PIAGGIO Carnaby 200

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Stores code Description

020363Y 20 mm guide

020459Y Punch for fitting bearing on steering tube

020458Y Puller for lower bearing on steering tube

005095Y Engine support

008564Y Flywheel extractor

020434Y Oil pressure control fitting

Tooling Carnaby 125 - 200

TOOL - 28

Main Page

Index of Topics5
Characteristics6
Safety Rules7
Maintenance Rules7
Vehicle Identification8
Dimensions and Mass9
Weights and Dimensions9
Electrical System10
Wheels and Tyres11
Frame Assembly14
Tightening Torques14
Front Suspension15
Front Brake15
Rear Suspension15
Rear Brake15
Cylinder Head16
Crankcase and Crankshaft16
Overhaul Data16
Assembly Clearances17
Cylinder - Piston Assy.17
Coupling Categories18
Piston Rings18
Engine Sealing Rings19
Engine Sealing Rings (1St Oversize)19
Engine Sealing Rings (2Nd Oversize)19
Engine Sealing Rings (3Rd Oversize)19
Crankshaft - Crankcase20
Fitting Clearances21
Crankshaft/ Crankcase Axial Clearance22
Slot Packing System22
Compression Ratio23
Recommended Products Table24
Tooling25
Index of Topics25
Appropriate Tools26
Maintenance38
Index of Topics38
Maintenance Chart39
Every 2 Years39
Carburettor42
Checking the Spark Advance42
Spark Advance Variation43
Revolution Limiter43
Spark Plug44
Hub Oil46
Air Filter47
Engine Oil48
Recommended Products48
Engine Oil Filter49
Oil Pressure Warning Light50
Checking the Ignition Timing50
Checking the Valve Clearance51
Cooling System51
Level Check51
Top-Up52
Braking System52
Recommended Products53
Headlight Adjustment54
SAS Filters Inspection and Cleaning54
Troubleshooting56
Index of Topics56
Engine Poor Performance57
Rear Wheel Spins at Idle57
Starting Difficulties57
Excessive Oil Consumption/Exhaust Smoke58
Insufficient Lubrication Pressure58
Engine Tends to Cut-Off at Full Throttle58
Engine Tends to Cut-Off at Idle58
Excessive Exhaust Noise59
High Fuel Consumption59
Engine Overheating59
SAS Malfunctions59
Transmission and Brakes60
Clutch Grabbing or Performing Inadequately60
Insufficient Braking60
Brakes Overheating60
Turn Signal Lights Malfunction61
Steering and Suspensions61
Heavy Steering61
Excessive Steering Play61
Noisy Suspension61
Suspension Oil Leakage62
Oil Leakage from Suspension62
Electrical System63
Components Arrangement68
Devices and Accessories80
Checks and Inspections82
Ignition Circuit82
No Spark Plug82
HV Coil Secondary Check83
Specific Tooling83
Electric Characteristic83
Pick-Up84
Voltage Value84
Specific Tooling84
Stator Check85
Voltage Regulator Check85
Recharge System Voltage Check86
Choke Inspection86
Turn Signals System Check87
Lights List88
Light Bulb Table88
Fuse Table89
Sealed Battery90
Pump Electrics Check91
Pump Supply91
If the Pump Does Not Work91
Engine from Vehicle94
Index of Topics94
Exhaust Assy. Removal95
Removal of the Engine from the Vehicle95
Engine99
Automatic Transmission100
Transmission Cover100
Specific Tooling100
Air Duct Filter101
Removing the Driven Pulley Shaft Bearing102
Refitting the Driven Pulley Shaft Bearing102
Baffle Roller102
Removing the Driven Pulley104
Inspecting the Clutch Drum104
Removing the Clutch105
Inspecting the Clutch106
Pin Retaining Collar106
Removing the Driven Half-Pulley Bearing107
Inspecting the Driven Fixed Half-Pulley107
Inspecting the Driven Sliding Half-Pulley109
Refitting the Driven Half-Pulley Bearing109
Refitting the Driven Pulley110
Driven Pulley Fitting110
Inspecting the Clutch Spring111
Refitting the Clutch111
Drive-Belt115
Removing the Driving Pulley116
Driving Pulley Removal118
Refitting the Driving Pulley119
Refitting the Transmission Cover120
End Gear120
Removing the Hub Cover120
Removing the Wheel Axle121
Removing the Hub Bearings121
Removing the Wheel Axle Bearings122
Inspecting the Hub Shaft123
Inspecting the Hub Cover123
Refitting the Wheel Axle Bearing123
Refitting the Hub Cover Bearings124
Refitting the Hub Bearings125
Refitting the Ub Cover125
