Beruflich Dokumente
Kultur Dokumente
*******
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 each
model should be checked at the official Piaggio sales network.
" Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
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
Liberty 125 - 150 (2009)
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 Sections marked with this symbol indicate the correct use of the vehicle
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
ENGINE ENG
SUSPENSIONS SUSP
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME
INDEX OF TOPICS
CHARACTERISTICS CHAR
Characteristics Liberty 125 - 150 (2009)
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.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
CHAR - 6
Liberty 125 - 150 (2009) Characteristics
Vehicle identification
CHAR - 7
Characteristics Liberty 125 - 150 (2009)
Engine
CHAR - 8
Liberty 125 - 150 (2009) Characteristics
Specification Desc./Quantity
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Cooling Forced-air circulation cooling.
Starter starter
Ignition Capacitive discharge ignition, with variable advance and sep-
arate HV coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug CHAMPION RG 6 YC
Alternative spark plug NGK CR7EB
Fuel system KEIHIN CVK 27 carburettor and vacuum-operated fuel pump.
Fuel Unleaded petrol (95 RON)
Exhaust silencer Absorption-type exhaust muffler with catalytic converter.
Emissions compliance EURO 3
Transmission
TRANSMISSION
Specification Desc./Quantity
Main drive Automatic expandable pulley variator with torque server, V-
belt, automatic self-ventilating centrifugal dry clutch
Final reduction gear Gear reduction unit in oil bath.
Capacities
CAPACITIES
Specification Desc./Quantity
Engine oil 1.10 l
Transmission oil 200 cm3
Fuel tank capacity about 7 litres (1.5 l of which is reserve)
CHAR - 9
Characteristics Liberty 125 - 150 (2009)
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Starter starter
Ignition Capacitive discharge ignition, with variable advance and sep-
arate HV coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug CHAMPION RG 6 YC
Alternative spark plug NGK CR7EB
Battery Sealed, 12 V / 10 Ah
Alternator alternating current
Brakes
BRAKES
Specification Desc./Quantity
Front brake 240mm drum brake with twin-plunger floating calliper.
Rear brake 140-mm drum brake with mechanical control activated by the
handlebar left-side lever.
Secondary air
CHAR - 10
Liberty 125 - 150 (2009) Characteristics
Carburettor
125cc Version
Kehin
CARBURETTOR SETTING
Specification Desc./Quantity
Type CVEK27
Throttle valve diameter 26.5
Diffuser diameter 26.4
Setting stamping 2701A
Maximum jet 82
Maximum air jet (on the body) 85
Tapered pin stamping NJHA
Throttle valve spring 130 180 gr.
Minimum jet 42
Idle air jet (on the body) 150
Idle mixture adjustment screw initial opening 2
Starter nozzle 42
Starter air jet (on the body) 1.5
Starter pin travel 10 mm (at 24)
Starter resistance 20 Ohm (at 24)
150cc Version
CHAR - 11
Characteristics Liberty 125 - 150 (2009)
Kehin
CARBURETTOR SETTING
Specification Desc./Quantity
Type CVEK27
Throttle valve diameter 26.5
Diffuser diameter 26.4
Setting stamping 2702B
Maximum jet 80
Maximum air jet (on the body) 130
Maximum air jet (on the body) MAJ2 80
Tapered pin stamping NELA
Throttle valve spring 130 180 gr.
Minimum jet 35
Idle air jet (on the body) 150
Idle mixture adjustment screw initial opening 2
Starter nozzle 42
Starter air jet (on the body) 1.5
Starter pin travel 10 mm (at 24)
Starter resistance 20 Ohm (at 24)
Tightening Torques
MOTORE
Name Torque in Nm
Ignition spark plug 10 to 15 Nm
Head cover screws 8 10
Head-cylinder stud bolt nuts 6 to 7 + 90 + 90 *
Screws fixing head and cylinder to crankcase 8 to 10
Chain tensioner pad screw 5 to 7 Nm
Timing chain tensioner screws 8 10 Nm
Timing chain tensioner central screw 5 to 6
Camshaft pulley screw 12 to 14
Rocking lever axle and camshaft bearing screw 3 to 4 Nm
Valve clearance adjustment lock nuts 7 9 Nm
Engine oil pre-filter cover: 25 to 28 Nm
Engine oil drainage cap 25 to 28
Alternator flywheel nut 40 44 Nm
Stator screws 3 to 4
Pick-up screws 3 to 4
Oil pump bulkhead screw 4 to 5
Timing chain/oil pump compartment cover screws 4 to 5 Nm
Oil decantation labyrinth sheet screws 7 to 8
Oil pump crown screw 8 to 10
Screws fixing oil pump to the crankcase 5 to 6
Oil pump coupling screws 7 9 Nm
Oil sump screws 8 to 10 Nm
Inlet manifold screw 7-9
Carburettor/manifold clamp screw 1.2 1.5 Nm
Screws fixing cables to starter motor 1.5 to 2.5
Starter screws 11 to 13
Transmission cover screws 11 13 Nm
Crankcase cooling cover screw 2 to 2.5
Nut locking clutch unit on pulley 55 to 60 Nm
Crankshaft pulley nut 18 to 20 + 90 Nm
Driven pulley shaft nut 40 44 Nm
Hub oil drainage screw 3 to 5 Nm
Rear hub cap screws 24 26 Nm
Wheel axle nut 115 125
Crankcase half union screw 8 to 10
Per assicurare una corretta coppia di bloccaggio lubrificare i dadi prima del montaggio.
CHAR - 12
Liberty 125 - 150 (2009) Characteristics
* Montando dei nuovi prigionieri, l'operazione di serraggio dei dadi comprende l'effettuazione di 3 rotazioni di 90 dopo il primo
bloccaggio a 67 Nm, pertanto: 67 Nm + 90 + 90 + 90 a passaggi incrociati.
