control unit Magneto flywheel Pick - up HV coil Spark plug Voltage regulator Headlights and automatic starter section HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity electronic control unit Carburettor heater...
  • Page 45 Liberty 125 - 200 4tempi Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP SECTION Specification Desc./Quantity Magneto flywheel Voltage regulator Pick - up Main fusible Battery (125) 12V - 9Ah Battery (200) 12V - 12Ah Starter relay Starter motor...
  • Page 46 Liberty 125 - 200 4tempi Electrical system Level indicators and enable signals section START PERMISSIVE BUTTONS AND LEVEL INDICATORS Specification Desc./Quantity electronic control unit Battery (200) 12V - 12Ah Battery (125) 12V - 9Ah Main fusible Key switch Engine oil pressure sensor...
  • Page 47 Liberty 125 - 200 4tempi Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity electronic control unit Indicators switch 4 Turn indicator bulbs 12V-10W Turn signal warning light bulbs 12V - 2W Main fusible Battery (125) 12V - 9Ah...
  • Page 48 Liberty 125 - 200 4tempi Electrical system Instruments and warning lights control board 4-PIN CONNECTOR Specification Desc./Quantity Ground lead (-) Left turn indicator Right turn indicator Contact not connected 6-PIN CONNECTOR Specification Desc./Quantity Fuel gauge High-beam warning light Engine oil warning light Fuse 7.5 A...
  • Page 49 Liberty 125 - 200 4tempi Electrical system Immobiliser The electric ignition system is fed with direct cur- rent and is protected by an antitheft immobilizer integrated to the control unit. The ignition system consists of: - electronic control unit - immobilizer aerial - master and service keys with built-in transponder - H.V.
  • Page 50 Liberty 125 - 200 4tempi Electrical system Detach the connector from the ECU and check the following: - Presence of battery potential difference between terminal 4 (Red/Blue) and earth - Presence of battery potential difference between terminals 4 (Red/Blue) and 8 (black), as shown in the figure.
  • Page 51 Liberty 125 - 200 4tempi Electrical system Once the control unit has been programmed, the control unit is inseparably matched with the MAS- TER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stor- ed one is deleted.
  • Page 52 Liberty 125 - 200 4tempi Electrical system If it does not work, replace the aerial. If no faults are found, replace the control unit. CAUTION BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS TO AVOID SPOILING A NEW CONTROL UNIT UNNECESSARILY.
  • Page 53 Liberty 125 - 200 4tempi Electrical system To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient. No spark plug When noticing no spark plug proceded as follows: - Pick-Up inspection.
  • Page 54 Liberty 125 - 200 4tempi Electrical system 020409Y Multimeter adaptor - Peak voltage detection Electric characteristic High voltage coil secondary resistance value High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm - Pick-Up Detach the ECU connector and connect the posi- tive terminal to connector no.
  • Page 55 Liberty 125 - 200 4tempi Electrical system Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety fuse.
  • Page 56 Liberty 125 - 200 4tempi Electrical system Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator.
  • Page 57 Liberty 125 - 200 4tempi Electrical system with the key switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the key switch. If battery potential is found, repeat the inspection from the connector to the ECU.
  • Page 58 Liberty 125 - 200 4tempi Electrical system Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit.
  • Page 59 Liberty 125 - 200 4tempi Electrical system Commissioning dry-charged batteries : 1) - Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1.26, corresponding to 30 Be at a minimum tem- perature of 15°C until the upper level is reached.
  • Page 60 Liberty 125 - 200 4tempi Electrical system After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15°...
  • Page 61 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 62 Liberty 125 - 200 4tempi Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Undo the 2 screws fixing the muffler to the hous- ing; then remove the whole muffler paying atten- tion to the interference between its supporting bracket and the cooling cover.
  • Page 63 Liberty 125 - 200 4tempi Engine from vehicle • Detach the electrical connections from starter motor, choke device, carburet- tor heater and flywheel magneto. • Detach the throttle cable and the fuel hose from the carburettor. • Detach the vacuum tube from the fuel tap on the intake manifold.
  • Page 64 INDEX OF TOPICS NGINE...

  • Page 65: Automatic Transmission

    Liberty 125 - 200 4tempi Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the rear plastic cover first by inserting a screwdriver in the corresponding slotted holes.
  • Page 66 Liberty 125 - 200 4tempi Engine Air duct filter - Unscrew the 2 fixing screws and slide off the filter. - Clean with water and milid soap. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover.

  • Page 67: Removing The Driven Pulley

    Liberty 125 - 200 4tempi Engine Refitting the driven pulley shaft bearing - Heat up the crankcase inside with the hot air gun. - Insert the bearing in its housing, refit the Seeger ring. N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING.

