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Nacional Motor, S.A., manufacturer of DERBI mopeds and scooters issues this manual with the object of documenting and simplifying to the utmost the task of stripping and assembling the DERBI 50 cc 6 speed engine. The intended purpose is to provide the maximum support to mechanics in the practice of their profession in the agencies and sub-agencies of our marque. In the lights of our policy of constant improvement, DERBI- NACIONAL MOTOR, S.A. reserves the right to introduce such modifications as it deems appropriate without prior notice. All the information included in this manual is based on the most recent data available at the time of publication. The drawings and photographs are intended to serve solely as reference material, and therefore may not be exactly the same as the components and parts in the model currently on sale. NACIONAL MOTOR, S.A. N.º 7077TH02002 Workshop Manual Manual de Taller 50 c.c.ENGINE 6 SPEED

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Page 1: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

Nacional Motor, S.A., manufacturer of DERBI mopeds andscooters issues this manual with the object of documenting andsimplifying to the utmost the task of stripping and assembling theDERBI 50 cc 6 speed engine.

The intended purpose is to provide the maximum support tomechanics in the practice of their profession in the agencies andsub-agencies of our marque.

In the lights of our policy of constant improvement, DERBI-NACIONAL MOTOR, S.A. reserves the right to introduce suchmodifications as it deems appropriate without prior notice.

All the information included in this manual is based on the mostrecent data available at the time of publication. The drawings andphotographs are intended to serve solely as reference material,and therefore may not be exactly the same as the components andparts in the model currently on sale.

NACIONAL MOTOR, S.A.

N.º 7077TH02002

Workshop Manual

Manual de Taller

50 c.c. ENGINE6 SPEED

Page 2: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info
Page 3: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

INDEX

- General Information ..........................................................................1

- Maintenance .....................................................................................1

- Suspensions ....................................................................................1

- Carburetor.........................................................................................1

- Reed Valve........................................................................................1

- Cooling System.................................................................................1

- Oil pump............................................................................................1

- Extraction and installation of motor ..................................................1

- Cylinder Head ..................................................................................1

- Cylinder - piston ................................................................................1

- Clutch................................................................................................1

- Crankshaft and gearbox....................................................................1

- Battery...............................................................................................1

- Starter motor .....................................................................................1

- Oil and fuel level pilot........................................................................1

- Magneto ............................................................................................1

- Electrical Wiring ..............................................................................17

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1. SERVICING RULES

- Use original DERBI spare parts or the parts and lubricants recommended by DERBI.Parts which do not comply with the DERBI design characteristics may cause damageto the scooter.

- In cases where specified, use the special tools designed for this model.

- On reassembly always use new gaskets.

- When tightening up a series of screws of nuts, start first with the larger diameterscrews or start with those on the inside or centre of the part, and apply the full torquespecified in two or three diagonal passes.

- Before stripping any parts of the engine, clean it thoroughly to prevent dirt getting intothe inside of the engine.

- Before assembly lubricate all rubbing surfaces.

- After assembly and before running the engine, ensure that all parts have been correctlyfitted and function properly.

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VEHICLE IDENTIFICATION

This manual includes informationwhich will be useful in servicing, main-tenance and repair operations on thefamilies of models: RACER, XTREME,DRD, and GPR.

SENDA R DRD

GPR Rácing Réplica

• The frame number is located on theright hand side of the steering tube.

• The engine number is located onthe left hand side of the engine,(beside the oil filler cap - gear-chan-ge - clutch).

Page 6: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

DIMENSIONSOVERALL LENGTH (mm.) ...............................2,050OVERALL WIDTH (mm.) .....................................695OVERALL HEIGHT (mm.) ................................1,300WHEELBASE (mm.) .........................................1,345

FRAME R SM

FRAME TYPE......................................................................................Multi-tubeFRONT SUSPENSION: TYPE ...........................................Showa inverted hydraulic forks FRONT SUSPENSION: STROKE/ BAR DIAMETER ...................175 mm. / 32 mm.OIL CAPACITY PER FRONT FORK BAR ..................................175 cc SAE 7.5 WREAR SUSPENSION: TYPE / STROKE .....................Single in-line shock-absorber / 180 mm.FRONT TYRE: SIZE .......................................................80/90x21” ..................100/80x17”FRONT TYRE: PRESSURE ............................................1.0 to 1.1 ....................1.7 to 1.8REAR TYRE: SIZE .........................................................110/80x18” .................130/80x17”REAR TYRE: PRESSURE ...............................................1.2 to 1.3 ....................2.0 to 2.1FRONT BRAKE: TYPE / SIZE ..................................................Hydraulic disc 220 mm.REAR BRAKE: TYPE / SIZE ....................................................Hydraulic disc 180 mm.TOTAL CAPACITY FUEL TANK ...........................................................5.5 litresTOTAL CAPACITY OIL RESERVOIR....................................................1.0 litreCOOLING LIQUID CAPACITY ..............................................................1.1 litre

ENGINEOPERATING CYCLE .........................................................................Two strokeBORE x STROKE............................................................................39.86 x 40 mm.NUMBER OF CYLINDERS ......................................................................OneTOTAL CUBIC CAPACITY ....................................................................49.9 ccMAXIMUM POWER.....................................................................8.5 CV at 9,000 rpmCOMPRESSION RATIO ..........................................................................13:1FUEL ......................................................................................Unleaded petrol 95 octaneADMISSION SYSTEM .......................................................................Reed valveSTARTER SYSTEM ...........................................................................Kick starterLUBRICATING SYSTEM......................................................................Oil pumpCOOLING SYSTEM.................................................Liquid-cooled with pump, radiator, and thermostat

CARBURETTORBRAND / TYPE............................................................................Dell´Orto / PHVA 14ENGINE IDLE SPEED .......................................................................1,900 ±100TURNS IDLE JET AIR SCREW .................................................................3DIFFUSER DIAMETER ........................................................................14 mm.# IDLE JET .............................................................................................#36# MAIN JET ..............................................................................................#73CONICAL NEEDLE: TYPE / STD ADJUSTMENT .................................A8/3rd SLIDE VALVE ...........................................................................................#30# EMULSIFIER TUBE ...........................................................................#211GACHOKE TYPE..................................................................................MECHANICAL# CHOKE JET ..........................................................................................#45FLOAT ....................................................................................................3.5 gr.

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GENERAL TECHNICAL SPECIFICATIONS

RACER MODELS

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TRANSMISSION R SM

PRIMARY DRIVE................................................................................Spur gearsPRIMARY DRIVE RATIO....................................................................3.5 (77/22)CLUTCH ........................................................................................Multi-disc oil bathGEAR BOX......................................................................................Constant meshGEAR RATIOS:

1st: ..........................................3.09 (34/11)2nd: .........................................2.00 (30/15)3rd:..........................................1.50 (27/18)4th: ..........................................1.20 (24/20)5th: ..........................................1.04 (23/22)6th: ..........................................0.95 (22/23)

TRANSMISSION OIL CAPACITY / TYPE ........................650 cc / AGIP GEAR SAE 10W40FINAL DRIVE ..................................................................................Chain and gearFINAL DRIVE RATIO......................................................4.41 (53/12) .................4.07 (53/13)

ELECTRICAL SYSTEMGENERATOR.........................................................................MAGNETO ALTERNATORVOLTAGE / GENERATOR POWER....................................................12V / 65WIGNITION TYPE .......................................................................................CDIIGNITION ADVANCE...................................................................1.2 mm before TDCSPARK PLUG.....................................................................NGK B10ES / CHAMPION N1CSPARK PLUG ELECTRODE GAP........................................................0.6 mm.BATTERY ...........................................................................................12 V / 4 A/hMAIN FUSE .............................................................................................4 A

GENERAL TECHNICAL SPECIFICATIONS

RACER MODELS

Page 8: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

DIMENSIONS

OVERALL LENGTH (mm.) .............2,035OVERALL WIDTH (mm.) ................800 ( R ) / 760 ( SM )OVERALL HEIGHT (mm.) ..............1,220WHEEL BASE (mm.) ......................1,355