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 35 40
Lower steering ring nut 12 14
handlebar fixing screw 45 55
FRAME ASSEMBLY
Name Torque in Nm
Engine-swinging arm pin 33 to 41
Frame-swinging arm bolt 64 - 72
Shock absorber - chassis nut 20 to 25
Shock absorber/engine pin 33 - 41 N.m
Rear wheel axle 104 126
Stand bolt 20 25
Front mudguard fixing screw 46
FRONT SUSPENSION
Name Torque in Nm
Fork bottom screw 20 25
Front wheel axle 45 to 50
Odometer drive screw 67
FRONT BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 20 25
Brake fluid pipe-calliper fitting 20 22
Calliper tightening screw 20 25
Disc tightening screw (Apply LOCTITE 243 medium-strength 8 12 Nm
threadlocker)
Oil bleeding valve 8 12
Overhaul data
Assembly clearances
CHAR - 13
Characteristics Liberty 125 - 150 (2009)
COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER
(125)
Name Initials Cylinder Piston Play on fitting
Coupling A 56.980 56.987 56.933 56.940 0.040 0.054
Coupling B 56.987 56.994 56.940 56.947 0.040 0.054
Coupling D 57.001 57.008 56.954 56.961 0.040 0.054
Coupling C 56.994 57.001 56.947 56.954 0.040 0.054
Coupling 1st oversize A1 57.180 57.187 57.133 57.140 0.040 0.054
Coupling 1st oversize B1 57.187 57.194 57.140 57.147 0.040 0.054
Coupling 1st oversize D1 57.201 57.208 57.154 57.161 0.040 0.054
Coupling 1st oversize C1 57.194 57.201 57.147 57.154 0.040 0.054
Coupling 2nd oversize A2 57.380 57.387 57.333 57.340 0.040 0.054
Coupling 2nd oversize B2 57.387 57.394 57.340 57.347 0.040 0.054
Coupling 2nd oversize C2 57.394 57.401 57.347 57.354 0.040 0.054
Coupling 2nd oversize D2 57.401 57.408 57.354 57.361 0.040 0.054
Coupling 3rd oversize A3 57.580 57.587 57.533 57.540 0.040 0.054
Coupling 3rd oversize B3 57.587 57.594 57.540 57.547 0.040 0.054
Coupling 3rd oversize C3 57.594 57.601 57.547 57.554 0.040 0.054
Coupling 3rd oversize D3 57.601 57.608 57.554 57.561 0.040 0.054
Piston rings
CHAR - 14
Liberty 125 - 150 (2009) Characteristics
CHAR - 15
Characteristics Liberty 125 - 150 (2009)
CHAR - 16
Liberty 125 - 150 (2009) Characteristics
Characteristic
Crankshaft/crankcase axial clearance A:
0.15 0.40
SHIMMING SYSTEM
Value measured Gasket thickness
0 0.1 0.8 0.05
0.1 0.3 0.6 0.05
0.3 - 0.4 0.4 0.05
Characteristic
Compression ratio
10.6 0.5: 1
CHAR - 17
Characteristics Liberty 125 - 150 (2009)
Products
CHAR - 18
INDEX OF TOPICS
TOOLING TOOL
Tooling Liberty 125 - 150 (2009)
APPROPRIATE TOOLS
Stores code Description
001330Y Tool for fitting steering seats
TOOL - 20
Liberty 125 - 150 (2009) Tooling
TOOL - 21
Tooling Liberty 125 - 150 (2009)
TOOL - 22
Liberty 125 - 150 (2009) Tooling
TOOL - 23
Tooling Liberty 125 - 150 (2009)
020375Y 28 x 30 mm adaptor
TOOL - 24
Liberty 125 - 150 (2009) Tooling
TOOL - 25
Tooling Liberty 125 - 150 (2009)
TOOL - 26
Liberty 125 - 150 (2009) Tooling
TOOL - 27
Tooling Liberty 125 - 150 (2009)
TOOL - 28
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance Liberty 125 - 150 (2009)
Maintenance chart
MAINTENANCE TABLE
Replacement
Check
* Check level every 3,000 km
** Replace every 2 years
Clean the external filter of the Secondary Air System (SAS) every 2 years
Km x 1,000 1 6 12 18 24 30 36 42 48 54 60 66 72
Safety locks
Ignition spark plug
Centre stand (lubrication)
Driving belt
Throttle control (adjustment)
Air filter
SAS filter
Oil net filter (cleaning)
Oil filter
Valve clearance
Electrical system and battery
Cylinder ventilation system
Brake control lever (greasing)
Brake fluid level **
Engine oil *
Hub oil
Headlight aiming adjustment
Brake pads
Sliding blocks / variable speed rollers
Tyre pressure and wear
Vehicle test ride
Idle speed
Odometer gear (greasing)
Suspension
Steering
Transmission
Operation time 80' 150' 160' 150' 175' 95' 270' 95' 175' 150' 160' 95' 270'
Hub oil
Check
MAIN - 30
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Troubleshooting Liberty 125 - 150 (2009)
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, then
soak it in a mixture of 50% petrol and 50% specific oil. Press
with your hand without squeezing, allow it to drip dry and refit.
Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed air
Dirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol and wash the
tank, if necessary. Replace the cock as a last resource.
Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace
if necessary.
Excessive drive belt wear Check it and replace, if necessary
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Oil level exceeds maximum Check for causes and fill to reach the correct level
Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Silencer obstructed Replace
Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-
aged parts and lubricate the movable guide of the driven pulley
with grease.
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Valve seat distorted Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings
Starting difficulties
START-UP PROBLEMS
Possible Cause Operation
Flat battery Check the state of the battery. If it shows signs of sulphation
replace it and bring the new battery into service charging it for
eight hours at a current of 1/10 of the capacity of the battery
itself
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components
Engine flooded Try starting-up with the throttle fully open. If the engine fails to
start, remove the spark plug, dry it and before refitting, make
the motor turn so as to expel the fuel excess taking care to
connect the cap to the spark plug, and this in turn to the ground.
If the fuel tank is empty, refuel and start up.
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance
Rpm too low at start-up or engine and start-up system dam- Check the starter motor and the kick-starter unit
aged
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Vacuum operated cock failure Check that fuel is adequately supplied through the pipe by ap-
plying a vacuum to the vacuum pipe
Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace
if necessary.
TROUBL - 32
Liberty 125 - 150 (2009) Troubleshooting
TROUBL - 33
Troubleshooting Liberty 125 - 150 (2009)
Insufficient braking
Brakes overheating
BRAKE OVERHEAT
Possible Cause Operation
Rubber gaskets swollen or stuck Replace gaskets.
Compensation holes on the pump clogged Clean carefully and blast with compressed air
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Defective piston sliding Check calliper and replace any damaged part.
TROUBL - 34
Liberty 125 - 150 (2009) Troubleshooting
Electrical system
Battery
BATTERY
Possible Cause Operation
Battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. If the
vehicle is not used for some time (1 month or more) the battery
needs to be recharged periodically. The battery runs down
completely in the course of 5 to 6 months. If the battery is fitted
on a motorcycle, be careful not to invert the connections, keep-
ing in mind that the black ground wire is connected to the
negative terminal while the red wire is connected to the terminal
marked+. Follow the instructions in the ELECTRICAL SYSTEM
chapter for the recharging of the batteries.
