Derbi GP1 50 cc Manuel d'instructions

GP150 cc

WORKSHOP MANUAL

DERBI - NACIONAL MOTOR, S.A., manufacturer of DERBI motorcycles and mopeds, has produced this

manual with the aim of documenting and simplifying as much as possible the work you need to do to in dis-

mantling and assembling the GP1 50 c.c.

The intention is to provide as much assistance as possible to mechanics working for our brand’s dealers and

sub-dealers.

Due to its constant commitment to improving its products, DERBI - NACIONAL MOTOR, S.A. Sociedad

Unipersonal reserves the right to introduce any modifications it deems fit, without prior warning.

All the information included in this manual is based on the latest data available at the time of its publication.

The drawings and photographs in this manual are for reference purposes only, and may therefore not be

exactly the same as the corresponding parts of the current model itself.

NACIONAL MOTOR, S.A.

INTRODUCTION

GENERAL INFORMATION

GENERAL TECHNICAL DATA

RECOMMENDED TOOLS

REGULAR MAINTENANCE

DISMANTLING

SEAT SIDE TRIM

COWLING

COWLING BOTTOM COVER

WATER-OIL TANK COVER

SIDE COVERS

SHIELD BOTTOM COVER

PETROL TANK COVER

HELMET HOLDER

FOOTRESTS

SIDE COVERS

SHIELD

DIRECT ACCESS TO THE BOTTOM OF THE CARBURETTOR

DISMANTLING FOOTRESTS

EXTRACTING COMPLETE AIR FILTER BOX

DISCONNECTING SECONDARY AIR PIPE

EXTRACTING CARBURETTOR AIR INTAKE PIPE

EXTRACTING CARBURETTOR

THE MACHINE’S ENGINE

DISMANTLING THE ENGINE

TRANSMISSION COVER

DISMANTLING DRIVEN PULLEY SHAFT SUPPORT BEARINGS

FITTING DRIVEN PULLEY SHAFT SUPPORT BEARINGS

DISMANTLING DRIVEN PULLEY

CHECKING CLUTCH BELL HOUSING

DISMANTLING CLUTCH

CHECKING CLUTCH

BRAKE RETAINING RING

DISMANTLING DRIVEN PULLEY HALF BEARINGS

CHECKING FIXED DRIVEN HALF PULLEY

CHECKING MOBILE DRIVEN HALF PULLEY

FITTING DRIVEN HALF PULLEY BEARINGS

CHECKING VARIATOR SPRING

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ASSEMBLING CLUTCH

FITTING DRIVEN PULLEY

TRANSMISSION BELT

DISMANTLING DRIVING PULLEY

MIXER GEARING AND BELT

CHECKING ROLLER CONTAINER

FITTING DRIVING PULLEY

FINAL REDUCTION

DISMANTLING ENGINE PINION

DISMANTLING HUB COVER

DISMANTLING OUTPUT PINION SHAFT

DISMANTLING OUTPUT PINION SHAFT BEARING

DISMANTLING DRIVEN PULLEY SHAFT BEARING

CHECKING THE HUB SHAFTS

CHECKING THE HUB COVER

FITTING DRIVEN PULLEY SHAFT BEARING

FITTING WHEEL PULLEY SHAFT BEARING

FITTING THE HUB COVER

MAGNETO COVER

DISMANTLING THE ENGINE

FITTING THE STATOR

FITTING THE MAGNETO COVER

MAGNETO AND STARTING

DISMANTLING THE STARTER MOTOR

DISMANTLING THE MAGNETO

CHECKING THE MAGNETO COMPONENTS

FITTING THE MAGNETO

FITTING THE STARTER MOTOR

CYLINDER UNIT AND TIMING

DISMANTLING THE SUCTION COLLECTOR

DISMANTLING THE CYLINDER HEAD

DISMANTLING THE PISTON CYLINDER

CHECKING THE CONNECTING ROD BIG END

CHECKING THE GUDGEON PIN

CHECKING THE PISTON

CHECKING THE CYLINDER

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CHECKING THE OIL SEALS

FITTING THE PISTON

CHECKING TIMING COMPONENTS

CRANKCASE

OPENING THE CRANKCASE

DISMANTLING THE CRANKSHAFT

DISMANTLING THE MAIN BEARINGS

FITTING THE MAIN BEARINGS

CHECKING THE CRANKSHAFT ALIGNMENT

FITTING THE CRANKSHAFT

REJOINING THE CRANKCASE

LUBRICATION

OIL PUMP

DISMANTLING

FITTING

FUEL SUPPLY

FORKS

SEBAC FORKS

MARZOCCHI FORKS

DISMANTLING THE FRONT SUSPENSION

INSPECTING THE FRONT FORKS

SHOCK ABSORBER AND SWINGING ARM

DISMANTLING

INSPECTION

FRONT WHEEL AND BRAKES

FRONT WHEEL DIAGRAM

DISMANTLING

INSPECTING THE FRONT WHEEL

DISMANTLING THE FRONT DISK CALLIPER

FITTING THE FRONT WHEEL

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REAR WHEEL AND BRAKES

REAR WHEEL DIAGRAM

DISMANTLING

DISMANTLING THE REAR DISK CALLIPER

INSPECTING THE REAR WHEEL

REFITTING THE REAR WHEEL

TRANSMISSION

DISMANTLING

INSPECTING THE TRANSMISSION CHAIN

CROWN WHEEL

REFITTING THE CROWN WHEEL AND THE TRANSMISSION CHAIN

COOLING SYSTEM

BLEEDING THE SYSTEM