FRAME R SM

FRAME TYPE......................................................................................PerimeterFRONT SUSPENSION: TYPE........................................PAIOLI conventional hydraulic forksFRONT SUSPENSION: STROKE / BAR DIAMETER ...190 mm. / 36 mm.........170 mm. / 36 mm.FRONT SUSPENSION: FORK BAR OIL CAPACITY ....285 cc SAE 10W ........270 cc SAE 10WREAR SUSPENSION: TYPE / STROKE .....................Single in-line shock absorber / 180 mm.STEERING ANGLE...............................................................26º..............................24.7ºFRONT TYRE: SIZE ........................................................80/90x21” ...................100/80x17”FRONT TYRE PRESSURE..............................................1.0 to 1.1......................1.7 to 1.8REAR TYRE: SIZE .........................................................110/80x18”...................130/80x17”REAR TYRE PRESSURE ................................................1.2 to 1.3......................2.0 to 2.1FRONT BRAKE: TYPE / SIZE .................................Hydraulic Disc 240 mm. .....Hydraulic Disc 260 mm.REAR BRAKE: TYPE / SIZE ....................................................Hydraulic Disc 180 mm.TOTAL CAPACITY, FUEL TANK...........................................................7.0 litresTOTAL CAPACITY, OIL RESERVOIR ...................................................1.0 litreCOOLING LIQUID CAPACITY .............................................................0.85 litre

ENGINEOPERATING CYCLE..........................................................................Two StrokeBORE x STROKE............................................................................39.86 x 40 mm.NUMBER OF CYLINDERS ......................................................................OneTOTAL CUBIC CAPACITY ....................................................................49.9 ccMAXIMUM POWER.....................................................................8.5 CV at 9,000 rpmFUEL ......................................................................................Unleaded petrol 95 OctaneCOMPRESSION RATIO ..........................................................................13:1ADMISSION SYSTEM .......................................................................Reed valveSTARTER SYSTEM ...........................................................................Kick starterLUBRICATION SYSTEM......................................................................Oil pumpCOOLING SYSTEM...................................................Liquid with pump, radiator, and thermostat

CARBURETTORBRAND / TYPE............................................................................Dell-Orto / PHVA 14ENGINE IDLE SPEED .......................................................................1,900 ± 100TURNS IDLE JET AIR SCREW ...............................................................23/4 DIFFUSER DIAMETER ........................................................................14 mm.# IDLE JET ..............................................................................................#32# MAIN JET .............................................................................................#71CONICAL NEEDLE: TYPE / STD. ADJUSTMENT ...............................A11/4thSLIDE VALVE ...........................................................................................#30# EMULSIFIER TUBE ...........................................................................#211GACHOKE TYPE..................................................................................MECHANICAL# CHOKE JET...........................................................................................#45FLOAT ....................................................................................................3.5 gr.

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GENERAL TECHNICAL SPECIFICATIONS

XTREME MODELS

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TRANSMISSION R SM

PRIMARY DRIVE................................................................................Spur gearsPRIMARY DRIVE RATIO....................................................................3.5 (77/22)CLUTCH ........................................................................................Multi-disc oil bathGEARBOX.......................................................................................Constant meshGEAR RATIOS:

1st:...........................................3.09 (34/11)2nd: .........................................2.00 (30/15)3rd: ..........................................1.50 (27/18)4th: ..........................................1.20 (24/20)5th: ..........................................1.04 (23/22)6th: ..........................................0.95 (22/23)

TRANSMISSION OIL CAPACITY / TYPE .......................650 cc / AGIP GEAR SAE 10W40FINAL DRIVE .................................................................................Chain and gearFINAL DRIVE RATIO......................................................4.07 (53/13) .................3.78 (53/14)

ELECTRICAL SYSTEM GENERATOR.........................................................................MAGNETO ALTERNATORGENERATOR VOLTAGE / POWER ..................................................12 V / 65 WIGNITION TYPE .......................................................................................CDIIGNITION ADVANCE ..................................................................1.2 mm. before TDCSPARK PLUG.....................................................................NGK B10ES / CHAMPION N1CSPARK PLUG ELECTRODE GAP........................................................0.6 mm.BATTERY............................................................................................12 V / 4 AhMAIN FUSE ..............................................................................................4 A

GENERAL TECHNICAL SPECIFICATIONS

XTREME MODELS

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DIMENSIONSOVERALL LENGTH (mm.) .............2,035OVERALL WIDTH (mm.) ................800 ( R ) / 760 ( SM )OVERALL HEIGHT(mm.) ...............1,220WHEELBASE (mm.) .......................1,355

FRAME R SM

FRAME TYPE......................................................................................Multi-tubeFRONT SUSPENSION: TYPE .....................................Marzocchi Conventional hydraulic forksFRONT SUSPENSION: STROKE / BAR DIAMETER...........................195 mm. / 41 mm.FRONT SUSPENSION: FORK BAR OIL CAPACITY........445 CC SAE 10W.......445 CC SAE 10WREAR SUSPENSION: TYPE / STROKE .................Single shock absorber progressive /180 mm.STEERING ANGLE...............................................................26º..............................24,7ºFRONT TYRE: SIZE ........................................................80/90x21”....................100/80x17”FRONT TYRE: PRESSURE.............................................1.0 to 1.1......................1.7 to 1.8REAR TYRE: SIZE..........................................................100/80x18”...................130/80x17”REAR TYRE: PRESSURE ...............................................1.2 to 1.3......................2.0 to 2.1FRONT BRAKE: TYPE / SIZE: ...............................Wavy hydr. disc 260 mm. ....Double hydr. disc 240 mm.REAR BRAKE: TYPE / SIZE....................................Wavy hydr. disc 218 mm. ..........Hydr. disc 218 mm.TOTAL CAPACITY, FUEL TANK...........................................................7,0 litresTOTAL CAPACITY, OIL RESERVOIR ...................................................1,0 litreCOOLING LIQUID CAPACITY .............................................................0,85 litre

ENGINEOPERATING CYCLE ..........................................................................Two strokeBORE x STROKE............................................................................39.86 x 40 mm.NUMBER OF CYLINDERS ......................................................................OneTOTAL CUBIC CAPACITY.....................................................................49.9 ccMAXIM UM POWER ...................................................................8.5 CV a 9,000 rpmCOMPRESSION RATIO ..........................................................................13:1FUEL ......................................................................................Unleaded petrol 95 octaneADMISSION SYSTEM .......................................................................Reed valveSTARTER SYSTEM ...........................................................................Kick starterLUBRICATION SYSTEM......................................................................Oil pumpCOOLING SYSTEM .................................................Liquid-cooled with pump, radiator and thermostat

CARBURETTORBRAND / TYPE............................................................................Dell´Orto / PHVA 14ENGINE IDLE SPEED ......................................................................1,900 ± 100TURNS IDLE JET AIR SCREW...............................................................2 3/4DIFFUSER DIAMETER .........................................................................14 mm.# IDLE JET ...............................................................................................#32# MAIN JET ..............................................................................................#71CONICAL NEEDLE: TYPE / STD ADJUSTMENT ................................A11/4th SLIDE VALVE ...........................................................................................#30# EMULSIFIER TUBE ...........................................................................#211GACHOKE TYPE..................................................................................MECHANICAL# CHOKE JET ..........................................................................................#45FLOAT ....................................................................................................3.5 gr.

GENERAL TECHNICAL SPECIFICATIONS

DRD MODELS

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TRANSMISSION R SM

PRIMARY DRIVE................................................................................Spur gearsPRIMARY DRIVE RATIO....................................................................3.5 (77/22)CLUTCH ........................................................................................Multi-disc oil bathGEARBOX.......................................................................................Constant meshGEAR RATIOS:

1st:...........................................3.09 (34/11)2nd: .........................................2.00 (30/15)3rd: ..........................................1.50 (27/18)4th: ..........................................1.20 (24/20)5th: ..........................................1.04 (23/22)6th: ..........................................0.95 (22/23)

TRANSMISSION OIL CAPACITY / TYPE .......................650 cc / AGIP GEAR SAE 10W40FINAL DRIVE ................................................................................Chain and gearsFINAL DRIVE RATIO......................................................4.07 (53/13) .................3.78 (53/14)

ELECTRICAL SYSTEMGENERATOR.........................................................................MAGNETO ALTERNATORVOLTAGE / GENERATOR POWER....................................................12V / 65WIGNITION TYPE .......................................................................................CDIIGNITION ADVANCE..................................................................1.2 mm. before TDC.SPARK PLUG.....................................................................NGK B10ES / CHAMPION N1CSPARK PLUG ELECTRODE GAP........................................................0.6 mm.BATTERY ...........................................................................................12 V / 4 A/hMAIN FUSE .............................................................................................4 A

GENERAL TECHNICAL SPECIFICATIONS

DRD MODELS

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DIMENSIONSOVERALL LENGTH (mm.) .............1,900OVERALL WIDTH (mm.) ................670OVERALL HEIGHT (mm.) ..............1,135WHEELBASE (mm.) .......................1,315