Heavy steering
STEERING HARDENING
Possible Cause Operation
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
TROUBL - 35
Troubleshooting Liberty 125 - 150 (2009)
Noisy suspension
NOISY SUSPENSION
Possible Cause Operation
NOISY SUSPENSION If the front suspension is noisy, check: that the front shock ab-
sorber works properly and the ball bearings are good condition.
Finally, check the locking torque of the wheel axle nut, the
brake calliper and the disc. Check that the swinging arm con-
necting the engine to the chassis and the rear shock absorber
work properly.
TROUBL - 36
INDEX OF TOPICS
Ignition
LEGENDA
29. Dispositivo accensione elettronica con commutatore lampeggiatori e starter
31. Contatti del commutatore a chiave
33. Fusibile 15A
34. regolatore di tensione
35. Bobina A.T.
41. Pick-up
ELE SYS - 38
Liberty 125 - 150 (2009) Electrical system
LEGENDA
33. Fusibile 15A
34. regolatore di tensione
39. Volano magnete
40. Regolatore di tensione
ELE SYS - 39
Electrical system Liberty 125 - 150 (2009)
LEGENDA
19. Pulsante avviamento
20. Motorino avviamento
21. Teleruttore avviamento
22. Stop freno anteriore e posteriore
23. Filamento per luce stop
31. Contatti del commutatore a chiave
32. Fusibile 7,5A
33. Fusibile 15A
34. regolatore di tensione
SCHEMA SERVIZI
ELE SYS - 40
Liberty 125 - 150 (2009) Electrical system
LEGENDA
1. Rel
2. Deviatore luci
3. Lampada luce di citt
4. Lampade per illuminazione strumento e spia luci
5. Spia luci abbaglianti
6. Filamento per luce di posizione posteriore
7. Filamento anabbagliante del proiettore
8. Filamento abbagliante del proiettore
9. Lampada illuminazione targa
10. Fusibile 7,5A
11. Fusibili 7,5A
12. Pulsante claxon
13. Claxon in c.c.
14. Spia pressione olio motore
15. Sensore pressione olio motore
16. Spia riserva carburante
17. Indicatore livello carburante
18. Trasmettitore livello carburante
29. Dispositivo accensione elettronica con commutatore lampeggiatori e starter
ELE SYS - 41
Electrical system Liberty 125 - 150 (2009)
30. Diagnostica
31. Contatti del commutatore a chiave
32. Fusibile 7,5A
33. Fusibile 15A
34. regolatore di tensione
36. Commutatore lampeggiatori
37. Lampade lampeggiatori
38. Lampade spie lampeggiatori
SCHEMA SERVIZI
LEGENDA
24. Potenziometro T.P.S
25. Sensore temperatura esterna
26. Riscaldatore carburatore
27. Starter automatico
28. Valvola MA J2 (solo versione 150cc)
29. Dispositivo accensione elettronica con commutatore lampeggiatori e starter
30. Diagnostica
31. Contatti del commutatore a chiave
33. Fusibile 15A
ELE SYS - 42
Liberty 125 - 150 (2009) Electrical system
LEGENDA
1. Rel
2. Deviatore luci
3. Lampada luce di citt
4. Lampade per illuminazione strumento e spia luci
5. Spia luci abbaglianti
6. Filamento 5W per luce di posizione posteriore
7. Filamento anabbagliante del proiettore
8. Filamento abbagliante del proiettore
9. Lampada illuminazione targa
10. Fusibile 7,5A
11. Fusibili 7,5A
12. Pulsante claxon
13. Claxon in c.c.
14. Spia pressione olio motore
15. Sensore pressione olio motore
16. Spia riserva carburante
17. Indicatore livello carburante
ELE SYS - 43
Electrical system Liberty 125 - 150 (2009)
Ignition circuit
All the control operations of the system that entail disconnecting cables (to check connections and the
devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls
might be irretrievably damaged.
The battery provides the basic power supply. The system is adjusted so that the start-up system im-
mediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected
to the Pick-Up by the chassis and the engine ground lead.
ELE SYS - 44
Liberty 125 - 150 (2009) Electrical system
To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis
ground connection bonding is efficient.
No spark plug
Electric characteristic
Pick-up resistance value
Pick-up resistance value: 105 124 Ohm
Electric characteristic
High voltage coil primary resistance value
High voltage coil primary resistance value: 0.4
0.5 Ohm
ELE SYS - 45
Electrical system Liberty 125 - 150 (2009)
If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis,
check the peak voltage with the multimeter adaptor.
Specific tooling
020409Y Multimeter adaptor - Peak voltage detection
Electric characteristic
High voltage coil secondary resistance value
High voltage coil secondary resistance value: ~ 3000 300 Ohm
- Pick-Up
Disconnect the control unit connector and connect
the positive terminal to connector No. 3 and the
negative terminal to connector No. 12 (see figure).
Use the start-up system to run the engine and
measure the voltage produced by the Pick-Up.
Replace Pick-Up if non-conforming values are
measured.
N.B.
THE MULTIMETER MUST BE SELECTED TO DETECT
CONTINUOUS VOLTAGE.
Electric characteristic
Pick-Up voltage value
Pick-Up voltage value: > 2 Volt
- H.V. coil
With the control unit and HV coil connected to the
circuit, measure the voltage of the coil primary dur-
ing the start-up test with the voltage peak adaptor
and connect the positive terminal to the ground
one and the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS
BLACK.
Electric characteristic
ELE SYS - 46
Liberty 125 - 150 (2009) Electrical system
The charging circuit consists of three-phase alternator and a permanent magneto flywheel.
The generator is directly connected to the voltage regulator.
In turn, the latter is directly connected to ground and to the battery positive passing through the 15A
safety fuse.
This system therefore requires no connection to the ignition key.
The three-phase alternator provides good recharge power and at low revs a good compromise is ach-
ieved between generated power and idle stability.
For this reason, it is very important that the idle speed is adjusted as prescribed.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
Switches check
To check buttons and switches, check that, according to their position, the continuity of contacts is
correct as indicated in the following charts.
KEY
Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red
Gre: Green Pr: Purple
ELE SYS - 47
Electrical system Liberty 125 - 150 (2009)
STARTER BUTTON
LIGHT SWITCH
HORN BUTTON
ELE SYS - 48
Liberty 125 - 150 (2009) Electrical system
Stator check
Electric characteristic
Ohm value:
0.7 0.9 Ohm
ELE SYS - 49
Electrical system Liberty 125 - 150 (2009)
Starter motor
KEY
1. Battery
2. Fuse A .
3. Starter remote control
4. Starter motor
ELE SYS - 50
Liberty 125 - 150 (2009) Electrical system
Horn control
KEY
1. Battery
2. Fuse A .
3. Key switch contacts
4. Fuse No. 2
5. Horn button
ELE SYS - 51
Electrical system Liberty 125 - 150 (2009)
6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If the horn does not work:
1) Check that fuses operate properly.
