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Piaggio NRG - Power - Purejet

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269 views248 pages

Piaggio NRG - Power - Purejet

Uploaded by

ramiro

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Available Formats

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WORKSHOP MANUAL

633265

NRG Power Purejet

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WORKSHOP
MANUAL

NRG Power Purejet

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 shown in this publication are available in all Countries. The availability of single versions
should be checked at the official Piaggio sales network.
"© Copyright 2007 - 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)

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WORKSHOP MANUAL
NRG Power Purejet
This workshop 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 fixing techniques and procedures. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are
unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along
with the specific 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.

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INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

PURE JET INJECTION INJ PJ

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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Characteristics NRG Power Purejet

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 open 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 solvent. Lubricate all the
work surfaces except the tapered couplings before refitting.
- 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 measurement. Using unsuitable
coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.

CHAR - 2

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NRG Power Purejet Characteristics

Vehicle identification
Frame prefix: ZAPC45200 ÷ 1001
Engine prefix: C452M

Dimensions and mass

DIMENSIONS AND MASS

Specification Desc./Quantity
Max length 1790 mm.
Max width 850 mm.
Seat height 795 mm.
Wheelbase 1280 mm
Dry weight 99 kg.

CHAR - 3

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Characteristics NRG Power Purejet

Engine

ENGINE
Specification Desc./Quantity
Engine type 2 stroke single cylinder Piaggio HI-PER2 PRO
PUREJET
Bore x stroke 40 X 39.3 mm
Cubic capacity 49.40 cc
Compression ratio 9.4 to 10.4 :1
Throttle body BING Ø18mm
Engine idle speed 1800 to 2000 r.p.m.
Air filter Sponge impregnated with fuel mixture (50% SE-
LENIA air filter oil and 50% unleaded petrol).
Starting system electric starter/kickstarter
Cooling system forced coolant circulation system
Lubrication Engine lubrication (piston, cylinder, crankshaft,
main bearings) with mixer oil.
Fuel supply With electric fuel pump, controlled by the ECU and
unleaded petrol (with 95 octane minimum) via
throttle body
Cooling system Through circulation of cooling liquid

CHAR - 4

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NRG Power Purejet Characteristics

Transmission

TRANSMISSION
Specification Desc./Quantity
Transmission With automatic expandable pulley variator, torque
server, V belt, automatic clutch, gear reduction
unit.

Capacities

CAPACITIES
Specification Desc./Quantity
Rear hub oil Quantity: approx. 75 cm³
Mixer oil 1.2 litres
Fuel tank capacity 6.5 litres (1.5 litres of reserve)

Electrical system

ELECTRICAL SYSTEM
Specification Desc./Quantity
Ignition type Electronic ignition system with integrated H.T. coil
managed by ECU
Ignition advance (before TDC) variable (integrated into the ignition system)
Recommended spark plug type CHAMPION RG6YCA
Battery 12V-9Ah
Main fuse 20A
Generator Three-phase alternating current

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity
Chassis type Welded tubular steel chassis with stamped sheet
reinforcements
Front suspension upside-down hydraulic telescopic fork.
Front suspension travel 75 mm
Rear suspension With coaxial spring and hydraulic shock absorber.
Chassis to engine support with swinging arm.

Brakes

BRAKES
Specification Desc./Quantity
Front brake Ø 220 mm disc brake with hydraulic linkage (r.h.
brake lever).
Rear brake Ø 175 mm disc (hydraulically controlled via lever
on left hand-side of handlebar)

CHAR - 5

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Characteristics NRG Power Purejet

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity
Front tyre Tubeless 120/70-13"
Rear tyre Tubeless 140/60 x 13''
Wheels With circles of 3.50 x 13" in light alloy.

Tightening Torques

STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut (safety locks) 35 to 40 Nm
Lower steering ring nut (safety locks) 8 to 10 Nm
Handlebar fixing pin (safety locks) 45 to 50 Nm

FRAME ASSEMBLY
Name Torque in Nm
Swinging arm-engine pin (safety locks) 33 to 41 Nm
Swinging arm-frame pin (safety locks) 64 to 72 Nm
Shock absorber - frame nut (safety locks) 20 to 25 Nm
Shock absorber-engine pin (safety locks) 33 to 41 Nm
Rear wheel axis (safety locks) 104 to 126 Nm
Bolt holding stand to the engine 18 to 19 Nm
Side stand fixing screw 12 ÷ 20
Side stand bracket fixing screw 15 ÷ 20
Rear rim fixing screw 20÷25

FRONT SUSPENSION
Name Torque in Nm
Front wheel axle nut (safety locks) 45 to 50 Nm
Wheel axle clamp screw 6 ÷ 7 Nm
Lower leg screw 15 to 20 Nm
Hydraulic cartridge stem nut 15 to 18 Nm

FRONT BRAKE
Name Torque in Nm
Viti fissaggio coperchio pompa freno 1,5 ÷ 2 Nm
Brake pump support fixing screw 7 to 10 Nm
Brake fluid pump - hose fitting 13 to 18 Nm
Brake fluid tube - calliper fitting 20 to 25 Nm
Calliper tightening screw 20 to 25 Nm
Disc tightening screw (safety locks - lock with 6 ÷ 7 Nm
LOCTITE THREADLOCK MEDIUM TYPE 243)
Oil bleed screw 7 to 10 Nm
Calliper coupling screw 20 to 25 Nm

REAR BRAKE
Name Torque in Nm
Fastening screws calliper to the crankcase 20 - 25

CHAR - 6

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NRG Power Purejet Characteristics

Name Torque in Nm
Brake reservoir cover fixing screw 2÷4 N·m (Grimeca) - 0,8÷1,5 N·m (Brembo) -
1,5÷2 N·m (Hengtong)
Brake pump support fixing screw 7 to 10 Nm
Brake fluid pump - hose fitting 13 to 18 Nm
Brake fluid tube - calliper fitting 20 to 25 Nm
Oil bleed screw 7 to 10 Nm

ENGINE UNIT
Name Torque in Nm
Clutch bell nut 40 to 44 Nm
Clutch lock ring nut 55 ÷ 60
nut locking driving pulley on the crankshaft 40 to 44 Nm
Start-up lever screw 12 ÷ 13
Flywheel nut 40 to 44 Nm
Flywheel fan screws 3÷4
Half-crank case joint bolts 12 ÷ 13
Bolts holding exhaust pipe to the crankcase 22 ÷ 24
Screws holding the filter box to the crank case 4÷5
Head nuts 10 ÷ 11
Temperature ECU sensor 18÷22 N·m
Termistore 6÷8 N·m
Starter screws 12 ÷ 13
Ignition spark plug 25 ÷ 30
Hub oil drainage cap 3÷5
Oil hub level dipstick Manual
Rear hub cap screws 12 ÷ 13
Transmission cover screws 12 ÷ 13
Inlet manifold screws 8÷9
Flywheel hood fixing screws 1÷2
Cylinder hood fixing screws 3.5 ÷ 5
Stator clamping screws 3÷4
Pick-Up clamping screw 4÷5
Mixer clamping screws 3÷4
Screw fixing brake lever to the journal on the en- 12 ÷ 13
gine

Overhaul data

Assembly clearances

Cylinder - piston assy.

CYLINDER-PISTON FITTING
Name Initials Cylinder Piston Play on fitting
Standard fitting M 39.997-40.004 39.943-39.95 0.047-0.061
Standard fitting N 40.004-40.011 39.95-39.957 0.047-0.061
Standard fitting O 40.011-40.018 39.957-39.964 0.047-0.061
Standard fitting P 40.018-40.025 39.964-39.971 0.047-0.061
1st oversize fitting M1 40.197-40.204 40.143-40.15 0.047-0.061
1st oversize fitting N1 40.204-40.211 40.15-40.157 0.047-0.061

CHAR - 7

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Characteristics NRG Power Purejet

Name Initials Cylinder Piston Play on fitting

1st oversize fitting O1 40.211-40.218 40.157-40.164 0.047-0.061
1st oversize fitting P1 40.218-40.225 40.164-40.171 0.047-0.061
2nd oversize fitting M2 40.397-40.404 40.343-40.35 0.047-0.061
2nd oversize fitting N2 40.404-40.411 40.35-40.357 0.047-0.061
2nd oversize fitting O2 40.411-40.418 40.357-40.364 0.047-0.061
2nd oversize fitting P2 40.418-40.425 40.364-40.371 0.047-0.061

Piston rings

SEALING RINGS
Name Description Dimensions Initials Quantity
Compression ring 40 A 0.10 to 0.25
Compression ring 40.2 A 0.10 to 0.25
1st oversize
Compression ring 40.4 A 0.10 to 0.25
2nd Oversize

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity
Connecting rod 11.750-0.05 A clearance E = 0.25
to 0.50
shoulder washer 0.5 ± 0.03 G clearance E = 0.25
to 0.50 - clearance
F = 0.20 to 0.75

CHAR - 8

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NRG Power Purejet Characteristics

Name Description Dimensions Initials Quantity

Half-shaft, trans- 13.75+0.040 C clearance E = 0.25
mission side to 0.50 - clearance
F = 0.20 to 0.75
Flywheel-side half- 13.75+0.040 D clearance E = 0.25
shaft to 0.50 - clearance
F = 0.20 to 0.75
Lining between the 40.64 H clearance E = 0.25
shoulders to 0.50 - clearance
F = 0.20 to 0.75
Cage 11.800-0.35 B clearance F = 0.20
to 0.75

Slot packing system

- Fit the cylinder without installing the basic gasket.
- Apply a centimetre dial gauge on the special tool
and zero it on the ground plane
- Fit the tool to the top of the cylinder fixing it with
two nuts to the studbolts and take the piston to the
T.D.C.
- The thickness of the gasket to fit will change de-
pending on the value detected. For this purpose,
there are three with different thicknesses

Specific tooling
020272Y Piston position check tool

SHIMMING SYSTEM
Name Measure A Thickness
Shimming 2.80 ÷ 3.04 0,4
Shimming 3.04 ÷ 3.24 0,6
Shimming 3.25 ÷ 3.48 0,8

CHAR - 9

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Characteristics NRG Power Purejet

Products

TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the
requirements of API GL3 specifi-
cations
AGIP CITY HI TEC 4T Oil for flexible transmission lubri- Oil for 2-stroke engines: SAE
cation (brake, throttle control and 5W-40, API SL, ACEA A3, JASO
mixer, odometer MA
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives
for increased adhesiveness
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines:
JASO FC, ISO-L-EGD
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-
based spray grease with NLGI 2;
ISO-L-XBCIB2
AGIP GREASE SM 2 Grease for the tone wheel revolv- Soap-based lithium grease con-
ing ring taining NLGI 2 Molybdenum di-
sulphide; ISO-L-XBCHB2, DIN
KF2K-20
AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid
MONTBLANC MOLYBDENUM Grease for driven pulley shaft ad- Molybdenum disulphide grease
GREASE justing ring and movable driven
pulley housing
AGIP GREASE PV2 Grease for the steering bearings, White anhydrous-calcium based
pin seats and swinging arm protective grease for roller bear-
ings; temperature range be-
tween -20 C and +120 C; NLGI 2;
ISO-L-XBCIB2.

CHAR - 10

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INDEX OF TOPICS

TOOLING TOOL

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Tooling NRG Power Purejet

TOOLING
Stores code Description
001330Y Tool for fitting steering seats

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Driver for OD 54 mm bearing

001467Y008 Pliers to extract 17 mm ø bear-

ings

001467Y009 Driver for OD 42 mm bearings

001467Y013 Pliers to extract ø 15-mm bear-

ings

001467Y014 Pliers to extract ø 15-mm bear-

ings

TOOL - 2

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NRG Power Purejet Tooling

Stores code Description

001467Y017 Bell for bearings, outside Ø 39
mm

001467Y021 Extraction pliers for ø 11 mm

bearings

001467Y029 Bell for bearings, O.D. 38 mm

002465Y Pliers for circlips

004499Y Camshaft bearing extractor

TOOL - 3

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Tooling NRG Power Purejet

Stores code Description

004499Y007 Half rings

006029Y Punch for fitting fifth wheel seat

on steering tube

020004Y Punch for removing fifth wheels

from headstock

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crank-

shaft alignment

020080Y Punch for removing 12-mm bear-

ings

020150Y Air heater support

TOOL - 4

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NRG Power Purejet Tooling

Stores code Description

020151Y Air heater

020162Y Flywheel extractor

020163Y Crankcase splitting plate

020164Y Driven pulley assembly sheath

020166Y Pin lock fitting tool

020168Y Water seal punch mount on half-

crankcase

TOOL - 5

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Tooling NRG Power Purejet

Stores code Description

020169Y Water pump crankshaft fitting
and removal spanner

020170Y Water pump/mixer command

gear extractor

020171Y Punch for driven pulley roller

bearing

020209Y Spring hook

020265Y Bearing fitting base

TOOL - 6

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NRG Power Purejet Tooling

Stores code Description

020272Y Piston position check tool

020325Y Brake-shoe spring calliper

020329Y MityVac vacuum-operated pump

020330Y Stroboscopic light for timing con-

trol

020331Y Digital multimeter

TOOL - 7

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Tooling NRG Power Purejet

Stores code Description

020332Y Digital rev counter

020334Y Multiple battery charger

020335Y Magnetic support for dial gauge

020340Y Flywheel and transmission oil

seals fitting punch

020357Y 32 x 35 mm adaptor
020358Y 37x40-mm adaptor
020359Y 42x47-mm adaptor

020362Y 12-mm guide

TOOL - 8

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NRG Power Purejet Tooling

Stores code Description

020363Y 20 mm guide

020409Y Multimeter adaptor - Peak volt-

age detection

020376Y Adaptor handle

020412Y 15 mm guide

020439Y 17 mm guide

020444Y Test probe removal / fitting tool

TOOL - 9

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Tooling NRG Power Purejet

Stores code Description

020456Y Ø 24 mm adaptor

020451Y Start-up crown lock

020452Y Tube for removing and refitting

the driven pulley shaft

020460Y Scooter diagnosis and tester

020481Y Control unit interface wiring

TOOL - 10

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NRG Power Purejet Tooling

Stores code Description

020565Y Flywheel lock calliper spanner

020469Y Reprogramming kit for scooter

diagnosis tester

020614Y Diagnostic tester programming

software

020615Y Carbon dam ring fitting kit

020616Y Fuel pressure control kit

020617Y Air pressure check kit

TOOL - 11

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Tooling NRG Power Purejet

Stores code Description

020620Y Water pump impeller stop

020621Y HV cable extraction adaptor

TOOL - 12

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INDEX OF TOPICS

MAINTENANCE MAIN

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Maintenance NRG Power Purejet

Maintenance chart

EVERY 2 YEARS
Action
Brake fluid - change
Coolant - change

AFTER 1000 KM
50'
Action
Hub oil - change
Oil mixer/throttle linkage - adjustment
Odometer cable - greasing
Steering - adjustment
Brake control levers - greasing
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 5000 KM OR 12 MONTHS, 25000 KM, 35000 KM AND 55000 KM

40'
Action
Hub oil level - check
Spark plug/electrode gap - replacement
Air filter - clean
Oil mixer/throttle linkage - adjustment
Coolant level - check
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 10000 KM OR 24 MONTHS AND 50000 KM

95'
Action
Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Oil mixer/throttle linkage - adjustment
Variable speed rollers - replacement
Odometer cable - greasing
Driving belt - check
Coolant level - check
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear

MAIN - 2

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NRG Power Purejet Maintenance

Action
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See CO regulation in the «Adjusting the engine idle» section

AT 15000 KM AND 45000 KM

65'
Action
Hub oil level - check
Spark plug/electrode gap - replacement
Air filter - clean
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Coolant level - check
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test
(**) See the regulations of the "Secondary air system" section

AT 20000 KMS AND 40000 KMS

120'
Action
Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Cylinder cooling system - check/cleaning
Oil mixer/throttle linkage - adjustment
Driving belt - check
Variable speed rollers - replacement
Mixer belt - replacement
Coolant level - check
Radiator - external cleaning/ check
Odometer cable - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check

MAIN - 3

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Maintenance NRG Power Purejet

Action
Vehicle and brake test - road test
(*) See CO regulation in the «Adjusting the engine idle» section

AT 30000 KM
130'
Action
Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Variable speed rollers - replacement
Coolant level - check
Odometer cable - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Flexible brake tubes - replacement
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test
(*) See CO regulation in the «Adjusting the engine idle» section
(**)See rules in the «Secondary Air System» section

AT 60000 KM
160'
Action
Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Variable speed rollers - replacement
Mixer belt - replacement
Coolant level - check
Radiator - external cleaning/ check
Odometer cable - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Flexible brake tubes - replacement
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check

MAIN - 4

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NRG Power Purejet Maintenance

Action
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test
(*) See CO regulation in the «Adjusting the engine idle» sectionp>
(**) Vedere norme della sezione «Sistema aria secondaria»

Spark plug
- Position the vehicle on its centre stand;
- Remove the centre cover by unscrewing the 2 set
screws;
- Disconnect the cover from the plug lead;
- Unscrew the spark plug using a spark plug span-
ner;
- Check the conditions of the spark plug, make
sure the insulation is intact and measure the gap
between the electrodes with a feeler.
- Adjust the gap if necessary, carefully bending the
side electrode.
In the event of defects replace the spark plug with
the prescribed type;
- Position the spark plug at the correct angle and
manually tighten it all the way down, then use the
specific spanner to tighten it to the prescribed tor-
que;
- Put the cover back over the spark plug;
- Reassemble the central cover.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN
THE MOTOR IS COLD. THE SPARK PLUG
MUST BE REPLACED EVERY 5000 KM. USE
OF STARTERS NOT CONFORMING OR SPARK
PLUGS NOT THOSE DESCRIBED CAN SERI-
OUSLY DAMAGE THE ENGINE.
Characteristic
Recommended spark plug type
CHAMPION RG6YCA

Electric characteristic
Electrode gap

MAIN - 5

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Maintenance NRG Power Purejet

0,55÷0,65 mm

Locking torques (N*m)

Spark plug 25 - 30 Nm

Hub oil

Check
Do the following to check the correct level:
1) Stand the vehicle on the centre-stand on flat
ground;
2) Remove the dipstick «A», and dry it with a clean
cloth. Reinsert it, screwing it in all the way;
3) Remove the stick and check that the oil level is
slightly over the second notch starting from the
lower end;
4) Screw the dipstick back in, checking that it is
locked in place.

Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications

Replacement
- Remove oil filler cap «A».
- Loosen oil draining cap «B» and allow for the
system to drain completely.
- Refit the draining cap and refill the hub with the
prescribed oil.

Characteristic
Rear hub oil
~ 85 cc

MAIN - 6

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NRG Power Purejet Maintenance

Air filter
-Remove the cap of the purifier, unscrewing the six
clamping screws and removing the filter.
Cleaning:
-Wash with water and neutral soap.
- Dry with a clean cloth and short blasts of com-
pressed air.
-Saturate with a 50% mixture of gasoline and oil.
-Drip dry the filter and then squeeze it between the
hands without wringing.
-Let it dry and refit it again.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR
FILTER, THIS WOULD RESULT IN AN EXCES-
SIVE WEAR OF THE PISTON AND CYLINDER.
Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased ad-
hesiveness

Checking the ignition timing

- Adjust the control cables:
Mix cable: see procedure indicated in "Mixer tim-
ing".
Throttle cable: adjust the set screw on the carbu-
rettor in such a way that the sheath has no back-
lash.
Splitter control cable: adjust set screw on the throt-
tle control to the handlebar in such a way that there
is no backlash on the throttle control.
Adjust all transmissions in such a way that their
sheathings show no sign of backlash.
Mixer Timing
- Using the transmission set screw on the crank-
case, with throttle control untwisted, adjust the
reference mark on the rotating plate so that it is

MAIN - 7

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Maintenance NRG Power Purejet

lined up with the reference mark on the mixer

body, as shown in the figure.
While doing this, the engine must be fuelled with a
2 % oil mixture (0.5 litre minimum if the reservoir
is empty).
CAUTION
IN CASE OF DISMANTLING OR RUNNING OUT
OF OIL IN THE RESERVOIR BLEED THE MIXER
AS FOLLOWS: REFILL THE OIL RESERVOIR
WHEN THE MIXER IS FITTED TO THE VEHICLE
AND THE ENGINE IS OFF, UNDO THE MIXER
PIPE FROM THE CARBURETTOR AND LOOS-
EN THE BLEED SCREWS (SEE THE ARROW IN
THE FIGURE) UNTIL THE OIL BEGINS TO
FLOW OUT. TIGHTEN THE SCREWS, START
UP THE ENGINE AND WAIT FOR OIL TO FLOW
OUT OF THE TUBE. RECONNECT THE DELIV-
ERY PIPE TO THE CARBURETTOR AND FIX IT
IN PLACE WITH THE RELEVANT METAL CLIP.
Recommended products
AGIP CITY TEC 2T Mixer oil
synthetic oil for 2-stroke engines: JASO FC, ISO-
L-EGD

Braking system

Level check
Proceed as follows:
- Rest the vehicle on its centre stand with the han-
dlebars perfectly horizontal;
- Check the level of liquid with the related warning
light «A».
A certain lowering of the level is caused by wear
on the pads.

