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Derbi GP1 125-250 c.c. User Manual

Derbi GP1 125-250 c.c.
246 pages
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GP1 125-250 c.c.
WORKSHOP MANUAL

Table of Contents

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Derbi GP1 125-250 c.c. Specifications

General IconGeneral
BrandDerbi
ModelGP1 125-250 c.c.
CategoryScooter
LanguageEnglish

Summary

General Technical Data

Chassis Tightening Torques

Lists torque values for various chassis fasteners and components.

Exhaust Pipe and Engine Lubrication Torques

Details torque specifications for exhaust system and engine lubrication components.

Cylinder Head and Transmission Torques

Provides torque values for cylinder head, timing system, and transmission parts.

Flywheel and Engine Crankcase Torques

Specifies torque values for flywheel, starter motor, and crankcase components.

Crankcase - Crankshaft - Connecting Rod Data

Covers oversizes engine 250, crankcase-crankshaft, and connecting rod bearing data.

Recommended Tools

Special Tools for Assembly and Adjustment

Lists special tools like air heaters, multimeters, and pliers for specific tasks.

Special Tools for Bearing and Shaft Work

Details tools for hub bearing fitting, engine support, and flywheel extraction.

Special Tools for Valve and Seal Work

Lists tools for valve removal, oil seal extraction, and pressure measurement.

Special Tools for Engine and Clutch Work

Covers tools for crankcase detachment, piston fitting, and drive pulley stop keys.

Special Tools for Pulley and Spring Work

Lists tools for valve cotter removal, guides, adaptors, and pump overhaul.

Special Tools for Engine Alignment and Measurement

Details tools for crankshaft alignment, guides, and magnetic stands.

Special Tools for Piston and Pulley Work

Covers tools for 15mm pliers, adapter rings, drifts, and flywheel extractors.

Periodic Maintenance

Maintenance Chart by Interval

Provides a detailed maintenance schedule based on mileage and time intervals.

Carburettor Maintenance

Instructions for disassembling, cleaning, and checking carburettor components.

Spark Plug Maintenance

Detailed instructions for checking, adjusting, and replacing the spark plug.

Air Filter Cleaning and Replacement

Details on cleaning and replacing the air filter, including cautions.

Engine Oil Check and Replacement

Instructions for checking and replacing engine oil, including torque specifications.

Checking Ignition Timing

Guidance on checking ignition timing using a stroboscopic lamp.

Checking Valve Clearance

Procedure for checking and adjusting valve clearance.

Braking System Level Check and Top-Up

Guidance on checking and topping up brake fluid, including cautions.

Dismantling

Engine

Exhaust Assembly Removal

Steps for unfastening and removing the exhaust manifold and muffler.

Engine Removal from Vehicle

Detailed procedure for disconnecting and removing the engine from the chassis.

Automatic Transmission Cover Removal

Instructions for removing the automatic transmission cover and related parts.

Driven Pulley Shaft Bearing Removal

Procedure for removing the driven pulley shaft bearing using specific tools.

Removing the Clutch

Detailed steps for clutch removal using specific tools and procedures.

Refitting the Clutch

Detailed steps for refitting the clutch using specific tools and procedures.

Refitting the Driven Pulley

Instructions for reinstalling the driven pulley, including belt checks.

Removing the Driving Pulley

Procedure for removing the driving pulley using specific tools.

Refitting the Driving Pulley

Instructions for refitting the driving pulley, including shim and nut tightening.

Removing the Flywheel Magneto

Steps for removing the flywheel magneto using specific tools.

Refitting the Flywheel Magneto

Instructions for refitting the flywheel magneto, including torque values.

Cylinder Assy. and Timing System

Covers removal and inspection of cylinder, camshaft, and timing system components.

Removing the Cylinder - Piston Assy.

Instructions for removing the cylinder, piston, rings, and pin.

Refitting the Piston Rings

Instructions for correctly installing piston rings onto the piston.

Refitting the Cylinder

Procedure for fitting the cylinder, base gasket, and ensuring lubrication.

Refitting the Timing System Components

Instructions for refitting timing system components, including chain and tensioner.

Crankcase - Crankshaft

Covers splitting crankcase halves, removing crankshaft, and related checks.

Refitting the Crankcase Halves

Instructions for assembling crankcase halves, including bulkhead, oil filter union, and gasket.

Oil Pressure Check

Procedure for checking oil pressure at different engine speeds.

Fuel Supply - Removing the Carburettor

Procedure for disconnecting and removing the carburettor from the engine.

Refitting the Carburettor

Instructions for cleaning and refitting the carburettor components.

Forks, Shock Absorber, Engine Support and Stand

Dismantling Front Suspension

Steps for dismantling the front suspension forks and their components.

Dismantling the Rear Suspension Assembly

Steps for dismantling the rear suspension arm and shock absorber.

Front Wheel and Brake

Dismantling the Front Brake System

Steps for dismantling the front brake caliper and related parts.

Assembling the Front Wheel

Instructions for lubricating, fitting, and tightening front wheel components.

Rear Wheel and Brakes

Dismantling the Rear Brake System

Steps for dismantling the rear brake caliper and related parts.

Bleeding the Brake System Pipe

Detailed procedure for bleeding air from the rear brake system pipes.

Cooling System

Water Pump Overhaul (Engine 125)

Procedure for overhauling the water pump, including component inspection.

Water Pump Overhaul (Engine 250)

Procedure for overhauling the water pump using special tools and press.

Electrical System

Electrical System GP1 125-250 Wiring Diagram

Presents the complete wiring diagram for GP1 125-250 models.

Ignition System Checks

Checks ignition circuit components, including HV coil and pick-up resistance.

Stator and Voltage Regulator Checks

Procedures for checking stator continuity and voltage regulator output.

Battery Initial Charge and Maintenance

Instructions for initial battery charging, capacity, and care.

Recharging the Battery

Procedure for recharging the hermetic (airtight) type battery.

Troubleshooting

Engine Poor Performance Troubleshooting

Diagnoses and solutions for poor engine performance issues.

Starting Difficulties Troubleshooting

Diagnoses and solutions for common engine starting problems.

Excessive Oil Consumption / Smoke Upon Exhaust

Troubleshooting steps for high oil consumption and smoky exhaust.

Insufficient Lubrication Pressure

Diagnoses and solutions for low lubrication pressure issues.

Engine Tends to Cut-Off at Full Throttle

Troubleshooting steps for engine stalling at full throttle.

Engine Tends to Stop at Idle

Diagnoses and solutions for engine stalling at idle speed.

Insufficient Braking

Troubleshooting steps for insufficient braking performance.

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