  • Page 68: Removing The Clutch

    Liberty 125 - 200 4tempi Engine Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft unit on the support to check the crankshaft alignment.
  • Page 69 Liberty 125 - 200 4tempi Engine - Prepare the locking tool for the driven pulley with the pins half-screwed in the tool set to «C». - Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes. After- wards make the support screw make contact with a minimum force.
  • Page 70 Liberty 125 - 200 4tempi Engine 1 mm Pin retaining collar - Remove the collar with the aid of 2 screwdrivers. - Remove the 3 guide pins and the movable half- pulley. Removing the driven half-pulley bearing - Remove the retaining ring using two flat blade screwdrivers.
  • Page 71 Liberty 125 - 200 4tempi Engine Inspecting the driven fixed half-pulley - Measure the external diameter of the pulley bush- ing. Characteristic Minimum diameter permitted Ø 40.96 mm Standard diameter Ø 40.965 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings.
  • Page 72 Liberty 125 - 200 4tempi Engine - To assemble the new ball bearing insert it com- pletely down in its housing with the specific punch and finally assemble the Seeger ring. Specific tooling 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle...
  • Page 73 Liberty 125 - 200 4tempi Engine Inspecting the clutch spring - Measure the unloaded length of the spring of the movable driven half-pulley. Characteristic Standard length: 106 mm Refitting the clutch Version 200 - Check the thickness of the clutch mass friction material.
  • Page 74 Liberty 125 - 200 4tempi Engine - Insert the driving belt into the pulley unit accord- ing to their direction of rotation. - Insert the pulley unit with the belt into the tool. - Slightly preload the spring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut.
  • Page 75 Liberty 125 - 200 4tempi Engine - Refit the clutch assembly following the fitting op- eration but in reverse order and using the calliper spanner. Lock the nut to the specified torque. CAUTION USE A BOX-SPANNER WITH SMALL CHAMFER SO AS NOT TO DAMAGE THE CLUTCH NUT.UPON FITTING THE...

  • Page 76: Removing The Driving Pulley

    Liberty 125 - 200 4tempi Engine VERSION 200 Specification Desc./Quantity Minimum width 21±0.2 mm Standard width 22±0.2 mm Removing the driving pulley Driving pulley removal - With the appropriate tool placed into the internal slots, remove the nut with the built-in Belleville washer.
  • Page 77 Liberty 125 - 200 4tempi Engine - Lock the driving pulley with the specific tool as shown in the figure. - Disassemble the central nut and the Belleville washer, remove the drive and the 2 washers. - Remove the stationary half pulley and the steel washer.
  • Page 78 Liberty 125 - 200 4tempi Engine - Check the guide shoes for the variator back-plate are not worn. - Check there is no wear in the roller housing, and the surfaces in contact with the belt on either of the pulley halves.
  • Page 79 Liberty 125 - 200 4tempi Engine Refitting the driving pulley - Correctly reassemble the previously removed Bendix back to its position. - Fit the steel shim washer in contact with the bushing and the fixed driving pulley together with the O-ring on the outside of the fan blades.
  • Page 80 Liberty 125 - 200 4tempi Engine - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread threadlock on the thread and screw the nut to the prescribed torque. -Avoid the half-pulley rotation using a calliper spanner N.B.
  • Page 81 Liberty 125 - 200 4tempi Engine Removing the hub cover - Empty the rear hub through the oil drainage tap located inside the hub cover - Remove the brake shoe and relevant spring - Remove the 7 flanged screws as shown in the figure.
  • Page 82 Liberty 125 - 200 4tempi Engine Removing the wheel axle bearings - Take out the clip on the outside of the gearbox cover. - Remove the bearing with the adequate tools ad- equately supporting the hub cover, as shown in the figure.
  • Page 83 Liberty 125 - 200 4tempi Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents.
  • Page 84 Liberty 125 - 200 4tempi Engine 020151Y Air heater 020150Y Air heater support -The wheel axle bearing on the cover, should be assembled with the specific tools Specific tooling 020364Y 25-mm guide 020360Y 52x55-mm Adaptor 020376Y Adaptor handle • Assemble the Seeger ring.
  • Page 85 Liberty 125 - 200 4tempi Engine Refitting the hub bearings - Insert the cover prepared in the crankcase taking care of inserting the gear of the pulley shaft on the intermediary gear. Refitting the ub cover - Fit a new gasket together with the centring dow- els.
  • Page 86 Liberty 125 - 200 4tempi Engine - Loosen the clamp and remove the carburettor from the manifold. -Remove the complete manifold acting on the 2 retainers as shown in the figure. - Remove the 2 self threading screws, left and right and the lateral base retaining screw on the crank- case base.