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NRG Power Purejet Maintenance

Top-up
Proceed as follows:
- Remove the tank cap by loosening the two
screws, remove the gasket and top up using only
the liquid specified without exceeding the maxi-
mum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
MAKE SURE THE BRAKE FLUID DOES NOT
GET INTO YOUR EYES OR ON YOUR SKIN OR
CLOTHES. IF THIS HAPPENS ACCIDENTALLY,
WASH WITH WATER.
CAUTION
BRAKE CIRCUIT FLUID IS VERY CORROSIVE;
MAKE SURE THAT IT DOES NOT COME INTO
CONTACT WITH THE PAINTWORK.
CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, IN OTH-
ER WORDS, IT ABSORBS MOISTURE FROM
THE SURROUNDING AIR. IF THE CONTENT OF
MOISTURE IN THE BRAKING FLUID EXCEEDS
A CERTAIN VALUE, BRAKING WILL BE INEF-
FICIENT.
NEVER USE BRAKE LIQUID IN OPEN OR PAR-
TIALLY USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS,
THE FLUID MUST BE CHANGED EVERY 20,000
KM OR ANYWAY EVERY TWO YEARS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH
REGARD TO THE CHANGING OF BRAKE FLU-
ID AND THE BLEEDING OF AIR FROM THE
CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT4 Synthetic fluid

Headlight adjustment
Proceed as follows:
1. Place the vehicle in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10 m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the vehicle is perpendicular to the screen;

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Maintenance NRG Power Purejet

2. Turn on the headlight and check that the bor-

derline of the projected light beam on the screen
is not lower than 9/10 of the distance from the
ground to the centre of vehicle headlamp and high-
er than 7/10;
3. Otherwise, regulate the headlight by adjusting
the screw «A», after removing the front grille.
N.B.
THE ABOVE PROCEDURE COMPLIES WITH
THE EUROPEAN STANDARDS REGARDING
MAXIMUM AND MINIMUM HEIGHT OF LIGHT
BEAMS. REFER TO THE STATUTORY REGU-
LATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.

MAIN - 10

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

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Troubleshooting NRG Power Purejet

This section makes it possible to find the solutions to use in troubleshooting.

For each breakdown, a list of the possible causes and respective interventions is given.

Engine

Poor performance

POOR PERFORMANCE
Possible Cause Operation
Defective fuel pump or damaged depression line Replace the pump or control lines
Fuel filter dirty or clogged Clean the coupling filter
Excess of encrustations in the combustion cham- Remove the encrustations
ber
Lack of compression wear of the piston rings or Check the worn parts and replace them
cylinder
Exhaust pipe clogged due to excessive encrusta- Replace the exhaust pipe and check the carbura-
tions tion and mixer timer
Air filter blocked or dirty Clean according to the procedure
Clutch slipping Check the centrifugal brake shoe assembly and /
or clutch bell and replace if necessary
Defective mobile pulley sliding Check the parts, change the faulty parts and lubri-
cate the driven pulley using only Montblanc-Mo-
libdenum Grease (dis. 498345) grease
Transmission belt worn Replace
Roller wear; Presence of oil; Dirt Clean the speed variator, replace the rollers if worn
out

Rear wheel spins at idle

REAR WHEEL
Possible Cause Operation
Intake manifold cracked or incorrectly tightened Make sure the manifold is not damaged and that it
is correctly tightened on the throttle body and
crankcase
Clutch fault Check the spring/friction mass and the clutch bell

Starting difficulties

DIFFICULTY IN STARTING
Possible Cause Operation
Defective fuel pump or damaged depression line Replace the pump or control lines
Battery flat 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
Altered fuel characteristics Drain off the fuel no longer up to standard; then,
refill
Defective spark plug or with incorrect electrode Remove the encrustation, restore the plug gap or
gap replace being sure to use the types of spark plug

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NRG Power Purejet Troubleshooting

Possible Cause Operation

recommended at all times. Bear in mind that many
problems engines have, derive from the use of the
wrong spark plug
Intake joint cracked or with a bad seal Replace the intake joint and check its tightness on
the crankcase and on the carburettor
Purifier-carburettor fitting damaged Replace

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation
Excess of encrustations in the combustion cham- Remove the encrustations
ber

Engine tends to cut-off at idle

ENGINE IDLE
Possible Cause Operation
Reed valve does not close Check / replace the reed pack
Spark plug defective or faulty Replace the spark plug with one with the specified
degree and check the plug gap

Transmission and brakes

Clutch grabbing or performing inadequately

CLUTCH
Possible Cause Operation
Tear or irregular functioning Check that the masses open and return normally
Check that there is no grease on the masses
Check that the clutch masses' contact surface with
the clutch bell is mainly in the middle with charac-
teristics equivalent on the three masses
Check that the clutch bell is not scored or worn
abnormally
Never operate the engine without the clutch bell

Insufficient braking

BRAKE SYSTEM FAULT

Possible Cause Operation
Poor braking The rear (drum type) brake is adjusted by regulat-
ing the special adjustment (on the wheel) bearing
in mind that, with the control levers in the rest po-
sition, the wheels must turn freely.
The braking action should begin when the brake
levers are pressed by about a third.
Check the brake pad wear.

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Troubleshooting NRG Power Purejet

Possible Cause Operation

If it is not possible to remove any problems by sim-
ply adjusting the transmissions, check the brake
pads and front brake disc, the brake shoes and the
rear drum. If you encounter excessive wear or
scoring, make the necessary replacements.
Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system,
(there must be no flexible movement of the brake
lever).
Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump break-
down, replace
The brake fluid has lost its properties Replace the front brake fluid and top up to the cor-
rect level in the pump
Brake noise Check the wear of the brake pads and/or shoes

Brakes overheating

BRAKE OVERHEATING
Possible Cause Operation
Defective piston sliding Check calliper and replace any damaged part.
Deformed brake disc Use a comparator to check the disc planarity with
the wheel correctly mounted

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 ÷ 6 months. If
the battery is fitted on a motorcycle, be careful not
to invert the connections, keeping in mind that the
black ground wire is connected to the negative ter-
minal while the red wire is connected to the termi-
nal marked+. Follow the instructions in the ELEC-
TRICAL SYSTEM chapter for the recharging of the
batteries.

Steering and suspensions

TROUBL - 4

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NRG Power Purejet Troubleshooting

Rear wheel

POOR ROAD HOLDING

Possible Cause Operation
Faulty suspension Check that the rear shock absorber and/or the
front fork is/are in good working order. Replace or
overhaul the front fork and/or replace the rear
shock absorbers in case of malfunction
Tyres deflated or damaged Check the correct pressure of the tyres and the
condition of the tread. Inflate to the correct pres-
sure or replace.
Loosen the anchorage points of the front and/or Check the tightness between the frame, swinging
rear suspension unit. arm and engine and the fixing of the wheels to the
hub and/or the axle. Check the correct tightening
of the steering ring nut.

Heavy steering

STEERING HARDENING
Possible Cause Operation
Torque not conforming Check the tightening of the top and bottom ring
nuts.
If irregularities continue in turning the steering
even after making the above adjustments, check
the seats in which the ball bearings rotate: replace
if they are recessed.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation
EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring
nuts.
If irregularities continue in turning the steering
even after making the above adjustments, check
the seats in which the ball bearings rotate: replace
if they are recessed.

Noisy suspension

NOISY SUSPENSION
Possible Cause Operation
Components of the front suspension damaged. Check the quiet operation in the compression or
release phases of the fork and if necessary over-
haul it. Check that there is no noise or seizing
during the wheel rotation; if there is, change the
wheel bearing.
Components of the rear suspension damaged. Check the absence of noise in the compression or
release of the suspension, if necessary check the
proper tightness to the swinging arm unit and the

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Troubleshooting NRG Power Purejet

Possible Cause Operation

absence of rust or replace the entire shock ab-
sorber. Check that there is no noise or seizing
during the wheel rotation; if there is noise or seiz-
ing overhaul the final reduction assembly.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation
Shock absorbers malfunctioning Replace the complete shock absorption unit
Hydraulic cartridge in the fork damaged. Replace the hydraulic cartridge

TROUBL - 6

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

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Electrical system NRG Power Purejet

1. Blinker switch device

2. Front left indicator with lamp
3. Horn button
4. Turn indicator selector.
5. High/low beam selector.
6. Rear brake stop button
7. Complete headlight
8. 2 lamps for parking light 12V-3W
9. Lamp for dipped beam light 12V - 35W
10.Lamp for high beam light 12V - 35W
11.Instrument unit
12.Rpm-timing sensor
13.Front brake stop button

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NRG Power Purejet Electrical system

14.Start button
15.Front right indicator with lamp
16.Key switch
17.Fuel warning light transmitter
18.Oil mix lamp control
19.Voltage regulator
20.H.T. coil
21.Pick-up
22.Magneto
23.Starter motor
24.Front right indicator with lamp
25.Complete resistance
26.Battery 12V-9A
27.Fuse 20A
28.Fuse 5A
29.Petrol injector
30.Air injector
31.Water temperature sensor
32.Throttle body sensor
33.Output for diagnostics
34.Complete taillight
35.Rear left indicator with lamp
36.Starter relay
37.Electronic cpu
38.Fuel pump
39.Horn

Conceptual diagrams

ELE SYS - 3

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Electrical system NRG Power Purejet

Ignition

IGNITION
Specification Desc./Quantity
1 Battery 12V - 9Ah
2 Fuse 20A
3 Key switch contacts
4 Voltage regulator
5 Ignition spark plug
6 HV coil
7 Flywheel magneto
8 Pick - up
9 CPU

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NRG Power Purejet Electrical system

Headlights and automatic starter section

LIGHTS AND TURN INDICATORS

Specification Desc./Quantity
1 Flywheel magneto
2 High beam bulb Type: H8
Power: 12V - 35W
Quantity: 1
3 Digital instrument unit
4 Voltage regulator
5 Low beam bulb Type: H8
Power: 12V - 35W
Quantity: 1
6 Fuse 20A

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Electrical system NRG Power Purejet

Specification Desc./Quantity
7 Key switch contacts
8 Battery 12V - 9Ah
9 Front parking light Type: All glass
Power: 12V - 3W
Quantity: 2
10 Turn indicator control device
11 Fuse 5A
12 Turn signal switch
13 4 turn indicator lamps 12V-10w

Battery recharge and starting

ELE SYS - 6

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NRG Power Purejet Electrical system

BATTERY CHARGER AND STARTING

Specification Desc./Quantity
1 Flywheel magneto
2 Rear light with LED
3 CPU
4 Voltage regulator
5 Starter motor
6 Fuse 20A
7 Key switch contacts
8 Battery 12V - 9Ah
9 Starter remote control
10 Starter button
11 Fuse 5A
12 Fuse 5A
13 Diode
14 Two brake light buttons
15 Mixture oil level sender
16 Resistor 47 Ohm 25W

Level indicators and enable signals section

ELE SYS - 7

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Electrical system NRG Power Purejet

CONSENSUSES AND LEVEL INDICATORS

Specification Desc./Quantity
1 Battery 12V - 9Ah
2 CPU
3 Fuse 20A
4 Key switch contacts
5 Water temperature sensor
6 Fuel level sending unit
7 Fuse 5A
8 Mixture oil level sender
9 Digital instrument unit
10 Wheel rpm sensor

Digital instrument panel

INSTRUMENT UNIT CONNECTOR

Specification Desc./Quantity
1 + Battery
2 + permanent power supply
3 Earth
4 Grounding for phonic wheel
5 Power supply to phonic wheel
6 Phonic wheel signal
7 Instrument light and parking light indicator
8 Instrument temperature mass
9 Not connected
10 Rpm indicator signal
11 Instrument temperature signal
12 Fuel level sensor
13 High-beam warning light
14 + Right direction indicator
15 + Left direction indicator
16 Low-oil warning light
17 Low-fuel warning light
18 Oil light check outlet
19 Injection warning light
20 Not connected

Checks and inspections

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NRG Power Purejet Electrical system

Battery recharge circuit

The recharge circuit has a three phase generator with permanent magneto.
The generator is directly connected to the voltage regulator. The voltage regulator is connected directly
to the earth and battery positive passing through the 15A protection fuse. Therefore this system does
not have a connection to the key switch. The three phase generator provides a significant recharge
power and at low rpm, a good compromise is obtained between distributed power and idle stability.

Stator check
Disconnect the connector from the voltage regu-
lator and check for continuity between each yellow
wire with the other two.
Ohm value: 0.7 - 0.9 Ohm.
Also check that each yellow wire is isolated from
the ground.
If non-conforming values are found, repeat the
checks on the stator; if incorrect values continue
to occur, replace the stator or repair the wiring.

Voltage regulator check

With the battery perfectly charged and the lights
off, measure the voltage at the battery leads with
the engine running at high rpm.
The voltage must not exceed 15.2 volts.
If higher voltages are found, replace the regulator.
If voltages under 14 volts are found, carry out the
checks for the stator and related wiring.

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Electrical system NRG Power Purejet

Recharge system voltage check

Connect an ammeter induction clamp to the volt-
age regulator positive cable. Measure the battery
voltage and turn on the lights with the engine off
and wait until the voltage settles at around 12 volts.
Start the engine and measure the current distrib-
uted by the circuit with the lights on and engine at
high rpm.
If the current value is less than 10A, repeat the test
using a new regulator and/or stator instead.

Starter motor
Specifications
- Rated voltage 12V.
- Rated power 0.25 kW.
- Left rotation viewed from pinion side.
- Connection to engine with pinion and crown
wheel on transmission side crankshaft.
- Control with button
Tests to perform to check the electrical starter
Static test
Remove the left side panel.
Check the resistance of the induced brush unit.
Reference value: < or equal to 1 Ohm
- Use a lift to adequately support the vehicle.
- Remove the stand and support.
- Use a multimeter to check the continuity of the
positive and negative power supply cable.
- Make sure the connections are good.
If no faults are found, replace the starter.

Specific tooling
020331Y Digital multimeter

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NRG Power Purejet Electrical system

Dynamic tests
Check the battery voltage after it has not been
used for a few hours.
Voltage < or equal to 12.5 V.
Check the density of the electrolyte of each ele-
ment.
Bé = 30 ÷ 32
Specific weight: 1.25 ÷ 1.26
Make sure the negative terminals (battery nega-
tive and starter negative) are correctly connected
to each other and to the frame.

- Connect the diagnostic tester.

- Connect an ammeter induction clamp to the neg-
ative power supply cable of the starter.
- Disconnect the fuel injection connector.
- Turn to «ON».
- Select the «PARAMETERS» function.
- Start the engine (making sure the vehicle cannot
move) long enough to measure the rpm and starter
absorption.
- Absorption at drag rpm: from 15 to 25A.
- Drag rpm: from 500 to 550 rpm
N.B.
THE VALUE OF DECLARED RPM IS THAT IN-
DICATED BY THE DIAGNOSTIC TESTER
Specific tooling
020460Y Scooter diagnosis and tester

Carry out a no-load absorption test.

Remove the transmission cover.
Remove the starter pinion.

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Electrical system NRG Power Purejet

With the starter motor in no-load, maximum absorption must be 10 A with power supply voltage ≥ 12V.

STARTER MOTOR
Specification Desc./Quantity
Starter motor
Voltmeter
Starter motor contactor
Start button
Battery 12V-9Ah
Ammeter
See also
Centre-stand
Side fairings

Turn signals system check

The turn signal circuit is managed by an intermit-
tent device.
If there is a fault in the turn signal circuit check:
- The 5A fuse indicated in the photo by removing
the air duct.
- Use a multimeter to check if there is + 12V voltage
on the BLUE-BLACK wire to the turn signal con-
nector.

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NRG Power Purejet Electrical system

- To make sure the lamps work, apply a +12V volt-

age to the WHITE-BLUE wire of the turn indicator
switch for the right lamps and to the PINK wire for
the left lamps.

The oil mix lamp carries out a timed check for 3

seconds every time the key is switched to ON. The
check is controlled by the turn indicator device
which applies a 12V voltage to the oil warning
lamp.
If the check is not carried out when the key is
switched to ON, check:
- If the lamp is working
- The 5A fuse indicated in the photo by removing
the air duct.

- Use a multimeter to check if there is 12V voltage at the 2 YELLOW oil mix lamp control wires when
the key is turned to ON
- The oil mix lamp is working

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Electrical system NRG Power Purejet

To access the oil mix lamp control remove the right panel. Remember that the +12V voltage to the 2
YELLOW oil mix lamp control lasts 3 minutes from when the key is switched to ON.

INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT

1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a normal tester.
- If the voltage exceeds 12.60 V, the battery may 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 equal to 14.40÷14.70V
-Initial charge voltage equal to 0.3÷0.5 for nominal capacity
-Duration of the charge: 10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the battery
-Duration of the charge: 5 h

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NRG Power Purejet Electrical system

WARNING
-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF
RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON-
TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Dry-charge battery
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-
TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF
COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP-
PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF REACH OF CHILDREN
Characteristic
Battery
12V-9Ah

Commissioning dry-charge batteries:

1) Once the short closed tube and caps are removed, add sulphuric acid to the elements, of a type for
batteries with a specific gravity of 1.26, corresponding to 30° Bé at a temperature of at least 15°C until
reaching the upper level.
2) Let it sit for two hours.
3) Use the specific battery charger (single or multiple) to charge to an intensity equal to around 1/10 of
the capacity until the voltage has reached a value of around 2.7 V per element. The density of the acid
should be about 1.27, corresponding to 31° Bé, and the values have stabilised. The duration of the
charging operations must be 15 - 20 hours.
4) Once the charging is complete, level out the acid (add distilled water or remove excess acid), put
on the caps and clean carefully.
5) Once these operations have been completed, install the battery on the vehicle, correctly following
the connections described in point 3) «Battery charging».
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE
THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE-
SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO
ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger

ELE SYS - 15

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Electrical system NRG Power Purejet

Battery maintenance
The battery is the electric device that requires the
most careful monitoring and diligent maintenance.
The maintenance rules are:
1) Check the level of the electrolyte
Check regularly that the electrolyte level is at up-
per level. Use only distilled water to top up the
level.
If the battery needs topping up very frequently,
check the vehicle electrics: the battery is probably
working in overload conditions which will lead to
rapid deterioration.
2) Check the charge
After topping up the electrolyte, check the density
using a densimeter (see figure).

CHECKING ELECTROLYTE DENSITY

Specification Desc./Quantity
Keep the tube vertical
Check with bare eye
The float must be released
When the battery is charged, the density should be 30 ÷ 32 Bé corresponding to a specific weight of
1.26 ÷ 1.28 at a temperature not under 15° C.
If the density falls below 20° Bé, the battery is completely run down and needs to be recharged. When
a battery is being charged the voltage of each element must be 2.6 ÷ 2.8V.
The discharge limit of each element is 1.8V.
When charging is completed, check the level and density of the electrolyte as well as the voltage of
each element. If the vehicle is not used for long periods of time (1 month or longer) the battery must be
periodically recharged.
The battery will completely discharge over three months. When the battery is refitted onto the vehicle,
be careful not to invert the connections: remember that the ground wire (black) needs to be connected
to the negative (-) terminal, while the red wire is connected to the terminal marked with the positive
(+) sign.
3) Recharging 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.
FIRST DETACH THE NEGATIVE LEAD BEFORE REMOVING THE BATTERY FROM THE VEHICLE.
Normal charging on the bench is done with the specific battery charger (single or multiple), positioning
the battery charger selector on the type of battery to recharge at a current of 0.9A for around 6 ÷ 8

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NRG Power Purejet Electrical system

hours. The connections with the power supply source must be made by connecting the corresponding
poles (+ with + and - with -). The battery caps must be removed during charging.

Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger

4) Cleaning the battery

The battery should always be kept clean, especially the upper part, and the terminals protected with
vaseline.
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.
CAUTION
IN EMERGENCIES, THE CHARGING TIME CAN BE DECREASED TO 5-6 HOURS.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST
USED SHORTENS THE LIFE OF THE BATTERY.

ELE SYS - 17

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Electrical system NRG Power Purejet

ELE SYS - 18

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

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Engine from vehicle NRG Power Purejet

Removal of the engine from the vehicle

1. Detach the battery.
2. Remove the exhaust assy.
3. Remove the rear wheel.
4. Remove the rear brake cable.
5. Detach the electrical connection to the fly-
wheel.
6. Detach the throttle and mixer cables.
7. Detach the mixture oil, fuel, and vacuum
pump outlet tubing.
8. Detach the H.T. cable from the spark plug.
9. Remove the rear shock-absorber fixing bolt
from the engine.
10.Remove the nut on the l.h.s., and hence re-
move the engine - swing-arm fixing bolt.

Locking torques (N*m)

Engine-swinging arm bolt 33 ÷ 41 Shock ab-
sorber-engine pin 33 to 41 Nm Rear wheel axle
nut 104 ÷ 126

ENG VE - 2

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INDEX OF TOPICS

ENGINE ENG

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Engine NRG Power Purejet

Automatic transmission

Transmission cover
- Loosen the 15 screws and remove the transmis-
sion cover with the aid of a mallet.
N.B.
THE CRANKCASE IS SLIGHTLY BLOCKED BY
THE TIGHT FIT BETWEEN THE SHAFT OF THE
DRIVEN HALF-PULLEY AND THE BEARING
HOUSED ON THE CRANKCASE.

Air duct
- Remove the Radiator grill
- Remove the air conveyor by disengaging the
special joints

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side
to avoid damaging the coated surface and use the
driven pulley shaft or a pin of the same diameter
to remove the bearing.
N.B.
IN CASE OF DIFFICULTY A STANDARD 8MM-
INSIDE DIAMETER EXTRACTOR CAN BE
USED.