Flywheel Cover126
Removing the Stator127
Refitting the Stator127
Refitting the Flywheel Cover127
Removing the Flywheel Magneto128
Inspecting the Flywheel Components129
Refitting the Flywheel Magneto129
Refitting the Starter Motor129
Removing the Intake Manifold130
Removing the Timing System Drive130
Removing the Cam Shaft132
Removing the Cylinder Head133
Removing the Valves133
Removing the Cylinder - Piston Assy.134
Inspecting the Small End136
Inspecting the Wrist Pin137
Caratteristiche Tecniche138
Inspecting the Piston139
Inspecting the Piston Rings139
Removing the Piston140
Choosing the Gasket141
Refitting the Piston Rings142
Refitting the Cylinder142
Inspecting the Cylinder Head143
Inspecting the Timing System Components144
Inspecting the Valve Sealings145
Inspecting the Valve Housings145
Inspecting the Valves146
Inspecting the Springs and Half-Cones149
Refitting the Valves149
Inspecting the Cam Shaft150
Refitting the Head and Timing System Components151
Refitting the Intake Manifold154
Splitting the Crankcase Halves154
Crankcase - Crankshaft154
Inspecting the Crankshaft Alignment157
Сrankshaft Alignment158
Inspecting the Crankcase Halves159
Inspecting the Crankshaft Plain Bearings160
Refitting the Crankcase Halves160
Lubrication Circuit161
Oil Pressure Check163
Oil Pump165
Removing the Oil Sump169
Inspecting the By-Pass Valve169
Refitting the Oil Sump170
SAS Valve170
Inspecting the One-Way Valve170
Inspecting the Cut-Off171
Fuel Supply172
Removing the Carburettor173
Refitting the Carburettor181
Inspecting the Automatic Choke Device186
Adjusting the Idle188
Suspensions191
Index of Topics191
Removing the Front Wheel192
Front Wheel Hub Overhaul192
Specific Tooling193
Refitting the Front Wheel195
Handlebar196
Front Fork196
Front Fork197
Spring Length Check198
Recommended Products200
Steering Bearing206
Steering Bearing207
Removing the Rear Wheel208
Refitting the Rear Wheel209
Swing-Arm209
Shock Absorbers212
Exhaust Bracket213
Centre-Stand215
Index of Topics217
Interventions Rules218
Rear Brake Calliper218
Front Brake Calliper219
Rear Brake Disc222
Disc Inspection223
Front Brake Disc223
Front Brake Pads225
Rear Brake Pads226
Rear - Combined227
Front Brake Pump229
Rear Brake Pump - Combined230
Index of Topics232
Cooling System232
Circuit Diagram233
Cooling Circuit233
Electric Fan Check234
Electric Fan Operation Check234
Thermoswitch Operation Check235
Coolant Replacement236
Thermostat236
Chassis239
Seat240
Rear Rack241
Rear Handlebar Cover241
Instrument Panel241
Front Handlebar Cover242
Headlight Assy.243
Legshield244
Knee-Guard246
Removing the Ignition Key-Switch When on *Off*246
Removing the Ignition Key-Switch When on *Lock*247
Front Wheel Housing247
Taillight Assy.247
Footrest248
Side Fairings249
Rear Mudguard251
Helmet Bay251
Fuel Tank253
Front Mudguard254
Radiator Fan254
Expansion Tank255
Radiator Cover255
Pre-Delivery256
Index of Topics256
Aesthetic Inspection257
Tightening Torques Inspection257
Electrical System257
Levels Check258
Road Test258
Static Test259
Functional Inspection259
Time260
Crankcase262
Crankshaft263
Cylinder Assy.264
Cylinder Head Assy.265
Rocker Arms Support Assy.266
Cylinder Head Cover267
Chain Tensioner268
Oil Filter269
Driven Pulley270
Final Gear Assy.272
Final Drive272
Driving Pulley273
Flywheel Magneto274
Transmission Cover274
Exhaust Pipe276
Air Cleaner277
Frame278
Legshield Spoiler280
Side Covers281
Footrests282
Rear Cover283
Rear Shield283
Central Cover284
Underseat Compartment285
Mudguard286
Expansion Tank288
Radiator289
Rear Shock Absorber290
Steering Column Bearings291
Handlebar Covers292
Handlebar Components293
Swinging Arm294
Brake Hoses295
Seat Lock297
Instrument Panel298
Luggage Rack299
Locks300
Turn Signal Lights301
Front Wheel302
Rear Wheel303
Electric Start304
Fuel Pump305
Electric Devices306
Electric Devices307
Secondary Air Box308

PIAGGIO Carnaby 200 - Page 28

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