2) Check the key switch and horn button contacts.
3) If the components are not damaged, check wiring for continuity.
Choke Inspection
ELE SYS - 52
Liberty 125 - 150 (2009) Electrical system
KEY
1. Battery
2. Fuse A .
3. Key switch contacts
4. Control unit.
5. Turn indicator switch.
6. Right turn indicator bulbs
7. Left turn indicator bulbs
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
- If the turn indicators do not work, proceed as fol-
lows:
- Disconnect the electronic control unit connector
and check that there is voltage between terminal
9 (Orange) and the earth connection with the key
switch set to "ON".
- Check that the same happens between terminal
9 (Orange) and terminal 12 (Black).
ELE SYS - 53
Electrical system Liberty 125 - 150 (2009)
level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If faults are detected:
1) With a multimeter, check resistance values be-
tween the White-Green cable and the Black cable
of the fuel level transmitter by moving the arm with
the float.
2) If the transmitter operates correctly but the in-
dication on the instrument panel is not exact,
check that the cable harnesses between them are
not interrupted.
Electric characteristic
Resistance value when the tank is full
<= 7
Resistance value when the tank is empty
90 +13/-3
Lights list
BULBS
Specification Desc./Quantity
1 High/low beam light bulb Type: Halogen (H4)
Power: 12V - 55/60W
Quantity: 1
2 Front side light bulb Type: All glass
Power: 12V 5W
ELE SYS - 54
Liberty 125 - 150 (2009) Electrical system
Specification Desc./Quantity
Quantity: 1
3 Front turn indicator light bulb Type: Spherical
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
4 Rear turn indicator light bulb Type: SPHERICAL
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
5 Stop and tail light bulb Type: Spherical
Power: 12V 21/5W
Quantity: 1
6 12V - 2W warning light bulbs Type: All glass
Function: Turn indicators
Quantity: 2
7 12V - 1.2W warning light bulb Type: All glass
Function: engine oil, high-beam lights, fuel reserve
Quantity: 3
8 Instrument panel lighting bulbs Type: All glass
Power: 12V 1.2W
Quantity: 4
9 License plate bulb Type: ALL GLASS
Power: 12V - 5W
Quantity: 1
Fuses
ELE SYS - 55
Electrical system Liberty 125 - 150 (2009)
FUSE CHART
Specification Desc./Quantity
1 FUSE A Threshold of operation: 15A
Location: Battery compartment
Protected circuits: Battery-powered, ECU, recharge
circuit, live power supply to carburettor heater, automatic
starter, circuits protected by fuses No. 1-2-3-4.
2 Fuse No. 1 Threshold of operation: 7.5
Location: front part
Protected circuits: Instrument panel bulbs, license
plate light bulb, rear tail light, front light bulb
3 Fuse No. 2 Threshold of operation: 7.5
Location: front part
Protected circuits: horn, oil pressure warning light, low
fuel indicator and warning light, stop light, starter button.
4 Fuse No. 3 Threshold of operation: 7.5
Location: front part
Protected circuits: Low-beam light bulb
5 Fuse No. 4 Threshold of operation: 7.5
Location: front part
Protected circuits: high-beam light bulb, high-beam
warning light
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-
quired, before storing the vehicle and afterwards every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up
Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 to 14.70V
- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
ELE SYS - 56
Liberty 125 - 150 (2009) Electrical system
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h
Battery installation
2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulfuric
acid.
ELE SYS - 57
Electrical system Liberty 125 - 150 (2009)
ELE SYS - 58
Liberty 125 - 150 (2009) Electrical system
ELE SYS - 59
Electrical system Liberty 125 - 150 (2009)
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,
disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
ELE SYS - 60
INDEX OF TOPICS
ENG VE - 62
Liberty 125 - 150 (2009) Engine from vehicle
See also
Helmet bay
Exhaust assy. Removal
ENG VE - 63
INDEX OF TOPICS
ENGINE ENG
Liberty 125 - 150 (2009) Engine
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
Specific tooling
020423Y Driven pulley lock wrench
Air duct
ENG - 65
Engine Liberty 125 - 150 (2009)
Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
ENG - 66
Liberty 125 - 150 (2009) Engine
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020412Y 15-mm guide
Characteristic
Max. value clutch bell
Max. value: 134.5 mm
Clutch bell standard value
Standard value: 134 - 134.2 mm
ENG - 67
Engine Liberty 125 - 150 (2009)
Specific tooling
020074Y Support base for checking crankshaft
alignment
020335Y Magnetic mounting for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 68
Liberty 125 - 150 (2009) Engine
Characteristic
Check minimum thickness
1 mm
Specific tooling
020375Y 28 x 30 mm adaptor
ENG - 69
Engine Liberty 125 - 150 (2009)
Characteristic
Minimum diameter permitted
40.96 mm
Standard diameter
40.965 mm
Characteristic
Minimum admissible diameter:
41.08 mm
Standard diameter
41.035 mm
ENG - 70
Liberty 125 - 150 (2009) Engine
Specific tooling
020424Y Driven pulley roller casing fitting
punch
- To assemble the new ball bearing insert it com-
pletely down in its housing with the specific punch
and finally assemble the Seeger ring.
Specific tooling
020375Y 28 x 30 mm adaptor
020376Y Adaptor handle
020439Y 17-mm guide
Specific tooling
ENG - 71
Engine Liberty 125 - 150 (2009)
Recommended products
AGIP GREASE SM 2 Grease for the C-ring of
the tone wheel
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
Characteristic
Standard length:
106 mm
ENG - 72
Liberty 125 - 150 (2009) Engine
Drive-belt
BELT SIZE
Specification Desc./Quantity
Minimum width 21.5 mm
Standard width 22.5 0.2 mm
ENG - 73
Engine Liberty 125 - 150 (2009)
Specific tooling
020368Y driving pulley lock wrench
- Check that the internal bushing is not abnormally worn and measure inner diameter.
N.B.
DO NOT LUBRICATE OR CLEAN THE BUSHING.