  • Page 87: Removing The Stator

    Liberty 125 - 200 4tempi Engine Removing the stator - Remove the electric terminal of the minimum oil pressure switch. - Remove the two Pick-Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure.
  • Page 88 Liberty 125 - 200 4tempi Engine Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS...
  • Page 89 Liberty 125 - 200 4tempi Engine Refitting the starter motor - Fit a new O-ring on the starter and lubricate it. - Fit the starter on the crankcase, locking the two screws to the prescribed torque. N.B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS.
  • Page 90 Liberty 125 - 200 4tempi Engine - Remove the internal hex screw and the counter- weight shown in the figure. - Remove the camshaft command pulley and its washer. - Remove the command sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner pad.

  • Page 91: Removing The Cylinder Head

    Liberty 125 - 200 4tempi Engine - Remove the pin of the rocking levers from the flywheel side holes. - Remove the rocking levers and the elastic wash- N.B. MARK THE ROCKING LEVERS ASSEMBLE POSITION, SO AS TO AVOID THE INVERSION OF INLET WITH THE OUT- LET.

  • Page 92: Inspecting The Small End

    Liberty 125 - 200 4tempi Engine - Remove the oil seals with the appropriate tool. - Remove the lower spring supports. Specific tooling 020431Y Valve oil seal extractor Removing the cylinder - piston assy. - Remove the chain guide pad.
  • Page 93 Liberty 125 - 200 4tempi Engine Rod small end check-up: Standard diameter 15+0.015+0.025 mm Inspecting the wrist pin - Check the outer diameter of the gudgeon pin. Characteristic Standard pin diameter 14.996 ÷ 15 mm Minimum diameter permitted Ø 14.994 mm - Calculate the piston pin coupling clearance.

  • Page 94: Inspecting The Piston

    Liberty 125 - 200 4tempi Engine Maximum allowable run-out: 0.05 mm - The cylinder rectifying operation should be car- ried out with a surfacing that respects the original angle. - The cylinder surface roughness should be 0.9 micron. - This is indispensable for a good seating of the sealing rings, which in turn minimises oil consump- tion and guarantees optimum performance.
  • Page 95 Liberty 125 - 200 4tempi Engine Inspecting the piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter. Using the piston, insert the rings perpendicularly to the cylinder axis.

  • Page 96: Removing The Piston

    Liberty 125 - 200 4tempi Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the pin stop ring onto the appropriate tool.
  • Page 97 Liberty 125 - 200 4tempi Engine Characteristic Standard compression ratio 10.6 ± 0.5 CYLINDER BASE GASKET THICKNESS Specification Desc./Quantity Value measured 1 ÷ 1.1 Thickness 0.8 ± 0.05 Value measured 1.1 ÷ 1.3 Thickness 0.6 ± 0.05 Value measured 1.3 ÷ 1.4 Thickness 0.4 ±...
  • Page 98 Liberty 125 - 200 4tempi Engine Refitting the piston rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston.

  • Page 99: Inspecting The Cylinder Head

    Liberty 125 - 200 4tempi Engine 020427Y Piston fitting band Inspecting the cylinder head - Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear.
  • Page 100 Liberty 125 - 200 4tempi Engine - Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole assembly.
  • Page 101 Liberty 125 - 200 4tempi Engine - If the width of the impression on the valve seat or the diameter of the valve guide exceed the speci- fied limits, replace the cylinder head. - Check width of the impression on the valve seat «V»...
  • Page 102 Liberty 125 - 200 4tempi Engine 79.6 mm - If the checks above give no failures, you can use the same valves. For best sealing results, it is ad- visable to grind the valves. Grind the valves gently with a fine-grained lapping compound. During grinding, keep the cylinder head in a horizontal position.
  • Page 103 Liberty 125 - 200 4tempi Engine Refitting the valves - Lubricate the valve guides with engine oil. - Place the lower plates of the valve spring on the head. - Use the punch to fit the 2 sealing rings one at a time.
  • Page 104 Liberty 125 - 200 4tempi Engine - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
  • Page 105 Liberty 125 - 200 4tempi Engine -Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque. Locking torques (N*m) Locking torque 28 ÷ 30 - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque.
  • Page 106 Liberty 125 - 200 4tempi Engine - Refit the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - While doing so, fit the chain onto the control cam- shaft pulley and keep the reference 2V in corre- spondence with the reference mark on the head.
  • Page 107 Liberty 125 - 200 4tempi Engine Locking torques (N*m) Locking torque 11 ÷ 13 - Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed torque. Locking torques (N*m) Locking torque 5 - 6 - Adjust the valve clearance.
  • Page 108 Liberty 125 - 200 4tempi Engine - Refit the cylinder head cover, tightening the 4 clamping screws to the prescribed torque. - Refit the fan and the housing. - Reassemble the oil pump control, the chain com- partment cover, the by-pass and the oil sump as described in the lubrication chapter.
  • Page 109 Liberty 125 - 200 4tempi Engine 0.15 ÷ 0.40 mm Splitting the crankcase halves Remove the 11 coupling screws to the crankcase. - Separate the crankcase while keeping the crank- shaft in one of the two halves of the crankcase.
  • Page 110 Liberty 125 - 200 4tempi Engine - Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram.
  • Page 111 Liberty 125 - 200 4tempi Engine Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
  • Page 112 Liberty 125 - 200 4tempi Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean the all surfaces and oil ducts. - On the transmission side crankcase half, take particular care cleaning the housing and oil ducts...
  • Page 113 Liberty 125 - 200 4tempi Engine - Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and di- mensions.
  • Page 114 Liberty 125 - 200 4tempi Engine - The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like those for the crankshaft. 3 - The main bushings are subdivided into 3 thickness categories; see the table below: N.B.
  • Page 115 Liberty 125 - 200 4tempi Engine - Lubricate the main bushings and insert the crank- shaft in the transmission side crankcase half. - Reassemble the two crankcase halves. - Fit the 11 screws and tighten them to the pre- scribed torque.
  • Page 116 Liberty 125 - 200 4tempi Engine Conceptual diagrams ENG - 116...