ENG - 2

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NRG Power Purejet Engine

Refitting the driven pulley shaft bearing

-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.
N.B.
WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.
CAUTION
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED
SURFACE.

Removing the driven pulley

- Lock the clutch bell housing with the specific tool.
- Remove the nut, the clutch bell housing and the
whole of the driven pulley assembly.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE
DRIVE PULLEY MOUNTED.
Specific tooling
020565Y Flywheel lock calliper spanner

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.
- Measure the inner diameter of the clutch bell.

Characteristic
Clutch bell diameter/standard value
Ø 107+0.2 +0 mm
Clutch bell diameter/max. value allowed after
use
Ø 107.5 mm
Eccentricity measured /max.
0.20 mm

ENG - 3

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Engine NRG Power Purejet

Removing the clutch

- Equip the tool with long pins screwed into position
«A» from the outside, insert the entire driven pulley
in the tool and put the central screw under stress.
CAUTION
THE TOOL WILL BE DEFORMED IF THE CEN-
TRAL SCREW IS TIGHTENED UP TOO FAR.

- Using a 34 mm socket wrench remove the clutch

locking nut.
- Loosen the central screw thereby undoing the
driven pulley unit
- Separate the components.

Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction
material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EX-
HIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE AN-
OTHER.
VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS
TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.
Characteristic
Check minimum thickness
1 mm

ENG - 4

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NRG Power Purejet Engine

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

- Remove the three guide pins and the mobile half

pulley.

Removing the driven half-pulley bearing

- Remove the roller bearing with the special ex-
tractor inserted from the bottom of the fixed half-
pulley.
CAUTION
POSITION THE HOLDING EDGE OF THE EX-
TRACTION PLIERS BETWEEN THE END OF
THE BEARING AND THE BUILT IN SEALING
RING.
Specific tooling
001467Y029 Bell for bearings, O.D. 38 mm
- Remove the ball bearing retention snap ring.
- Expel the ball bearing from the side of the clutch
housing by means of the special tool.
N.B.
PROPERLY SUPPORT THE HALF-PULLEY SO
AS NOT TO DEFORM THE SLIDING SURFACE
OF THE DRIVING BELT
Specific tooling
020376Y Adaptor handle
020363Y 20 mm guide

ENG - 5

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Engine NRG Power Purejet

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work
surface of the belt. If there are, replace the half-
pulley..
- Make sure the bearings do not show signs of un-
usual wear.
- Measure the external diameter of the pulley bush-
ing.

Characteristic
Stationary driven half-pulley/Standard diame-
ter
Ø 33.965 to 33.985 mm
Stationary driven half-pulley / Minimum diam-
eter admitted after use
Ø 33.96 mm

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two O-
rings.
- Measure the inside diameter of the mobile half-
pulley bushing.

Characteristic
Mobile driven half-pulley/ Maximum diameter
allowed
Ø 34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile
half-pulley.
- Fitting the half-pulley on the bushing.

Recommended products
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20

- Make sure the pins and collar are not worn, reassemble the pins and collar.

ENG - 6

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NRG Power Purejet Engine

- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This
operation must be done through one of the holes inside the bushing until grease comes out of the
opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended products
AGIP GREASE SM 2 Grease for the tone wheel revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.
- Fit the ball bearing retention snap ring.
- Fit the new roller bearing with the wording visible
from the outside.
CAUTION
PROPERLY SUPPORT THE HALF-PULLEY TO
PREVENT DAMAGE TO THE THREADED END
WHILE THE BEARINGS ARE BEING FITTED.
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020362Y 12 mm guide
020171Y Punch for Ø 17 mm roller case

Refitting the driven pulley

• Check the surfaces contacting with the belt.
• Insert the new oil seals and the O-rings on the
mobile half-pulley.
• Fit the half-pulley on the bushing.
CAUTION
WHILE FITTING THE MOBILE DRIVEN HALF-
PULLEY, TAKE CARE NOT TO DAMAGE THE
OIL SEALS.

• Check that pins and collar are not worn, refit pins and collar.
• Use a bent tip oiler to lubricate the pulley unit with approx. 6 gr grease. This operation must be per-
formed through one of the holes into the bushing until the grease starts leaking from the opposite hole.
This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended products
AGIP GREASE SM 2 Grease for odometer transmission gear case
Lithium grease with NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

ENG - 7

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Engine NRG Power Purejet

• Measure the free length of the mobile driving half-

pulley.

Characteristic
Standard length:
110 mm

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley
does not show signs of deformation
- Measure the free length of the spring

Characteristic
Standard length
118 mm
Minimum length allowed after use
XXXX

Refitting the clutch

- Preassemble the driven pulley group with spring,
sheath and clutch.
- Position the spring with the sheath
- Insert the components in the tool and preload the
spring being careful not to damage the plastic
sheath and the end of the threaded bar.

- Reassemble the nut securing the clutch and tight-

en to the prescribed torque.
CAUTION
SO AS NOT TO DAMAGE THE CLUTCH NUT
USE A SOCKET WRENCH WITH SMALL
CHAMFER.
CAUTION
POSITION THE NON-CHAMFERED SURFACES
OF THE NUT IN CONTACT WITH THE CLUTCH
Locking torques (N*m)

ENG - 8

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NRG Power Purejet Engine

Nut locking clutch unit on pulley 55 ÷ 60 Nm

Refitting the driven pulley

• Refit the driven pulley assembly, the clutch bell
and the nut using the specific tool.

Specific tooling
020565Y Flywheel lock calliper spanner

Locking torques (N*m)

Locking torque: 40 ÷ 44 N·m

Drive-belt
- Make sure the driving belt is not damaged and
does not have cracks in the toothed grooves.
- Check the width of the belt.

Characteristic
Transmission belt/Minimum width
17.5 mm

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.
- Remove the central nut with the related washer,
then remove the drive and the plastic fan.
- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the
rollers and contrast plate fitted loosely on it do not come off.

Specific tooling
020451Y Start-up crown lock

ENG - 9

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Engine NRG Power Purejet

Inspecting the rollers case

1) Check that the bushing and the sliding rings of
the mobile pulley do not show signs of scoring or
deformation.
2) Check the roller running tracks on the contact
pulley; there must not be signs of wear and check
the condition of the contact surface of the belt on
the half-pulleys (mobile and stationary).
3) Check that the rollers do not show signs of
marked facetting on the sliding surface and that
the metallic insert does not come out of the plastic
shell borders.
4) Check the integrity of the sliding blocks of the
contact plate.

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inside
diameter «A».
- Measure outside diameter «B» of the pulley slid-
ing bushing shown in the figure.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSH-
ING.
Characteristic
Driving pulley / Maximum diameter:
20.12 mm
Driving pulley/ Standard diameter:
20.021 mm
Driving pulley bushing/ Diameter maximum:
XXX mm
Driving pulley bushing/ Standard diameter:
20 -0.020/-0.041mm

ENG - 10

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NRG Power Purejet Engine

Refitting the driving pulley

- Manually move the mobile driven half-pulley
away pulling it towards the clutch unit and insert
the belt repeating the direction of rotation of the
first fitting.
N.B.
IT IS GOOD PRACTICE ALWAYS TO FIT THE
BELT SO THE WORDING CAN BE READ, IN
THE CASE THAT THIS DOES NOT SHOW A
FITTING SIDE.

- Refit the particular components of the assembly

(roller container assembly with bushing, limiting
washer, stationery half-pulley, cooling fan belt with
drive, washer and nut).
- Tighten the lock nut to torque 20 Nm and then
perform a final 90° lock preventing the rotation of
the drive pulley with the specific tooling.
N.B.
REPLACE THE NUT WITH A NEW ONE AT EV-
ERY REFIT
CAUTION
IT IS MOST IMPORTANT WHEN FITTING THE
DRIVING PULLEY UNIT THAT THE BELT IS
FREE INSIDE IN ORDER TO AVOID MAKING A
WRONG TIGHTENING WITH THE POSSIBLE
LATER DAMAGE OF THE CRANKSHAFT
KNURLING.
Specific tooling
020451Y Start-up crown lock

Locking torques (N*m)

Crankshaft pulley nut 18 to 20 + 90° N.m

End gear

ENG - 11

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Engine NRG Power Purejet

Removing the hub cover

• Remove the transmission cover
• Remove the clutch assembly
• Discharge the rear hub oil.
• Remove the 5 screws indicated in the figure.
• Remove the hub cover with driven pulley shaft.

Removing the wheel axle

- Remove the intermediate gear and the complete
gear wheel axle.
- When removing the intermediate gear pay atten-
tion to the various shim adjustments.

Removing the wheel axle bearings

- Remove the oil seal and the seeger ring.
- Remove the bearing by pushing from the outside
towards the inside of the gear compartment, using
the appropriate punch.

Specific tooling
020363Y 20 mm guide
020376Y Adaptor handle
020358Y 37x40-mm adaptor

ENG - 12

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NRG Power Purejet Engine

Removing the driven pulley shaft bearing

- Remove the seeger ring inside the cover.
- Remove the oil seal from the outside.
- Remove the centring dowels and position the
cover on a plane.
- Position the special tool on the internal track of
the bearing and remove said bearing with the aid
of a press.

Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
- Position the special tube on the internal raceway
of the bearing and from the shaft toothed side as
indicated in the figure. Expel the driven pulley shaft
with the aid of a press.

Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft

Inspecting the hub shaft

- Check that the three shafts exhibit no wear or
deformation on the toothed surfaces, at the bear-
ing housings and at the oil guards.
- In case of anomalies, replace the damaged com-
ponents.
- Check that the fitting surface is not dented or dis-
torted.
- If faults are found, replace the hub cover.

ENG - 13

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Engine NRG Power Purejet

Refitting the driven pulley shaft bearing

- Support the inner track of the bearing from the
outside of the hub cover with the specific tool posi-
tioned under the press and insert the driven pulley
axle.
- Refit the oil seal flush with the cover.

Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft

• Heat the hub cover and insert the bearing with

the specific punch.
• Fit the snap ring with the concave or radial part
on the bearing side.
N.B.
FIT THE BALL BEARING WITH THE SHIELD
FACING THE OIL SEAL.
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020439Y 17 mm guide
020358Y 37x40-mm adaptor

Refitting the wheel axle bearing

- Heat the half crankcase on the transmission side
using a thermal gun.
- After lubricating its outer strip, insert the bearing
with the special adapter with the aid of a hammer.
- Refit the seeger ring and the oil seal using the 42
x 47 mm adapter and the handle.

Specific tooling
020151Y Air heater
020376Y Adaptor handle
020363Y 20 mm guide
020359Y 42x47-mm adaptor

ENG - 14

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NRG Power Purejet Engine

Refitting the ub cover

• Refit the complete wheel axis.
• Refit the intermediate gear being careful of the
two shim adjustments.
• Apply LOCTITE 510 for surfaces on the hub cov-
er and refit it with the complete pulley shaft.
• Insert the 5 screws and tighten them to the pre-
scribed torque.
N.B.
CLEAN THE CONTACT SURFACES OF THE
HUB COVER AND THE HALF CRANKCASE OF
RESIDUE FROM PREVIOUS GASKETS BE-
FORE APPLYING A NEW ONE.
Locking torques (N*m)
Locking torque: 11 to 13 Nm

Flywheel cover

Removing the stator

- Remove the flywheel cover.

• Use a specific compass wrench and a 15 mm

Allen wrench to remove the flywheel lock-nut.

Specific tooling
020565Y Flywheel lock calliper spanner

ENG - 15

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Engine NRG Power Purejet

• Use a specific extractor to remove the flywheel

Specific tooling
020162Y Flywheel extractor

• Remove the two studs of the revolutions sensor

to the coolant inlet pipe.

• Remove the coolant inlet duct

• Remove the two stator fixing screws

• Remove the stator with wiring and revolution
sensor

Locking torques (N*m)

Flywheel nut 40 to 44 N.m

Refitting the stator

- To refit, perform the removal procedures in the reverse direction.

ENG - 16

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NRG Power Purejet Engine

Refitting the flywheel cover

• Fit the rubber seal on the flywheel con-
nector and around the inlet coolant
hose.

• Keeping the flywheel connector rubber

clamp on the coolant inlet hose, refit
the flywheel cover paying attention in
inserting the strap in the groove.
• Tighten the 4 studs, noting that the two
longer golden screws are inserted in
the 2 top holes and are also responsi-
ble for restraining the secondary air-
box.

Cylinder assy. and timing system

• Remove the flywheel cover using the 4 screws
shown in the figure.

ENG - 17

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Engine NRG Power Purejet

Removing the cylinder head

• Use a TORX 20 wrench to remove the air feeding
line from the injection head as shown in the figure.

• Remove the injection head, including the fuel in-

jector and the pressure regulator, using the 2
screws shown in the figure

• Remove the spark plug

• Remove the temperature sensor shown in the
figure

To remove the air injector, extract the dust cover

and use a screwdriver to remove the injector as
shown in the figure
N.B.
BE CAREFUL NOT TO DAMAGE THE INJEC-
TOR PLASTIC SUPPORT

ENG - 18

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NRG Power Purejet Engine

• Remove the coolant outlet union from the head

with the relevant O-ring, using the two screws, as
shown in the figure.

• Remove the head inside recirculation duct as

shown in the figure.

• Remove the head using the 4 screws as shown

in the figure.

ENG - 19

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Engine NRG Power Purejet

Removing the cylinder - piston assy.

• Remove the cylinder holding the piston in order
to prevent damage

• Remove the 2 plug stops by a screwdriver inser-

ted into the special slits on the piston
• Remove piston pin and remove the piston
N.B.
USE PAPER OR A CLOTH TO CLOSE THE CYL-
INDER HOUSING MOUTH ON THE CRANK-
CASE TO PREVENT SLIPPAGE OF ONE OF
THE PIN LOCKING RINGS INTO THE CASE.

• Remove the roller from the connecting rod as

shown in the figure

• Remove the piston sealing rings

CAUTION
NOTE THE ASSEMBLY POSITIONS OF THE
LININGS TO PREVENT INVERTING THE POSI-
TION IN CASE OF REUSE.
N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING
RINGS DURING REMOVAL.

ENG - 20

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NRG Power Purejet Engine

Inspecting the small end

- Measure the internal diameter of the small end
using an internal micrometer.
N.B.
IF THE DIAMETER OF THE ROD SMALL END
EXCEEDS THE MAXIMUM DIAMETER AL-
LOWED, SHOWS SIGNS OF WEAR OR OVER-
HEATING REPLACE THE CRANKSHAFT AS
DESCRIBED IN THE "CRANKCASE AND
CRANKSHAFT" CHAPTER".
Characteristic
Rod small end: standard diameter
17 +0.011-0.001
Rod small end: maximum allowable diameter
17,060 mm

Inspecting the wrist pin

- Check the wrist pin external diameter using a mi-
crometer

Characteristic
Wrist pin: standard diameter
12 +0.005 +0.001 mm

Inspecting the piston

- Measure the bearings on the piston using a bore
meter
- Calculate the piston-pin coupling clearance.

Characteristic
Wrist pin housing: standard diameter
12 +0.007 +0.012
Wrist pin housing: standard clearance
0.002 ÷ 0.011 mm

ENG - 21

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Engine NRG Power Purejet

- Measure the outer diameter of the piston, per-

pendicular to the pin axis.
- Take the measurement in the position shown in
the figure
To classify the cylinder-piston fitting, check the ap-
propriate table

Inspecting the cylinder

• Check that the cylinder exhibits no seizure. If it
does, replace or adjust it, while respecting the al-
lowable oversizes.
• Use a bore meter to measure the cylinder inside
diameter according to the directions shown in the
figure.

• Check that the fitting surface with the head is not worn or deformed
To classify the fitting, refer to the tables.

Inspecting the piston rings

• Alternatively, insert the 2 sealing rings into the
cylinder.
• Insert the rings in an orthogonal position relative
to the cylinder axis, using the piston.
• Measure the sealing ring opening by a feeler
gauge, as shown in the figure.

• If the values are higher than those prescribed on the chart, replace the rings

ENG - 22

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NRG Power Purejet Engine

Removing the piston

• Insert the roller in the connecting rod

• Fit piston and wrist pin on the connecting rod, with

piston facing the outlet

• Insert the wrist pin stop ring in the specific tool

with the aperture in the position shown on the tool,
as in the figure

• Place the wrist pin stop ring into position using a

punch

Specific tooling
020166Y Pin lock fitting tool

ENG - 23

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Engine NRG Power Purejet

• Fit the wrist pin stop using the plug as shown in

the figure

pipe from the injection head.

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NRG Power Purejet Engine

- Remove the air injector

- The carbon dam ring must be broken to be re-
moved.
- Carefully clean the air injector and the seat re-
moving any carbon residues.
- Check that the sealing rings exhibit no wear, or
replace them.
- To refit, use a new carbon dam ring.
- Use the specific tool to fit the carbon dam ring.
We recommend doing this in several steps to en-
sure a correct widening of the ring as shown in the
photo.

Specific tooling
020615Y Carbon dam ring fitting kit
- Position the specific tool with the rung facing the
injector as shown in the figure.

- Use the specific tool to tighten the carbon dam

ring seat as shown in the figure.
- Take several steps to ensure a correct insertion
into the seat.
- Refit the air injector in its seat on the head quickly
to prevent the carbon dam ring from expanding
again.

Specific tooling
020615Y Carbon dam ring fitting kit

Crankcase - crankshaft
• Remove flywheel and stator
- Remove the driving pulley
- Remove the driven pulley
- Remove the mixer

ENG - 27

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Engine NRG Power Purejet

- Remove the throttle body with manifold, diaphragm, gasket and blade support
- Remove the volumetric compressor
- Remove the thermal unit
- Remove the starter

See also
Removing the driven pulley
Removing the driving pulley
Cylinder assy. and timing system
Removal

Splitting the crankcase halves

- Remove the 8 crankcase half clamping screws
shown in the figure

- Insert the guard on the crankshaft as shown in

the figure.

- Use the specific tool to remove the crankcase half

on the flywheel side. Place the tool being careful
to correctly centre it
- Use a 17 mm Allen wrench to remove the crank-
case half on the flywheel side.
N.B.
IF SEPARATION REQUIRES FORCING, USE A
THERMAL GUN TO HEAT THE CRANKCASE IN
THE BENCH BEARING ZONE
Specific tooling
020151Y Air heater
020163Y Crankcase splitting plate

ENG - 28

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NRG Power Purejet Engine

- Install the specific tool with relevant guard on the

transmission side crankcase half. Use four M6
screws of a suitable length.
- Use a 17 mm Allen wrench to remove the crank-
shaft from the transmission side crankcase half.

Removing the crankshaft

- Install the specific tool on the half crankcase on
the transmission side using four M6 screws of an
adequate length.
- Remove the crankshaft from the transmission
side half crankcase

Specific tooling
020163Y Crankcase splitting plate

Removing the crankshaft bearings

- Bearings may be left on the crankcase halves or
on the crankshaft.
- Use the specific tool to remove any bearings left
on the crankshaft.
N.B.
HALF-RINGS MUST BE INSERTED ON THE
BEARINGS BY STRIKING THEM WITH A MAL-
LET.
Specific tooling
004499Y Camshaft bearing extractor
004499Y007 Half rings

ENG - 29

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Engine NRG Power Purejet

- Use the specific tool to remove any bearings left

on both crankcase halves.

Specific tooling
001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54 mm bearing

Refitting the crankshaft bearings

- This operation requires assembly by temperature
- Dip the bearings in oil bath when this is still cold.
Avoid contact between bearings and container.
- Use an appropriate amount of oil (approx.1 l)

- Gradually heat the container with a thermal gun

until the oil temperature reaches approx. 150°.
- Check the temperature using a multimeter provi-
ded with thermal probe
N.B.
IF THE BEARINGS WERE IMMERSED INTO
HOT OIL, THEY WOULD BE IMMEDIATELY
DAMAGED.

- Place the crankshaft on the special support

- Alternately introduce the 2 bearings to insert
them home.
- If required, use a specific pipe to ensure their in-
sertion.
N.B.
THIS OPERATION SHOULD BE PERFORMED
QUICKLY AND WITH PRECISE MOVES. OTH-
ERWISE, START OVER.
Specific tooling
020265Y Bearing fitting base

ENG - 30

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NRG Power Purejet Engine

008119Y009 Tube to assemble shafts and

axles

Inspecting the crankshaft components

- Check for any abnormal wear on the eccentric
track.
- To check using the dial gauge, see the section
«Checking crankshaft alignment»

Inspecting the crankshaft alignment

With the specific tool shown check that the eccen-
tricity of the surfaces of diam. «A»-«B»-« C» are
within 0.03 mm. (reading limit on the dial gauge);
in addition, check the eccentricity of diam. «D», for
which a maximum reading of 0.02 mm is permitted.
In the case where eccentricity is not much above
prescribed levels, straighten the shaft by acting
on the counterweights with a shim or tighten them
in a clamp (with an aluminium bushing) as re-
quired..

Specific tooling
020335Y Magnetic support for dial gauge
020074Y Support base for checking crankshaft
alignment

ENG - 31

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Engine NRG Power Purejet

Inspecting the crankcase halves

- Remove the oil seals from both crankcase halves
using a screwdriver.

- Clean the fitting surfaces removing Loctite resi-

dues and residues of the paper seal on the cylin-
der.
- For this operation, use specific products available
on the market. Avoid any method that may impair
the crankcase fitting surfaces.
- To facilitate this operation, remove the rotor.
Please note that the threading is anticlockwise.
- Check the fitting surfaces and the bearing and oil
seal capacities.

