PIAGGIO Runner 125 - User Manual

SERVICE STATION MANUAL
633616 (IT)-633617(EN)-633618 (FR)-633619
(DE)-633620 (ES)- 633621 (PT)- 633622 (NL)- 633623
(EL)
Runner 125 - 200

Summary

SERVICE STATION MANUAL

Runner 125 - 200

Title of the service manual for the Runner 125-200 model.

CHARACTERISTICS

Rules

Describes general safety rules for maintenance operations.

Safety rules

Outlines safety precautions for maintenance tasks.

Maintenance rules

Provides guidelines for using parts, tools, and procedures.

Vehicle identification

Details chassis and engine prefixes for different models.

Dimensions and mass

Lists weight and dimensional data of the vehicle.

Engine

Provides detailed technical specifications for the 125cc and 200cc engines.

Transmission

Describes the transmission system components and operation.

Capacities

Lists various fluid capacities for the vehicle.

Electrical system

Lists electrical components for 125cc and 200cc models.

Frame and suspensions

Details the chassis frame and suspension system structure.

Brakes

Describes the front and rear braking systems.

Wheels and tyres

Details specifications for wheels, tyres, and tyre pressure.

Carburettor

Details the Kehin CVEK-30 carburettor specifications for 125cc and 200cc versions.

Tightening Torques

TORQUE IN NM BY TYPE OF TIGHTENED MATERIAL

Lists torque specifications for various screw types and materials.

MAINTENANCE

Maintenance chart

Provides a maintenance schedule for various vehicle components.

MAINTENANCE TABLE

Details maintenance operations (check, clean, adjust, lubricate, replace).

Carburettor

Describes disassembly, cleaning, and checks for the carburettor.

Checking the spark advance

Details the procedure for checking and verifying ignition advance.

Spark plug

Describes the procedure for servicing the spark plug.

Hub oil

Details the procedure for checking and replacing hub oil.

Air filter

Describes the removal, washing, and saturation of the air filter.

Engine oil

Explains the function and importance of engine oil.

Checking the ignition timing

Details the procedure for checking ignition timing.

Checking the valve clearance

Describes how to check and adjust valve clearance.

TROUBLESHOOTING

Engine

Troubleshooting for engine performance issues.

Poor performance

Lists possible causes and operations for poor engine performance.

Starting difficulties

Troubleshooting for difficult engine starting.

Excessive oil consumption;Exhaust smoke

Troubleshooting for excessive oil consumption or smoke.

Insufficient lubrication pressure

Troubleshooting for low lubrication pressure.

Engine tends to cut-off at full throttle

Troubleshooting for engine cutting off at full throttle.

Engine tends to cut-off at idle

Troubleshooting for engine cutting off at idle.

Insufficient braking

Troubleshooting for insufficient braking performance.

Brakes overheating

Troubleshooting for brake overheating issues.

Turn signal lights malfunction

Troubleshooting for turn signal light malfunctions.

STEERING CONTROLS AND SUSPENSIONS

Troubleshooting for steering controls and suspension issues.

ELECTRICAL SYSTEM

KEY (With electric pump)

Key to components in the electrical diagram with electric pump.

KEY (Without electric pump)

Key to components in the electrical diagram without electric pump.

Immobiliser

Explains the immobiliser system, its components, and diagnosis.

DIAGNOSTIC CODES

Diagnostic codes

Explains immobiliser system status codes via LED flashes.

DIAGNOSTIC CODE - 1 FLASH

Details the meaning and troubleshooting for a 1-flash diagnostic code.

DIAGNOSTIC CODE - 2 FLASHES

Details the meaning and troubleshooting for a 2-flash diagnostic code.

DIAGNOSTIC CODE - 3 FLASHES

Details the meaning and troubleshooting for a 3-flash diagnostic code.

IGNITION CIRCUIT

Ignition circuit

Explains the ignition system's operation, power supply, and grounding.

