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PIAGGIO Carnaby 200 User Manual

PIAGGIO Carnaby 200
310 pages
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SERVICE STATION MANUAL
633986 IT-633987 EN-633988 FR-633989 DE-633990
ES-633991 PT-633992 OL-633993 EL
Carnaby 125 - 200

Table of Contents

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PIAGGIO Carnaby 200 Specifications

General IconGeneral
Engine TypeSingle cylinder, 4-stroke
Displacement198 cc
Fuel SystemCarburetor
CoolingLiquid cooled
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Weight146 kg
Max Torque17 Nm
TransmissionCVT
Rear SuspensionTwo hydraulic shock absorbers with adjustable preload
Fuel Tank Capacity7.5 liters

Summary

CHARACTERISTICS

Rules

General safety and maintenance rules for vehicle operations.

Engine

Technical specifications for the 125cc and 200cc engines.

Brakes

Specifications and details for the braking system.

Assembly clearances

Specifications for cylinder and piston assembly clearances.

TOOLING

Appropriate Tools

List and description of specialized tools required for service.

MAINTENANCE

Maintenance chart

Schedule of maintenance tasks based on time or mileage.

Engine oil

Procedures for engine oil replacement and filter change.

Cooling system

Procedures for coolant level check and top-up.

Braking system

Procedures for checking brake fluid levels.

TROUBLESHOOTING

Engine

Common engine performance and starting issues and their solutions.

Electrical system

Troubleshooting for battery and turn signal malfunctions.

Steering and suspensions

Troubleshooting for steering hardening, play, and suspension noise.

ELECTRICAL SYSTEM

KEY

Key to electrical diagram symbols and component identification.

Checks and inspections

Procedures for checking ignition circuit components like Pick-Up and coils.

Fuses

Location and function of the electrical system fuses.

Sealed battery

Maintenance and charging instructions for the sealed battery.

ENGINE FROM VEHICLE

Removal of the engine from the vehicle

Step-by-step guide for engine removal from the frame.

ENGINE

Removing the cylinder head

Procedure for removing the cylinder head.

Removing the cylinder - piston assy.

Procedure for removing the cylinder and piston assembly.

Crankcase - crankshaft

Procedures for splitting and inspecting crankcase halves.

Lubrication

Conceptual diagrams and checks for the lubrication system.

Oil pressure check

Procedure for checking engine oil pressure.

Carburettor

Detailed procedure for removing the carburettor.

Adjusting the idle

Procedure for adjusting engine idle speed and carburettor settings.

SUSPENSIONS

Front

Procedures for removing and overhauling the front wheel and hub.

Front fork

Procedures for fork removal and overhaul.

Rear

Procedures for removing and refitting the rear wheel and brake disc.

Shock absorbers

Procedures for removing and refitting shock absorbers.

BRAKING SYSTEM

Rear brake calliper

Procedures for removing and refitting the rear brake calliper.

Front brake calliper

Procedures for removing, overhauling, and refitting the front brake calliper.

Front brake pads

Procedures for removing and refitting front brake pads.

Front

Procedure for bleeding the front brake system.

COOLING SYSTEM

Coolant replacement

Procedures for emptying and refilling the cooling system.

Thermostat

Procedures for removing, checking, and refitting the thermostat.

CHASSIS

Front handlebar cover

Procedures for removing the front handlebar cover.

Legshield

Procedures for removing the legshield and related components.

Fuel tank

Procedures for removing the fuel tank.

Radiator fan

Procedures for removing the radiator fan.

PRE-DELIVERY

Tightening torques inspection

Inspection of safety locks and clamping screws.

Road test

Procedures for road testing the vehicle after assembly.

Functional inspection

Comprehensive functional checks of vehicle systems.

TIME

Engine

Time required for engine removal, refitting, and oil change.

Cylinder assy.

Time for cylinder-piston replacement and ring service.

Carburettor

Time for intake manifold, carburettor, and choke replacement/adjustment.

Fuel tank

Time for fuel tank float, breather, tank, and valve replacement.

Radiator

Time for radiator thermal switch, water, fan, and pipe replacement.

Front wheel

Time for brake disc, rim, axle, bearings, and tyre replacement/service.

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