FRAME R Racing

FRAME TYPE......................................................................................PerimeterFRONT SUSPENSION: TYPE..................................................Inverted hydraulic forks FRONT SUSPENSION: STROKE / BAR DIAMETER........120 mm./ 35 mm...........95 mm./ 35 mm.FRONT SUSPENSION: FORK BAR OIL CAPACITY.........175 cc SAE 10W .........140 cc SAE 10WREAR SUSPENSION: TYPE / STROKE .................Progressive single shock ......Progressive single shock

absorber / 120 mm. ............absorber / 110 mm.STEERING ANGLE.................................................................................24.5ºFRONT TYRE: SIZE ........................................................90/90x16”.....................90/80x17”FRONT TYRE: PRESSURE.............................................1.7 to 1.8......................2.0 to 2.1REAR TYRE: SIZE..........................................................120/80x16”...................110/80x17”REAR TYRE: PRESSURE ...............................................1.7 to 1.8......................2.0 to 2.1FRONT BRAKE: TYPE / SIZE .................................................Hydraulic disc 260 mm.REAR BRAKE: TYPE / SIZE ....................................................Hydraulic disc 220 mm.OVERALL CAPACITY, FUEL TANK.....................................................7.25 litresOVERALL CAPACITY, OIL RESERVOIR ..............................................1.0 litreCOOLING LIQUID CAPACITY ..............................................................1.1 litre

ENGINEOPERATING CYCLE ..........................................................................Two strokeBORE x STROKE............................................................................39.86 x 40 mm.NUMBER OF CYLINDERS ......................................................................OneTOTAL CUBIC CAPACITY.....................................................................49.9 ccMAXIMUM POWER ....................................................................9.0 CV at 9,000 rpmCOMPRESSION RATIO ..........................................................................13:1FUEL ......................................................................................Unleaded petrol 95 OctaneADMISSION SYSTEM........................................................................Reed valveSTARTER SYSTEM ...........................................................................Kick starterLUBRICATION SYSTEM......................................................................Oil pumpCOOLING SYSTEM.................................................Liquid-cooled with pump, radiator, and thermostat

CARBURETTORBRAND / TYPE ..........................................................................Dell´Orto / PHVA 17.5ENGINE IDLE SPEED ......................................................................1,900 ± 100TURNS IDLE JET AIR SCREW..................................................................3DIFFUSER DIAMETER .......................................................................17.5 mm.# IDLE JET ...............................................................................................#34# MAIN JET ..............................................................................................#98CONICAL NEEDLE: TYPE / STD ADJUSTMENT ................................A15/4th SLIDE VALVE ...........................................................................................#40# EMULSIFIER TUBE ..........................................................................#212FACHOKE TYPE..................................................................................MECHANICAL# CHOKE JET...........................................................................................#50FLOAT ....................................................................................................3.5 gr.

GENERAL TECHNICAL SPECIFICATIONS

GPR MODELS

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TRANSMISSIONPRIMARY DRIVE................................................................................Spur gearsPRIMARY DRIVE RATIO....................................................................3.5 (77/22)CLUTCH ........................................................................................Multi-disc oil bathGEARBOX.......................................................................................Constant meshGEAR RATIOS:

1st: ...........................................3.09 (34/11)2nd:..........................................2.00 (30/15)3rd: ..........................................1.50 (27/18)4th:...........................................1.20 (24/20)5th:...........................................1.04 (23/22)6th:...........................................0.95 (22/23)

TRANSMISSION OIL VOLUME / TYPE...........................650 cc / AGIP GEAR SAE 10W40FINAL DRIVE .................................................................................Chain and gearsFINAL DRIVE RATIO .........................................................................3.71 (52/14)

ELECTRICAL SYSTEM GENERATOR.........................................................................MAGNETO ALTERNATORVOLTAGE / GENERATOR POWER ...................................................12V / 65WIGNITION TYPE .......................................................................................CDIIGNITION ADVANCE .................................................................1.2 mm. before TDC.SPARK PLUG.....................................................................NGK B10ES / CHAMPION N1CSPARK PLUG ELECTRODE GAP........................................................0.6 mm.BATTERY ...........................................................................................12 V / 4 A/hMAIN FUSE .............................................................................................4 A

GENERAL TECHNICAL SPECIFICATIONS

GPR MODELS

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MAINTENANCE SCHEDULE

KMS. / MONTHS (whichever comes first)

CHECKS 1000 / 2 5000 / 12 10000 / 24 15000 / 36 20000 / 48 25000 / 60

Gearbox/Clutch oil REPLACE REPLACE CHECK REPLACE CHECK

Rear shock absorber CHECK CHECK CHECK CHECK CHECK

Tightness of fastenings TIGHTEN TIGHTEN TIGHTEN TIGHTEN TIGHTEN TIGHTEN

Battery (level) CHECK CHECK CHECK CHECK CHECK

Spark plug CLEAN REPLACE REPLACE REPLACE REPLACE REPLACE

Final drive chain TIGHTEN UP CHECK REPLACE CHECK REPLACE CHECK

Carburettor ADJUST ADJUST ADJUST ADJUST ADJUST ADJUSTCLEANING CLEANING CLEANING CLEANING CLEANING CLEANING

Cylinder / cylinder head

pistonCLEAN UP CLEAN UP

Tightness of cylinder head TIGHTEN UP TIGHTEN UP TIGHTEN UP TIGHTEN UP TIGHTEN UP TIGHTEN UP

Piston rings CHECK REPLACE CHECK REPLACE CHECK

Air filter CLEAN CLEAN CLEAN CLEAN CLEAN

Oil filter REPLACE REPLACE

Front forks hydraulic fluid REPLACE REPLACE

Steering play CHECK TIGHTEN UP CHECK TIGHTEN UP CHECK TIGHTEN UP

Inlet reed valve CHECK CHECK

Brake hoses CHECK CHECK CHECK CHECK

Brake pads CHECK CHECK CHECK CHECK CHECK CHECK

Brake fluid CHECK REPLACE CHECK REPLACE CHECK

Engine coolant CHECK CHECK REPLACE CHECK REPLACE CHECK

Tyres CHECK CHECK CHECK CHECK CHECK CHECK

Rims / spokes CHECK CHECK CHECK CHECK CHECK CHECK

Fuel and oil hoses CHECK REPLACE CHECK REPLACE CHECK

Oil pump setting CHECK CHECK CHECK

SPARK PLUGS USED IN THE DERBI MANUAL GEARBOX ENGINES 2002

SENDA R/SM 50 X-TREM/DRD EURO-I (W.V.T.A.)

GPR 50 R/REPLICA EURO-I (W.V.T.A.)BULTACO LOBITO 50 EURO I (W.V.T.A.)BULTACO ASTRO 50 EUROI (W.V.T.A.)