  • Page 117: Oil Pressure Check

    Liberty 125 - 200 4tempi Engine Oil pressure check - After removing the cover protections as descri- bed in the "Flywheel" chapter, disconnect the elec- trical connexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure...
  • Page 118 Liberty 125 - 200 4tempi Engine Removal - Remove the transmission cover and the com- plete drive pulley beforehand - Install the base of the appropriate tool on the oil guard using the screws provided. - Screw the threaded bar onto the base of the tool and extract the oil guard.
  • Page 119 Liberty 125 - 200 4tempi Engine - Preassemble the oil seal with the appropriate tool, positioning the screws - Place the sheath over the crankshaft - Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase...
  • Page 120 Liberty 125 - 200 4tempi Engine - Use the nut to move the base of the tool until you can see end of the oil seal driving stroke - Remove all of the tool components following the procedure in reverse order...
  • Page 121 Liberty 125 - 200 4tempi Engine - Remove the central screw with Belleville washer, as shown in the diagram. - Remove the chain with the pulley. - Remove the crankshaft control pinion. - Remove the oil pump acting on the 2 retainers as shown in the figure.
  • Page 122 Liberty 125 - 200 4tempi Engine Measure the distance between the outer rotor and the pump body; see figure. Characteristic Admissible limit clearance: 0.20 mm Check the axial clearance of the rotors with a trued bar as reference, as shown in the figure.
  • Page 123 Liberty 125 - 200 4tempi Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete drive pulley assembly with belt and the sprocket wheel, as described in the Transmis- sion chapter. - Drain the oil from the sump as described above.

  • Page 124: Fuel Supply

    Liberty 125 - 200 4tempi Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump.

  • Page 125: Removing The Carburettor

    Liberty 125 - 200 4tempi Engine N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR- RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB- TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-...
  • Page 126 Liberty 125 - 200 4tempi Engine - Remove the guard, the bracket and the auto- choke unit. - Remove the two screw fasteners and the auto- choke support, together with the gasket. - Remove the screw fastener shown in the dia- gram, the lever and the accelerator pump spring.
  • Page 127 Liberty 125 - 200 4tempi Engine - Remove the four screw fasteners shown in the diagram and the float bowl, together with the gas- ket. - Remove the accelerator pump piston together with the washer, the boot, the O-ring and the spring, as shown in the diagram.
  • Page 128 Liberty 125 - 200 4tempi Engine -Remove the maximum nozzle. -Remove diffuser. - Remove the sprayer tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM- AGE IT.
  • Page 129 Liberty 125 - 200 4tempi Engine - Remove the idle flow screw with the O-ring and the spring. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PIN SEATING, STARTER NOZZLE, THROTTLE VALVE CONTROL VALVE SHAFT.
  • Page 130 Liberty 125 - 200 4tempi Engine - For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section controlled by flow screw, progression holes near the throttle valve. - For the starter circuit, blow the connection pipe properly with the jet.
  • Page 131 Liberty 125 - 200 4tempi Engine - Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindric part directed to the diffuser.
  • Page 132 Liberty 125 - 200 4tempi Engine - Remove the float bowl drain screw, thoroughly clean it and blow out the passage. - The float bowl vent and the accelerator pump contain one-way valves and, as such, should be blown out gently with compressed air from inside the float chamber.
  • Page 133 Liberty 125 - 200 4tempi Engine - Check the accelerator pump control arm shows no signs of abnormal or excessive wear. - Check the clearance of the arm, at the end of its travel, is 3 ± 0.1 mm - Check the return spring on the accelerator pump control arm has not been over-extended or de- formed.
  • Page 134 Liberty 125 - 200 4tempi Engine - Check the diaphragm has not hardened and is not broken. - Replace with a new one if necessary. - Re-fit the needle to the vacuum valve. - Ensure the spring is correctly positioned, both on the needle and in its seat.
  • Page 135 Liberty 125 - 200 4tempi Engine - Ensure the piston is retracted at room tempera- ture. Characteristic Piston projection starter automatico Walbro 10 mm ~ 24°C - The auto-choke piston should gradually extend when power is supplied to its electrical heater ter- minals.
  • Page 136 Liberty 125 - 200 4tempi Engine ~ 15 Ω Adjusting the idle - The engine does not need frequent idle adjust- ments, however it is very important to make any adjustments fully respecting some standards. - Before adjusting the carburettor make sure to re-...
  • Page 137 Liberty 125 - 200 4tempi Engine - carbon dioxide percentages (CO2), the percent- age of carbon dioxide has an inverted course com- pared to the percentage of(CO), values over 12.5% are considered correct. Non complying val- ues indicate lack of tightness in the exhaust sys- tem.
  • Page 138 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 139 Liberty 125 - 200 4tempi Suspensions Front suspension This section is devoted to operations that can be carried out on the suspension. Front Front wheel hub overhaul Ball bearings to hub - Fit the spacer - Fit the ball bearings and bushes and position the seal rings.