CVT ROLLERS
Specification Desc./Quantity
Minimum diameter permitted 18.5 mm
Standard diameter 260.1 mm
ENG - 74
Liberty 125 - 150 (2009) Engine
ENG - 75
Engine Liberty 125 - 150 (2009)
Specific tooling
020368Y driving pulley lock wrench
Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock
ENG - 76
Liberty 125 - 150 (2009) Engine
Specific tooling
020423Y Driven pulley lock wrench
End gear
ENG - 77
Engine Liberty 125 - 150 (2009)
Specific tooling
001467Y009 Driver for OD 42-mm bearings
001467Y013 Calliper to extract 15-mm bear-
ings
Specific tooling
020376Y Adaptor handle
020364Y 25-mm guide
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
ENG - 78
Liberty 125 - 150 (2009) Engine
Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020363Y 20-mm guide
See also
Removing the driven pulley
- Check that the fitting surface is not dented or distorted. - Check the load capacity of the bearings and
the brake camshaft. - If faults are found, replace the hub cover.
Specific tooling
020150Y Air heater mounting
020151Y Air heater
- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of
the hub cover using the adequate tools
Specific tooling
020376Y Adaptor handle
ENG - 79
Engine Liberty 125 - 150 (2009)
Specific tooling
020151Y Air heater
020150Y Air heater mounting
-The wheel axle bearing on the cover, should be assembled with the specific tools
Specific tooling
020364Y 25-mm guide
020360Y 52x55-mm Adaptor
020376Y Adaptor handle
Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the
specific heat gun.
Specific tooling
020150Y Air heater mounting
020151Y Air heater
ENG - 80
Liberty 125 - 150 (2009) Engine
Flywheel cover
ENG - 81
Engine Liberty 125 - 150 (2009)
Cooling hood
On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggest
to intervene on the vacuum socket inserting on the intake manifold widening the hole from 0.4 mm to
1.5 mm. Remember that such operation must have performed on a disassembled manifold which must
be cleaned afterwards.
Cooling fan
ENG - 82
Liberty 125 - 150 (2009) Engine
ENG - 83
Engine Liberty 125 - 150 (2009)
Specific tooling
020565Y Flywheel lock calliper spanner
Specific tooling
008564Y Flywheel extractor
- Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate.
ENG - 84
Liberty 125 - 150 (2009) Engine
Flywheel nut 52 to 58
ENG - 85
Engine Liberty 125 - 150 (2009)
See also
Removing the driving pulley
Transmission cover
Removal
ENG - 86
Liberty 125 - 150 (2009) Engine
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
ENG - 87
Engine Liberty 125 - 150 (2009)
Specific tooling
020431Y Valve oil seal extractor
Characteristic
Connecting rod small end check-up: Maximum
diameter
ENG - 88
Liberty 125 - 150 (2009) Engine
15.030 mm
Connecting rod small end check-up: Standard
diameter
15+0.015+0.025 mm
Characteristic
Standard pin diameter
14.996 to 15 mm
Minimum diameter permitted
14.994 mm
Characteristic
Piston pin bore - standard diameter
15+0.001 +0.006
ENG - 89
Engine Liberty 125 - 150 (2009)
Characteristic
Maximum allowable run-out:
0.05 mm
ENG - 90
Liberty 125 - 150 (2009) Engine
Specific tooling
020430Y Pin lock fitting tool
ENG - 91
Engine Liberty 125 - 150 (2009)
Specific tooling
020428Y Piston position check mounting
ENG - 92
Liberty 125 - 150 (2009) Engine
Specific tooling
020426Y Piston fitting fork
ENG - 93
Engine Liberty 125 - 150 (2009)
Characteristic
Maximum admitted unevenness: Cylinder
head check
0.05 mm
STANDARD DIAMETER
Specification Desc./Quantity
Standard diameter A 32.5 to 32.525
Standard diameter B 20 to 20.021
Standard diameter C 12 to 12.018
ENG - 94
Liberty 125 - 150 (2009) Engine
Characteristic
Standard drainage guide diameter
5.012 mm
Standard intake guide diameter
5.012 mm
ENG - 95
Engine Liberty 125 - 150 (2009)
Characteristic
Wear limits:
Max. 1.6 mm.
Characteristic
Minimum diameter admitted - Intake:
4.96 mm
Minimum diameter admitted - Exhaust:
4.95 mm
Standard clearance - Intake:
0.013 to 0.040 mm
Standard clearance - Exhaust:
0.025 to 0.052 mm
Maximum clearance admitted- Intake:
0.062 mm
Maximum clearance admitted - Exhaust:
0.072 mm
Characteristic
Standard valve length - Intake:
80.6 mm
Valve standard length: Exhaust
ENG - 96
Liberty 125 - 150 (2009) Engine
79.6 mm
Characteristic
Valve spring length
33.9 to 34.4 mm
ENG - 97
Engine Liberty 125 - 150 (2009)
Specific tooling
020306Y Punch for assembling valve seal
rings
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
Characteristic
Standard diameter Bearing A
: 32.5 mm -0.025 -0.050 mm
Standard diameter Bearing B
20 -0.020 -0.041 mm
Minimum admitted diameter bearing A
: 32.440 mm
Minimum admitted diameter bearing B
: 19.950 mm
Intake cam height
27.512 mm
Exhaust cam height
27.212 mm
ENG - 98
Liberty 125 - 150 (2009) Engine
Characteristic
Maximum axial clearance admitted
0.42 mm
Characteristic
Minimum diameter permitted
11.970 mm
Maximum diameter allowed
12.030 mm
ENG - 99
Engine Liberty 125 - 150 (2009)
-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.
ENG - 100
Liberty 125 - 150 (2009) Engine
ENG - 101
Engine Liberty 125 - 150 (2009)
Characteristic
Spark plug
Champion RG6YC
Electric characteristic
Electrode gap
0.8 mm
ENG - 102
Liberty 125 - 150 (2009) Engine
Crankcase - crankshaft
Specific tooling
020262Y Crankcase splitting plate
020335Y Magnetic mounting for dial gauge
Characteristic
Standard clearance
ENG - 103
Engine Liberty 125 - 150 (2009)
0.15 to 0.40 mm
Characteristic
Standard clearance
0.20 to 0.50 mm
ENG - 104
Liberty 125 - 150 (2009) Engine
Characteristic
Standard clearance
0.036 to 0.054 mm
Characteristic
Distance between the shoulders
55.67 to 55.85 mm
- Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces
shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart
below.
STANDARD DIAMETER
Specification Desc./Quantity
Category 1 28.998 to 29.004
Category 2 28.004 to 29.010
ENG - 105
Engine Liberty 125 - 150 (2009)
Specific tooling
020074Y Support base for checking crankshaft
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
ENG - 106
Liberty 125 - 150 (2009) Engine
ENG - 107
Engine Liberty 125 - 150 (2009)
Characteristic
Standard driving depth
1.35 to 1.6
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- The standard bushing diameter after driving is variable on the basis of a coupling selection.