SENDA R/SM 50 X-TREM/DRD SPAIN / FRANCE

GPR R/REPLICA 50 SPAIN / FRANCEBULTACO LOBITO 50 SPAINBULTACO ASTRO 50 SPAIN

SPARK PLUG MODEL

NGK B8ES

CHAMPION N3C

NGK B10ES

CHAMPION N1C

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TORQUE SETTINGS TABLE

TORQUE SETTINGDESCRIPTION METRIC m kg. Nm Thread SealerUpper shock absorber-frame securing 10x125 3.0 to 4.0 30 to 40Lower shock absorber-swinging arm securing 12x175 5.5 to 6.5 55 to 65Lower shock absorber-link arms securing 12x175 5.5 to 6.5 55 to 65Suspension link arm-frame securing 12x175 5.5 to 6.5 55 to 65Suspension link arm-swinging arm securing 12x175 5.5 to 6.5 55 to 65Rear Engine mount frame swinging shaft 12x150 6.0 to 7.0 60 to 70Swinging shaft 14x150 7.0 to 8.0 70 to 80Front engine to frame 10x150 3.5 to 4.0 35 to 40Lower engine mount to frame 8x125 2.5 to 2.8 25 to 28Steering forks to frame securing 25x100 9.0 to 13.0 90 to 130Fork leg plug 8x125 1.7 to 1.9 17 to 19Exhaust pipe to cylinder 6x100 0.9 a1.2 9 to 12Exhaust pipe to frame securing 8x125 1.7 to 1.9 17 to 19Exhaust pipe silencer to frame 8x125 1.7 to 1.9 17 to 19Exhaust pipe silencer to frame 6x100 0.8 to 1.0 8 to 10Steering arm clamps-fork bars 8x125 2.0 to 2.4 20 to 24Handlebar to Steering arm 8x125 2.0 to 2.4 20 to 24Clip-on bar to Steering arm 8x125 1.7 to 1.9 17 to 19 LOCTITE 243Front wheel axle 12x150 5.5 to 6.5 55 to 65Front wheel axle 14x150 7.0 to 8.0 70 to 80Front brake caliper 8x125 1.7 to 1.9 17 to 19 LOCTITE 243Front brake caliper 6x100 1.0 to 1.2 10 to 12 LOCTITE 243Rear wheel axle 12x150 5.5 to 6.5 55 to 65Rear wheel axle 14x150 7.0 to 8.0 70 to 80Rear brake caliper 8x125 1.7 to 1.9 17 to 19 LOCTITE 243Rear brake disc 8x100 1.7 to 1.9 17 to 19 LOCTITE 243Rear brake disc 6x100 10.9 1.1 to 1.2 11 to 12 LOCTITE 243Front brake disc 6x100 10.9 1.1 to 1.2 11 to 12 LOCTITE 243Rear wheel drive sprocket 8x125 1.7 to 1.9 17 to 19 LOCTITE 243Rear wheel drive sprocket 6x100 8.8 0.8 to 1.0 8 to 10Cylinder head to cylinder securing screw 6x100 1.0 to 1.2 10 to 12Cylinder head securing nut 7x100 1.9 to 2.2 19 to 22Magneto to crankshaft 10x100 3.5 to 4.5 35 to 45Ignition base plate to crankcase 5x80 0.25 to 0.35 8 to 10 LOCTITE 243Clutch cover 6x100 0.8 to 1.0 8 to 10Crankshaft engine pinion 10x100 3.5 to 4.5 8 to 10Crankcase half securing screws 6x100 0.8 to 1.0 8 to 10 LOCTITE 243Starter motor to crankcase 6x100 0.8 to 1.0 32 to 38Cylinder head thermistor 14x150 3.2 to 3.8 32 to 38Cylinder head thermostat nut 24x100 2.5 to 4.0 25 to 40Clutch hub 12x150 3.5 to 4.5 35 to 45Crankcase oil drain plug 10x150 1.0 to 1.5 10 to 15Counterweight pinion and counterweight 5x80 0.35 to 0.45 3.5 to 4.5 LOCTITE 243Crankcase primary shaft bearing lock 5x80 0.35 to 0.45 3.5 to 4.5Gearbox output pinion lock 5x80 0.35 to 0.45 3.5 to 4.5 LOCTITE 243

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NUMBER REFERENCE DESCRIPTION

1 00H05400451 GPR CRANKSHAFT OIL SEAL ASSEMBLY TOOL

2 00H05400581 STARTER SHAFT OIL SEAL ASSEMBLY TOOL

3 00H05401561 SELECTOR SHAFT OIL SEAL ASSEMBLY TOOL

4 00H05300041 GPR CLUTCH HUB SECURING TOOL

5 00H05600251 INTERMEDIATE PINION NEEDLE BEARING ASSEMBLY TOOL

6 00H05600241 PRIMARY SHAFT NEEDLE BEARING ASSEMBLY TOOL

7 00H05300151 GPR 75 ENGINE SPLITTING PUSHER TOOL

8 00H05300841 CRANKSHAFT OIL SEAL GUIDE BUSH

9 00H05600351 GPR FINAL DRIVE SHAFT OIL SEAL GUIDE PIN

10 00H05600341 GPR 75 STARTER SHAFT OIL SEAL GUIDE PIN

11 00H05600331 GPR DECLUTCH SHAFT OIL SEAL GUIDE PIN

12 00H05600261 WATER PUMP SHAFT OIL SEAL GUIDE PIN

13 00F05300021 MAGNETO ALTERNATOR EXTRACTOR TOOL

14 00G05300011 MAGNETO ALTERNATOR ROTATION LOCK

15 00H05600321 BALANCE SHAFT GEAR EXTRACTOR TOOL (COUNTERWEIGHT)

16 00H05600231 BALANCE SHAFT GEAR SECURING TOOL (COUNTERWEIGHT)

SPECIAL TOOLS

Page 17: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Withdraw the fork bars from the ste-ering arms, loosening the clampscrews securing them.

- Secure the fork bar in a bench vice,protecting the face of the vice withcheek pieces of soft metal so as notto scratch or damage the bars, andproceed to loosen the upper forkplug screw.

- Withdraw the upper fork plug screw,together with the pre-load distancepiece and the suspension spring.

- Get ready a container to drain thehydraulic fluid out of each fork bar,and proceed to measure the quan-tity of fluid (pump each fork leg barso as to ensure that it is completelydrained).

3-1

STRIPPING DOWN THE FRONT SUSPENSION

Page 18: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Extract the oil seal dust ring and thelocking circlip.

- Locate the Allen screw in the baseof the fork leg and loosen it in orderto free the hydraulic assembly andthe bar.

- Separate the fork leg and the barwith a firm movement.

- Extract the aluminium hydraulic unitsupport stop on the interior of thefork leg.

3-2

Page 19: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Next extract the hydraulic cartridgethrough the upper end of the forkbar.

- Grip the fork leg in a bench vicewith soft metal cheek pieces overthe faces and place a cloth over itsmouth so as to avoid causing dama-ge and remove the oil seal using alever. Always replace the oil sealwhen refitting the assembly.

- Proceed to clean and degrease allthe components of the front suspen-sion, in order to check these parts.

- Check the degree of wear on thefork bar guide bush. Replace it if itshows signs of damage over morethan 30% of its entire surface.

- Check the degree of wear on thefork leg guide bush. Replace it if itshows signs of damage over morethan 30% of its entire surface.

3-3

Page 20: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Using X-bar calibration blocks and adial comparator micrometer moun-ted on a fixed rigid support, checkthe amount of mis-alignment of thebar.

Service limit: 0.2 mm

- Check the length of the fork suspen-sion spring, and also check forsigns of deformation and/or whetherit is out of parallel.

- Check the condition of the returnspring and the nylon guide in thehydraulic assembly, together withthe O-ring seal.

Replace them in the event that theyare deformed or show evident signsof damage.

- Clean and degrease all the ele-ments comprising the assembly inorder to proceed to re-assembly.

3-4

Page 21: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Proceed to re-assemble theassembly, paying particular atten-tion to the correct torque setting forthe hydraulic cartridge - fork leg,and also to the assembly of the oilseal, placing a little suspension oilon the oil seal lips and inserting itusing the special insertion tool.Refill with hydraulic oil, and do notforget to insert the pre-load bushbetween the spring and the fork legplug.

3-5

SUSPENSIÓN Suspension stroke cc oil / bar Type of oil(mm.)

MARZOCCHI R DRD 485 R DRD 445 AGIP 10 WPAIOLI X TREME 190 X TREME 285 AGIP 10 WSEBAC GPR R 120 GPR R 175 AGIP 10 WMARZOCCHI SM DRD 465 DRD SM 445 AGIP 10 WPAIOLI X TREME SM 175 X TREME SM 270 AGIP 10 WSEBAC GPR Racing 95 GPR Racing 140 AGIP 10 W

STRIPPING DOWN THEREAR SUSPENSION- The rear shock absorber assembly

is maintenance-free, and there areno external adjustments possible,and consequently in the event ofmalfunction, the entire faulty unitmust be replaced.

- In R DRD models maintenancemust be carried out on the rear sus-pension link assembly which provi-des the progressivity to the wholeunit: this maintenance work consistsof stripping down the links, cleaningand re-lubrication of the link bea-rings in the event of intensive off-road usage of the machine, in parti-cular if such areas are very dusty ormuddy.

Page 22: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

STRIPPING DOWN THECARBURETTOR- Slacken off the carburettor - inlet

manifold and the air filter outletsecuring clamps. Disconnect thefuel, oil and fuel tap vacuum linehoses, and withdraw the carburet-tor.

- Slacken off the carburettor coversecuring screw, and withdraw thecover together with the throttlecable, the fuel valve, and the doserconical needle.

- Compress the gas valve returnspring against the cover and extractthe throttle cable terminal throughthe channel in the fuel valve.

4-1

Page 23: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Remove the piston valve - cold startsystem (choke) securing clamp andwithdraw the assembly.

- Remove the air volume adjustmentscrew (compensator) in the lowspeed circuit (idle circuit).

- Remove the carburettor float cham-ber securing screws and the carbu-rettor float chamber, in order to gainaccess to the jets: main, idle, andchoke, together with the float andthe float needle valve.

4-2

Page 24: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

ASSEMBLING THECARBURETTOR- Thoroughly clean all the compo-

nents of the carburettor using sol-vent (take care not to damage thecarburettor float gasket and the coldstart piston valve O-ring).

- Using compressed air thoroughlyblow clean all the carburettor air-way orifices, together with those foroil and fuel.

- Using a balance, check the weightof the float. This is marked on thefloat itself (3.5 grams). Replace thepart if it exceeds the stated weight.

4-3

Page 25: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Check that the cone at the end ofthe fuel flow control pin and the floatconnector stud spring are in goodcondition: if they are not in goodcondition, replace with a new com-ponent.