CHECKING THE WATER PUMP

THERMOSTAT

DISMANTLING

CHECKING

FITTING

ELECTRICAL SYSTEM

GP1 50C.C. WIRING DIAGRAM

GP1 50C.C. WIRING DIAGRAM (SWITZERLAND)

CHECKING CONNECTORS

STEPS FOR THE INSPECTION

DIGITAL INSTRUMENTS UNIT

IGNITION

AUTOMATIC CHOKE AND LIGHTS

BATTERY RECHARGE AND STARTING

LEVEL INDICATORS

TURN INDICATORS AND HORN

CHECKS AND CONTROLS

CHECKING PICK-UP

REFITTING IGNITION

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CHECKING THE STATOR

CHECKING THE VOLTAGE REGULATOR

OPERATIONS

FUSES

DISMANTLING THE BATTERY

BATTERY-INITIAL CHARGE

CAPACITY

INSPECTING THE CHARGING CONDITIONS

RECHARGING

CHECKING THE ELECTRICAL SYSTEM

TROUBLESHOOTING

ENGINE

REAR WHEEL TURNS WITH ENGINE TICKING OVER

DIFFICULTY STARTING

EXCESSIVE CONSUMPTION OF OIL/SMOKY EXHAUST

THE ENGINE TENDS TO STOP AT FULL THROTTLE

THE ENGINE TENDS TO STOP WHEN TICKING OVER

HIGH FUEL CONSUMPTION

EXCESSIVELY NOISY EXHAUST

ENGINE OVERHEATING

FAULTS

TRANSMISSION AND BRAKES PULLING OR ABNORMAL CLUTCH OPERATION

POOR BRAKING POWER

BRAKES OVERHEATING

ELECTRICAL WIRING

STEERING AND SUSPENSION – REAR WHEEL

STIFF STEERING

TOO MUCH PLAY IN STEERING

NOISY SUSPENSION

SUSPENSION LEAKING OIL

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REGULATIONS

This section describes the machine’s general safety and maintenance work rules.

SAFETY REGULATIONS

- In the event of having to carry out work on the engine while this is running, ensure that the area is well

ventilated, where possible using extractor fans. Never leave engines running in closed spaces. Exhaust gases

are poisonous.

Petrol is extremely inflammable and in certain conditions may explode. Smoking must not be allowed in the

work area, nor should there be naked flames or sparks.

MAINTENANCE REGULATIONS

- Use genuine DERBI spare parts and lubricants recommended by the manufacturer. Non-genuine or unau-

thorised parts may damage the engine.

Always use new gaskets and oil seals during re-assembly.

After dismantling, clean the components with solvents that are non-inflammable or with a high flammability

point. Lubricate all working surfaces before assembling, excluding tapered joints.

After assembly, check that all components have been correctly fitted and that they are functioning perfectly.

For dismantling, checking and assembly operations, use only tools with metric measurements. Metric screws,

nuts and bolts are not interchangeable with imperial measurement joining devices. Using unsuitable tools

and joining devices may damage the engine.

- In the case of work on the engine involving the electrical circuitry, check that electrical connections have

been correctly fitted.

N.B.

Indicates a note that gives key information to make the procedure easier and clearer.

ATTENTION

Indicates specific procedures that must be carried out to avoid damage to the machine.

WARNING

Indicates specific procedures that must be followed to avoid possible accidents to the person repairing the

machine.

GU O S

SGUOS

MAINTENANCE

REGULATIONS

CHARACTERISTIC DIMENSION/VALUE

Maximum length

Maximum height

Length between axles

Handlebar width

Handlebar height

Total weight of machine

GP1 50 c.c. C451M

GP1

c.c.

MACHINE ENGINE PREFIX FRAME PREFIX

VTHPR1A1A

DIMENSIONS AND WEIGHT

1875 mm.

1212 mm.

1338 mm.

705 mm.

1050 mm.

117 kg.

CHARACTERISTIC DIMENSION/VALUE

Engine type

Diameter per stroke

Cubic capacity

Compression ratio

Carburettor

CO regulation

Tick over

Air filter

Ignition system

Lubrication

ENGINE

Single cylinder 2-stroke

40 x 39.3 mm

49.40 cm3

11.3 ÷ 12.8 :1

DELL’ORTO PHVA 17,5 ID

3.5%±0.5

1800 ÷ 2000 rpm

Sponge soaked in oil for filters.

Electric starter motor.

Carried out using the mixture oil, and variable depen-

ding on the engine revs and the throttle butterfly valve

aperture by means of a pump driven by the crankshaft

by way of a toothed belt.

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