- Check the cleaning and efficiency of the unidir-

ectional valve of the oil supply to the pump case.
- Check the correct installation of the reference
dowels.

ENG - 32

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NRG Power Purejet Engine

Refitting the crankshaft

- Place the transmission side crankcase half on
two wooden supports.
- Refit the water pump rotor (note that the thread-
ing is anticlockwise)
- Use the thermal gun to heat the bearing seat to
approx. 120°.
N.B.
MAKE SURE THAT THERE IS THE NECESSA-
RY SPACE IN THE LOWER SIDE TO INSERT
THE CRANKSHAFT.
- Insert the crankshaft using a firm movement until
the bearing reaches home.
N.B.
CHECK THAT THE CONNECTING ROD IS
PLACED ACCORDING TO THE CYLINDER AX-
IS. IF ASSEMBLY IS UNSUCCESSFUL, START
OVER FOLLOWING THE HEATING RULES
AND BEING CAREFUL TO THE SHAFT INSER-
TION MOVEMENT. DO NOT LUBRICATE THE
SHAFT SINCE THE CRANKCASE HALF FIT-
TING SURFACES MAY BE SOILED.
- Let the crankcase half temperature settle with the
crankshaft temperature.
- Install the specific crankcase separation plate
again without installing the crankshaft guard.
- Keep the central thrust screw loosened during
assembly.
- Move the 4 fixing screws to the end of stroke and
loosen them again by the same angle (e.g. 90°)
- When temperature has settled, pre-load the
thrust screw of the tool manually until the bearing
ball backlash is zeroed.
N.B.
AN EXCESSIVE PRE-LOAD MAY CHANGE THE
CRANKCASE BEARING POSITION.

ENG - 33

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Engine NRG Power Purejet

- Prepare the fitting surface using the recommen-

ded product applying a thin layer after degreasing
the surface with a suitable solvent (e.g. trichloro-
ethylene)

Recommended products
Loctite 510 Liquid sealant
Gasket

- Assemble the equipment need to close the crank-

case half (screws, wrench).
- Heat the crankcase half on the flywheel side us-
ing the thermal gun, with the same procedure on
the transmission side crankcase half.

- Keep the transmission side crankcase half in hor-

izontal position to introduce the flywheel side
crankcase half with a firm and precise move.
N.B.
WEAR GLOVES WHEN HANDLING THE
CRANKCASE HALF. DO NOT USE RAGS FOR
THIS OPERATION.

- Insert at least 3 fixing screws and tighten quickly.

- Insert 5 more screws and tighten at the prescribed torque.

Locking torques (N*m)

Crankcase closing screws: 12 -13 Nm

ENG - 34

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NRG Power Purejet Engine

Refitting the crankcase halves

- Prepare the coupling surface with LOCTITE 510
applying a thin layer of it after degreasing the sur-
face using a suitable solvent (e.g. trichloroethy-
lene)
- Heat the flywheel-side half crankcase with a ther-
mal gun.

Recommended products
Loctite 510 Liquid sealant
Gasket

- Keeping the half crankcase on the transmission

side, insert the flywheel side half crankcase with a
clean precise movement
- Insert at least three clamping screws and tighten
up rapidly
- Insert the other 5 screws and tighten them to the
specified torque.

Locking torques (N*m)

crankcase coupling screws 11 - 13
- Move the crankcase separation plate in a position
back from the one indicated in the figure
- Install the special magnetic support with dial
gauge at the end of the crankshaft
- Check the axial clearance of the crankcase
If this is not within the maximum limit allowed, re-
peat the crankcase coupling procedure

Specific tooling
020335Y Magnetic support for dial gauge

Characteristic
Axial clearance with warm crankcase
0.10 ÷ 0.12 mm
Axial clearance with cold crankcase
0.06 to 0.08 mm
Limit value with cold crankcase
0.02 ÷ 0.03 mm

ENG - 35

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Engine NRG Power Purejet

Air compressor

Removal
Air compressor removal

- Remove the throttle body manifold

- Remove the air piping union from the injection
head using a Torx 25mm wrench

- Remove the air piping support bracket fixing

screw from the transmission covers.

- Remove the 4 screws fixing the air compressor

to the crankcase, as shown in the figure.
- Remove the air compressor

ENG - 36

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NRG Power Purejet Engine

Overhaul
Air compressor check

- Check the presence of any unusual wear, traces

of overheating on the roller contacting with the ec-
centric, as shown in the figure.

- Use a feeler gauge to measure the axial play of the control roller by placing the blade between roller
and one of the two shim adjustments.

Characteristic
Standard axial play:
XXX
Allowable limit after use:
XXX

- Check that the O-ring exhibits no breakage or

squashing.

- Remove the flywheel cover.

- Turn the crankshaft to check that the eccentric
track exhibits no unusual wear or signs of over-
heating.

Refitting
Air compressor refitting

ENG - 37

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Engine NRG Power Purejet

- Place the shaft with the eccentric at its lower dead

point.
- Insert the compressor into the crankcase, cor-
rectly placing the reference dowels.

- Refit the sealing ring.

- Refit the 4 fixing screws tightening to the prescri-
bed torque.

Locking torques (N*m)

Air compressor fixing screws: 3 - 4 Nm

- Refit the air pipe support bracket fixing screw on

the transmission cover.
- Refit the air piping union on the injection head.

- Refit the throttle body manifold.

- Refit the flywheel cover.

Lubrication

ENG - 38

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NRG Power Purejet Engine

Crankshaft oil seals

Refitting
- Install a new oil seal on the flywheel side using
the specific tool punch. The flywheel side oil seal
can be recognised by the smaller diameter.
N.B.
USE OF THE TOOL IS NOT COMPATIBLE WITH
THE MOUNTED KEY
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
- Install a new oil seal on the transmission side us-
ing the specific tool provided with adapter ring. The
transmission side oil seal can be recognised by the
larger diameter.

Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch

- Lubricate bearings and connecting rod head us-

ing 2T oil.

- Refit the thermal unit

- Refit the compressor
- Refit the throttle body
- Refit the flywheel - stator
- Refit the mixer
- Refit the driven pulley
- Refit the driving pulley

Oil pump

ENG - 39

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Engine NRG Power Purejet

Removal
- Remove the transmission cover
- Remove driving pulley
- Remove the 2 screws shown in the figure

- Remove the pipe gasket from the case as shown

in the figure

- Remove the pipe from the oil inlet union in the

pump case

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NRG Power Purejet Engine

Refitting
- To refit, perform the removal procedures in the
reverse direction.
- Perform purging after refitting, using the screw
shown in the figure.

ENG - 41

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Engine NRG Power Purejet

ENG - 42

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INDEX OF TOPICS

SUSPENSIONS SUSP

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Suspensions NRG Power Purejet

Sospensioni anteriore

This section is devoted to operations that can be carried out on the suspension.

Front

Removing the front wheel

- Support the vehicle in such a way that the front
wheel is raised.
- Using two 18 mm hexagonal wrenches remove
the front wheel axle.

Refitting the front wheel

- When refitting, pay attention in repositioning the odometer drive correctly.

Locking torques (N*m)

Wheel fixing nut 40 to 50 N.m

Handlebar

Removal
- Remove the front handlebar cover.
- Remove the rear handlebar cover.
- After removing the transmissions and discon-
necting the electrical terminals, remove the bolt
«A» and the handlebar
- Check all components and replace faulty parts.
N.B.
IF THE HANDLEBAR IS BEING REMOVED TO
REMOVE THE STEERING, TILT THE HANDLE-
BAR FORWARD TO AVOIDING DAMAGING
THE TRANSMISSIONS.

SUSP - 2

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NRG Power Purejet Suspensions

Refitting
When refitting, tighten to the prescribed torque and
apply the recommended grease to the threaded
cone.

Recommended products
AGIP GREASE PV2 Grease for control levers
on the engine
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2

Locking torques (N*m)

Locking torque: 65 to 70 N•m

Front fork

Removal
- Remove the front brake calliper.
- Remove the odometer cable from the reduction
gear box.
- Remove the front mudguard.
- Remove the handlebar.
After removing the steering ring-nut using the spe-
cial tool, lean the vehicle on one side and extract
the steering tube.

Specific tooling
020055Y Wrench for steering tube ring nut

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Suspensions NRG Power Purejet

- Remove screw 1 fixing the screw to the stem and

remove the stanchion heating it if necessary with
the specified heater, then remove sealing ring 2
and seeger 3.
- Using nut 4, remove the spring stem and bushing.
The damper is an integral part of the stem and
cannot therefore be overhauled, so if you need to
work on the damper (loss of fork oil), carry out the
operations mentioned above and replace the
shock absorber-stem unit.
When refitting, tighten to the prescribed torque and
apply the recommended grease to the threadlock
nut.

Specific tooling
020150Y Air heater support
020151Y Air heater

Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock

Locking torques (N*m)

Stud-stanchion fixing screw 20 to 25 N•m Nut
tightening torque 20 to 25 N•m

Replace seal ring

- Remove the wheel axle.

- Remove the screw (4).
- Remove the stanchion (3).
- Remove the dust guard (1).
- Insert the new sealing ring after lubricating the
inside parts of the ring and paying attention not to
damage it.
- Insert the stanchion appIying the recommended
product to the clean surface.
- Lock the screw (4).

Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock

SUSP - 4

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NRG Power Purejet Suspensions

Rod disassembly

- Remove the dust guard (1) using a screwdriver

to prise it out.
- Remove the seeger (2) and remove the power
pipe.
N.B.
GREASE THE SPRINGS AND THE BUSHINGS
BEFORE REFITTING, WITH A SMALL QUANTI-
TY OF GREASE (AROUND 3 GR.)
Recommended products
AGIP GREASE MU3 Grease for odometer
transmission gear case
Soap-based lithium grease with NLGI 3; ISO-L-
XBCHA3, DIN K3K-20

Refitting
Lubricate the seats and the balls with the grease
recommended.
- Lock at the prescribed torque and turn the key
anticlockwise by 90° to 100°.

Specific tooling
020055Y Wrench for steering tube ring nut

Locking torques (N*m)

Locking torque: 50 to 60 Nm

Steering column

Removal
Lower and upper races from frame removal

SUSP - 5

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Suspensions NRG Power Purejet

- Only remove the seats if it is strictly necessary.

- Using the special tool remove the upper fifth
wheel seat by putting the special tool into the lower
part of the headstock as indicated in the figure.
- By inserting the punch into the top of the tube,
remove the lower fifth wheel seat from the head-
stock.

Specific tooling
020004Y Punch for removing fifth wheels from
headstock

Refitting
Lower and upper races from frame refitting

- Using the special tool, refit the upper and lower

bearing seats on the headstock.

Specific tooling
001330Y Tool for fitting steering seats

Steering bearing

Removal
Disassemble steering locking ring nut

- Remove the handlebar.

- Remove the bearing of steering ring nut using the
specific tool.

Specific tooling
020055Y Wrench for steering tube ring nut

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NRG Power Purejet Suspensions

Overhaul slew ring seat on fork

Check the condition of the fifth wheel and the fifth

wheel seat on the fork (steering tube). Replace if
there are faults.
- Support the fork properly.
- Using the special tool, remove the fifth wheel seat
on the steering tube as shown in the photograph
by applying small mallet blows.

Specific tooling
020004Y Punch for removing fifth wheels from
headstock
Always use a new fifth wheel seat on refitting.
- Using the special tool, refit the fifth wheel seat
with the aid of a few mallet blows and bring it as
far as the stop shown in the photo.

Specific tooling
006029Y Punch for fitting fifth wheel seat on
steering tube

Refitting
Rimontaggio ghiera di bloccaggio sterzo

- After locking the first ring nut in place, lock the

second ring nut using a specific tool.

Specific tooling
020055Y Wrench for steering tube ring nut

Locking torques (N*m)

Locking torque: 30 to 40 Nm

Rear

SUSP - 7

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Suspensions NRG Power Purejet

Removing the rear wheel

- Use a screwdriver as a lever between the drum
and the cover.
-Straighten the split pin and remove the cap.
-Remove the wheel acting on the central fixing
point.
WARNING
-ALWAYS USE NEW SPLIT PINS FOR REFIT-
TING.

Shock absorbers

Removal
To replace the shock absorber you just need to
remove the battery access flap to get and remove
the shock absorber/ frame anchorage nut. Then
remove the shock absorber/engine anchorage
nut.

Refitting
When refitting, tighten the shock absorber/frame anchorage nut and the shock absorber/engine pin at
the prescribed torque.

Locking torques (N*m)

Shock absorber/frame nut torque 20 to 25 Nm Shock absorber/engine pin torque 33 to 41 N·m

SUSP - 8

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NRG Power Purejet Suspensions

Centre-stand
Assembly and staking of stand pivot pin to bracket

- Caulk the end of the pin «P» between the two

punches shown in the figure.
- After caulking it must be possible for the stand to
turn freely.
N.B.
UPON REFITTING USE NEW O-RING AND PIN,
GREASE THE SPRING ATTACHMENTS AND
THE PIN.

Expelling stand pivot pin from bracket

- Remove the stand support bracket from the en-

gine.
- Drill a 5 mm hole in the bracket so that the pin
«P» can come out.

Changing the complete stand

- Work on the screws shown in the figure.

- When refitting, secure to the prescribed torque.

Locking torques (N*m)

Stand screw torque 18.5 to 19 Nm

SUSP - 9

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Suspensions NRG Power Purejet

SUSP - 10

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INDEX OF TOPICS

PURE JET INJECTION INJ PJ

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pure jet injection NRG Power Purejet

Introduction
EMS injection system
The injection system has an incorporated injection and ignition.
Injection is direct and pneumatic, by air electro-injector and fuel electro-injector.
Injection and ignition are phased on the 2T cycle by a phonic wheel on the flywheel and phase rpm
sensor with reluctance variation.
Fuel preparation and ignition are controlled on the basis of the engine rpm and of the gas valve opening.
Further correction is made according to the following parameter:
coolant temperature.
The ECU stabilises the idle at 2000 RPM for any temperature of use, by suitably managing the air
injector controls, fuel injector and HV coil. Fuel preparation therefore changes according to the use
temperature.
During running, fuel preparation is controlled on the basis of the engine rpm signals, coolant tempera-
ture, and gas valve position in relation to preset mapping.
The fuel injection circuit consists of:
- Fuel filter
- Pump feeding duct with auto-bleeding
- Fuel pump
- Fuel injector
- Pressure regulator
The injector mounting is connected by two snap on pipes. The continuous circulation prevents the fuel
from boiling. The pressure regulator is placed in output of the injector mounting . The fuel pump is
controlled by the ECU; this ensures safety of the vehicle.
The power supply circuit consists of:
- Volumetric compressor with unidirectional valve controlled by the eccentric on the crankshaft
- Flexible lines connecting to the injector mounting
- Pressure regulator
- Air injector
The ignition circuit consists of:
- ECU
- H.V. coil
- H.V. cable
- Shielded cap
- Spark plug
The ECU manages ignition with an optimum control of the advance and of the coil magnetisation time.
The ECU injection-ignition system manages the engine functions by a default program. This injection
system allows reaching great results as regards:

INJ PJ - 2

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NRG Power Purejet pure jet injection

- Fuel consumption reduction

- Lubricant consumption reduction
- Discharge emission reduction. Emissions are further limited by the catalyser.
The injection system allows these results by:
Air washing of cycle 2T
- Stratified load
- Fine nebulisation by pneumatic injection
These results are obtaining without impairing the delivery features of torque and power Should any
input signals be missing, acceptable engine performance is ensured to allow the user to reach the
workshop.
Of course this cannot happen when the phase rpm signal is missing, or when the fault concerns control
curcuits:
- Fuel pump
- HV coil
- Injectors
- TPS ( Throttle Position Sensor )
The ECU is provided with a self-diagnosis system and informs the user by the lamp into the instrument
panel. The signals are given in two ways:
- Flashing light
- Solid light
The flashing light denotes a medium fault that requires a check at the workshop. The engine may work
normally or in limited conditions.
The solid light denotes serious faults that impair the engine functions.

precautionary measures
1.Before fixing any part of the injection system, check any registered faults. Never disconnect the battery
before checking for faults.
2. The power supply system is pressurised at 250 ÷ 800 KPa (2.5 ÷ 8 BAR). Before disconnecting the
snap on attachment of a fuel line, check that there are no free flames and do not smoke. Act with caution
to prevent spraying in the eyes.
3. When fixing electric components, operate with battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is more than 12V.
5. When washing the vehicle, be careful of the electric components and wiring.
6. When an ignition fault is detected, start the checks from the battery and the injection system con-
nections.
7. Before disconnecting the ECU connector, perform the following steps in the order shown: Set the
switch to "OFF" then disconnect the battery. Failure to comply with this rule may damage the ECU.
8. Do not invert the polarity when fitting the battery.

INJ PJ - 3

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pure jet injection NRG Power Purejet

9. To prevent damage, disconnect and reconnect the ECU system connectors only if required. Before
reconnecting, check that the connectors are dry.
10. During electrical checks, do not force the tester tips into the connectors. Do not perform tests not
specifically required by the manual. Perform electrical checks using the interface wiring specific tool.
11. At the end of every check performed with the diagnostic tester, protect the system connector with
the cap. Failure to comply with this rule may damage the ECU.
12. Before reconnecting the quick couplings of the power supply system, check that the terminals are
perfectly clean.
13. During repairs, do not remove the compressed air line clamps. If required, replace the rubber hose.
14. If you have to remove the air injector, replace the carbon dam sealing ring.
15. Do not perform voltage checks on the spark plug when it is not fitted on the head. Power supply
voltages are very high. Hazard of dangerous electric shock. In addition, the air - fuel mixture leaking
from the spark plug may cause fire.
16. Do not switch to «ON» during repair procedures when the tank is empty. While on the road, do not
use the reserve if it could deplete the fuel.
17. Do not disconnect the battery leads when the engine is running.
18. If the fuel is completely depleted, refuel with at least 4 litres. This will enable safe triggering of the
fuel pump
Specific tooling
020481Y Control unit interface wiring

troubleshooting

suggestions for diagnosis

1 A failure of the injection system may most probably depend on the connections rather than the com-
ponents.
Before troubleshooting the injection system, perform the following checks:
1. Power supply
Battery voltage
Burnt fuse
Connectors
2. Ground to frame
3. Air supply
Volumetric compressor
Supply line
4. Fuel supply
Faulty fuel pump
Dirty fuel filter

INJ PJ - 4

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NRG Power Purejet pure jet injection

Fuel supply vent clogged

5. Ignition system
Faulty spark plug
Faulty coil
Faulty screened cap
6. Suction circuit
Air filter dirty
7. Others
Incorrect reset of the gas valve position sensor
2 Injection system faults may be caused by loosened connectors. Make sure that all connections are
efficient.
Check the connections as follows:
1. check that the terminals are not bent.
2. check that the connectors are properly engaged.
3. check if the fault can be fixed by slightly vibrating the connector.
3 Check the entire system before replacing the ECU
If the fault is fixed by replacing the ECU, install the original ECU again and check if the fault occurs
again.
4 For troubleshooting, use a multimeter with internal resistance of more than 10 Ohm / V.
Inappropriate instruments may damage the ECU.
The preferred instruments have a definition of more than 0.1V and 0.5 Ohm , precision must be more
than ±2%.

menù diagnosis tester

Menu of the diagnostic tester
The specific scooter diagnostic tester is provided with a specific software for the diagnostic of the
PUREJET injection system .

Specific tooling
020460Y Scooter diagnosis and tester

The diagnostic tester is provided with a base setting menu.

To select the various functions, proceed as follows:
1. Press «ESC» and «OK» and keep them pressed while enabling the battery power.
2. The display shows the following menu: ECU DIAGNOSTIC, LINK TO PC, CONTRAST SET, LAN-
GUAGE SET, BUZZER SET, VERSION
3. Select ECU diagnostic
4. Select the software for the PUREJET system
5. Wait until the modules are loaded

INJ PJ - 5

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pure jet injection NRG Power Purejet

6. The diagnostic tester is ready for use. The selected software will stay in memory also for the next
uses
N.B.
IF THE SCOOTER DIAGNOSTIC TESTER IS NOT LOADED WITH THE SYSTEM SOFTWARE, UP-
GRADE WITH A PC, THE PROGRAMMING KIT AND THE SOFTWARE TO LOAD. SET THE
DIAGNOSTIC TESTER TO FUNCTION «LINK TO PC» IN THE MENU.
The main menu of the diagnostic tester has the following functions:
• PARAMETERS
• ERRORS
• PARAMETERS STORED
• ERROR CLEARING
• ACTIVE DIAGNOSTIC
• TPS RESET
• CALIBRATION
• ECU INFORMATION
To access the individual functions, the tester must be connected to the vehicle diagnostic outlet and
the ECU must be on.