- Check the condition of the cold startpiston valve. Replace the unit ifsigns of damage are found on thevulcanised sealing seat, or on themetal piston body itself (scratchesand/or corrosion exceeding 25% ofthe total surface area).

- Check the size of the jets with refe-rence to the numbering stamped onthe jets, and install the correct jets(see table of adjusts); failure toobserve this will have a negativeeffect on the performance of theengine.

- Check the position of the doserconical needle circlip. This shouldbe located in the central ring of thefive available. By moving the circlipto a ring further up the needle aweaker mixture is obtained, and bymoving the circlip further down theneedle a richer mixture is obtained;this is to allow adjustment for veryextreme climatic conditions.

4-4

Page 26: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Replace the doser conical needle ifany signs of damage are observedon its circumference, as shown inthe figure.

- Check that there are no signs ofscratches on the minimum circuit airadjustment screw conical tip, sincethis would affect its performance.

- Also check that there are no signsof scratches on the slide valve.Replace in the event that suchscratches cover more than 25% ofits total surface area.

- Take car to install a new slider valveof identical characteristics (refer tothe marking on the base of the com-ponent).

- Completely re-assemble the carbu-rettor.

- Re-mount the carburettor onto theengine, and connect the fuel, oil andfuel tap vacuum operating hosescorrectly.

4-5

Page 27: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Check that the throttle cable is ableto move the correct distance andthat its operation does not becomeblocked or stiff at any point in themovement.

- Adjust the ply on the throttle controlon the handlebar by tightening orslackening the throttle cable sleevetensioner located beside the throttletwist grip control until a play of 3 to5 mm is obtained.

- Remove the right hand side bodywork cover in order to gain accessto the air filter cover, withdraw theair filter cover. Withdraw the air filterfoam, and wash it in soap andwater, then squeeze out and drythoroughly. Once dry soak it in spe-cial air filter oil, and reinstall.

- Start the engine and warm it upslightly.

- Proceed to adjust the idle speed,using the following procedure:

- Turn the slide valve rest stop screwuntil the engine does not stall (scre-wing in).

- Screw the minimum circuit air adjus-ter screw fully home, but without for-cing it. Then unscrew 1 1/2 turns.Start the engine again if it has sta-lled during this operation.

4-6

- Turn the slide valve rest stop screw again, slowlyscrewing in and out, until a stable idle speed of 1,800± 50 rpm is obtained (use an external rev counter forthis purpose).

- Rev up the engine fast using the throttle control, andcheck that the engine accelerates and deceleratesbrilliantly and fast, with no soft spots. If this is notobtained, repeat the carburettor adjustment procedu-re again from the first step.

- For models with a carburettor heater, proceed accor-ding to the following information in order to achieveproper operation.

Page 28: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

PTC CONTROLTHERMOSTAT

Y / G BLACK

BLACK

YELLOW

AC SUPPLYFROM REGULATOR

PTCCARBURETTORHEATER

Thermostat control

- Check that the power supply rea-ches the thermostat connecting alamp between the Yellow/Green andYellow cables.

- To check the outputs, black cables,it is necessary to reduce the tempe-rature of the thermostat to 5ºC andthen check the output between theblack cables using a 12 v bulb.

Check the thermal resistance of thecarburettor

- Check the resistance of the PTC ata temperature of between 15º and20ºC.

Resistance value: 8Ω ± 3

4-7

BRAND

DELL´ORTODELL´ORTODELL´ORTODELL´ORTO

DELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTOMAG.MARELLIDELL´ORTODELL´ORTODELL´ORTOARBEO

DELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTODELL´ORTO

DELL´ORTOMAG.MARELLIMAG.MARELLIMAG.MARELLIDELL´ORTO

MODEL

PHVA 14DDPHVA 12DDPHVA14DDPHVA14DD

PHVA 14 DDPHVA 14 DDPHVA 12 DDPHVA 14 DDPHVA 14 DDPHVA 17.5 EDPHVA 14 DDSHA 12-12 TPHBN 12 BS PHBN 12 FSPHBN 12 BSPHBN 12 FSPHBN 12 FS 18 OM 1 BAPHVA 17.5 EDPHVA 14 DDPHBG 20 BSSHA 12-12 MR

PHVA 14 DDPHVA 17.5 TSPHVA 17.5 EDPHVA 14 DDPHVA 12 DDPHVA 14 DDPHVA 17.5 TSPHVA 17.5 EDPHBG 20 BSPHBG 20 BSPHBG 20 BS

PHVA 17.5 ED18 0M 1DA14 OM 1CA12 OM 1RAPHVA14DD

VEHICLE

SENDAR/SM 2000 (Spain,Fra)SENDAR/SM 2000 (Italy)SENDAR-2000 (W.V.T.A.)GILERA ZULU (W.V.T.A.)

SENDA-R/FENIX (Spain)SENDA-R (France)SENDA-R (Italy)SENDA-R (Austria)SENDA-R (Germany/95)SENDA-R 100 (SouthAmerica)SENDA SM (Austria)SENDA/FENIX (Spain)SENDA L (Germany)SENDA L (Germany)SENDA L (Austria)SENDA L (Austria/93)SENDA L (Belgium)SENDA R 100/FENIX 100FENIX 100 (South Am.)FENIX (Austria)BI-3 75 EnduroCAMPERA

GPR 50R W.V.T.A.GPR 50R (Spain)GPR 50R (Spain)GPR 50R (France)MITO (Italy)MITO (Austria)GPR 100 (SouthAm.)GPR 100 R (SouthAm.)GPR 50 1994GPR 75 1992GPR 75 1989 BULTACO LOBITO (Spain)BULTACO LOBITO (Spain)BULTACO LOBITO (France)BULTACO LOBITO (Italy)BULT.LOBITO, ASTRO (WVTA)

MAIN JET

71655354

736065606283636458585656649086568870

54989870687696969590

115

8892878453

NEEDLEPOS

A11/4thA11/4thA11/3rdA11/3rd

A8/3rdA11/3rdA11/4thA11/3rdA11/3rdA7/3rdA8/3rd

A2/3rdA2/3rdA2/3rdA2/3rdA2/3rdAJ/2ndA7/3rd

A11/3rdW9/1st

A11/3rdA15/4thA15/4thA11/3rdA8/3rdA13/4thA15/4thA15/4thW9/3rdW9/2nd

W20/2nd

A29/2ndAG/2ndAE/4thAI/4th

A29/3rd

THROTTLEVALVE

30304040

303030404040301030303030303404040

Standard

3040403030404040403040

4033540

CHOKEJET

45455050

45504550505045

505050505055505065

4550504545455050656565

5055555550

FLOAT [gm]

3.53.53.53.5

3.53.53.53.53.53.53.53.53.53.53.53.53.54.53.53.54

3.5

3.53.53.53.53.53.53.53.5444

3.54.54.54.53.5

IDLEJET

SENDA R/SM 2000GILERA

32363334

SENDA R/L/SM - FENIX - CAMPERA36363838343436

3232323232

34/35343248

Ø 1,0GPR -MITO

3434343638343434484845

BULTACO LOBITO / ASTRO

3034/3535/3535/35

33

AIR

2 3/42 1/21 3/4

2 +/- 1/4

32 1/22 1/22 1/42.5

2 1/23

3 1/23 1/23.53.5

3 1/22.5

2 1/22 1/21 1/21.5

3/433

2 1/23 1/42 1/2

32 3/41 1/21 1/22 1/2

1 3/42.52.75

21 3/4

CARBURETTOR

EMULSIFIER

211 GA211 GA208 GA208 GA

211 GA210 GA211 GA208 GA208 GA212 FA211 GA

39210 FA210 FA210 FA210 FA210 FA

G8212 FA208 GA262 AU

Ø 1,75mm

208 GA212 FA212 FA208 GA211 GA210 FA212 FA212 FA264 AU262 AU258 BP

212 FAG8G8G8

212 GA

Page 29: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

STRIPPING DOWN THEREED VALVE- Withdraw the carburettor from the

engine

- Remove the inlet nozzle securingscrews, as is, and then it is possibleto gain access and withdraw thereed valve.

- Check that there are no signs ofcracking, deformation or breaking inthe valve reed petals. If signs ofdamage are present, replace them.

- Remove the opening limiter plateand inlet valve reed petal securingscrews and check that there are nocracks in the securing base of thepetals. If cracks are found, replacethe valve reeds.

ASSEMBLING THE VALVEREEDS- Assemble in reverse order to strip-

ping down, paying particular atten-tion to the correct positioning of theopening limiter plate and the reeds(it is necessary to mate the beve-lling). Elimination of the openingheight limiter will change the perfor-mance of the engine and may affectengine reliability.

- Check the reed valve box O-ringand replace if it shows signs ofdamage. Install a new gasket.

