PIAGGIO Runner 125 Leitfaden

SERVICE STATION MANUAL

633616 (IT)-633617(EN)-633618 (FR)-633619

(DE)-633620 (ES)- 633621 (PT)- 633622 (NL)- 633623

(EL)

Runner 125 - 200

SERVICE STATION

MANUAL

Runner 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

Runner 125 - 200

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of

Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio

vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any

significant changes to vehicle characteristics or to specific repair operations will be communicated by

updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment

and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special

tools, along with the special tool catalogue.

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

VIRGIN CIRCUIT

DIAGNOSTIC CODES

DIAGNOSTIC CODE - 1 FLASH

DIAGNOSTIC CODE - 2 FLASHES

DIAGNOSTIC CODE - 3 FLASHES

IGNITION CIRCUIT

BATTERY RECHARGE CIRCUIT

STATOR CHECK

VOLTAGE REGULATOR CHECK

RECHARGE SYSTEM VOLTAGE CHECK

TURN SIGNALS SYSTEM CHECK

FUSES

DASHBOARD

SEALED BATTERY

DRY-CHARGE BATTERY

BATTERY INSTALLATION

PUMP ELECTRICS CHECK

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

This section describes the general specifications of the vehicle.

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.

Characteristics Runner 125 - 200

CHAR - 8

Vehicle identification

Vehicle 125

Chassis prefix: ZAPM46300 ÷ 1001

Engine prefix: M463M

Vehicle 200

Chassis prefix: ZAPM46400 ÷ 1001

Engine prefix: M464M

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification Desc./Quantity

Kerb weight 137 ± 5 kg

Maximum load Driver + passenger + baggage (180 Kg)

Wheelbase 1340 mm

Saddle height 815 mm

Overall length 1890 mm

Overall width 750 mm

Overall height 1260 mm

Runner 125 - 200 Characteristics

CHAR - 9

Engine

TECHNICAL DATA 125

Specification Desc./Quantity

Engine single-cylinder, four-stroke

Bore x stroke 57 x 48.6 mm

Cubic capacity 124 cm³

Compression ratio 11.5 ÷ 12.5 : 1

Ignition advance (before TDC) From 10° ± 1° at 2000 rpm to 34° ± 1° at 6500 rpm

Kehin Carburettor CVEK-30

Max. speed 108 km/h

Timing system single overhead camshaft driven by a chain on the left-hand

side, 4 valves, three-arm rocking lever with set screw.

intake valve clearance 0.10 mm

Valve clearance: discharge 0.15 mm

Air filter sponge, impregnated with mixture (50% oil and 50% unleaded

petrol).

Starting system Electric starter with Bendix gear

Lubrication With lobe pump (inside crankcase) controlled by a chain with

double filter: mesh and paper

Fuel supply With unloaded petrol, carburettor and electric pump

Engine - wheel ratio Short: 1/28.02

Engine - wheel ratio Long: 1/8.41

TECHNICAL DATA 200

Specification Desc./Quantity

Engine single-cylinder, four-stroke

Bore x stroke 72 x 48.6 mm

Characteristics Runner 125 - 200

CHAR - 10

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