• To connect the scooter diagnostic tester, raise

the seat
• Remove the left detail shown in the figure

• Extract the grip from the support clip

INJ PJ - 6

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NRG Power Purejet pure jet injection

• Remove the cover from the diagnostic grip

• Connect the diagnostic tester wiring

• Connect the power supply cable with battery ter-

minals to the diagnostic tester
• Connect the terminals to the battery respecting
the polarity: RED (+) - BLACK (-)
N.B.
FAILURE TO DO SO MAY PERMANENTLY IM-
PAIR THE DIAGNOSTIC TESTER

• To disconnect the tester, remove the terminals from the battery

• Remove the connector from the outlet
• Reapply the protection cap to the outlet to prevent dirt from laying onto the contacts
• Refit the battery cover

PARAMETETERS
Specification Desc./Quantity
ENGINE RPM Displays the regime of the engine in all conditions,
including the start-up
ENGINE TEMP. °C Indicates the coolant temperature
THROTTLE OPEN. % Indicates the % of opening of the throttle valve
T. FUEL INJECT. MS Time of opening the fuel injector
AIR INJECTION T. MS Time of opening the air injector
(air- fuel spray)
ADVANCE IGN. ° Advance ignition in degrees before the TDC

INJ PJ - 7

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pure jet injection NRG Power Purejet

Specification Desc./Quantity
VOLTAGE SENSOR V Denotes the voltage of the TPS sensor
TEMP. ENGINE V Denotes the voltage of the coolant temperature in-
dicator
TPS1 OUTPUT V Indicates the TPS1 voltage indicator
TPS2 OUTPUT V Indicates the TPS2 voltage indicator
TPS1 RESET V Indicates the reset voltage of the TPS1 indicator
(voltage referring to the ground)
TPS2 RESET V Indicates the reset voltage of the TPS2 indicator
(voltage referring to the positive 5V)
VOLT. BATT. V Indicates the power supply voltage of the ECU
(normally identical to the power of the vehicle bat-
tery)
T. OF DWELL MS Indicates the core dwell time of the H.V. coil
MIN RPM Indicates the number of engine revolutions set in
the ECU for checking the minimum
INST. CONS.L/H Indicates instantaneous fuel consumption
D. CYCLE CONS. % Indicates the ratio in % between the time in "ON"
and the time in "OFF" of the consumption meter
control indicator (this vehicle is not fitted with this
instrument)
ENGINE STATUS Displays the engine status:
STALL (stationary)
CRANK (starting)
IDLE (idle)
RUN (running)
RUNNING HOURS Displays the engine running time (in hours)
S.T. FUEL PUMP. Denotes the status of the fuel pump (OFF - ON)
TPS TO RESET Indicates the need to repeat the reset of the TPS
indicators (YES- NO)
All the parameters can be displayed by selecting the 4 pages. In case of need, all the parameters can
be stored in the tester by pressing the «TAB» key at the selected time. The parameters are stored as
long as the power of the diagnostic tester is inserted.

ERRORS
Specification Desc./Quantity
G11 P0115 Engine temperature indicator: the voltage of the
coolant temperature indicator is near 0V (short cir-
cuit) or 5V (open circuit).
Temperature indicator off
Light off
G11 P0217 Engine temperature high: the coolant tempera-
ture signal voltage has reached too low voltages.
They denote a very high temperature, higher than
what can be indicated by the instrument panel.
Flashing light
G20 P1120 TPS OFFSET The voltage of TPS signals is not as expected.
Engine is in idle.
Light on
G20 P1123 TPS TPS signals missing
Voltage close to 0V (short circuit)
Voltage close to 5V (open circuit)
Engine to forced idle

INJ PJ - 8

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NRG Power Purejet pure jet injection

Specification Desc./Quantity
Flashing light
G21 P1124 TPS1 OFFSET TPS1 signal is not as expected.
Light off
G21 P1125 TPS1 TPS1 signal missing.
Voltages close to 0V (short circuit)
Voltages close to 5V (open circuit)
Light on
G22 P1127 TPS2 OFFSET TPS2 signal is not as expected.
Light off
G22 P1128 TPS2 TPS2 signal missing
Voltage close to 0V (short circuit)
Voltage close to 5V (open circuit)
Light on
G30 P0560 Battery voltage ECU power supply voltage is below 8.5V or is too
high
Flashing light
G30 P1560 voltage sensor The TPS sensor and coolant temperature sensor
supply voltage are not as expected.
Light off
G30 P1561 Sensor 2 TPS voltage sensor and coolant temperature sen-
sor are not as expected (high temperature).
Engine remains at forced idle
Light on
G40 P0219 Runaway rpm The engine has reached excessive rpm.
Light on
G40 P0335 Rpm pickup The ECU cannot properly recognise the rotation
speed or the engine phase point.
Engine with stall
Light on
G40 P0700 Belt CVT With engine idle or during start up, the automatic
transmission or the clutch has required an excess
driving force. The fault is registered when the en-
gine management is not as expected for 3 con-
secutive times.
Light off
G50 P0251 Fuel injector The ECU has detected an interruption in the injec-
tor circuit. The fault can only be recognised in the
presence of phase - rpm
Light on
G50 P0350 H.V. coil The ECU has detected an interruption in the HV
coil primary supply circuit. The fault can only be
recognised in the presence of phase - rpm.
Engine without injection
Light on
G60 P0230 Fuel pump The ECU has detected an interruption or short cir-
cuit on the power supply line of the pump.
Light on
G60 P0650 Check lamp. The ECU has detected an interruption or short cir-
cuit on the injection indicator supply.
Open circuit: indicator always off
Circuit to ground: light always on
G60 P1561 Temp. indicator The ECU has detected an interruption or a short
circuit on the temperature indicator circuit.
Light off

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Specification Desc./Quantity
G60 P1160 Air injector The ECU has detected an interruption in the injec-
tor circuit. The fault can only be recognised in the
presence of phase - rpm
Light on
Faults are reported by a dark dot on one of the
reference columns. The recognition occurs in 3
modes:
- Dot on the column marked «A». The fault is
«CURRENT» and present during the check

- Dot on the column marked with «O». The letter

denotes «OCCURRED». The fault has occurred
and has been fixed during the same period of use.
The fault may be intermittent and not present dur-
ing the check

- Dot on the column marked with «M». The letter

denotes «STORED», the faults displayed in
«CURRENT» or «OCCURRED» automatically
shifts to «STORED» after switching to «OFF». The
passage to «STORED» always occurs at the end
of the period of use.
N.B.
THE FAULT CAN BE SIGNALLED IN A SINGLE
MODE. THAT IS, THE «CURRENT» AND
«STORED» CONDITIONS CANNOT COEXIST.

Parameters stored
This function displays the parameters stored previously. As already specified in the description of the
parameter function, parameters are stored by pressing the «TAB» key at the selected time.
The diagnostic tester can contain a single memorisation.
It is cancelled out automatically as soon as power is disconnected from the tester.
Error clearing
This function clears any faults and settings recorded by the ECU auto-diagnostic function.
Active diagnosis

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This function is very useful for making an efficiency check of the main components of the system and
related circuits.
The components involved are:

ACTIVE DIAGNOSTICS
Specification Desc./Quantity
AIR INJECTOR Wait for the sound confirming 5 openings
FUEL INJECTOR Wait for the sound confirming 5 openings
HV COIL Wait for the sound confirming 5 coil magnetic ac-
tivity (weak signal)
FUEL PUMP Wait for the sound confirming the pump rotation for
approx. 30 seconds.
TEMPERATURE INDICATOR The indicator increases to display an average tem-
perature, then returns to the rest position (to per-
form with cold engine)
CHECK LAMP The light is normally on. The diagnostic is con-
firmed when the light turns off briefly.
ODOMETER Instrument not present on the vehicle
CONSUMPTION GAUGE Instrument not present on the vehicle
When the various diagnostics are enabled, the tester displays its results «ENDED SUCCESSFULLY»
or «FAILED».
The tester results must always be combined with sound or visual checks.
The tester can confirm transmission of the command but cannot check the actual power supply or
efficiency of the circuit under testing.

Resetting the TPS

This function allows combining the throttle body with the ECU.
Calibration
This function makes it possible to insert new calibrations to the ECU with the product developments.
ECU information
The tester displays the following information:
- N. SER. = ECU serial number
- HW REV = Hardware revision N°
- ECU SW = ECU software reference
- CALIBR = Calibration reference

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terminal layout on cpu

1 - Ground
2
3 - Fuel injector (negative)
4 - To diagnosis indicator (negative)
5 - Coolant temperature indicator (button negative)
6 - Analogue rev. counter signal
7 - Signal TPS 1
8
9 - Coolant temperature sensor (positive)
10 - SignalTPS 2
11
12 - HV coil (negative)
13 - Air injector (negative)
14 - Fuel pump (negative)
15 - ECU power supply (+12V)
16 - Coolant sensor and TPS sensor ground
17 - Power supply (+12V)
18 - TPS sensor positive (+5V)
19 - Phase rpm sensor positive
20 - Phase rpm sensor negative

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21 - Serial line for diagnostic tester

EMS system diagram

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EMS SYSTEM
Specification Desc./Quantity
1 Digital instrument unit
2 Fuse 5A
3 Key switch contacts
4 EMS diagnostic socket
5 Fuel pump
6 Battery 12V - 9Ah
7 Fuse 20A
8 Air injector
9 Throttle position sensor
10 HV coil
11 Flywheel magneto
12 Voltage regulator
13 Fuel injector
14 Water temperature sensor
15 Injection ECU

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cpu power circuit

ECU POWER SUPPLY CIRCUIT

Specification Desc./Quantity
1 Digital instrument unit

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Specification Desc./Quantity
2 Fuse 5A
3 Fuel pump
4 Key switch contacts
5 Fuse 20A
6 Battery 12V - 9Ah
7 Air injector
8 HV coil
9 Voltage regulator
10 Fuel injector
11 Injection ECU
1-Turn the key switch to the «ON» position
Check the following conditions:
- Ignition light on steady
- Fuel pump activated for approx. 4-5 seconds
YES point 2 NO point 3 NO point 4 NO point 6 NO point 14
2- The ECU supplies are currently present.
GO TO point 9
N.B.
WHEN THE SWITCH IS ON «ON», ALL SERVICES ARE ACTIVATED. IF THERE ARE ANY FAULTS,
REFER TO SECTION «VEHICLE ELECTRICS».
3- The ignition light is flashing.
GO TO point 5
4- The ignition light does not switch on and the pump is correctly activated. Perform all the checks
required in the injection light section.
5- Connect the diagnostic tester of scooter. Select the «errors» function and check the faults that are
signalled in current status.
GO TO point 7 GO TO point 8

Specific tooling
020460Y Scooter diagnosis and tester
6-The fuel pump did not start, but the ignition light is normally switched on. Perform all the checks
required in the «pump supply» section.
GO TO point 13
7- In current mode, the tester signals faults relating to:
- engine temperature
- TPS
Make all checks reported in the relating sections The ECU supply meets specs.
8- In current mode, the tester signals faults relating to the "battery voltage"
GO TO point 10
9- Connect the diagnostic tester of the scooter. Select the errors function. Check faults relating to «bat-
tery voltage » in stored status
YES point 15 NO point 16

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Specific tooling
020460Y Scooter diagnosis and tester

10- Measure the battery voltage.

GO TO point 11
GO TO point 12
11- Voltage is lower than 8.5 V. Recharge the battery.
GO TO point 15
12- The battery voltage is between 8.5 and 14.5 V
GO TO point 18
13- The ECU supplies are currently present. For a complete check, perform the check as described at
point «A»
14- The ignition light did not switch on. The fuel pump is not activated. When connecting the diagnostic
testers, the following message appears: «the ECU does not respond, check all connections».
GO TO point 19

Specific tooling
020460Y Scooter diagnosis and tester

15- Check the charger.

GO TO point 17
16- The ECU supplies are conform.
17- Check all electrical installation connections for any possible problems that are related to loosening
or oxidation.
GO TO point 20
18- Check the main supply.
GO TO point 20
19- Check the power supply to panel.
GO TO point 20
20- Prepare the interface wiring with adapter 3. Install the specific tool as described here:
- Remove the 20A fuses
- Disconnect the connector from the ECU
- Connect the specific tool to the vehicle installation, not connecting the ECU
- Re-connect the 20A fuse
This toll, mounted this way, allows all checks on the installation sections
GO TO point 21

Specific tooling
020481Y Control unit interface wiring

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21- Check on the ground connection.

Check the ground connection on pin n°1 by using
the multimeter.
1 - battery positive = battery voltage
YES point 22 NO point 23

22- The ground line is efficient.

GO TO point 24
23- Check and restore where necessary the direct
ground line to the battery.
GO TO point 21
24- Check the main supply.
Check the presence of battery positive voltage on
pin 15.
1 - 15 = battery voltage
YES point 25 NO point 26

25- The supply is conform.

26- Check the efficiency of the 15A fuse and of the
connections to the fuse-holder (red - blue)
YES point 27 NO point 28
27- Restore the continuity of the line connecting
fuse with pin 15 (blue cable)
GO TO point 24
28- If connections are conform and the fuse is
burnt, proceed as follows: Disconnect the follow-
ing connectors:
- Air injection
- Fuel injection
- H.V. core.
- Voltage adjuster
GO TO point 29
29- Remove the burnt fuse. Check the mass insu-
lation of the pin 15 supply line
1 - 15 = Ohm infinite
YES point 31 NO point 30

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30- Restore the wiring insulation.

GO TO point 29
31- Connect the specific tool to the ECU. Mount a
new 20A fuse. Check the presence of battery volt-
age between pin 15 and pin 1 ( the fuse does not
burn)
1 - 15 = V battery
YES point 33 NO point 32
32- The fuse is again burnt. Check the wiring more
accurately and, if necessary, replace the ECU.
GO TO point 31
33- Make a good visual check of the wiring to avoid
possible causes for short circuits. If there are no
faults, check any possible short circuits in the lines
connecting the following components:
- air injector
- fuel injector
- H.V. coil
- Voltage adjuster
GO TO point 24
34- After confirmation of the correct main supply
(point B) check the power supply to panel. Check
the following conditions:
1 - 17 = battery voltage (switch on «ON»)
1 - 17 = 0V (switch on «OFF»)
YES point 35 NO point 36
35- The ECU power supply to panel is conform.
36- Check the efficiency of the 20A fuse and of the connections to the fuse-holder red - blue.
YES point 37 NO point 40
37- Check the efficiency of the key switch.
YES point 39 NO point 38
38- Replace the key switch.
GO TO point 34
39- Restore the continuity of the wiring from fuse holder to pin 17
GO TO point 34
40- If connections are conform and the fuse is burnt, proceed as follows: Disconnect the following
connectors:
- Disconnect the specific tool 020481Y from the ECU

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- Remove the 2 5 A fuses

- Remove the connector of the fuel pump
GO TO point 41

Specific tooling
020481Y Control unit interface wiring

41- Remove the burnt 20A fuse. Check the mass

insulation of the supply line of pin 17 with the
switch on «ON»
1 - 17 = Ohm infinite
YES point 43 NO point 42
42- Restore the mass insulation of the wiring or of
the key switch.
GO TO point 34
43- Re-connect the specific tool with the ECU
Mount a new 20A. fuse Check the following con-
ditions:
1 - 17 = battery voltage (switch on «ON»)
1 - 17 = 0 Volt (switch on «OFF»)
YES point 45 NO point 44

44- IlThe fuse is again burnt. Check the wiring more accurately and, if necessary, replace the ECU
GO TO point 34
45- Make a good visual check of the wiring to avoid possible causes for short circuits. Reconnect the
5 A fuses. If there are no anomalies, check any possible short circuits or absorbance on the supply
circuit of the fuel pump.
GO TO point 34

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diagnosis tester connection circuit

COMPONENTS LAYOUT:
1 ECU
2 Diagnostic outlet
A + Under-panel
B + Fixed
Connect the scooter diagnostic tester.
Enter the main menu and select a function.
If the diagnostic tester returns «ECU not responding, check connections», proceed as follows.

Specific tooling
020460Y Scooter diagnosis and tester

1. Check that the insertion of the connection to the

vehicle is correct.
YES point 3 NO point 2
2. Restore the connection.
3. Turn to «OFF», wait a few seconds and turn
again to «ON». If the fault persists, make the fol-
lowing checks:
GO TO point 4
4. Check the ECU supplies.

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GO TO point 5
5. Disconnect tester from diagnostic connector.
Check the continuity of the ground line between
diagnostic connector and vehicle mass.
Diagnostic connector Pin «2» - Battery negative =
continuity
YES point 7 NO point 6

6. Restore the continuity of the ground line.

7. Connect the interface wiring.
Do not connect the wiring with the ECU. Check the
continuity of the line between the diagnostic con-
nector and ECU.
Pin 3 = diagnostic connector
Pin 21 = continuity
YES point 9 NO point 8

Specific tooling
020481Y Control unit interface wiring
8. Restore the wiring continuity.
9. Check the insulation of the line connecting the
diagnostic connector with the ECU.
(Keep the ECU disconnected)
21 - 15 > 1MOhm
21 - 1 > 1MOhm
YES point 11 NO point 10

10. Restore the wiring connection.

11. The diagnostic tester connection meets specs. If the problem persists, check the diagnostic tester
and the ECU, if necessary.

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Injection lamp circuit

THERMIC: 1 - 4
CONDITIONS: Key selector set to «ON», engine off
STANDARD:Less than 0.1 V
THERMIC: 1 - 4
CONDITIONS: Key selector set to "ON", engine on, no fault detected
STANDARD: Battery voltage

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INJECTION LAMP CIRCUIT

Specification Desc./Quantity
1 Digital instrument unit
2 Fuse 5A
3 Key switch contacts
4 Fuel pump
5 Injection ECU

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Specification Desc./Quantity
6 Fuse 20A
7 Battery 12V - 9Ah
The injection lamp must go on every time «ON» is switched on and remain on until the engine is started.
When the autodiagnosis detects a fault, it turns on the lamp based on the level of priority:
• PRIORITY 1 = FLASHING
• PRIORITY' 2 = ON
See autodiagnosis
Turning on of the lamp is controlled by the ECU by managing the negative. If necessary check the
operation of the ECU.
Using the scooter tester select the «enable diagnosis» function.
Activate the «check - lamp» diagnosis with the switch in the «ON» position and engine off. The light
which is normally on, which go off for an instant confirming that the ECU is operational.
The operation of the autodiagnosis lamp is also enabled on the injection lamp circuit.

Specific tooling
020460Y Scooter diagnosis and tester

1. Connect the scooter diagnostic tester . Select the errors function. Check the presence of error P0650
CHECK LAMP
YES point 3 NO point 2

Specific tooling
020460Y Scooter diagnosis and tester

2. Control circuit and lamp are efficient

3. Any faults in current status would be perceived
before connecting the diagnostic circuit. To check
the circuit, proceed as follows.
GO TO point 4
4.Connect the interface wiring to the system, omit-
ting the connection to the ECU. Switch to «ON»
and check the following condition:
1 - 4 = battery voltage
lamp off

Specific tooling
020481Y Control unit interface wiring

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5- Remove the 5A fuse (white lead) and check the

presence of voltage.
1 - 4 = 0V
YES point 6 NO point 7

6. The lamp control circuit is efficient.

7. Access the instrument unit and disconnect the
8-pin connector. Check the positive insulation of
the connection line to the ECU
1 - 4= 0V
Restore the wiring in case of faults

8.Battery voltage is lacking and the lamp is off.

Access the instrument unit and disconnect the 2
electrical connectors. Check the presence of volt-
age between white lead (+) and black lead (-)
Black(2/4) - White(5/8) = battery voltage with
switch to «ON»
YES point 10 NO point 9

9. Positive power to panel missing. This comes

from the switch and the 5A fuse. Power supply is
shared by the fuel level indicator and other uses.
Restore the wiring continuity.
GO TO point 8
10. Check the instrument panel injection lamp.
YES point 12 NO point 11
11. Replace the lamp.
12. Check the continuity of the negative line from
the instrument unit to the ECU
GREY(1/4) - pin 4 = 0Ohm (continuity)
If there is no continuity, restore the wiring.

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13. Battery voltage is missing and the lamp is on.

Access the instrument unit and disconnect the 8-
pin connector. Check the ground insulation of the
connection line
1 - 4 > 1MOhm
In case of faults, restore the wiring.

throttle position sensor circuit (T.P.S.)

TERMINALS: 16 (-) - 18 (+)
CONDITIONS: Key switch set to «ON»
STANDARD VALUES: 5V
TERMINALS: 16 - 7
CONDITIONS: Key switch set to «ON», opening the gas gradually
STANDARD VALUES: V= progressive increase
TERMINALS: 16 - 10
CONDITIONS: Key switch set to «ON», opening the gas gradually
STANDARD VALUES: V= progressive decrease

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THROTTLE POSITION SENSOR CIRCUIT (T.P.S.)

Specification Desc./Quantity
1 Key switch contacts
2 Fuse 20A
3 Battery 12V - 9Ah
4 Injection ECU
5 Coolant temperature sensor
6 Valve position sensor
The throttle position sensor (TPS) is a built-in part of the throttle body and cannot be removed. The
sensor receives 5V power (electronically determined) from the ECU. The 5V power is used for the TPS
sensor circuit and coolant temperature circuit. The TPS sensor is a double reading sensor, which means
two resistive tracks which generate two opposite signals defined as TPS1 and TPS2. The TPS1 signal
increases with increased throttle opening. The TPS2 signal decreases with increased throttle opening.
The two signals are equivalent at a single point corresponding to average opening (50%). The two
signals are converted to a percentage value of throttle opening. The dual reading system allows for
greater control, since the TPS1 and TPS2 signals are compared to each other and a reference map. If
missing or out of line TPS signals are detected autodiagnosis is activated and the related fault code is
generated. Faults are generated according to three priority levels. The TPS signals in combination with
the rpm-timing signal are the basic reference for the operation of the built-in injection - ignition system.

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The throttle position sensor and related circuit can be checked by using the scooter tester.

Specific tooling
020460Y Scooter diagnosis and tester

For the check, proceed as follows.