5-1

Page 30: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

COOLING SYSTEM- Drain the engine coolant comple-

tely, and proceed to strip down thepump to cylinder and the pump toradiator hoses.

- Remove the water pump coversecuring screws and remove thewater pump cover.

- Slacken off the water pump impellersecuring screw and remove it byunscrewing.

- Withdraw the water pump shaft (1)and the impeller pinion (2).

- Change the water pump seals ifthere is the slightest sign of leakageof coolant liquid or water from thebreather hole.

- Fit the new seals according to thedrawing attached.

6-1

Page 31: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

3

21

ASSEMBLY

- Fit the water pump shaft and theimpeller pinion.

- Fit the washer (3).

- Fit the crankcase cover.

- Fit the pump impeller (1) and thesecuring nut (2). Tighten up to tor-que setting 0.2 m.kg.

- Fit the water pump cover gasket,the water pump cover, and the twohoses.

- Fill the transmission with the recom-mended oil (see page 2-2).

- Fill the cooling liquid circuit (seepage 10-2).

- Proceed in the reverse order untilthe step last mentioned.

- Eliminate the remains of the gasketand coolant deposits on the waterpump components

- Install a new water pump cover gas-ket.

- Proceed to refill and bleed the coo-ling liquid circuit in accordance withthe following procedure:

- Place an external feed reservoirfilled with AGIP closed circuit Plus30 coolant at a height of approxima-tely 2m from the floor, in order toproceed to refill the coolant circuitfrom the expansion vessel.

- Start up the engine and maintain itat idle speed.

- Open up the feeder reservoir cockand allow the coolant fluid to flowfreely until the minimum level in theexpansion vessel is reached.

6-2

Page 32: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

Thermometer

Neither must touch the wallsor base of the container

Thermoswitch

Thermometer

Thermostat must betotallysubmerged

Neither must touch the wallsor base of the container

- Remove the bleed screw from thewater pump cover and do not reins-tall it until the coolant fluid flows outwith no bubbles.

- Close the plug-valve of the expan-sion vessel. Heat up the engine untilthe thermostat opens.

- Check that the radiator body warmsup; if it fails to warm up this indica-tes that the thermostat has failed toopen, or that there are air bubblesinside the coolant liquid circuit.

- Stop the engine and allow to cool.

- Refill the expansion reservoir withcoolant liquid until the minimumlevel in the reservoir is reached(when the engine heats up the levelwill rise owing to the expansion ofthe liquid in the circuit.

- Check the electric circuit of theoverheating warning lamp on theinstrument panel by disconnectingthe temperature sensor connectorspade and connecting the terminalto earth via a short length of cable,then operate the contact and thewarning light on the instrumentpanel should light up.

- In order to check the cylinder headtemperature sensor, as well as theelectric fan operating thermos-switch (only in versions fitted withthis equipment) submerge the ope-rative part of these components in acontainer of water (without it tou-ching the sides of the container)and heat up the water. Connect anohmmeter between the metal bodyof the devices and the connectorterminal, and check that as the tem-perature of the water rises, theresistance reading at the sensorfalls; if this is not the case, replacethe thermo-switch.

- The thermostat should be checked by submerging itin a container of water (without touching the sides orbottom) and heating the water. Using a thermometernote the temperature when the contact starts toopen and again when it stops opening (fully openposition).

6-3

Inspection of the thermoswitch

Measurement temperature valve opening

Sensor ON OFF

Cylinder headcooloant 124 ± 3ºC 114 ± 3ºCtemperature

Electric fanthermo-swich 97 ± 3ºC 85 ± 3ºC

Temperature ºC 67±3ºC 75ºC

Thermostat opening (mm.) 0,1 3,0

Page 33: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

THERMOCONTACFUSE 4 AMP 4AMP

R/BL

IGNITION SWITCH

BATTERY

FAN

R/BL RED / BLACK + FROM IGNITION SWITCHWH WHITE + FROM FAN

- + WH

- In order to check the correct opera-tion of the expansion reservoir capoverpressure valve, use a manome-ter with an appropriate adapter forthe thread of the cap.

- In vehicles equipped with the elec-tric fan, fan operation should alsobe checked after filling and bleedingthe cooling circuit, as per the follo-wing specifications:

- In the event that the electric fandoes not come into operation, checkthe following:

1. Main fuse

2. Battery voltage charge

3. The electrical circuit operating thefan.

- If no anomalies or faults are disco-vered in these areas, proceed toreplace the electric fan thermo-switch, which is located on theupper radiator cover.

6-4

CONNECTION TEMPERATURE ºC

OFF - ON 97 ± 3

ON - OFF 85 ± 3

Page 34: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

STRIPPING DOWN THE OILPUMP- Remove the inspection cover loca-

ted on the clutch side crankcasehalf.

- Slacken off the oil pump inlet andoutlet hose securing clamps.

- Plug the inlet hose to prevent drai-ning the oil reservoir.

- Remove the pump operating cable,disconnecting it first from the opera-ting lever arm and then from the sle-eve stop on the clutch side crankca-se half.

- Remove the two Allen screws secu-ring the pump to the clutch sidecrankcase half, and withdraw thepump.

- Turn the pump rotation shaft byhand to check that it rotates smo-othly.

- Check the condition of the O-ringand the shaft oil seal. Replace ifthey show signs of damage.

- The oil pump is a safety item for theproper operation of the engine andin the event that it becomes faulty, itshould be replaced and not repai-red.

7-1

Page 35: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

ASSEMBLING THE OIL PUMP- Proceed in the reverse order to that specified

for stripping down, shown above.

- Pay particular attention to ensuring that thecastellated drive connection between thepump shaft and the gearing in the clutch sidecrankcase half is properly engaged.

- Proceed to bleed the oil pump according tothe following procedure:

- Fit the oil supply hose from the oil reservoirto the oil pump.

- Using a syringe fill the pump outlet hose withAGIP Speed oil, and connect it between theoil pump and the carburettor.

- Withdraw the pump bleed screw.

- Feed the carburettor with a 2% mixture ofAGIP Speed oil and petrol from an indepen-dent source.

- Start the engine and maintain it at idlespeed. Turn the oil pump control lever to itsfull open position, and keep it in this positionuntil the oil flows out of the pump bleed orifi-ce without any bubbles.

- Fit the pump bleed screw and check that theoil flows freely through the end of the outlethose which is connected to the carburettor.

- Stop the engine and remove the independentsupply of fuel-oil mixture. Reconnect thepetrol feed from the fuel tank.

- Fit the pump control cable and adjust theplay in the cable until the arrow on the con-trol lever arm is opposite the reference markon the pump body (and the throttle control iscompletely closed).

- Refill the oil reservoir with oil until it reachesthe maximum mark.

7-2

Page 36: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

PULLING THE ENGINEFROM THE FRAME

Models: RACER, XTREME - DRD

- Remove all the plastic componentsaround the fuel tank. Take care withthe joint between the plastic ele-ments with the fuel tank, and to thefront grille protecting the radiator.

- Withdraw the exhaust pipe andsilencer assembly.

Models:

GPR R and GPR Racing Replica

- Extract the lateral securing screwsattaching the screen to the fairingand the frame, on both sides, andthen extract the entire unit.

- Open the cover of the fuel tank fai-ring. Remove the screws from thebattery inspection cover and thenthe battery inspection cover.

- Withdraw the helmet box, turning itto one side and raising it by thefront, and in this way easy access tothe engine components is achieved.

8-1

Page 37: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Remove the water pump to radiatorcoolant liquid hose. Have a trayready to catch the coolant liquid.

- Disconnect the following electricalconnections:

1. Magneto to HT coil;

2. Coolant liquid temperatures sen-sor;

3. Ignition connection cable fromHT coil to spark plug.

- Remove the carburettor:

1. Fuel cock vacuum operatinghose;

2. Fuel supply;

3. Engine oil supply from oil pump.

- Withdraw the clutch operatingcable. Before withdrawing the cable,slacken off all tension in the cable atthe clutch cable tensioner on thehandlebar lever.

8-2

Page 38: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Remove the oil pump inspectioncover on the clutch side crankcasehalf, and disconnect the operatingcable from the terminal. Disconnectthe hoses (oil reservoir supply to oilpump, and oil pump supply to car-burettor).

- Remove the gear shift pedal fromthe gearbox, and also the kick startpedal.

- Drain off the oil from the clutch-sidecrankcase half and gearbox. Thedrain plugs are located in theunderside of the crankcase and inthe clutch cover.

8-3

Page 39: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Remove the final drive chain, ope-ning the connecting link noting thecorrect position of the link clip.

- First slacken off completely theengine to frame mounting bolts, andthen remove.

- Withdraw the engine from theframe, pulling towards the front androtating slightly.