  • Page 140: Front Fork

    Liberty 125 - 200 4tempi Suspensions Front fork Overhaul O-ring renewal and rod disassembly - Remove the wheel axle. - Remove the lower screw (1). - Discharge the oil in the suspension. - Remove the stem. - Replace the sealing rings (3-4) with new ones.
  • Page 141 Liberty 125 - 200 4tempi Suspensions Steering lock ring nut Steering bearing upper race - Lubricate race and balls with Z2 grease. - Tighten to the specified torque and then rotate the tool through 80° - 90° in an anticlockwise di- rection.

  • Page 142: Removing The Rear Wheel

    Liberty 125 - 200 4tempi Suspensions Removing the rear wheel - Use a screwdriver as a lever between the drum and the cover. -Straighten the split pin and remove the cap. -Remove the wheel acting on the central fixing point.
  • Page 143 Liberty 125 - 200 4tempi Suspensions - Caulk the end of the pin «P» between the two punches shown in the figure. - After caulking it must be possible for the stand to turn freely. N.B. UPON REFITTING USE NEW O-RING AND PIN, GREASE THE SPRING ATTACHMENTS AND THE PIN.
  • Page 144 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 145: Rear Brake Calliper

    Liberty 125 - 200 4tempi Braking system Once the muffler and the wheel have been re- moved, follow these steps: 1.Remove the shoe spring using the specific span- ner. 2. Remove the shoe with the aid of a lever. 3. Refit the new shoes giving a few taps with the mallet.
  • Page 146 Liberty 125 - 200 4tempi Braking system Screw tightening calliper to the support 20 ÷ 25 Calliper to tube connection 8 ÷ 12 Nm Front brake calliper Removal - Detach the oil brake hose from calliper, pouring the fluid inside a container.

  • Page 147: Front Brake Disc

    Liberty 125 - 200 4tempi Braking system - Secure the tube connection to the caliper with the required torque. - Before reassembly, the parts must be perfectly clean and bear no traces of oil, diesel fuel, grease, etc.. They must therefore be washed thor- oughly in denatured alcohol before proceeding.

  • Page 148: Front Brake Pads

    Liberty 125 - 200 4tempi Braking system Disc Inspection - Remove the wheel and check for unevenness of the disc. Maximum permissible out of true is 0.1 mm. If the value measured is greater, fit a new disc and re- peat the check.

  • Page 149: Recommended Products

    Liberty 125 - 200 4tempi Braking system Front -Once the bleed valve is closed, fill the system with brake liquid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in...
  • Page 150 Liberty 125 - 200 4tempi Braking system AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Locking torques (N*m) Oil bleed screw 8 ÷ 12 Front brake pump -After removing the front and rear handlebar covers, act on the two stand fixing points (see the figure).
  • Page 151 Liberty 125 - 200 4tempi Braking system AFTER WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH. THE SEALING RINGS MUST BE IMMERSED IN THE OPER- ATING LIQUID. Refitting Before fitting, the parts must be perfectly clean and free of traces of oil, diesel fuel, grease, etc..
  • Page 152 INDEX OF TOPICS CHAS HASSIS...
  • Page 153 Liberty 125 - 200 4tempi Chassis Taking apart approached cover motor Remove the 2 implantations. Seat - Unscrew the 2 fixing screws and remove the sad- Saddle After checking the homologation specifications, it was concluded that the strap on the saddle is redun- dant.