Connect the diagnostic tester to the vehicle. Select the «parameters» function. The following values
are reported:
THROTTLE OPEN. %
The displayed value refers to the valve opening percentage. Check that a progressive actuation of the
valve corresponds to an equal increase of the opening percentage value. A 0% percentage denotes
the minimum position (approx. 20% opening)
TPS1 OUTPUT = V
TPS2 OUTPUT = V
The displayed tensions refers to the TPS1 and TPS2 signals. Progressively open the valve and check
the following conditions:
TPS1 - Increases progressively
TPS2 - Decreases progressively
Set the valve opening to 50% and check that at this value the signals TPS1 and TPS2 are equal or very
close (a few hundreds volts difference).
N.B.
FOR A MORE PRECISE CHECK, PROGRESSIVELY OPEN THE VALVE DIRECTLY BY THE
THROTTLE BODY. USING A FLEXIBLE TRANSMISSION CAUSES AN IRREGULAR OPENING
TPS1 ZERO = V
TPS2 ZERO = V
TPS TO REST = (NO - YES)
The TPS signal reset function is used when signals TPS are efficient.

Select the errors function.

Check the following errors and relevant ISO codes:

ERROR AND ISO WARNING ORIGIN ENGINE BEHAV- INJECTION

CODE IOUR LIGHT
P1123 Both TPS signals missing. Acknowl- Forced idle Flashing
TPS edgement occurs when voltages are
close to:
0V = short circuit
5V = open circuit
In the event of intermittent fault, the sys-
tem switches to the "occurred" status.
To reset the function, switch ON - OFF

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- ON to allow switching to the stored sta-

tus.
P1125 TPS1 signal missing. Acknowledge- Free On
TPS1 ment occurs when the signal voltage is
close to:
0V = short circuit
5V = open circuit
P1128 TPS2 signal missing. Acknowledge- Free On
TPS2 ment occurs when the signal voltage is
close to:
0V = short circuit
5V = open circuit
P1120 The voltage of both TPS signals in not Stays idle On
TPS OFFSET as expected. The fault is recognised by
comparing the signals with the power
supply polarity
P1124 The voltage of TPS1 signal in not as ex- Free Off
TPS1OFFSET pected. The fault is recognised by com-
paring the signals with the TPS1 power
supply polarity
P1127 The voltage of TPS2 signal in not as ex- Free Off
TPS2 pected. The fault is recognised by com-
paring the signals with the TPS2 power
supply polarity
P1560 The TPS sensor and coolant tempera- Off
SENSOR ture sensor power supply voltage do not
VOLTAGE meet specs.
P1561 (*) The TPS sensor and temperature sen- Forced idle On
VOLTAGES sor power supply voltage does not meet
SENSOR 2 specs. Too high voltages may be rec-
ognised.
If one or more errors are detected, or differences are detected between the values shown in the pa-
rameters, check the circuit and sensor using the troubleshooting procedure.
1. Install the interface wiring ECU.
Specific tooling
020481Y Control unit interface wiring
Omit the connection to the ECU. Disconnect the connector of sensor TPS and of the coolant temper-
ature sensor.

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GO TO point 2
2. Use a multimeter to check the wiring continuity.
N° 1 (TPS) - 16 (ECU) = Ohm Continuity
N° 2 (TPS) - 7 (ECU) = Ohm Continuity
N° 3 (TPS) - 10 (ECU) = Ohm Continuity
N° 4 (TPS) - 18 (ECU) = Ohm Continuity
YES point 4 NO point 3
3. Restore or replace the wiring.
GO TO point 2
4. Check the earth insulation of the wiring with disconnected battery power supply
1 - 16 > 1 MOhm
1 - 7 > 1 MOhm
1 - 10 > 1 MOhm
1 - 18 > 1 MOhm
YES point 6 NO point 5
5. Replace or restore the wiring.
GO TO point 4
6. Check the wiring positive insulation.
N.B.
THE CHECK SHOULD BE PERFORMED WITH THE BATTERY CONNECTED, KEY SWITCH SET
TO «ON» AND EFFICIENT FUSES.
1 - 16 = 0 Volt
1 - 7 = 0 Volt
1 - 10 = 0 Volt
1 - 18 = 0 Volt
YES point 8 NO point 7
7. Restore or replace the wiring.
GO TO point 6
8. Check the reciprocal insulation of the TPS sen-
sor connection lines.
16 - 7 - 10 - 18
Reciprocal insulation > 1 MW
Check the connector efficiency.
YES point 10 NO point 9
9. Replace or restore the wiring.
GO TO point 8
10. Connect the ECU connector, switch to «ON».
Check the TPS sensor power supply.

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16(-) - 18(+) = 5 V
YES point 12 NO point 11

11. Carefully check the ECU power supply. Re-

place the ECU if required.
GO TO point 10
12. Connect the TPS sensor connector and meas-
ure the voltage.
16(-) - 18 (+) = 5 V
YES point 14 NO point 13

13. Voltage measured: 0 V or much lower than 5V.

Check the connector and replace the throttle body,
if required.
Replacement
Resetting
GO TO point 12
14. Measure the voltage of the TPS1 and TPS2
16 - 7 = V TPS1 (increasing with the opening from
0.5 to 4.5V)
16 - 10 = V TPS1 (decreasing with the opening
from 4.5 to 0.5V)
Voltage variations must be progressive with gas
opening, without stall or direction reversal. The
sum of voltages TPS1 and TPS2 must be constant
and with values slightly lower than the TPS sensor
power supply voltage.
YES point 16 NO point 15

15. Check the TPS and ECU connectors and replace the throttle body, if required.
Replacement
Resetting
GO TO point 14
16. Check that the voltage values of signals TPS1 and TPS2 measured match those shown by the
diagnostic tester in the «parameters» function.
YES point 18 NO point 17

Specific tooling
020481Y Control unit interface wiring
020460Y Scooter diagnosis and tester

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17. When slightly different voltage values are found, check the ECU connector more thoroughly and
replace the ECU if required.
18. TPS sensor and circuit meet specs.

T.P.S. signal reset

The throttle body is supplied with gas valve and is precalibrated. Precalibration entails regulating the
minimum opening of the gas valve to obtain a certain flow of air under preset reference conditions.
Pre-calibration results in an optimum air capacity for the engine management during start up or during
idle running, and at any possible temperature during the use of the vehicle. This is allowed by the
electronic management of the engine and by its capacity to work with very lean air - fuel mixtures. In
fact, pre-calibration results in an air capacity which, with idle and hot engine, is much higher than the
actual requirements.
To achieve higher engine performance, increased rpm are not due to the gas valve opening increase,
but are enabled by the ECU.
When the ECU perceives a slight increase in the gas valve opening, it enables the engine to fast rotation
and excludes the idle and the CUT OFF management.
This result can be obtained by recovering the pre-calibration and keying tolerances of the TPS sensor
on the throttle body.
This occurs by resetting the signals TPS1 and TPS2, i.e., by reporting the voltage values TPS1 and
TPS2 corresponding to the pre-calibration position to the ECU.
These voltage values will be recognised as suitable by the ECU only if falling within the design default
ranges.
The throttle body pre-calibration register is sealed with paint and must not be tampered with.
The signals TPS1 and TPS2 may be reset as follows:
- Automatic reset
- Manual reset

Specific tooling
020460Y Scooter diagnosis and tester

automatic T.P.S. reset

AUTOMATIC RESET
Automatic reset already occurs at the end of the assembly line when the battery power is connected
and switched to «ON». In order to prevent resetting the signals TPS1 and TPS2 not corresponding to
the actual pre-calibration position of the throttle body, the ECU should only be powered after checking
that the valve command sector is correctly abutted against the register. A slight tensioning of the flexible
transmission commanding the throttle body may impair the reset precision and the injection control.

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A greater tensioning causes signals TPS1 and TPS2 whose voltage is not as expected by the ECU,
which cancels the reset procedure.
To check that TPS signals are properly reset, use the following procedure:
1- Connect the scooter diagnostic tester
Select the «parameters» function and visualise the indicator showing the «TPS to reset»
GO TO point 2
GO TO point 4
2. The diagnostic tester responds YES. Continue to make the following checks:
- The throttle body is not tampered with
- The control transmission is correctly registered
- The connector of the throttle body is correctly connected
- The electric circuit control meets specs.
GO TO point 3
3. Carry out the manual reset procedure.
4. The diagnostic tester responds NO. The reset procedure was successful.
GO TO point 5
5. For a further confirmation, check the following indications of the "parameters" function.
TPS1 OUTPUT V 0.64
TPS2 OUTPUT V 4.27
TPS1 ZERO V 0.64
TPS2 ZERO V 0.72
The voltage reported here corresponds to a possible condition.
GO TO point 6
6. Check the following conditions:
TPS1 OUTPUT = TPS1 ZERO
TPS2 OUTPUT + TPS2 ZERO = 5V
YES point 7 NO point 8
7. The TPS reset meets specs.
8. Repeat the reset procedure using the manual mode.

Specific tooling
020460Y Scooter diagnosis and tester

Manual T.P.S. reset

MANUAL RESET
This procedure is required when the ECU or the throttle body is replaced. Before resetting, check the
following conditions:
- The throttle body has not been tampered in pre-calibration
- The throttle body connector is properly inserted

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- The control transmission is properly installed and adjusted

Proceed to manually reset the signals TPS1 and TPS2 as follows:
1- Connect the scooter diagnostic tester
Select «RESET TPS» from the menu. By using this procedure, the following indications are visualised.
GO TO point 2
2. Check for possible errors
Wait
GO TO point 3
GO TO point 4
3. Errors present
Cancel all errors
Press a key
GO TO point 5
4. No errors
Press a key
GO TO point 6
5. Check the auto-diagnostic content and make the necessary repairs
GO TO point 1
6. TPS reset in process
Wait
GO TO point 7
7. Key «OFF»
Press a key
GO TO point 8
8. Check the abut of the throttle body
Push OK to proceed
GO TO point 9
9. Wait
GO TO point 10
10. Key on «ON»
Press a key
GO TO point 11
11. Wait
GO TO point 12
12. Check for possible errors
Wait
GO TO point 13
13. No errors

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Press a key
GO TO point 14
14. Wait
GO TO point 15
15. TPS resetting successful
Press a key
GO TO point 16
16. The manual procedure is completed. For a further confirmation, check that the indications reported
in the parameters function comply with the instructions given for automatic reset.

rpm-timing sensor circuit

TERMINALS: 19 - 20
CONDITIONS: Engine driven by the starter (500-600 RPM)
STANDARD VALUES: V = 3.5 - 4
TERMINALS: 19 - 20
CONDITIONS: Idle engine
STANDARD VALUES: V = 11 - 12

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RPM-TIMING SENSOR
Specification Desc./Quantity
1 Fuse 20A
2 Battery 12V - 9Ah
3 Key switch contacts
4 Pick - up
5 Injection ECU
This built-in injection and ignition system, requires a prompt perception of the rotation speed and angular
position of the crankshaft. With each engine cycle the ECU, must manage the following, in order:
• Petrol injector
• Air injector
• H.T. coil
Each actuator is managed with a specific timing. This is made possible by the rpm timing sensor from
a phonic wheel on the external diameter of the magneto rotor. The magneto is subdivided into 24 sectors
and has 23 control teeth of the air gap variations at the nucleus of the pick-up. This is a reluctance
variation type, it has its own magnetism and produces alternating voltage. When the magneto rotates,
each of the teeth changes the magnetic activity of the nucleus, generating a complete alternation. These
continue every 15° making a precise measurement of the rotation speed possible, even at a periodic
level. The perception of the angular position occurs via alternations separated by 30° of rotation due to
the missing teeth. The electrical lines connected with the ECU are polarised to guarantee correct timing.
The positive peak of the alternated signal is separated from the negative by around 2° of rotation.
The ECU autodiagnosis checks the rpm - timing signal, even if this activity is limited to recognition of
signal irregularities within an engine cycle. These cases occur with missing combined with a signal to
the driver via the injection lamp going on. This is different than a clean interruption of the signal, which
leads to the engine going off without any recognition of the fault by the autodiagnosis. When the rpm -
timing signal is missing, management of the following actuators also fails:
• Petrol injector
• Air injector
• H.T. coil
• Petrol pump
1- Connect the scooter diagnostic tester. Select the «errors» function on the menu. Check the presence
of the error:
P0335 PICK UP RPM
YES point 2
GO TO point 3

Specific tooling
020460Y Scooter diagnosis and tester
2. The ECU has detected instability of the phase rpm signal. Proceed as follows, regardless of the
storage status (current - occurred - stored).

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GO TO point 4
3. The ECU has detected no fault relating to the phase - rpm signal. The signal may be totally missing.
To check, proceed as follows.
GO TO point 4
4. Connect the interface wiring. Omit the connection to the ECU. Disconnect the connector from the
flywheel magneto.
GO TO point 5

Specific tooling
020481Y Control unit interface wiring

5. Check the continuity of the connection lines of

the sensor from the ECU to the flywheel connector
19 - red lead= Ohm continuity
20 - brown lead= Ohm continuity
YES point 7 NO point 6

6. If continuity is not detected, restore or replace

the wiring.
GO TO point 5
7. Check the ground insulation of the lines
1 - 19 > 1MOhm
1 -20 > 1MOhm
YES point 9 NO point 8

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8. Restore the insulation or replace the wiring.

GO TO point 7
9. Check the reciprocal insulation of the lines
19 - 20 > 1MOhm
YES point 11 NO point 10

10. Restore the insulation or replace the wiring.

GO TO point 9
11. Check the line positive insulation.
1 - 19 = 0V
1 - 20 = 0V
YES point 13 NO point 12
N.B.
THE CHECK SHOULD BE PERFORMED WITH
THE BATTERY CONNECTED, KEY SWITCH
SET TO «ON» AND EFFICIENT FUSES.

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12. Restore the insulation or replace the wiring.

GO TO point 11
13. Connect the flywheel connector and repeat the
insulation checks from earth and from positive.
1 - 19 > 1MOhm
1 - 20 > 1 MOhm
YES point 15 NO point 14

14. Restore or replace the stator with phase - rpm

sensor.
GO TO point 17
15. Check the phase - rpm sensor resistance
19 - 20 = Ohm…… at 20°
(detected 106.7W)
YES point 17 NO point 16
N.B.
IF THE CHECK IS DONE WHEN THE ENGINE IS
HOT, RESISTIVE VALUES WILL BE HIGHER
16. When out of tolerance resistive values are de-
tected, replace the stator with phase - rpm sensor.
17. Measure the alternated voltage produced by
the phase - rpm sensor with engine driven by the
starter.
19 - 20 = 3.5 ¸ 4 V ~
(at 500 - 600 RPM)
YES point 19 NO point 18

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18. Check the magnetic activity and gap of the

phase - rpm sensor. Replace the stator if required.
GO TO point 17
19. Connect the interface wiring to the ECU. Check
the alternated voltage upon start up and at idle.
19 - 20 = 3.5 - 4 V~
(start up)
19 - 20 = 11 - 12 V~ (idle)
YES point 21 NO point 20

20. If voltages are very different, replace the ECU

GO TO point 19
21. The phase - rpm sensor and relevant circuit are efficient.

H.T. coil circuit

TERMINALS: 1 - 12
CONDITIONS: Engine stopped, switch in any position
STANDARD VALUES: Battery voltage

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PETROL INJECTION CIRCUIT

Specification Desc./Quantity
1 Key switch contacts
2 Fuse 20A
3 Injection ECU
4 Air injector
5 Battery 12V - 9Ah
6 HV coil
7 Fuel injector
The ignition system with built-in injection is an induction type. Ignition is managed based on two pa-
rameters:
• Ignition lead
• Dwell time
The ignition lead curve is optimised based on the rpm and engine load perceived by the TPS1 and
TPS2 sensors. The dwell time is optimised based on the power required by the H.T. coil. The dwell time
is optimised based on the power required by the H.T. coil.
Naturally longer dwell times are used during starting phases.

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The ECU autodiagnosis also checks the coil power circuit and detects interruptions and shorts. Check-
ing is normally only done in the presence of the rpm - timing signal (engine running). Any faults are
signalled to the driver via the injection lamp. In addition to protect the vehicle, the injector power is
interrupted, its operation is not automatically reset, thus preventing use with backfiring. To reset oper-
ation, it is necessary to switch «ON» to «OFF» and then «ON». The fault is recorded without the
possibility of moving to «PAST EVENTS».

CIRCUIT DIAGNOSIS
1- Connect the scooter diagnostic tester. Select the active diagnostic function.
GO TO point 2

Specific tooling
020460Y Scooter diagnosis and tester

2. Start the diagnostic of H.V. coil. Check if 5 ignitions are controlled. These can be detected by the
noise produced by the magnetic activity and from the spark on the plug. If this check is not possible,
use an external spark plug and check the 5 sparks directly.
YES point 3 NO point 4 NO point 5
3. There are 5 sparks. The ignition system is working. For greater certainty, continue with the auto-
diagnostic check in order to highlight stored errors.
4. No sparks present, even if the result is: "test successful". Continue with circuit checks. If there are
no faults, replace the ECU
GO TO point 2
5. No sparks present. The result is: «test failed» Repeat the diagnostic and, if necessary, replace the
ECU.
GO TO point 2

CHECKING THE auto-diagnostic MESSAGE

1- Connect the scooter diagnostic tester. Select the «errors» function on the menu. Check if there are
any errors on the H.V. coil.
P0350 H.V. COIL
YES point 3 YES point 4 NO point 2

Specific tooling
020460Y Scooter diagnosis and tester

2. No errors. To be more sure, check:

- Spark plug
· H.V. coil secondary
- Shielded cap
- Ignition timing
3. Error on the H.V. coil in current status. Continue with circuit checks.
4. Error on the H. V. coil in «occurred» or stored status. Continue with circuit checks. Possible problems:

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- Uncertain contacts
- Lacking insulation

CHECKING THE ELECTRIC CIRCUIT

1. Connect the interface wiring. Do not connect the ECU. Disconnect the connector of the H.V. coil
primary.
GO TO point 2

Specific tooling
020481Y Control unit interface wiring

2. Check that there is a positive battery voltage to

the connector supplying the primary with the
switch in any position.
1 - blue cable (positive) = battery voltage
YES point 4 NO point 3
N.B.
TO MAKE THIS CHECK, USE A SMALL SOCK-
ET. PAY ATTENTION NOT TO DAMAGE THE
CONNECTOR

3. Check the efficiency of the 20A fuse. If neces-

sary, restore the wiring. See ECU supply.
GO TO point 2
4. Check the continuity of the control line of the
coil.
12 - violet - black= continuity
YES point 6 NO point 5
N.B.
TO MAKE THIS CHECK, USE A SMALL SOCK-
ET. PAY ATTENTION NOT TO DAMAGE THE
CONNECTOR
5. Restore the wiring.
GO TO point 4
6. Check the insulation - from positive - of the con-
trol line of the coil.
1 - 12 = 0V
YES point 8 NO point 7

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7. Restore the wiring

GO TO point 6
8. Check the insulation - from negative - of the
control line of the coil.
1 - 12 > 1MOhm
NO point 9
GO TO point 10

9. Restore the wiring.

GO TO point 8
10. Check the resistance of the primary wiring of
the H.V. coil.
Standard value: 0.63 ± 0.03 Ohm at 23°C
YES point 12 NO point 11

11. If notably different resistances are detected,

replace the H.V. coil.
GO TO point 10
12. Check the ground insulation of the primary wir-
ing. To make this check, measure the resistance
between one of the primary poles and the bar sup-
porting the coil to the frame.
Standard value> 1MOhm
YES point 14 NO point 13

13. If lower values are detected, replace the H.V.

coil.
GO TO point 12
14. Check the resistance of the screened cap as
shown in the figure
Standard value= 5 KOhm ±
YES point 16 NO point 15

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15. Replace the screened cap.

GO TO point 14
16. Reconnect the following components:
- Shielded cap
- H.V. coil supply connector
- ECU interface wiring:
GO TO point 17
17. With the engine idle, measure the induced
voltage produced by the H.V. coil primary. In this
case, use the digital multimeter and the peak vol-
tages adaptor.
1 - 12 = 300V (peak)
Minimum allowable voltage ³ 200V (peak)
Standard voltage at start-up= about 350V
(peak)
YES point 18 NO point 19
N.B.
USE THE ADAPTER WITH THE POSITIVE
PROD ON PIN 12. IF THE ENGINE DOES NOT
START, CHECK THE INDUCED VOLTAGE AT
THE START-UP
Specific tooling
020331Y Digital multimeter
020409Y Multimeter adaptor - Peak voltage de-
tection
18. The system is efficient, check timing.
19. If the detected voltage is much lower than the minimum allowable, check the core dwelling time
reported in the «parameters» function of the diagnostic tester
T. OF DWELL =
6 ms (start-up)
2 ÷ 3 ms (idle)
YES point 20 NO point 21
20. Replace the H.V. coil
21. Replace the ECU

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ignition timing check

The ignition advance is electronically determined
on the basis of the ECU parameters. For this rea-
son, it is not possible to state reference values
based on the engine rpm.
The ignition advance value can be detected by the
parameters function of the diagnostic tester. The
degrees displayed in the parameters function may
be checked for matching with the actual ignition
command degrees.