8-4

Page 40: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

FITTING THE ENGINE INTO THE FRAME- Follow the indications for stripping down as

given above, but in reverse order.

- Take care to ensure that the electrical con-nections for the magneto, the spark plug,and the engine temperature sensor arecorrectly made.

- Install the fuel supply hose to the carburettorand the vacuum line for the fuel cock, and inaddition the oil hoses from the oil reservoir tothe pump and from the pump to the carburet-tor.

- Install correctly and ensure proper operationof the throttle control and oil pump controlcables.

- Fill and bleed the oil pump (please refer tothe specific section in this manual).

- Install the clutch cable properly and adjustfor correct play using the tensioner at thehandlebar clutch lever.

- Refill the gearbox-clutch assembly andcheck for correct level (please refer to thespecific section in this manual).

- Install the final drive chain, and take care toensure that the connector link and clip arecorrectly secured.

- Fill the cooling circuit and bleed (please referto the specific section in this manual).

8-5

Page 41: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

9-1

STRIPPING DOWN THECYLINDER HEAD- Drain the coolant liquid, removing

the hoses fitted to the water pump.

- Place a tray ready to catch the coo-lant

- Remove the hose from cylinderhead to the radiator.

- Disconnect the electrical connectorspade on the temperature sensor.

- Disconnect the HT cable from thespark plug cap and withdraw thespark plug

- First slacken off and then extract inthis order, the M6 screws and thenthe M7 nuts.

- Withdraw the cylinder head andcylinder head gasket from the cylin-der. Clean off the remains of thegasket and coke deposits withoutscratching or degrading the surfa-ces.

- Using a feeler gauge and a straightedge check the mating surfaces forwarping, both on the cylinder headand on the cylinder.

Maximum permitted out of true:

0.1 mm.

- Follow the instructions given above for strip-ping down the cylinder head, in reverseorder.

- Fit a new cylinder head gasket, first ensuringthat the mating surfaces are perfectly clean,both on the cylinder head and on the upperface of the cylinder. Do not apply any form ofsealant.

- Tighten the M7 nuts and then the M6screws, and finally torque up to a torque set-ting of 18 to 20 Nm following a cross patternsequence.

- Refit the hose between the cylinder headand the radiator correctly.

- Fit a new spark plug.

- Reconnect the temperature sensor andsparkplug electrical connections.

- Refill the cooling circuit with AGIP coolant,and bleed the circuit (please refer to the spe-cific section in this manual).

FITTING THE CYLINDER HEAD

Page 42: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

STRIPPING DOWN THECYLINDER AND THEPISTON- Drain the coolant out of the engine.

- Strip down the cylinder head.

- Remove the cooling circuit hosebetween the cylinder and the waterpump.

- Withdraw the cylinder, pulling gentlyupwards.

- Remove the cylinder base gasket.

- Place a clean rag in the opening ofthe crankcase to prevent anyobjects from falling accidentally intothe crankcase.

- Remover the gudgeon pin securingclips and then:

- The gudgeon pin;

- The Piston;

- The connecting rod big endbearing.

- If the gudgeon pin needs to be pus-hed to extract it, support the con-necting rod firmly from the otherside to prevent it being damaged orbent out of shape.

- Proceed to clean the componentsand to eliminate the remains of thecylinder gaskets and coke depositsgently (avoid scratching the outsidesurface of the piston).

- Perform a visual check of the condi-tion of the connecting rod big-end.

- If there are signs of damage on theneedle bearing contact surface,replace the connecting rod.

- Perform a visual check of the condi-tion of the connecting rod big endbearing; if signs of damage arefound to the needles or if there arecracks in the cage, it should bereplaced.

- Withdraw the piston rings by ope-ning them at their ends, and liftingthem from the opposite side.

10-1

Page 43: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

CHECKING THE CYLINDERAND THE PISTON- Check the piston ring gaps, inser-

ting them into the cylinder bore andmeasuring the gap with a feelergauge.

Maximum permitted piston ring gap:0.5 mm.

- Check the amount of wear in thecylinder, using an alexometer.Calibrate the alexometer previouslyusing the dimensions given in thetable of cylinder - piston families.

- Perform measurements across twoperpendicular axes and at three dif-ferent heights.

Service limit: 0.05 mm.

- Check the diameter of the pistonover the diameter perpendicular tothe gudgeon pin and at a distanceof 15 mm from the bottom edge ofthe piston skirts.

Service limit: 0.06 mm.

10-2

ABCD

Family Piston ± 0.0025

39,845

39,850

39,855

39,860

Cilinder ± 0.0025

39,870

39,875

39,880

39,885

Play

0.02

0 -

0.03

0

Page 44: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

ASSEMBLING THECYLINDER AND THEPISTON- Install the piston rings.

- Install a new cylinder base gasket.

- Install the needle bearing cage, thegudgeon pin and the circlips, firstlubricating the components withAGIP Speed oil. Pay attention to theposition reference mark on thecrown of the piston (the arrowshould point towards the exhaustport).

- Take care to ensure that the lugs onthe gudgeon pin circl ips pointupwards. Ensure that the circlipsare seated fully home in their groo-ves.

- Compress the rings into the interiorof their grooves

- And take care to ensure that theydo not ride up over the fixed stoppins.

- Lubricate both the interior wall ofthe cylinder and the outside of thepiston and the piston rings.

- Fit the cylinder and check that thepiston is correctly orientated (withthe arrow pointing towards theexhaust port).

- Fit a new cylinder head gasket andre-assemble the cylinder head.

- Fit a new spark plug.

- Reconnect the electrical connectorsfor the temperature sensor and thespark plug.

- Refill the cooling circuit with AGIPcoolant liquid, and bleed the coolingcircuit (please refer to the specificsection in this manual).

10-3

Page 45: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

11-1

STRIPPING DOWN THECLUTCH ASSEMBLY- Drain the coolant liquid from the

engine.

- Drain the oil from the transmission,by extracting the two drain plugs(clutch side crankcase half andunderside of crankcase, also remo-ving all hoses and operating cables

- Extract the oil pump, with tubes andcable.

- Remove the kick start pedal.

- Remove the clutch side crankcasehalf securing screws and the crank-case half.

- This gives access to the set ofassemblies comprising the primarydrive, the clutch, the starter system,and the gear selector shaft.

- Strip down all the screws and clo-sing springs on the clutch driveplate.

- Withdraw the set of driven clutchplates and driving clutch plates.

- Unlock the clutch hub securing nutlock washer, and remove the clutchhubs. Special care should be takenwith the central bushing and the setof washers.

Page 46: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- In order to free off the torqueapplied to the balance shaft gearsecuring nut, in those engines fittedwith this unit (1), insert the specialtool (part number 00H05600231).

- Using the special tool (part number00G05300011), fitted to the flywhe-el, block the crankshaft from tur-ning, and proceed to slacken off thecrankshaft output gearing securingnut.

- Check the thickness of the clutchlining on each disc using a calipergauge.

Service limit: 3.6 mm.

- Replace any disc which showssigns of losing its lining, thermal fati-gue (heat discolouration), deforma-tion, or which has damage on theexternal castellation.

- Check the clutch discs for warping.

Service limit: 0.15 mm.

- Replace any discs which have lostany lining, show signs of thermalfatigue (heat discolouration), orwhich has damage on the internalcastellation.

11-2

Page 47: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

CHECKING THE CLUTCHASSEMBLY

- Check the clutch drive hub:

1. Scratching on the castellations;

2. Play in the rivets and silent-blocks attaching to the gearing;

3. Condition of the bearing turningon the primary shaft.

- If major damage is observed, repla-ce the clutch hub.

- Check for scratching and chippingon the bearing surface of the discs;if damage is found, replace the part.

- Check the drive plate assembly andthe axial needle bearing, and repla-ce any damaged parts.

- Check the free length of the spring,and replace the part if it is longerthan the service limit.

Service Limit: 30 mm.

- Using a square, check the spring forparallelism. Replace the spring inthe event that it is deformed.

11-3

Page 48: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

4

31

2

ASSEMBLING THE CLUTCH- Refit in reverse order to stripping

down.

- Remember to install the clutch hubsupport washers (both driven anddriving hubs).

- Keep the following steps in mindwhen installing the balance shaft inthose engines which are fitted withthis unit. (Faulty installation will giverise to an excessive level of vibra-tion.)

- Align reference mark 1 punched inthe engine output pinion with refe-rence mark 2 on the crankcase, andreference mark 3 punched on theface of the balance shaft pinion withits reference mark 4 on the crankca-se.