BATTERY RECHARGE CIRCUIT

Battery recharge circuit

Explains the recharge system with a three-phase alternator and voltage regulator.

STATOR CHECK

Stator check

Details checks for stator connections, earth isolation, and resistance.

VOLTAGE REGULATOR CHECK

Voltage regulator check

Details voltage measurements to check the regulator and stator.

RECHARGE SYSTEM VOLTAGE CHECK

Recharge system voltage check

Measures current generated by the recharge system using an ammeter.

TURN SIGNALS SYSTEM CHECK

Turn signals system check

Checks turn indicator circuit voltage and wiring continuity.

FUSES

Fuses

Lists fuse table showing position, capacity, and protected circuits.

DASHBOARD

Dashboard

Identifies and explains the function of each indicator and control on the dashboard.

SEALED BATTERY

Sealed battery

Details battery voltage checks and charging modes.

DRY-CHARGE BATTERY

Dry-charge battery

Details filling, charging, and checking a dry-charged battery.

BATTERY INSTALLATION

Battery installation

Details battery cover removal, connection, and refitting steps.

PUMP ELECTRICS CHECK

PUMP SUPPLY

Details fuel pump supply based on engine conditions.

ENGINE FROM VEHICLE

Exhaust assy. Removal

Details the steps for removing the exhaust assembly.

Removal of the engine from the vehicle

Outlines the initial steps for engine removal from the vehicle.

ENGINE

Automatic transmission

Describes operations on the automatic transmission.

Transmission cover

Details removing and refitting the transmission cover.

Removing the driven pulley shaft bearing

Details removing the driven pulley shaft bearing.

Refitting the driven pulley shaft bearing

Details refitting the driven pulley shaft bearing.

Removing the driven pulley

Describes the removal of the driven pulley assembly.

Inspecting the clutch drum

Details inspecting the clutch drum for wear and measuring diameter.

Checking the bell working surface eccentricity

Describes checking the clutch bell's working surface eccentricity.

Removing the clutch

Details removing the clutch using specific tools.

Inspecting the clutch

Describes checking the clutch mass friction material thickness and condition.

Drive-belt

Describes checks for drive-belt wear, damage, and width.

Removing the driving pulley

Details the procedure for removing the driving pulley.

Inspecting the rollers case

Describes inspecting the rollers case for wear and dimensions.

Refitting the driving pulley

Details refitting the movable half-pulley and complete bushing unit.

Refitting the flywheel magneto

Details refitting the flywheel magneto, including torque and air gap checks.

Removing the stator

Details removing the stator and its wiring.

Refitting the stator

Describes refitting the stator and flywheel, including harness placement.

Removing the intake manifold

Describes removing the intake manifold.

Removing the cylinder head

Details removing the cylinder head, including nuts and gasket.

Removing the valves

Describes removing valves, cotters, springs, and oil guards.

Removing the cylinder - piston assy.

Details removing the cylinder, piston, base gasket, and piston seals.

Choosing the gasket

Describes determining correct cylinder base gasket thickness based on piston protrusion.

Refitting the piston rings

Details fitting piston rings, including oil scraper, middle, and top rings.

Refitting the cylinder

Describes refitting the cylinder with base gasket using specific tools.

Inspecting the cylinder head

Describes checking cylinder head surface, camshaft, and rocker pin wear.

Inspecting the timing system components

Details inspecting guide shoe, tensioner, camshaft pulley, and sprocket wheel.

Inspecting the valves

Describes measuring valve stems, calculating clearance, and checking contact surfaces.

Inspecting the cam shaft

Describes inspecting cam shaft for wear, height, and related components.

Refitting the head and timing system components

Details refitting the head and timing system components, including chain and tensioner.

Adjust valve clearance

Describes adjusting valve clearance and fitting the spark plug.

Crankcase - crankshaft

Details initial steps for splitting crankcase halves, removing various units.