ENG - 108
Liberty 125 - 150 (2009) Engine
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
- The main bushings are subdivided into 3 thickness categories; see the table below:
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE
THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
MAIN BEARINGS
Specification Desc./Quantity
B Blue
C Yellow
E Green
ENG - 109
Engine Liberty 125 - 150 (2009)
Specific tooling
020425Y Punch for flywheel-side oil seal
Lubrication
ENG - 110
Liberty 125 - 150 (2009) Engine
Conceptual diagrams
ENG - 111
Engine Liberty 125 - 150 (2009)
Characteristic
Minimum pressure admitted
3.2 atm.
ENG - 112
Liberty 125 - 150 (2009) Engine
Removal
Specific tooling
020622Y Transmission-side oil seal punch
Refitting
ENG - 113
Engine Liberty 125 - 150 (2009)
ENG - 114
Liberty 125 - 150 (2009) Engine
- Use the nut to move the base of the tool until you
can see end of the oil seal driving stroke
- Remove all of the tool components following the procedure in reverse order
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE
ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.
Oil pump
Removal
ENG - 115
Engine Liberty 125 - 150 (2009)
Inspection
Characteristic
Maximum clearance admitted
0.12 mm
ENG - 116
Liberty 125 - 150 (2009) Engine
Characteristic
Admissible limit clearance:
0.20 mm
Characteristic
Limit values admitted:
0.09 mm
Refitting
ENG - 117
Engine Liberty 125 - 150 (2009)
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 118
Liberty 125 - 150 (2009) Engine
Fuel supply
SOLO VERSIONE150 cm EURO 3
ENG - 119
Engine Liberty 125 - 150 (2009)
Electric characteristic
Solenoid resistance
35.5 40.5 mm at 20C
ENG - 120
Liberty 125 - 150 (2009) Engine
ENG - 121
Engine Liberty 125 - 150 (2009)
ENG - 122
Liberty 125 - 150 (2009) Engine
ENG - 123
Engine Liberty 125 - 150 (2009)
ENG - 124
Liberty 125 - 150 (2009) Engine
-Remove diffuser.
ENG - 125
Engine Liberty 125 - 150 (2009)
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the
nozzle support hides other inaccessible internal calibrations.
- Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE EXHAUST IS EXTREMELY SMALL AND IS ORIENTED TO THE
THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAY-
ING.
ENG - 126
Liberty 125 - 150 (2009) Engine
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
- Check that the coupling surfaces, the chamber and the diaphragm are not dented.
-Check that the depression valve housing pipe is not scratched.
- Check that the throttle valve and the shaft do not show abnormal wear.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
- Wash and blow the minimum nozzle properly and
reassemble it.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that
there are no fuel infiltration.
ENG - 127
Engine Liberty 125 - 150 (2009)
Spring
Ball
Nozzle
IN VALVE (M)
Ball
Spring
Nozzle
N.B.
THE IN VALVE NOZZLE, CORRESPONDING TO THE AC-
CELERATION PUMP, IS MILLED.
ENG - 128
Liberty 125 - 150 (2009) Engine
Level check
- Check that the float reference is parallel to the tank coupling surface
- If different positions are detected, change the plunger control metal plate direction to obtain the position
described above.
ENG - 129
Engine Liberty 125 - 150 (2009)
ENG - 130
Liberty 125 - 150 (2009) Engine
ENG - 131
Engine Liberty 125 - 150 (2009)
Characteristic
Starter pin travel
10 mm (at 24)
Starter resistance
20 Ohm (at 24)
Check aut. Kehin max. time starter
5 min
ENG - 132
Liberty 125 - 150 (2009) Engine
ENG - 133
INDEX OF TOPICS
SUSPENSIONS SUSP
Liberty 125 - 150 (2009) Suspensions
Front suspension
Front
Handlebar
Removal
SUSP - 135
Suspensions Liberty 125 - 150 (2009)
Front fork
Removal
To remove the front fork, remove the front and rear handlebar covers.
Remove the handlebar from the steering tube and place it on the rear shield back plate being careful
not to damage the bodywork supporting points.
Remove the front wheel and disconnect the brake calliper and the brake pipes from the fork.
Remove the upper fifth wheel using a wrench for the steering fifth wheel ring nut.
Lower the fork and the front mudguard.
See also
Front handlebar cover
SUSP - 136
Liberty 125 - 150 (2009) Suspensions
Overhaul
Sealing ring replacement and stem removal
Refitting
To refit the fork, carry out the removal operations but in reverse order, observing the prescribed tight-
ening torques of the steering fifth wheels.
Steering column
Refitting
Lower and upper seating on the chassis
SUSP - 137
Suspensions Liberty 125 - 150 (2009)
Steering bearing
Steering bearing upper seat
Removal
Lower and upper seating from the chassis
Rear
SUSP - 138
Liberty 125 - 150 (2009) Suspensions
Shock absorbers
Removal
Centre-stand
Ejection of the stand fixing pin from the bracket
SUSP - 139
Suspensions Liberty 125 - 150 (2009)
SUSP - 140
INDEX OF TOPICS
CHASSIS CHAS
Chassis Liberty 125 - 150 (2009)
Seat
Side fairings
See also
Knee-guard
Rear rack
CHAS - 142
Liberty 125 - 150 (2009) Chassis
Driving mirrors
CHAS - 143
Chassis Liberty 125 - 150 (2009)
See also
Front handlebar cover
Instrument panel
See also
Rear handlebar cover
CHAS - 144
Liberty 125 - 150 (2009) Chassis
Headlight assy.
See also
Front handlebar cover
CHAS - 145
Chassis Liberty 125 - 150 (2009)
See also
Rear rack
Taillight assy.
Seat
Legshield
CHAS - 146
Liberty 125 - 150 (2009) Chassis
See also
Knee-guard
Footrest
Knee-guard
CHAS - 147
Chassis Liberty 125 - 150 (2009)
See also
Knee-guard
Taillight assy.
CHAS - 148
Liberty 125 - 150 (2009) Chassis
Footrest
CHAS - 149
Chassis Liberty 125 - 150 (2009)
See also
Frame central cover
Knee-guard
See also
Frame central cover
Air filter
CHAS - 150
Liberty 125 - 150 (2009) Chassis
Rear mudguard
Helmet bay
See also
Frame central cover
Frame central cover
CHAS - 151
Chassis Liberty 125 - 150 (2009)
spoiler
See also
Footrest
Fuel tank
See also
Frame central cover
CHAS - 152
Liberty 125 - 150 (2009) Chassis
Front mudguard
CHAS - 153
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Liberty 125 - 150 (2009) Pre-delivery
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Electrical system
Electrical system:
- Main switch
- Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights
- Adjusting the headlights according to the regulations currently in force
- Rear light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator
- Instrument panel warning lights
- Horn
- Starter
PRE DE - 155
Pre-delivery Liberty 125 - 150 (2009)
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic braking system fluid level.
