PIAGGIO Carnaby 125 Guide

SERVICE STATION MANUAL

633986 IT-633987 EN-633988 FR-633989 DE-633990

ES-633991 PT-633992 OL-633993 EL

Carnaby 125 - 200

SERVICE STATION

MANUAL

Carnaby 125 - 200

The descriptions and illustrations given in this publication are not binding. While the basic specifications

as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all countries. The availability of single

versions should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL

Carnaby 125 - 200

This service station 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 repairing techniques and procedures.

Any significant changes made to the vehicle characteristics or to specific repair operations will be

promptly communicated by updates to this manual. Nevertheless, no work can be satisfactory if the

necessary equipment and tools are not available. It is therefore advisable to read the sections of this

manual relating to special tools as well as the tool catalogues.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sectionsmarked with this symbol indicatethe correct use of thevehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well-

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water

and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working

area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that

you do not breathe in the dust produced by the wear of the friction material. 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.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all

the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling

members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make

suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.

Carnaby 125 - 200 Characteristics

CHAR - 7

Vehicle identification

The chassis prefix «A» is located near the right

shock absorber connection to the frame.

The engine prefix «B» is stamped near the left

shock absorber lower support.

VEHICLE IDENTIFICATION 125

Specification Desc./Quantity

Frame prefix ZAPM 60200

Engine prefix M28FM

VEHICLE IDENTIFICATION 200

Specification Desc./Quantity

Frame prefix ZAPM 60100

Engine prefix M601M

Characteristics Carnaby 125 - 200

CHAR - 8

Dimensions and mass

WEIGHTS AND DIMENSIONS 125

Specification Desc./Quantity

Kerb weight 154 ± 5 kg

Maximum weight allowed 350 kg

Overall height 1.175 mm

Width 755 mm

Wheelbase 1.370 mm

Length 2,025 mm

WEIGHTS AND DIMENSIONS 200

Specification Desc./Quantity

Kerb weight 154 ± 5 kg

Maximum weight allowed 350 kg

Overall height 1.175 mm

Width 755 mm

Wheelbase 1.370 mm

Length 2,025 mm

Engine

ENGINE 125

Specification Desc./Quantity

Type Single-cylinder, 4-stroke

Cubic capacity 124 cm³

Bore x stroke 57.0 x 48.6 mm

Compression ratio 12 ± 0.5: 1

Engine idle speed 1650 ± 100 rpm

Timing system 4 valves, single overhead camshaft, chain-driven.

Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm

Max. Power 11 kW at 9,750 rpm

MAX. torque 12 Nm at 8,000 rpm

Carnaby 125 - 200 Characteristics

CHAR - 9

Specification Desc./Quantity

Lubrication Enginelubricationwithlobepump(insidecrankcase)controlled

by a chain with double filter: mesh and paper.

Lubrication pressure 4 bar

Minimum lubrication pressure (100° C) 0.8 bar

Fuel supply KEIHIN CVEK 30 carburettor and electrical fuel pump.

Cooling Forced-circulation coolant system.

Fuel Unleaded petrol (95 RON)

Exhaust muffler absorption-type exhaust muffler with catalytic converter.

Emission regulations EURO 3

ENGINE 200

Specification Desc./Quantity

Type Single-cylinder, 4-stroke

Cubic capacity 198 cm³

Bore x stroke 72 x 48.6 mm

Compression ratio 11 ± 0.5 : 1

Engine idle speed 1650 ± 100 rpm

Timing system 4 valves, single overhead camshaft, chain-driven.

Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm

MAX. power 14.5 kW at 9,000 rpm

MAX torque 16.5 Nm at 7.250 rpm

Lubrication Enginelubricationwithlobepump(insidecrankcase)controlled

by a chain with double filter: mesh and paper.

Lubrication pressure 4 bar

Minimum lubrication pressure (100° C) 0.8 bar

Fuel supply KEIHIN CVEK 30 carburettor and electrical fuel pump.

Cooling Forced-circulation coolant system.

Fuel Unleaded petrol (95 RON)

Exhaust muffler absorption-type exhaust muffler with catalytic converter.

Emission regulations EURO 3

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque server, V-

belt, self-ventilating dry automatic centrifugal clutch and trans-

mission housing with forced-circulation air cooling.

Final reduction Gear reduction unit in oil bath.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 1.10 l

Transmission oil 250 cm³

Cooling system fluid ~ 2 l

Fuel tank (reserve) ~ 10 l (2 l)

Electrical system

ELECTRICAL SYSTEM 125

Specification Desc./Quantity

Start-up Electric

Ignition Capacitive discharge ignition, with variable advance and sep-

arate HV coil.

Ignition advance 10° at 2.000 rpm - 29° at 6.750 rpm

Characteristics Carnaby 125 - 200

CHAR - 10

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