Inspecting the crankshaft alignment

Details installing drive shaft, measuring misalignment, and checking shaft components.

Lubrication

Information on the lubrication system.

Oil pressure check

Details checking oil pressure at different RPMs and temperatures.

Removing the carburettor

Details removing the Kehin carburettor from the engine.

Adjusting the idle

Details adjusting engine idle speed and carburettor flow screw using emission analysis.

SUSPENSIONS

Front

Details operations on the front suspension system.

Removing the front wheel

Describes removing the front wheel, brake caliper, and axle.

Front wheel hub overhaul

Details overhauling the front wheel hub, including bearing removal.

Handlebar

Details removing and refitting the handlebar.

Front fork

Details overhauling the front fork, including removing legs, springs, and oil.

Rear

Details operations on the rear suspension system.

Removing the rear wheel

Describes removing the rear wheel, muffler, and shock absorber bracket.

Swing-arm

Details checking the swinging arm assembly and its bushings.

Shock absorbers

Details removing and refitting shock absorbers.

Centre-stand

Details removing and refitting the centre stand.

BRAKING SYSTEM

Rear brake calliper

Details removal and overhaul of the rear brake caliper.

Front brake calliper

Details removal and overhaul of the front brake caliper.

Rear brake disc

Describes refitting brake disc to hub, respecting rotation and torque.

Disc Inspection

Details checking rear brake disc thickness and rotation regularity.

Front brake pads

Describes removing front brake pads, checking thickness and condition.

Rear brake pads

Describes removing rear brake pads, checking thickness and condition.

Fill

Details bleeding the front brake system using a vacuum pump.

Front brake pump

Details removing and overhauling the front brake pump.

Overhaul

Details overhauling the brake pump, checking body, piston, and spring.

COOLING SYSTEM

Circuit diagram

Presents the circuit diagram of the cooling system.

Water pump - overhaul

Details overhauling the water pump, including bearings, ceramic seal, and rotor.

Water pump ceramic seal

Explains the water pump ceramic seal, its function, and running-in period.

Check components

Describes checking water pump rotor, shaft, bearing seats, and drive for wear.

Thermostat

Describes checking thermostat opening temperature and travel.

Removal

Details removing thermostat cover and thermostat.

CHASSIS

Seat

Describes removing the vehicle seat.

Rear handlebar cover

Details removing the rear handlebar cover and associated wiring.

Front handlebar cover

Describes removing rear-view mirrors and handlebar cover fittings.

Headlight assy.

Details removing the front shield, wiring, and headlight assembly.

Frame central cover

Describes removing saddle, screws, air ducts, and frame central cover.

Legshield

Describes removing legshield central cover, screws, and plastic parts.

Front central cover

Details removing ignition key-switch, shield back plate, and immobilizer aerial.

Front wheel housing

Describes removing front fork, wheel well stud, brake pipe, and odometer transmission.

Taillight assy.

Describes removing taillight unit screws.

Footrest

Describes removing footrest screws.

Side fairings

Details removing side fairing parts A, B, and C.

Air filter

Details removing air filter housing, clamps, and blow-by tube.

Helmet bay

Details removing battery, saddle, covers, panels, wiring, and helmet compartment.

Fuel tank

Details removing fuel tank components, central chassis cover, and side fairings.

Front mudguard

Describes loosening screws to remove the front mudguard.

Expansion tank

Details removing front shield, expansion tank cap, and coolant pipes.

Lower cover

Describes removing footrests, front wheel compartment screws, and lower cover.

PRE-DELIVERY

Aesthetic inspection

Details appearance checks: paintwork, plastics, scratches, and dirt.

Tightening torques inspection

Lists checks for safety locks and clamping screws, and specific torque inspections.

Electrical system

Details checks for electrical system components like switches, lights, and indicators.

Levels check

Lists checks for hydraulic fluid, hub oil, and engine coolant levels.

Road test

Details checks during a road test: cold start, instruments, throttle, brakes, suspension.