The following is required for this check:

• Diagnostic tester
• Stroboscopic lamp
• Adapter for the H.V. cable signal
Remove the flywheel cover. Adjust the adapter for
detecting the H.V. cable signal to a position be-
tween the 4th and the 5th reference and install it
between the spark plug and the original cap. Con-
nect the induction clips of the stroboscopic lamp to
the screened cable of the adapter according to
their polarity. Select the lamp control to the con-
ventional engine 2T position (1 spark = 1 rev). With
engine idle, set a degree phasing on the lamp
equal to the indication of the advance shown in the
tester parameters.

Check that the fifth to last tooth in the direction of

rotation is aligned with the rpm - phase sensor
core, as shown in the figure. The position denotes
the top dead centre.

Checking a clear lack of correspondence of the advance values, continue with checks on the phase -
rpm sensor and the ECU.
N.B.
THE STROBOSCOPIC LAMP CANNOT DISPLAY A FLYWHEEL KEYING ERROR. TO THIS PUR-
POSE, IF YOU HAVE ANY DOUBTS, CHECK THAT THE FLYWHEEL POSITION INDICATED IN
THE FIGURE ACTUALLY MATCHES THE TOP DEAD CENTRE.

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Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light for timing control
020621Y HV cable extraction adaptor

compressed air system

Direct injection in the cylinder takes place by pressure of the compressed air. The injection pressure is
vital to ensuring the correct fuel preparation and pulverisation of the mix.
The system consists of the following components:
- Volumetric compressor
- Injectors support
- Connecting union
- Fuel pressure regulator control chamber
- Air injector
The mechanical installation of these components is described in the chapter relating to engine. This
section of the manual deals with the pneumatic inspections on the system.
To perform pneumatic inspections on the compressed air system, proceed as follows.
1- Remove the air supply duct of the injectors and install the air pressure control kit
GO TO point 2
N.B.
BE VERY CAREFUL WHEN CLEANING THE PARTS AND MAKING THE PROPER CONNECTION
OF UNIONS. ANY IMPURITY MAY DAMAGE THE AIR INJECTOR. AVOID REMOVING THE RUB-
BER HOSE FROM THE BRASS HOSE HOLDERS. IF REQUIRED, REPLACE THE HOSE.
Specific tooling
020617Y Air pressure check kit

2- Remove the following electrical connectors:

- Air injector
- Fuel injector
- H.V. coil
Remove the ignition spark plug.
GO TO point 3
3- Connect the scooter diagnostic tester. Select
the parameters function. Start the starter for 15
seconds and check the following:
Engine rpm > or = 500 RPM
Air pressure at the end of test > or = 4 BAR
YES point 5 NO point 4 NO point 6

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4- The engine rpm and pressures are lower than

specifications. Check the battery and starter sys-
tem.
GO TO point 3
5- Engine rpm and pressure are as expected.
Check that the pressure remains stable over time.
YES point 16 NO point 8
6- Engine rpm are as expected and pressure is
lower than specifications. Check that the pressure
remains stable over time.
YES point 7 NO point 8
7- Replace the volumetric compressor.
GO TO point 3
8- Pressure decreases very quickly. Check if there
are any fuel leaks from the injector mounting .
YES point 9 YES point 10 NO point 11
9- There are leaks at the coupling to the head. Re-
place the O-Ring between air injector and support.
GO TO point 3
10-There are leaks at the pressure regulator cov-
er. Replace the full injector mounting .
GO TO point 3
11- Use water with soap or foam to check the seal
of the volumetric compressor connection hose to
the injector mounting
YES point 13 NO point 12
12- Restore the seals or replace the hose.
GO TO point 3

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13- Bring the system to pressure again and as

soon as the starter stops rotating, close the com-
pressor connection pipe at the shunting with the
manometer by a flat and long pincer. Check the
pressure progress.
GO TO point 14
GO TO point 15

14- Pressure decreases with the same trend. Check the seals on the injector mounting , replace the air
injector if required.
GO TO point 3
15- Pressure remains unchanged. The compressor unidirectional valve is not efficient. Replace the
volumetric compressor
GO TO point 3
16- Refit the ignition spark plug and connect the cap. Connect the following connectors:
- H.V. coil
- Fuel injector
- Air injector
Use the diagnostic tester to remove the faults registered during pressure check.
GO TO point 17

Specific tooling
020460Y Scooter diagnosis and tester

17- Start the engine and check the air pressure with engine idle and free from loads at medium rpm.
Standard air pressure = 5 ÷ 5.5 bar (500 ÷ 550 Kpa)
N.B.
AIR PRESSURE DURING THE ENGINE OPERATION IS FAIRLY CONSTANT SINCE THE IN-
CREASE OF CAPACITY OF THE PUMP IN RELATION TO THE INCREASE OF RPM IS PARTLY
COMPENSATED BY THE LONGER OPENING TIME OF THE AIR INJECTOR. TO CONFIRM THIS,
CHECK THAT THE PRESSURE INCREASES UP TO ABOUT 8 BAR (800 KPA) AFTER SWITCHING
TO THE "OFF" POSITION WHEN THE ENGINE RUNS AT HIGH RPMS.

air injector circuit

TERMINALS: 1 - 13
CONDITIONS: Engine stopped, switch in any position
STANDARD VALUES: Battery voltage

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AIR INJECTOR
Specification Desc./Quantity
1 Key switch contacts
2 Fuse 20A
3 Battery 12V - 9Ah
4 Air injector
5 HV coil
6 Voltage regulator
7 Injection ECU
8 Fuel injector
The air injector is the main component of the electrical-pneumatic injection. To make things easier, the
injector is called an air injector, even if a mixture of air and petrol is actually injected. Direct injection of
petrol transported by the compressed air makes it possible to obtain a fine mist of the mixture within
the cylinder. The ECU runs the air injector by checking the time and opening time. This makes it possible
to achieve better results in terms of pollution and consumption. The ECU autodiagnosis also checks

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the air injector circuit. A fault is detected if the circuit is interrupted or if there is a short towards the earth
or positive. Any faults are signalled to the driver via the injection lamp. If a fault is present the engine
will not run. The fault is only recognised when the rpm - timing sensor is present. For this reason when
there is a fault memorisation changes from the "current event" state to "past event" state when the
engine stops. To check the air injector electrical circuit, proceed as follows.
1 - Connect the scooter tester. Select the "enable diagnosis" function.
GO TO point 2

Specific tooling
020460Y Scooter diagnosis and tester

2- Enable the air injector diagnostic. Check the 5 sounds that denote the air injector activation. Check
the tester response.
YES point 3 NO point 4 NO point 5
3- The air injector has enabled 5 times and the tester has returned "test finished successfully". The air
injector and relevant circuit are currently efficient. For greater certainty, continue with the auto-diag-
nostic check in order to highlight stored errors.
4- The injector has not been enabled and the tester has returned "test failed". Repeat the diagnostic
and, if necessary, replace the ECU.
GO TO point 2
5- The air injector has not been enabled and the tester has returned «test finished successfully». Check
the air injector circuit.
6- Connect the scooter diagnostic tester Select the «errors» function. Check the presence of error
P1160 AIR INJECTOR.
GO TO point 7
YES point 8 YES point 9

Specific tooling
020460Y Scooter diagnosis and tester

7- No error present. The injector electrics are efficient. Check the compressed air circuit to inspect the
injector seal.
8- Air injector error in current status. Check the air injector circuit.
9- Air injector error in stored status. Check the circuit for false contacts or uncertain insulation.
10- Connect the interface wiring. Omit the connection to the ECU. Disconnect the air injector connector.
GO TO point 11

Specific tooling
020481Y Control unit interface wiring

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11 - Check the battery positive voltage to the blue

lead of the power supply connector of the air in-
jector.
1 - blue lead (positive) = V battery
YES point 13 NO point 12
N.B.
THIS CONNECTOR ALLOWS AN EASY CHECK
USING THE MULTIMETER PRODS. DO NOT IN-
SERT THE PRODS INTO THE PINS.

12- Check the efficiency of fuse 20A and restore

the wiring if required.
GO TO point 11
13- Check the continuity of the air injector control
line.
13 - pink (injector connector) = continuity
YES point 15 NO point 14
N.B.
THIS CONNECTOR ALLOWS AN EASY CHECK
USING THE MULTIMETER PRODS. DO NOT IN-
SERT THE PRODS INTO THE PINS.
14- Restore the wiring.
GO TO point 13
15- Check the air injector control line positive in-
sulation.
1 - 13 = 0V
YES point 17 NO point 16

16- Restore the wiring.

GO TO point 15
17- Check the air injector control line negative in-
sulation.
1 - 13 > or = 1MOhm
YES point 19 NO point 18

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18- Restore the wiring.

TO GO point 17
19- Check the air injector winding resistance
standard value= ... Ohm
YES point 21 NO point 20

20- If very different resistive values are detected,

replace the air injector.
GO TO point 19
21- Check the air injector winding negative insu-
lation.
1 - any pin of the injector> or = 1MOhm
YES point 23 NO point 22

22- Replace the air injector.

GO TO point 21
23- Connect the specific tool to the ECU. Connect
the air injector connector. Check the presence of
voltage to the ECU.
1 - 13 = V battery (engine off and any position
of the switch)
YES point 25 NO point 24

Specific tooling
020481Y Control unit interface wiring
24 - Voltage is close to 0V and the injector is open. Carefully check the control line insulation. Replace
the ECU if required.

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25 - The air injector control circuit is efficient. The air injector opening time can be checked when the
engine is running by the «parameters» menu
AIR INJECTION T. mS =
6 ÷ 7 mS (start up at 20° C)
~ 1.6 mS (idle at 20° C)
~ 1.4 mS (idle at 60° C)
The values are indicative but useful for diagnostics. Command failures or unusual opening times are
always caused by the ECU.

fuel pump circuit

TERMINALS: 1 - 14
CONDITIONS: Switch in «ON» position after the engine timing
STANDARD VALUES: less than 0.1 V
TERMINALS: 1 - 14
CONDITIONS: Switch in «ON» position after timing with engine still
STANDARD VALUES: Battery voltage

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FUEL PUMP CIRCUIT

Specification Desc./Quantity
1 Fuel pump
2 Key switch contacts
3 Injection ECU
4 Fuse 20A
5 Battery 12V - 9Ah
The fuel pump is a piston type supplied with a di-
rect current motor. It is designed to distribute high
pressure with small deliveries and little absorption,
thus suited for use on reduced horse power en-
gines. Given the reduced absorption, the pumped
is powered directly by the ECU without using relay
switches. The pump is powered for 4 - 5 seconds
after switching to «ON» this lets the system bleed

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and get rid of the fuel aged by boiling within the

injector support. Subsequent management of the
pump is combined with the presence of the rpm
timing signal. This guarantees the safety of the ve-
hicle in the event of an accident. The ECU auto-
diagnosis also checks the pump electrical circuit.
A fault is recognised in the event of an interrupted
circuit or short. The fault is recognised with a pri-
ority level of 3, this means registered by the auto-
diagnosis but not signalled by turning on the
injection lamp. Naturally, this fault causes the en-
gine to fail and is easily recognisable on an acous-
tic level due to the failure of the pump to rotate.
- The footrest needs to be removed to access the
fuel pump.
- In order to gain access to the fuel pump it is nec-
essary to remove the foot rest board
- A connection is present at the pump entrance
with with the derivation of two tubes, respectively:
A: fuel arrival tube
B: fuel drainage tube
In the case of replacement, do not invert the order
of the two tubes during reassembly.

1- Switch to the «ON» position. Listen for activation of the pump for 4-5 seconds
YES point 3 NO point 2
2 - Proceed with the auto-diagnostic and control circuit checks.
3 - Check whether the pump activation starts up again when trying to start the engine.
YES point 4 NO point 5
4- The pump control circuit is efficient.
5- Check the auto-diagnostic and the phase - rpm signal.
6- Connect the scooter diagnostic tester Select the «active diagnostic» function
GO TO point 7
Specific tooling
020460Y Scooter diagnosis and tester
7- Check that the tank is adequately topped up and proceed with the activation of the «fuel pump»
diagnostic. Listen for 10 consecutive activations of around 4 seconds of the fuel pump. Check the
outcome on the diagnostic tester.
YES point 8 NO point 9 NO point 10

INJ PJ - 57

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pure jet injection NRG Power Purejet

8- The fuel pump was activated 10 times and the tester returned the «test successfully completed»
outcome. The pump and the relative circuit are currently efficient. For greater certainty, proceed with
the auto-diagnostic check in order to highlight any errors in stored status.
9- The pump remained inactive and the tester returned the «test failed» outcome. Repeat the diagnostic
and, if necessary, replace the ECU.
GO TO point 7
10- The fuel pump was not activated and the tester returned the «test successfully completed» outcome.
Proceed with checking the pump and the relative electric circuit
11- Connect the scooter diagnostic tester, select the «errors» function. Check for the presence of error
PO230 FUEL PUMP.
YES point 13 YES point 14 NO point 12

Specific tooling
020460Y Scooter diagnosis and tester

12- No error present. The pump's electric command circuit is efficient. For a more complete check,
proceed with the check on the fuel supply circuit.
13- Fuel pump error in occurred or stored status. Proceed with the check on the pump and the control
circuit, paying particular attention to false contacts or uncertain insulation.
14- Fuel pump error in actual state. Proceed with the check on the fuel pump supply circuit.

15- Connect the interface wiring. Omit the connection with the ECU. Disconnect the fuel pump supply
connector.
GO TO point 16

Specific tooling
020481Y Control unit interface wiring

16- Turn the switch to the «ON» position. Check

for the presence of positive battery voltage at the
orange pump supply connector wire.
1 - ORANGE = battery voltage
NO point 17
GO TO point 18
N.B.
AVOID DAMAGING THE CONNECTOR PIN.
USE A PIN ADAPTOR IF NECESSARY.

INJ PJ - 58

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NRG Power Purejet pure jet injection

17- Check the efficiency of the 20 A fuse, the key

switch and restore the wiring if necessary.
18- Check the continuity of the petrol pump control
line.
14 - green/blue (pump con.) = continuity
N.B.
AVOID DAMAGING THE CONNECTOR PIN.
USE A PIN ADAPTOR IF NECESSARY.

19 - Restore the wiring.

GO TO point 18
20 - Check the fuel pump control line positive in-
sulation.
1 - 14 = 0V
YES point 22 NO point 21

21- Restore the wiring.

GO TO point 20
22 - Check the fuel pump control line negative in-
sulation.
1 - 14 = 1 MOhm
YES point 24 NO point 23

23- Restore the wiring.

GO TO point 22
24- Check the fuel pump winding continuity.
Standard resistance = …….Ohm (5Ohm measured)
N.B.
IF THE CHECK IS DONE ON A NEW PUMP, HIGHER RESISTANCE VALUES MIGHT RESULT DUE
TO THE FACT THAT THE MANIFOLD HAS NOT BEEN BROKEN IN.

INJ PJ - 59

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pure jet injection NRG Power Purejet

If there are difficulties in doing the check directly

on the pump, proceed with the check through the
wiring. Reconnect the fuel pump connector and
measure the resistance between the specific tool's
pins, keeping the switch in the «OFF» position.
14 - 17 =…….Ohm (5Ohm measured)
YES point 26 NO point 25

25- A resistance of around 0 Ohm indicates the

presence of a short circuit. A resistance signifi-
cantly greater than the standard values indicates
low conductivity. In these cases, replace the
pump.
GO TO point 24
26- Keeping the ECU conditions disconnected and
pump connector connected, check that with the
key switch in the «ON» position, the pump starts
to rotate each time that pin 14 is grounded.
1 - 14 (bridged) = pump activated
YES point 28 NO point 27

27- There is electric absorption but the pump does not rotate. Replace the pump due to mechanical
damage.
GO TO point 24
28- Especially in case an error is verified in the «occurred» or «stored» state, repeat activation of the
pump several times in order to distinguish any faults deriving from a manifold that is not perfectly effi-
cient.
GO TO point 29
GO TO point 30
29- Some pauses are present. Check the connectors more carefully and replace the pump, if necessary.
30- The pump rotates normally. The pump connection electric system is efficient. Connect the ECU and
check that the pump activates for around 4 seconds each time the switch is turned «ON» and constantly
when the rpm- phase (engine in rotation) signal is present). Replace the ECU if there are any faults.
GO TO point 31
31- For a more complete fuel pump check, it is best to proceed with the checks on the current absorbed
and the hydraulic characteristics of the pump.

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NRG Power Purejet pure jet injection

petrol injector circuit

TERMINALS: 1 - 3
CONDITIONS: Engine stopped, switch in any position
STANDARD VALUES: Battery voltage

PETROL INJECTION CIRCUIT

Specification Desc./Quantity
1 Key switch contacts
2 Fuse 20A
3 Injection ECU
4 Air injector
5 Battery 12V - 9Ah
6 HV coil
7 Fuel injector
The petrol injector receives pressurised fuel through the supply system. The ECU runs the injector by
checking the time and opening time. The fuel is injected into the compressed air chamber this forming
the rich titre air petrol mixture to be injected into the cylinder via the air injector. The petrol injector
prepares the mixture when the air injector is still closed and the air injector injects the mixture when the

INJ PJ - 61

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pure jet injection NRG Power Purejet

petrol injection has finished. The operation of the petrol injector is always very important in all engine
operating phases, but particularly during idling and starting. The ECU autodiagnosis also checks the
petrol injector control circuit. A fault is detected if the circuit is interrupted or if there is a short towards
the earth or positive. Any faults are signalled to the driver via the injection lamp. If a fault is present the
engine will not run. The fault is only recognised when the rpm - timing sensor is present, i.e. when the
ECU controls opening of the injector. For this reason when there is a fault, recognition changes from
the «current event» state to «past event» state when the engine stops.
1 - Connect the scooter tester. Select the enable diagnosis function.
GO TO point 2

Specific tooling
020460Y Scooter diagnosis and tester

2- Activate the fuel injector diagnostic. Listen for 5 fuel injector activations. Check the diagnostic tester
response.
YES point 3 NO point 4 NO point 5
3- The fuel injector was activated 5 times and the tester returned the «test completed successfully»
outcome. The fuel injector and the relative circuit are efficient. For further certainty, proceed with the
auto-diagnostic test in order to avoid any errors in the stored status.
4- The injector remained inactive and the tester returned the outcome «test failed». Repeat the diag-
nostic and replace the ECU if necessary.
5- The fuel injector remained inactive and the tester returned the «test completed successfully» out-
come. Check the fuel injector circuit.
6- Connect the scooter diagnostic tester. Select the «errors» function on the menu. Check the presence
of any errors PO251 FUEL INJECTOR.
YES point 8 YES point 9 NO point 7

Specific tooling
020460Y Scooter diagnosis and tester

7- No error present. The injector electric part is sufficient. Proceed with the injector hydraulic inspections.
8- Fuel injector error in current status. Check the fuel injector circuit.
9- Fuel injector error in occurred or stored status. Check the injector circuit with special attention to false
contacts of uncertain insulation.

INJ PJ - 62

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NRG Power Purejet pure jet injection

coolant temperature sensor circuit

COOLANT TEMPERATURE SENSOR

Specification Desc./Quantity
1 Digital instrument unit
2 Key switch contacts
3 Fuse 5A
4 Fuse 20A
5 Battery 12V - 9Ah
6 Injection ECU
7 Coolant temperature sensor

INJ PJ - 63

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pure jet injection NRG Power Purejet

INJ PJ - 64

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INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

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Braking system NRG Power Purejet

Front brake calliper

Removal
• Check that the brake piping, gasket
and fitting are in good condition. If you
see any oil on the brake calliper and/on
the components of the system, it is
necessary to replace them.
• - Disconnect the oil line from the cal-
liper, collecting the oil in a container.
• - Remove the two clamps highlighted
in the diagram.

Overhaul
- Remove the calliper assembling bolts and take out the internal bodies and components. If necessary,
in order to make it easier to take out the plungers, inject (shorts blasts of) compressed air through the
brake fluid pipe.
- Check that the cylinders of the internal and external body of the calliper do not show scratches or signs
of erosion; otherwise, replace the entire calliper.
CAUTION
ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS
SERVICED.
Insert the following: - sealing rings (1-2);
- pistons (3);
- locate the OR seal inside a calliper body (4).
- Join the inner and outer bodies via fixing bolts. Refit the pads and breathe any air inside the circuit
(see previous paragraphs).
- Locate the calliper on the disc and secure to the supporting bracket tightening the fixing bolt.
- Tighten the tube joint on the calliper at the prescribed torque.
- When refitting the components, they must be perfectly clean and free from any trace of oil, fuel, grease,
etc... It is therefore necessary to carefully clean them with denatured alcohol.
The seal rings must be immersed in the operating liquid; Protective solution PRF1 may be used.
CAUTION
RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS.
AFTER WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A
CLEAN CLOTH.
Locking torques (N*m)
Calliper coupling screw 20 to 25 Nm Oil bleed screw 7 to 10 Nm

BRAK SYS - 2

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NRG Power Purejet Braking system

1 DUST GUARDS
2 SEALING RINGS
3 PLUNGERS
4 O-RING GASKET

Refitting
• Refit the pincer on the support and
tighten the screws at the prescribed
torque.
• Refit the tube complete with fitting with
new copper gaskets.
• Bleed the air from the system.

Locking torques (N*m)

Brake fluid tube calliper 20 ÷ 25 Nm Fastening
screws calliper to the crankcase 20 - 25 Oil
bleed screw 7 to 10 Nm

Front brake disc

Removal
- Remove the front wheel loosening the axle
clamp.
-Remove the six fastenings of the disc.

Refitting
-When refitting, position the disc correctly making sure that it rotates in the right direction.