- Rear hub oil level
- Engine coolant level.
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
PRE DE - 156
Liberty 125 - 150 (2009) Pre-delivery
Static test
Functional inspection
Functional Checks:
Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the chassis and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 157
INDEX OF TOPICS
TIME TIME
Liberty 125 - 150 (2009) Time
Engine
ENGINE
Code Action Duration
1 001001 engine from frame - removal and re-
fitting
TIME - 159
Time Liberty 125 - 150 (2009)
Crankcase
CRANKCASE
Code Action Duration
1 001133 Engine crankcase - Replacement
2 001153 Crankcase halves gasket - Replace-
ment
3 002031 Rear wheel hub bearings - Replace-
ment
TIME - 160
Liberty 125 - 150 (2009) Time
Crankshaft
DRIVING SHAFT
Code Action Duration
1 001117 Crankshaft - Replacement
2 001099 Oil seal, flywheel side - Replacement
TIME - 161
Time Liberty 125 - 150 (2009)
Cylinder assy.
CYLINDER ASSEMBLY
Code Action Duration
1 001002 Cylinder-Piston - Replacement
2 001107 Cylinder / piston - Inspection / clean-
ing
TIME - 162
Liberty 125 - 150 (2009) Time
HEAD ASSEMBLY
Code Action Duration
1 001045 Valves - Replacement
2 001056 Head gasket - change
3 001126 Head - Replacement
TIME - 163
Time Liberty 125 - 150 (2009)
TIME - 164
Liberty 125 - 150 (2009) Time
HEAD COVER
Code Action Duration
1 001089 Head cover - Replacement
2 001088 Head cover gasket - Replacement
3 001159 Oil vapour recovery tank - Service
4 001093 Spark plug - Replacement
5 001097 Cooling hood - Replacement
6 001091 Head cover sealing ring
7 001074 Oil vapour recovery pipe - Replace-
ment
TIME - 165
Time Liberty 125 - 150 (2009)
Chain tensioner
CHAIN TIGHTENER
Code Action Duration
1 001129 Chain tensioner - Service and Re-
placement
2 001124 By pass lubrication - Replacement
TIME - 166
Liberty 125 - 150 (2009) Time
Oil filter
OIL FILTER
Code Action Duration
1 001123 Oil filter -Replacement
2 001160 Oil pressure sensor - change
3 003064 Engine oil - change
4 001102 Net oil filter - change / Cleaning
TIME - 167
Time Liberty 125 - 150 (2009)
Flywheel cover
FLYWHEEL COVER
Code Action Duration
1 001087 Flywheel cover - Replacement
2 001163 Secondary air-exhaust manifold -
Replacement
3 001161 Secondary air filter - Replacement /
Cleaning
4 001174 SAS valve - Replacement
5 001164 Secondary air-crankcase manifold -
Replacement
TIME - 168
Liberty 125 - 150 (2009) Time
Driven pulley
TIME - 169
Time Liberty 125 - 150 (2009)
Oil pump
OIL PUMP
Code Action Duration
1 001051 Belt/Timing chain - Replacement
2 001125 Chain guide pads - Replacement
3 001042 Oil pump - Overhaul
4 001112 Oil pump - Replacement
5 001130 Oil sump - Replacement
6 001100 Oil seal clutch side - Replacement
7 001122 Oil pump chain - Replacement
TIME - 170
Liberty 125 - 150 (2009) Time
TIME - 171
Time Liberty 125 - 150 (2009)
Driving pulley
DRIVING PULLEY
Code Action Duration
1 001066 Driving pulley - Removal and refitting
2 001086 Driving half-pulley - Replacement
3 001177 Variator rollers / slides - Replace-
ment
4 001011 Drive belt - Replacement
TIME - 172
Liberty 125 - 150 (2009) Time
Transmission cover
Starter motor
TIME - 173
Time Liberty 125 - 150 (2009)
STARTING MOTOR
Code Action Duration
1 001020 Starter motor - Replacement
2 001017 Start-up pinion - Replacement
Flywheel magneto
MAGNETO FLYWHEEL
Code Action Duration
1 001109 Cooling fan - Replacement
2 001173 Rotor - Replacement
3 001067 Stator - Removal and Refitting
4 001058 Flywheel - Replacement
TIME - 174
Liberty 125 - 150 (2009) Time
TIME - 175
Time Liberty 125 - 150 (2009)
Carburettor
CARBURETTOR
Code Action Duration
1 001082 Carburettor heating resistor - Re-
placement
2 001013 Intake hose - Replacement
3 004122 Carburettor-filter bellow - Replace-
ment
4 001081 Automatic choke - Replacement
5 001008 Carburettor - Inspection
6 001063 Carburettor - Replacement
TIME - 176
Liberty 125 - 150 (2009) Time
Exhaust pipe
SILENCER
Code Action Duration
1 001009 Silencer - Replacement
2 001136 Exhaust emissions - Adjustment
3 001095 Silencer heatshield - Replacement
Silencer fixing
Please take note that, starting from chassis serial number ZAPM3810000003971, the two M8 x 50
silencer fixing flaged head screws have been replaced by two M8 x 50 internal hexagonal cylindrical
head screws.