Static test

Details static controls after test ride: starting, starter, steering, leaks.

Functional inspection

Details functional checks for braking, clutch, engine, and other systems.

TIME

Engine

Lists repair codes, actions, and durations for engine operations.

Crankcase

Lists repair codes, actions, and durations for crankcase components.

Crankshaft

Lists repair codes, actions, and durations for crankshaft components.

Cylinder assy.

Lists repair codes, actions, and durations for cylinder and piston units.

Cylinder head assy.

Lists repair codes, actions, and durations for cylinder head assembly components.

Rocker arms support assy.

Lists repair codes, actions, and durations for rocking lever unit components.

Cylinder head cover

Lists repair codes, actions, and durations for cylinder head cover components.

Chain tensioner

Lists repair codes, actions, and durations for chain tightener components.

Oil filter

Lists repair codes, actions, and durations for oil filter and sensor.

Driven pulley

Lists repair codes, actions, and durations for driven pulley components.

Oil pump

Lists repair codes, actions, and durations for oil pump and related parts.

Final gear assy.

Lists repair codes, actions, and durations for final reduction gears and axle.

Driving pulley

Lists repair codes, actions, and durations for driving pulley components.

Transmission cover

Lists repair codes, actions, and durations for transmission cover components.

Starter motor

Lists repair codes, actions, and durations for starter motor components.

Flywheel magneto

Lists repair codes, actions, and durations for flywheel magneto and secondary air components.

Belt cooling duct

Lists repair codes, actions, and durations for belt cooling tube components.

Carburettor

Lists repair codes, actions, and durations for carburettor and intake manifold.

Exhaust pipe

Lists repair codes, actions, and durations for muffler and exhaust components.

Air cleaner

Lists repair codes, actions, and durations for air cleaner components.

Frame

Lists repair codes, actions, and durations for frame and footrest components.

Centre-stand

Lists repair codes, actions, and durations for stand components.

Legshield spoiler

Lists repair codes, actions, and durations for front shield and spoiler components.

Side fairings

Lists repair codes, actions, and durations for side fairing components.

Rear cover

Lists repair codes, actions, and durations for rear cover components.

Central cover

Lists repair codes, actions, and durations for central cover and fuel tank lid.

Mudguard

Lists repair codes, actions, and durations for mudguard components.

Fuel tank

Lists repair codes, actions, and durations for fuel tank and valve components.

Rear shock-absorber

Lists repair codes, actions, and durations for rear shock absorber.

Handlebar covers

Lists repair codes, actions, and durations for handlebar covers.

Handlebar components

Lists repair codes, actions, and durations for handlebar components.

Swing-arm

Lists repair codes, actions, and durations for swinging arm components.

SWINGING ARM

Lists repair codes, actions, and durations for swinging arm components.

Instrument panel

Lists repair codes, actions, and durations for instrument panel components.

Locks

Lists repair codes, actions, and durations for locks and key switch.

Turn signal lights

Lists repair codes for rear lights and indicators.

Front wheel

Lists repair codes, actions, and durations for front wheel components.

Rear wheel

Lists repair codes, actions, and durations for rear wheel components.

Fuel pump

Lists repair codes, actions, and durations for fuel pump components.

Electric devices

Lists repair codes, actions, and durations for various electrical devices.

Helmet bay

Lists repair codes, actions, and durations for helmet bay components.

Rear side fairings

Lists repair codes, actions, and durations for rear side fairing components.

Front suspension

Lists repair codes, actions, and durations for front suspension components.

Cooling system

Lists repair codes, actions, and durations for cooling system components.

Braking system

Lists repair codes, actions, and durations for braking system components.

PIAGGIO Runner 125 Specifications

General

Displacement	124 cc
Fuel System	Carburetor
Transmission	Automatic CVT
Width	700 mm
Engine Type	Four-stroke single cylinder
Front Suspension	Telescopic fork
Front Brake	Disc