  • Page 154: Rear Rack

    Liberty 125 - 200 4tempi Chassis Rear rack • Operating from the rear and using a screwdriver, remove the plastic cap of the central screw cover. • Remove the central and the 2 side screws. Driving mirrors • With the register screw completely tightened, screw the mirror stem all the way down on the handlebars.

  • Page 155: Instrument Panel

    Liberty 125 - 200 4tempi Chassis Rear handlebar cover • Remove the front handlebar fairing • Unscrew the speedometer transmission connec- tion and remove it • Disconnect the instrument unit and electrical con- trol connections • Cut the band holding the front brake hoses to the instrument unit •...
  • Page 156 Liberty 125 - 200 4tempi Chassis Front handlebar cover • Remove the 2 screws in the rear handlebar cover and the screw under the headlamp. • Pull up and detach the front handlebar cover, disconnect the headlight assembly connections. Headlight assy.
  • Page 157 Liberty 125 - 200 4tempi Chassis Frame central cover • Remove the rear luggage rack • Remove the saddle • Remove the spark plug access cover, unscrew the 2 screws joining the helmet compartment clamp with the footrest. • Unscrew the 2 side screws placed on the bumper rings.
  • Page 158 Liberty 125 - 200 4tempi Chassis • Unscrew the lower 2 screws, then remove the shield after having disconnected the turn signal connections See also Knee-guard Footrest Knee-guard • Remove the 4 external screws of the counter- shield and the 3 located inside the front glove box •...
  • Page 159 Liberty 125 - 200 4tempi Chassis Removing the ignition key-switch when on *off* • Remove the shield back plate • Push the lock body until the stop spring does not show grooves. • Keep the lock body blocked with a screwdriver and remove the spring with a pair of pliers.
  • Page 160 Liberty 125 - 200 4tempi Chassis Footrest • Remove the countershield • Remove the frame central cover • Unscrew the screws that secure the passenger footrest and remove it • Unscrew the footrest stop screw and remove the • Remove the 2 external rubber caps of the screws securing the footrest and unscrew them •...

  • Page 161: Air Filter

    Liberty 125 - 200 4tempi Chassis Air filter • Unscrew the 7 cover screws and remove the cover to reach the filter sponge. • To disassemble the filter housing, unscrew the 2 bottom screws and disconnect the manifold con- nections, the carburettor and the external air in- take.
  • Page 162 Liberty 125 - 200 4tempi Chassis Helmet bay • Remove the helmet compartment central cover. • Remove the battery and the fuse box. • Remove the fuel tank cap and the start-up remote control switch. • Unscrew the rear fixing screw and lift the helmet compartment.

  • Page 163: Front Mudguard

    Liberty 125 - 200 4tempi Chassis See also Frame central cover Front mudguard • Leaving the front wheel assembled, disassemble the steering tube from the vehicle • Unscrew the 3 screws securing it and remove them • Remove the speedometer transmission and brake hose, then remove the mudguard N.B.
  • Page 164 Liberty 125 - 200 4tempi Chassis - Remove the two screws at the lower part of the inner shield fairing - Remove the two screws located behind the front grille. CHAS - 164...
  • Page 165 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 166 Liberty 125 - 200 4tempi Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting plastic parts - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing...
  • Page 167 Liberty 125 - 200 4tempi Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
  • Page 168 Liberty 125 - 200 4tempi Pre-delivery Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 169 INDEX OF TOPICS TIME...
  • Page 170 Liberty 125 - 200 4tempi Time Engine ENGINE Code Action Duration 001001 engine from frame - removal and re- fitting TIME - 170...
  • Page 171 Liberty 125 - 200 4tempi Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement 001153 Half crankcase gasket - Replace- ment 002031 Rear wheel hub bearings - Replace- ment TIME - 171...
  • Page 172 Liberty 125 - 200 4tempi Time Crankshaft DRIVING SHAFT Code Action Duration 001117 Crankshaft - Replacement 001099 Oil seal, flywheel side - Replacement TIME - 172...
  • Page 173 Liberty 125 - 200 4tempi Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder-Piston - Replacement 001107 Cylinder / piston - Inspection / clean- TIME - 173...
  • Page 174 Liberty 125 - 200 4tempi Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001056 Head gasket - change 001126 Head - Replacement TIME - 174...
  • Page 175 Liberty 125 - 200 4tempi Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Rocking lever valve - Replacement 001049 Valves - Adjustments TIME - 175...