TIME - 177
Time Liberty 125 - 150 (2009)
Air cleaner
AIR CLEANER
Code Action Duration
1 001014 Air filter - Replacement/Cleaning
2 001015 Air filter box - Replacement
TIME - 178
Liberty 125 - 150 (2009) Time
Frame
CHASSIS
Code Action Duration
1 004001 Chassis - Replacement
2 004004 Stand - Replacement
3 001053 Stand pin - Replacement
TIME - 179
Time Liberty 125 - 150 (2009)
Legshield spoiler
TIME - 180
Liberty 125 - 150 (2009) Time
Rear cover
REAR COVER
Code Action Duration
1 004174 Glove-box remote opening linkage -
Replacement
2 004065 Knee-guard - Removal and refitting
3 004131 Rear rack mounting bracket - Re-
placement
4 004082 Glove-box packing - Replacement
5 004081 Glove comparment door - Replace-
ment
TIME - 181
Time Liberty 125 - 150 (2009)
Central cover
CENTRAL COVER
Code Action Duration
1 004059 Spark plug inspection flap - Replace-
ment
2 004106 Helmet compartment band - Re-
placement
3 004085 Fairing (1) - Replacement
4 004013 Side/rear bumper pipes - Replace-
ment
TIME - 182
Liberty 125 - 150 (2009) Time
Underseat compartment
UNDERSEAT COMPARTMENT
Code Action Duration
1 005046 Battery cover - change
2 004016 Helmet compartment - Removal and
Refitting
3 001027 Filter bellow - Replacement
TIME - 183
Time Liberty 125 - 150 (2009)
Plate holder
SUPPORT PLATE
Code Action Duration
1 004136 License plate holder mounting - Re-
placement
2 005048 number plate holder - Replacement
3 005131 number plate light support - Replace-
ment
4 005031 number plate light bulb - Replace-
ment
5 005032 number plate light glass - Replace-
ment
TIME - 184
Liberty 125 - 150 (2009) Time
Mudguard
MUDGUARD
Code Action Duration
1 004002 Front mudguard - Replacement
2 004009 Rear mudguard - Replacement
TIME - 185
Time Liberty 125 - 150 (2009)
Fuel tank
FUEL TANK
Code Action Duration
1 004168 Fuel tank cap - Replacement
2 005010 Tank float - Replacement
3 004112 Cock-carburettor hose - Replace-
ment
4 004005 Fuel tank - Replacement
5 004007 Fuel valve - Replacement
6 004109 Fuel tank breather - Replacement
TIME - 186
Liberty 125 - 150 (2009) Time
Rear shock-absorber
TIME - 187
Time Liberty 125 - 150 (2009)
TIME - 188
Liberty 125 - 150 (2009) Time
Handlebar covers
HANDLEBAR COVERS
Code Action Duration
1 004019 Handlebar rear section - Replace-
ment
2 004018 Handlebar front section - Replace-
ment
3 005078 Odometer glass - Replacement
4 005076 Clock \ Pile - Replacement
5 005014 Odometer - Replacement
6 005038 Instrument panel warning light bulbs
- Replacement
7 004099 Odometer housing - Replacement
TIME - 189
Time Liberty 125 - 150 (2009)
Handlebar components
HANDLEBAR COMPONENTS
Code Action Duration
1 004066 Driving mirror - Replacement
2 002037 Brake or clutch lever - Replacement
3 002071 Left hand grip - Replacement
4 003001 Handlebar - Removal and refitting
5 005017 Stop switch - Replacement
6 002024 Front brake pump - Removal and Re-
fitting
7 003061 Accelerator transmission - adjust
8 002060 Complete throttle control - Replace-
ment
9 004162 Mirror mounting and/or brake pump
fitting U-bolt - Replacement
10 002059 Right hand grip - Replacement
11 002063 Throttle control transmission - Re-
placement
TIME - 190
Liberty 125 - 150 (2009) Time
Swing-arm
SWINGING ARM
Code Action Duration
1 001072 Engine / frame swinging arm fitting -
Replacement
2 003080 Swinging arm on chassis - Replace-
ment
TIME - 191
Time Liberty 125 - 150 (2009)
Brake hoses
BRAKE PIPING
Code Action Duration
1 002007 Front brake shoes/pads - Remov.
and Refitt
2 002039 Front brake calliper - Removal and
Refitting
3 002021 Front brake hose - Remov. and Re-
fitt.
4 002047 Front brake fluid and system bleed-
ing plug - Repl.
TIME - 192
Liberty 125 - 150 (2009) Time
Seat
SEAT
Code Action Duration
1 004003 Saddle - Replacement
2 004008 Luggage rack - Replacement
3 004062 Luggage rack cover - Replacement
TIME - 193
Time Liberty 125 - 150 (2009)
TIME - 194
Liberty 125 - 150 (2009) Time
Front wheel
FRONT WHEEL
Code Action Duration
1 003038 Front wheel axle - Remov. and Refit.
2 002011 Odometer drive - Replacement
3 003040 Front wheel bearings - Replacement
4 003047 Front tyre - Replacement
5 003037 Front wheel rim - Removal and Re-
fitting
6 004123 Front wheel - Replacement
7 002041 Brake disc - Replacement
TIME - 195
Time Liberty 125 - 150 (2009)
Rear wheel
REAR WHEEL
Code Action Duration
1 002002 Rear brake pads/shoes - Repl.
2 004126 Rear wheel tyre - Replacement
3 001016 Rear wheel - Replacement
4 001071 Rear wheel rim - Removal and Refit-
ting
TIME - 196
Liberty 125 - 150 (2009) Time
Electric devices
ELECTRICAL DEVICES
Code Action Duration
1 001023 Control unit - Replacement
2 005035 Headlight remote control - Replace-
ment
3 005001 Electrical system - Replacement
4 001094 Spark plug cap - Replacement
5 001069 HV coil - replace
6 005052 Fuse - Replacement
7 005025 Battery fuse box - Replacement
8 005009 Voltage regulator - Replacement
9 005011 Start-up solenoid - Replacement
10 005007 Battery - change
11 005114 Electrical system - Service
TIME - 197
Time Liberty 125 - 150 (2009)
Electronic controls
ELECTRIC CONTROLS
Code Action Duration
1 005039 Lights switch - Replacement
2 005006 Light or turning indicator switch - Re-
placement
3 005040 Horn button - Replacement
4 005003 Horn - Replacement
5 005041 Starter button - Replacement
6 005016 Key switch - Replacement
7 004096 Lock series - Replacement
8 005072 Immobilizer aerial - Replacement
TIME - 198
Liberty 125 - 150 (2009) Time
Transmissions
TRANSMISSIONS
Code Action Duration
1 002051 Odometer transmission assembly -
Replacement
2 002049 Odometer cable - Replacement
3 002053 Rear brake transmission complete -
replacement
TIME - 199
Time Liberty 125 - 150 (2009)
Front suspension
FRONT SUSPENSION
Code Action Duration
1 003010 Front suspension - Service
2 003048 Fork oil seal - Replacement
3 003076 Fork sleeve - Replacement
4 003079 Fork stem - Replacement
5 003051 Complete fork - Replacement
6 003069 Front fork oil - Replacing
TIME - 200
A
Air filter: 150
B
Battery: 35, 39, 47, 56, 57
Brake: 192
Bulbs:
C
Carburettor: 11, 121, 126, 176
Checks: 44
E
Electric: 197
F
Fuel: 34, 119, 152, 186
Fuses: 55
H
Headlight: 145
Horn: 51
Hub oil: 30
I
Identification: 7
Instrument panel: 144
M
Maintenance: 6, 30
Mirrors: 143
O
Oil filter: 167
R
Recommended products:
S
Shock absorbers: 139
Spark plug: 45
Start-up:
Suspension: 36, 200
T
Tank: 152, 186
Transmission: 9, 34, 65, 76, 86, 173
Tyres: 10
V
Vehicle: 7, 62