Locking torques (N*m)

Disc tightening screw 8 - 12

BRAK SYS - 3

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Braking system NRG Power Purejet

Disc Inspection
Checking the disc is important; it must be perfectly
clean, with no sign of rust, oil or grease or other
dirt and must not show signs of deep scoring.

Characteristic
New rear disc thickness
4.0 mm
Disc thickness at wear limit (front)
3.5 mm

• Using the appropriate tool, measure

how much the disc protrudes when the
wheel is fitted properly. The protrusion,
measured near the external edge of
the disc, must be less than 0.1 mm.
• If a value is measured other than the
specified value, remove the front wheel
(Front/Rear Suspension chapter) and
check the protrusion of the disc. Maxi-
mum permissible out of true is 0.1 mm.
If the value measured is greater, re-
place the disc and repeat the check.
• If the problem persists, check and re-
place the wheel hub if necessary.

Specific tooling
020335Y Magnetic support for dial gauge

Front brake pads

BRAK SYS - 4

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NRG Power Purejet Braking system

Removal
• Remove the pin split ring located at the
back of the calliper body.
• Remove the pin, paying attention in re-
covering the spring, hence remove the
pads.
• The pads must be replaced if the work-
ing thickness is less than 1.5 mm

Refitting
- To reassemble perform the above steps in re-
verse order. Position the leaf spring with the arrow
facing up.

Fill

BRAK SYS - 5

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Braking system NRG Power Purejet

Front
-Once the bleed valve is closed, fill the system with
brake liquid to the maximum level.
-Undo the bleed screw.
-Apply the tube of the special tool to the bleed
screws.
When bleeding it is necessary to fill the oil tank in
continuation while working with a MITYVAC pump
on the bleed screws until no more air comes out of
the system.
The operation is finished when just oil comes out
of the bleed screws.
-Do up the bleed screw.
-When the operation is over, tighten up the oil
bleed screw to the prescribed torque.
N.B.
IF AIR CONTINUES TO COME OUT DURING
PURGING, EXAMINE ALL THE FITTINGS:
IF SAID FITTINGS DO NOT SHOW SIGNS OF
BEING FAULTY, LOOK FOR THE AIR INPUT
AMONG THE VARIOUS SEALS ON THE PUMP
AND CALLIPER PISTONS.
CAUTION
- DURING THE OPERATIONS, THE VEHICLE
MUST BE ON THE STAND AND LEVEL.
N.B.
DURING PURGING FREQUENTLY CHECK THE
LEVEL TO PREVENT AIR GETTING INTO THE
SYSTEM THROUGH THE PUMP.
WARNING
- BRAKING CIRCUIT FLUID IS HYGROSCOPIC.
IT ABSORBS HUMIDITY FROM THE SUR-
ROUNDING AIR.
IF THE LEVEL OF HUMIDITY IN THE BRAKING
FLUID EXCEEDS A GIVEN VALUE, BRAKING
EFFICIENCY WILL BE REDUCED.
THEREFORE, ALWAYS USE FLUID FROM
SEALED CONTAINERS.
UNDER NORMAL DRIVING AND CLIMATIC
CONDITIONS YOU SHOULD CHANGE THIS
LIQUID EVERY TWO YEARS.
IF THE BRAKES ARE USED INTENSELY AND/
OR IN HARSH CONDITIONS, CHANGE THE
FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION,
BRAKE FLUID MAY LEAK FROM BETWEEN

BRAK SYS - 6

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NRG Power Purejet Braking system

THE BLEED SCREW AND ITS SEAT ON THE

CALLIPER.
CAREFULLY DRY THE CALLIPER AND DE-
GREASE THE DISC SHOULD THERE BE OIL
ON IT.
Specific tooling
020329Y MityVac vacuum-operated pump

Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT4 Synthetic fluid

Locking torques (N*m)

Oil bleed screw 8÷12

Front brake pump

-After removing the front and rear handlebar covers, act on the two stand fixing points (see the figure).
- Disconnect the tube, collecting the brake oil in a container.

- On refitting, perform the operation in reverse.

- Tighten the hydraulic line to the prescribed torque
and bleed the system.

Locking torques (N*m)

Brake fluid pump - hose fitting 20 ÷ 25 Nm

Removal
- Bleed the circuit and drain the brake fluid through
the bleeding screw located on the calliper and ac-
tuate the brake lever until no more fluid flows out.
-Remove the oil pump from the handlebar; remove
the brake lever and then remove the wheel cylin-
der.
1 - Tank cap screw.
2. Tank cover.
3. Diaphragm.
4. Bellows.
5. Sealing ring.
6. Piston.
7. Gasket.

BRAK SYS - 7

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Braking system NRG Power Purejet

8 - Spring
CAUTION
- THE PRESENCE OF BRAKE FLUID ON THE
DISC OR BRAKE PADS REDUCES THE BRAK-
ING EFFICIENCY.
IN THIS CASE, REPLACE THE PADS AND
CLEAN THE DISC WITH A HIGH-QUALITY SOL-
VENT.
CONTACT WITH BRAKE FLUID WILL DAMAGE
PAINTED SURFACES.
RUBBER PARTS SHOULD NEVER BE LEFT IN
ALCOHOL FOR LONGER THAN 20 SECONDS.
AFTER WASHING, THE PIECES MUST BE
DRIED WITH A BLAST OF COMPRESSED AIR
AND A CLEAN CLOTH.
THE SEALING RINGS MUST BE IMMERSED IN
THE OPERATING LIQUID.

Refitting
Before fitting, the parts must be perfectly clean and
free of traces of oil, diesel fuel, grease, etc.. They
should be washed thoroughly in denatured alcohol
before proceeding.
- Reinstall the individual parts in the reverse order
to the removal, paying attention to the correct po-
sitioning of the rubber parts in order to ensure leak
tightness.
1 - Tank cap screw.
2. Tank cover.
3. Diaphragm.
4. Bellows.
5. Sealing ring.
6. Piston.
7. Gasket.
8. Spring.

BRAK SYS - 8

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INDEX OF TOPICS

COOLING SYSTEM COOL SYS

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Cooling system NRG Power Purejet

System bleed
1. Fill the circuit through the expansion tank to
the maximum level.
2. Fasten the rubber line to the drain fitting on
the head and thread it into the expansion
tank mouth..
3. Loosen the fitting and restore the tank level.
4. Start up the engine and wait until only cool-
ant exits from the line, then tighten the fitting
on the head..
5. Turn off the engine, restore the level of liquid
to the maximum level, then close the expan-
sion tank..
6. Heat up the engine to normal operating tem-
perature in order to eliminate any air forma-
tion in the main lines..
7. Stop the engine and let it cool, then check
that the level of coolant in the expansion tank
to the maximum;; refill it.

Water pump - overhaul

- Remove the pick-up/coolant inlet hose clamp
- Remove the transmission cover
- Remove the mixer
- Setup the special as shown in the picture
N.B.
WHEN SECURING THE TOOL, PAY ATTEN-
TION NOT TO OVERLOAD THE PLASTIC IM-
PELLER.
Specific tooling
020167Y Arrest key for impeller pump

COOL SYS - 2

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NRG Power Purejet Cooling system

- Remove the mixer/water pump drive-belt with the

two sprockets

- Remove the split ring from the shaft together with

the bearings
- Remove the steel washer

- Using the air heater, warm up the crankcase in

the area around the water pump bearings as
shown in the picture.

- With the aid of the special tool, loosen the impel-

ler shaft turning the spanner clockwise (left-hand-
ed thread)
- As the thread is fully disengaged, extract the
shaft with the aid of pliers.

Specific tooling
020169Y Water pump crankshaft fitting and re-
moval spanner

- Using the special hook, remove the sealing ring from its housing as shown in the picture.

Specific tooling
020209Y Spring hook

COOL SYS - 3

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Cooling system NRG Power Purejet

- Ensure the shaft is not abnormally worn and the

bearings not noisy. Otherwise, replace shaft and
bearings
- Carefully clean oil seal and bearing housings

- Use a new oil seal to refit

- Position the new oil seal on the special tool with
the main lip facing the bearings as shown in the
picture

- Lubricate the oil seal and push it home using the

special tool as shown in the picture

Specific tooling
020168Y Water seal punch mount on half-
crankcase

- Insert the shaft, with bearings, into its housing by

pushing and turning it at the same (turn anticlock-
wise for tightening)
- Turn it rapidly to the end of the threading.
- Should this operation prove difficult, do not carry
on; instead, start over by reheating the crankcase
N.B.
FAILURE TO OBSERVE THIS RULE MAY RE-
SULT IN DAMAGE TO THE THREAD OF THE
COPPER INSERT ON THE IMPELLER, OR SEP-
ARATION OF THIS FROM THE IMPELLER IT-
SELF.
Specific tooling
020169Y Water pump crankshaft fitting and re-
moval spanner

COOL SYS - 4

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NRG Power Purejet Cooling system

Using the air heater, warm up the water pump

bearing housing, without directing the air flow di-
rectly against the oil seal
- Lubricate the end of the water pump shaft on the
oil seal side, using the recommended product.

Recommended products
AGIP GREASE MU3 Grease for odometer
transmission gear case
Soap-based lithium grease with NLGI 3; ISO-L-
XBCHA3, DIN K3K-20

Thermostat

Removal
• Detach the coolant hose from the
head, partially draining the system.
• Remove the cylinder head.
• Remove the two fixing screws and
hence the thermostat.

Check
1) Visually check that the thermostat is not dam-
aged.
2) Fill a metallic container with approx. 1 litre of
water.
Immerge the thermostat, and keep it in the centre
of the bowl.
Immerge the multimeter temperature probe, and
keep it close to the thermostat.
Heat up the bowl using the thermal gun.
Check the thermostat opening start temperature:
Heat up until the thermostat is completely open.
3) Replace the thermostat if not working properly.
CAUTION

COOL SYS - 5

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Cooling system NRG Power Purejet

TO EXECUTE THE TEST CORRECTLY, MAKE

SURE NEITHER THE THERMOSTAT NOR THE
THERMOMETER TOUCHES THE CONTAINER.
Specific tooling
020331Y Digital multimeter
020151Y Air heater

Characteristic
Thermostat check: Opening start temperature
60±2°C

Refitting
• Refit the thermostat onto the head, fol-
lowing the removal operations in the
reverse order, and paying attention in
inserting the groove on the thermostat
on the reference on the head.

COOL SYS - 6

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INDEX OF TOPICS

CHASSIS CHAS

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Chassis NRG Power Purejet

Frame central cover

• Remove the top and bottom fairings.
• Remove the 2 Philips screws fixing the
footrest.
• Remove the 3 Allen screws located
around the fuel filler cap.
• Remove the fuel filler cap.

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NRG Power Purejet Chassis

Footrest
• Remove the centre frame cover.
• Remove the 10 screws (5 for each
side), hence remove the footrest.

• Remove the side fairing from the foot-

rest, by removing the two screws join-
ing this to the spoiler and the knee-
guard.

See also
Frame central cover
Frame central cover

Side fairings
• Remove the top l.h.s. and r.h.s. fair-
ings, by removing the 3 side screws
and the screw located underneath the
taillight

CHAS - 3

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Chassis NRG Power Purejet

• Remove the lower fairings, removing

the 2 side screws and the central join-
ing screw located underneath the
spark plug cover.

License plate holder

• Remove the top fairing joining element
located behind the taillight.
• Remove the 2 screws joining the top
side fairings.
• Remove the 4 lower screws joining the
front wheel housing cover with the low-
er side fairings.

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NRG Power Purejet Chassis

• Remove the metallic clip joining the

rubber bellow to the tank and loosen
the 3 screws fixing to the knee-guard

• Remove the 2 top screws fixing the

tank to the frame and lower the tank so
to disconnect the inlet and outlet fuel
hoses from the pump.
• Remove the tank completely paying at-
tention to avoid fuel spillage.

Front central cover

- Mediante cacciavite a croce rimuovere la vite
come indicato in figura.
- Rimuovere la mascherina.

CHAS - 5

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Chassis NRG Power Purejet

CHAS - 6

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INDEX OF TOPICS

PRE-DELIVERY PRE DE

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Pre-delivery NRG Power Purejet

Aesthetic inspection
Appearance checks:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt

Tightening torques inspection

Lock check
- Safety locks
- clamping screws
Safety locks

Rear shock absorber upper fixing

Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut

Electrical system
Electrical system
- Main switch
- Headlamps: high beam, low beam, position and parking lights and the respective warning lights
- Adjusting the headlights according to the regulations currently in force
- Tail light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument lighting
- Instrument panel: fuel and temperature indicator
- Instrument panel warning lights
- Horn
- Starter

PRE DE - 2

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NRG Power Purejet Pre-delivery

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 OPEN FLAMES OR SPARKS AWAY FROM THE BATTERY DURING CHARGING.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; 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 - 3

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Pre-delivery NRG Power Purejet

Static test
Static control after the test ride:
- Starting when warm
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Functional inspection
Functional check:
Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories

PRE DE - 4

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INDEX OF TOPICS

TIME TIME

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Time NRG Power Purejet

This section is devoted to the time necessary to

carry out repairs.
The description and code for each operation is in-
dicated.

Engine

ENGINE
Code Action Duration
1 001001 Engine to chassis - Replace-
ment

TIME - 2

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NRG Power Purejet Time

Crankcase

CRANKCASE
Code Action Duration
1 001133 Engine crankcase - Replace-
ment

TIME - 3

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Time NRG Power Purejet

Crankshaft

CRANKSHAFT
Code Action Duration
1 001117 Crankshaft - Replacement
2 001118 Main bearings - Replacement
3 001099 Oil seal, flywheel side - Re-
placement
4 001100 Oil seal, clutch side - Re-
placement

TIME - 4

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NRG Power Purejet Time

Cylinder assy.

CYLINDER / PISTON
Code Action Duration
1 001002 Cylinder piston - Replace-
ment
2 001107 Cylinder / piston - Inspection /
cleaning

TIME - 5

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Time NRG Power Purejet

Cylinder head assy.

HEAD UNIT
Code Action Duration
1 001013 Intake manifold - Replace-
ment
2 001056 Head gasket - change
3 001057 Thermostat - Replacement
4 001093 Spark plug - Replacement
5 001126 Head - Replacement
6 007010 Bleed valve - Replacement
7 001178 Disc pack - Replacement
8 001083 Thermistor - Replacement
9 005111 Air injector - Replacement
10 005112 Air injector - Service
11 005110 Fuel injector mounting - Re-
placement

TIME - 6

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NRG Power Purejet Time

Driven pulley

DRIVEN PULLEY
Code Action Duration
1 001110 Driven pulley - Replacement
2 001022 Clutch - Replacement
3 001155 Clutch bell housing - Re-
placement
4 001012 Driven pulley - overhaul

TIME - 7

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Time NRG Power Purejet

Oil pump

OIL MIX PUMP

Code Action Duration
1 001018 Mixer - Replacement
2 001019 Mixer belt - replacement
3 001028 Mix movement gear socket -
Replacement

TIME - 8

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NRG Power Purejet Time

Final gear assy.

Underseat compartment

HELMET COMPARTMENT
Code Action Duration
1 004059 Spark plug inspection flap -
Replacement
2 004016 Helmet compartment - Re-
placement
3 005046 Battery cover - change

TIME - 21

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Time NRG Power Purejet

Plate holder

LICENSE PLATE HOLDER

Code Action Duration
1 005022 Rear turn indicators - Re-
placement
2 005068 Rear turn indicator bulb - Re-
placement
3 005005 Taillight - Replacement
4 005023 Rear tail light support - Re-
placement
5 005091 Turn indicator glass - Re-
placement

TIME - 22

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NRG Power Purejet Time

Mudguard

MUDGUARDS
Code Action Duration
1 004009 Rear mudguard - Replace-
ment
2 004052 Bumper - Replacement
3 004002 Front mudguard - Replace-
ment

TIME - 23

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Time NRG Power Purejet

Fuel tank

FUEL TANK
Code Action Duration
1 004005 Fuel tank - Replacement
2 005010 Tank float - Replacement
3 004011 Central chassis cover - Re-
placement
4 004072 Fuel filter - Replacement
5 004110 Fuel tank hose - Replace-
ment
6 004168 Fuel tank cap - Replacement
7 004170 Tank filler neck - Replace-
ment

TIME - 24

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NRG Power Purejet Time

Tank oil

OIL TANK
Code Action Duration
1 004017 Oil reservoir - Replacement
2 005018 Oil reservoir float - Replace-
ment
3 004095 Oil reservoir cock - Replace-
ment
4 004091 Oil reservoir hose - Replace-
ment

TIME - 25

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Time NRG Power Purejet

Rear shock-absorber

REAR SHOCK ABSORBER

Code Action Duration
1 003007 Rear shock absorbers - Re-
placement

TIME - 26

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NRG Power Purejet Time

Steering column bearings

STEERING FIFTH WHEELS

Code Action Duration
1 003002 Steering fifth wheel - Re-
placement
2 003073 Steering clearance - Adjust-
ment
3 004119 Bearing / upper steering fifth
wheel - Replacement

TIME - 27

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Time NRG Power Purejet

Handlebar components

HANDLEBAR COMPONENTS
Code Action Duration
1 003001 Handlebar - Replacement
2 002060 Complete throttle control -
Replacement
3 002059 Right hand grip - Replace-
ment
4 005017 Stop switch - Replacement
5 003059 Counterweight - Replace-
ment
6 002024 Front brake pump - replace
7 002037 Brake or clutch lever - Re-
placement
8 002047 Front brake fluid and air
bleeding system - Replace-
ment
9 003061 Accelerator transmission -
Adjustment
10 004066 Driving mirror - Replacement
11 002071 Left hand grip - Replacement
12 002067 Rear brake pump - Replace-
ment
13 002080 Rear brake oil bleeding sys-
tem - Replacement

TIME - 28

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NRG Power Purejet Time

Swing-arm

SWINGING ARM
Code Action Duration
1 001072 Engine / frame swinging arm
fitting - Replacement

TIME - 29

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Time NRG Power Purejet

Seat

SEAT
Code Action Duration
1 004003 Saddle - Replacement
2 004054 Seat lock hook - Replace-
ment
3 002083 Saddle opening transmission
- Replacement

TIME - 30

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NRG Power Purejet Time

Instrument panel

INSTRUMENT UNIT AND HANDLEBAR COVER

Code Action Duration
1 005014 Odometer - Replacement
2 004018 Handlebar front section - Re-
placement
3 004019 Handlebar rear section - Re-
placement
4 005078 Odometer glass - Replace-
ment

TIME - 31

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Time NRG Power Purejet

Turn signal lights

FRONT LIGHT
Code Action Duration
1 005067 Front turn indicator bulb - Re-
placement
2 005008 Front headlamp bulbs - Re-
placement
3 005002 Front headlamp - change
4 005012 Front turn indicator - Re-
placement

TIME - 32

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NRG Power Purejet Time

Front wheel

FRONT WHEEL
Code Action Duration
1 002041 Front brake disc - Replace-
ment
2 003040 Front wheel bearings - Re-
placement
3 003037 Front wheel rim- Replace-
ment
4 003047 Front tyre - Replacement
5 004123 Front wheel - Replacement
6 003038 Front wheel axle - Replace-
ment
7 005089 Tone wheel - Replacement
Grease tone wheel or drive
Please take note that the code has been intro-
duced:
900001 - Tone wheel / drive greasing - 15'.
Never mistake the codes 002011 (movement sen-
sor replacement) and 005089 (tone wheel replace-
ment) in the event of noise of the indicated
components. The grease recommended is TUTE-
LA MRM 2 (soap-based lithium grease with Mo-
lybdenum disulphide).

TIME - 33

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Time NRG Power Purejet

In the following points we indicate with an arrow

the area to be greased (1 - Drive, 2 - Tone wheel)

Rear wheel

REAR WHEEL
Code Action Duration
1 001071 Rear wheel rim - replace
2 001016 Rear wheel - Replacement
3 002070 Rear brake disc - Replace-
ment
4 004126 Rear wheel tyre - Replace-
ment
5 002028 Rear wheel hub - Replace-
ment

TIME - 34

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NRG Power Purejet Time

compressore aria

AIR COMPRESSOR
Code Action Duration
1 001168 Air compressor - Replace-
ment
2 004160 Compressed air hose - Re-
placement

TIME - 35

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Time NRG Power Purejet

Fuel pump

FUEL PUMP
Code Action Duration
1 004073 Fuel pump - Replacement
2 004137 Injector pump pipe - Replace-
ment
3 004086 Petrol pump depression tube
- Replacement
4 004072 Fuel filter - Replacement
5 004138 Fuel reverse pipe - Replace-
ment
6 001048 Injection pump - Replace

TIME - 36

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NRG Power Purejet Time

Electric devices

ELECTRICS
Code Action Duration
1 001023 Control unit - Replacement
2 001094 Spark plug cap - Replace-
ment
3 005001 Electrical system - Replace-
ment
4 005009 Voltage regulator - replace
5 005136 Resistance - Replacement
6 005044 Front lights cable unit- Re-
placement

TIME - 37

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Cooling system

COOLING SYSTEM
Code Action Duration
1 007001 Expansion tank - Replace-
ment
2 007002 Water cooler - Replacement
3 001052 Coolant and air bleed - Re-
placement
4 007024 Expansion tank cap - Re-
placement
5 007013 Expansion tank / radiator
connecting hose - Replace-
ment
6 007003 Delivery line and coolant re-
turn - Replacement
7 001170 Air duct - Replacement

TIME - 44

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