  • Page 176: Cylinder Head Cover

    Liberty 125 - 200 4tempi Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001159 Oil vapour recovery tank - Service 001093 Spark plug - Replacement 001097 Cooling hood - Replacement...
  • Page 177 Liberty 125 - 200 4tempi Time Chain tensioner CHAIN TIGHTENER Code Action Duration 001129 Chain tensioner - Service and Re- placement 001124 By pass lubrication - Replacement TIME - 177...

  • Page 178: Oil Filter

    Liberty 125 - 200 4tempi Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Replacement 003064 Engine oil - Change 001102 Mesh oil filter - Replacement / Clean- TIME - 178...
  • Page 179 Liberty 125 - 200 4tempi Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001163 Secondary air-exhaust manifold - Replacement 001161 Secondary air filter - Replacement / Cleaning 001174 SAS valve - Replacement 001164 Secondary air-crankcase manifold -...

  • Page 180: Driven Pulley

    Liberty 125 - 200 4tempi Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001155 Clutch bell housing - Replacement 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement TIME - 180...
  • Page 181 Liberty 125 - 200 4tempi Time Oil pump OIL PUMP Code Action Duration 001051 Belt/Timing chain - Replacement 001125 Chain guide pads - Replacement 001042 Oil pump - Overhaul 001112 Oil pump - Replacement 001130 Oil sump - Replacement 001100...
  • Page 182 Liberty 125 - 200 4tempi Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 004125 Rear wheel axle - Replacement 001156 Gear reduction unit cover - Replace- ment 003065 Gearcase oil - Replacement 001010 Gear reduction unit - Inspection...
  • Page 183 Liberty 125 - 200 4tempi Time Driving pulley DRIVING PULLEY Code Action Duration 001066 Driving pulley - Removal and refitting 001086 Driving half-pulley - replace 001177 Variator rollers / slides - Replace- ment 001011 Driving belt - Replacement TIME - 183...
  • Page 184 Liberty 125 - 200 4tempi Time Transmission cover Starter motor TIME - 184...

  • Page 185: Flywheel Magneto

    Liberty 125 - 200 4tempi Time STARTING MOTOR Code Action Duration 001020 Starter motor - Replacement 001017 Starter sprocket wheel - Replace- ment Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001109 Cooling fan - Replacement 001173 Rotor - Replacement 001067...
  • Page 186 Liberty 125 - 200 4tempi Time Belt cooling duct BELT COOLING PIPE Code Action Duration 001131 Transmission air inlet - Replacement 001132 Transmission air inlet pipe - Replace- ment 001170 Air manifold - replacement TIME - 186...
  • Page 187 Liberty 125 - 200 4tempi Time Carburettor CARBURETTOR Code Action Duration 001082 Carburettor heating resistor - Re- placement 001013 Intake hose - Replacement 004122 Carburettor-filter bellow - Replace- ment 001081 Automatic choke - Replacement 001008 Carburettor - Inspection 001063 Carburettor - Replacement...
  • Page 188 Liberty 125 - 200 4tempi Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001136 Exhaust emissions - Adjustment 001095 Muffler guard - Replacement Silencer fixing Please take note that, starting from chassis serial number ZAPM3810000003971, the two M8 x 50 silencer fixing flaged head screws have been replaced by two M8 x 50 internal hexagonal cylindrical head screws.

  • Page 189: Air Cleaner

    Liberty 125 - 200 4tempi Time Air cleaner AIR CLEANER Code Action Duration 001014 Air filter - Replacement/Cleaning 001015 Air filter box - Replacement TIME - 189...
  • Page 190 Liberty 125 - 200 4tempi Time Frame FRAME Code Action Duration 004001 Chassis - Replacement 004004 Stand - Replacement 001053 Stand bolt - Replacement TIME - 190...
  • Page 191 Liberty 125 - 200 4tempi Time Legshield spoiler MUFFLER - GLOVE COMPARTMENT Code Action Duration 004159 Plates / Stickers - Replacement 004149 Shield central cover - Replacement 004064 Front shield, front section - Removal and refitting 004079 Rear footrest - Replacement...
  • Page 192 Liberty 125 - 200 4tempi Time Rear cover REAR COVER Code Action Duration 004174 Glove-box remote opening linkage - Replacement 004065 Knee-guard - Removal and refitting 004131 Rear rack mounting bracket - Re- placement 004082 Glove-box packing - Replacement 004081...
  • Page 193 Liberty 125 - 200 4tempi Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replace- ment 004106 Under-saddle band - Replacement 004085 Fairing (1) - Replacement 004013 Side/rear bumper pipes - Replace- ment TIME - 193...
  • Page 194 Liberty 125 - 200 4tempi Time Underseat compartment UNDERSEAT COMPARTMENT Code Action Duration 005046 Battery cover - Replacement 004016 Helmet compartment - Removal and Refitting 001027 Filter bellow - Replacement TIME - 194...
  • Page 195 Liberty 125 - 200 4tempi Time Plate holder SUPPORT PLATE Code Action Duration 004136 License plate holder support - Re- placement 005048 Licence plate holder - Replacement 005131 number plate light support - Replace- ment 005031 Licence plate light bulb - Replace-...
  • Page 196 Liberty 125 - 200 4tempi Time Mudguard MUDGUARD Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 196...
  • Page 197 Liberty 125 - 200 4tempi Time Fuel tank FUEL TANK Code Action Duration 004168 Fuel tank cap - Replacement 005010 Tank float - Replacement 004112 Cock-carburettor hose - Replace- ment 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement...
  • Page 198 Liberty 125 - 200 4tempi Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting TIME - 198...
  • Page 199 Liberty 125 - 200 4tempi Time Steering column bearings STEERING COLUMN BEARINGS Code Action Duration 003002 Steering fifth wheels - Replacement 003073 Steering clearance - Adjustment TIME - 199...
  • Page 200 Liberty 125 - 200 4tempi Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004019 Handlebar rear section - Replace- ment 004018 Handlebar front section - Replace- ment 005078 Odometer glass - Replacement 005076 Clock \ Pile - Replacement 005014 Odometer - Replacement...
  • Page 201 Liberty 125 - 200 4tempi Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 004066 Rear-view mirror - Replacement 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 003001 Handlebar - Removal and refitting 005017 Stop switch - Replacement...
  • Page 202 Liberty 125 - 200 4tempi Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine / frame swinging arm fitting - Replacement 003080 Swinging arm on frame - Replace- ment TIME - 202...
  • Page 203 Liberty 125 - 200 4tempi Time Brake hoses BRAKE HOSES Code Action Duration 002007 Front brake shoes/pads - Remov. and Refitt 002039 Front brake line - Replacement 002021 Front brake hose - Remov. and Re- fitt. 002047 Front brake fluid and system bleed- ing plug - Repl.
  • Page 204 Liberty 125 - 200 4tempi Time Seat SEAT Code Action Duration 004003 Saddle - Replacement 004008 Luggage rack - Replacement 004062 Luggage rack cover - Replacement TIME - 204...
  • Page 205 Liberty 125 - 200 4tempi Time Turn signal lights TURN SIGNAL LIGHTS Code Action Duration 005002 Front headlamp - change 005012 Front turn indicator - Replacement 005067 Front turn indicator bulb - Replace- ment 005008 Front headlamp bulbs - Replacement...

  • Page 206: Front Wheel

    Liberty 125 - 200 4tempi Time Front wheel FRONT WHEEL Code Action Duration 003038 Front wheel axle - Replacement 002011 Odometer drive - Replacement 003040 Front wheel bearings - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim - Removal and Re-...

  • Page 207: Rear Wheel

    Liberty 125 - 200 4tempi Time Rear wheel REAR WHEEL Code Action Duration 002002 Rear brake pads/shoes - Repl. 004126 Rear wheel tyre - Replacement 001016 Rear wheel - Replacement 001071 Rear wheel rim - Removal and Refit TIME - 207...

  • Page 208: Electrical Devices

    Liberty 125 - 200 4tempi Time Electric devices ELECTRICAL DEVICES Code Action Duration 001023 Control unit - Replacement 005035 Headlight remote control - Replace- ment 005001 Electric system - Removal and reas- sembly 001094 Spark plug cap - Replacement 001069...
  • Page 209 Liberty 125 - 200 4tempi Time Electronic controls ELECTRIC CONTROLS Code Action Duration 005039 Lights switch - Replacement 005006 Light or turning indicator switch - Re- placement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement...
  • Page 210 Liberty 125 - 200 4tempi Time Transmissions TRANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement 002053 Rear brake transmission complete - replacement TIME - 210...
  • Page 211 Liberty 125 - 200 4tempi Time Front suspension FRONT SUSPENSION Code Action Duration 003010 Front suspension - Service 003048 Fork oil seal - Replacement 003076 Fork leg - Replacement 003079 Fork stem - Replacement 003051 Complete fork - replace 003069...
  • Page 212 Air filter: 161 Battery: 38, 45, 55, 58 Brake: 145–148, 150, 203 Carburettor: 11, 125, 129, 187 Fuel: 37, 124, 162, 197 Headlight: 156 Horn: Identification: 8 Instrument panel: 155 Maintenance: 7, 29 Mirrors: 154 Oil filter: 178 Shock absorbers: 142 Spark plug: 53 Start-up: Tank: 162, 197...

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Liberty 200 4tempi

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