- Fit the clutch hub 1 taking care notto alter the position of the balanceshaft and the engine output pinion.First engage the clutch hub with theengine output pinion 2 and thebalance shaft intermediate gear 3,then turn the intermediate starterpinion 4 with the hand until it enga-ges with the clutch hub; finally turnthe clutch hub to the left or to theright until it engages with the inter-mediate pinion secondary pinion 3.

- Take care to apply the correct tor-que both when tightening thecrankshaft gear nut and the clutchhub nut (do not forget to fit a newlock washer and to close it upagainst one of the flats of the nut),and in the case of the balance shaftintermediate pinion locking nutapply thread seal compound.Ensure that the correct torque isapplied to the clutch pressure platesecuring screws and the springs.

11-4

Page 49: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Fit the clutch discs in such a waythat the mark faces outwards.

- Fit the clutch pressure plate in sucha way that the DERBI logo faces thenotch in the driven clutch hub.

- Fit a new clutch cover gasket.

- Fit new lock washers on the oildrain plugs (in the crankcase andthe clutch side crankcase half) andtighten.

- Fill the gearbox - clutch assembly,using 650 cc of AGIP 10W40 Gearoil.

- Fit the clutch operating cable overthe lever located on the clutch sidecrankcase half, and check the freeplay at the clutch (left hand sidehandlebar) lever (play should beapproximately 5 mm).

- Start the engine and carry out abrief check of the correct operationof the gearbox and the clutch.

11-5

Page 50: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

STRIPPING DOWN THECRANKSHAFT AND THEGEARBOX- Withdraw the engine from the frame

and set it up on an engine stand.

- Strip down the thermodynamic sec-tion (cylinder head, cylinder, andpiston).

- Strip down the magneto alternator.

- Strip down completely the primarydrive assembly, including the startersystem and the gear selector shaft.

- First slacken off and then withdrawall the crankcase half securingscrews, from the left hand side ofthe engine.

- Extract the intermediate starter gearlocated on the end of the gearboxsecondary shaft, and additionallythe gear lock transfer and the stargear.

- Heat up the crankcase assemblyaround the seatings of the cranks-haft, primary shaft, and secondaryshaft bearings on both sides (toapproximately 60ºC).

12-1

Page 51: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Rest the crankcase on a woodenblock on its right hand side (primarydrive side). Fit the special tool (partreference number: 00H05300151)into the threaded sockets for thispurpose; with the operating pointresting centred on the crankshaft,proceed to separate the crankcasehalves. Do not use levers on thecrankcase mating surfaces (if thesesurface are damaged the crankcasemust be replaced).

- Now fit the special tool (part refe-rence number: 00H05300151) intothe threaded sockets for this purpo-se beside the crankcase in the righthand side crankcase half, and with-draw the crankshaft.

- After heating up the crankshaft bea-ring seatings in the crankcase toapproximately 60ºC, withdraw thebearings.

- Extract the selector fork guideshafts, and the selector drum andthe selector forks.

- Extract the gearbox in one singleoperation, by pulling on the twogearbox shafts.

12-2

Page 52: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

Y

X

- Clean and completely degrease thecrankshaft assembly, in order toproceed to checking.

- Using feeler gauges, check the late-ral play in the connecting rod at thebig end on the crankpin.

Service limit: 0.8 mm.

- Using a dial comparator gauge,determine the connecting rod bigend bearing play in the X and Yaxes.

Service limit: 0.05 mm.

- Replace the connecting rod andbearings in the event that the servi-ce limit is exceeded.

- Mount the crankshaft on a lathewhere it can be rotated and checkthe wobble between the crankshaftcheeks using two comparators setup perpendicular to the circumferen-ce of the supporting shafts (checkthat there are no burrs or scrat-ches).

Service limit: 0.06 mm.

12-3

Page 53: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

CRANKSHAFT ANDGEARBOX ASSEMBLY- Clean and lubricate the bearings

and check that they turn smoothly,with no flat spots or roughness.

- If any signs of damage are found,replace the bearings in pairs.

- In order to remove any damagedbearings use the special bearingextractor tool, after first heating upthe crankcase to approximately90ºC. Never reinstall any bearingsonce they have been extracted,because they will be damaged bythe operation of removing themfrom their seating.

- In order to replace the bearings,heat up the crankcase to approxi-mately 90ºC and prepare the bea-ring to be inserted by placing it in afreezer; this will make insertion ofthe bearing easy, almost without itneeding to be pushed. If it is neces-sary to apply force, use the specialbearing punch tool, which acts onlyon the outer ring of the bearing andthus avoids causing any damage.

- Clean and degrease the gearboxassembly and then proceed tocheck.

- Carry out a visual check on the gearteeth in the gearbox. If there areany signs of thermal fatigue (heatdiscolouration), or loss of the surfa-ce hardening, or any other irregularwear on the teeth (filing), replacethe damaged components. If thedamage is on the primary shaft theentire shaft must be replaced.

12-4

Page 54: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Proceed to strip down the secon-dary shaft completely, extracting theassembly securing circlip, and thenproceeding to separate all the pie-ces of the assembly in an orderlyfashion. Spread out a clean clothand place the parts on this cloth asthey are stripped down.

- Check that there is no burring orsigns of irregular wear on the studsand slots in the gear change lockingsystem in the sliding gears or ontheir striations.

- Check the condition of wear of therotation bushes in the free gears onthe secondary shaft.

- If they show signs of damage overmore than 25% of their surface,replace them. The fixed locating cir-clips in the assembly should also bereplaced.

- Check also the secondary shaftneedle bearings. Replace them ifthey show signs of damage.

12-5

Page 55: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

- Clean all the components of the gear-box and gear selector assembly, andadditionally the crankshaft, using anydegreasing agent.

- Re-assemble the gearbox secondaryshaft, taking particular care to ensurecorrect assembly of all the compo-nents, in order to avoid malfunctionand seizing.

- Fit the gearbox assembly into theright hand crankcase half, (the pri-mary and secondary shafts should beinserted meshed together at the sametime).

- First check the overall width of thesecondary shaft sub-assembly inclu-ding the adjusting shims on eachside.

Overall width of secondary shaft:MAX 87.700 mm.MIN 87.350 mm.

(there are different thicknesses ofshim available to ensure that thethickness is correct.)

- Next install the selector forks, theselector drum and the washers, andthe selector fork studs. Lubricate thesurface of the gear mechanism withAGIP gear 10W40.

- Check that the gearbox operatescorrectly, by selecting the differentgears, and turning the selector drumin both directions. If it seizes, checkonce again that the components havebeen correctly fitted. Leave the gear-box with neutral selected, and confirmthat all the elements in the assemblyare able to rotate freely.

- Fit the crankshaft into the right handside crankcase half.

- Fit a new crankcase sealing gasket,paying particular attention to the freepiece in the area of the admissionsystem.

- Heat up the left hand crankcase halfto approximately 60ºC, and close itonto the right hand crankcase half.Then fit the assembly securing studs,after first ensuring that they are scru-pulously clean.

- Crankcase joint securing screw tor-que setting: 6Nm (0,6 mkg).

- Check that the crankshaft and thegearbox shafts rotate freely after thecrankcase is completely closed.

12-6

2ª 6ª 4ª 3ª 5ª 1ª

Z-30 Z-22 Z-24 Z-27 Z-23 Z-34

- Check the axial play of the gearbox secondary shaft,which should be between 0.2 and 0.4 mm.

- Using the special installation punch tool (special tool,part reference number: 00H05400451), fit new seals onthe crankshaft, first applying AGIP Speed lubricant tothe lips.

- Refit the primary drive assembly.

- Refit the magneto - ignition system.

- Refit the cylinder, piston, and cylinder head assemblies.

- Remount the engine into the frame.

- Refill and bleed the cooling system, and the separateengine lubricating system.

- Refill the gearbox-clutch side crankcase half with oil.

- Start up the engine and carry out a brief check of all itsfunctions, and check the correct operation of the gear-box and the clutch.

Page 56: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

BATTERY MAINTENANCE

SERVICE INFORMATION

- Do not reverse the polarity of the battery.This could cause damage to some sensitiveelectronic devices.

- The battery produces explosive gases. Donot allow sparks or naked flames near thebattery especially when charging.

- The electrolyte contains sulphuric acid. If thiscomes into contact with the skin, it producesburns. If this occurs, wash the affected areawith plenty of water and consult a doctor.

- To avoid causing damage to sensitive equip-ment, do not disconnect the battery cables orother connections while the ignition switch isin the ON position, or while the engine is run-ning.

- Whenever possible charge the batteryslowly. Rapid charging should be used onlyin cases of emergency.

- Take the battery out of the machine in orderto charge it.

- Keep the breather tube free of obstruction,particularly while charging.

- Batteries if left unused lose their charge. Donot leave the battery for more than onemonth without giving it a top-up charge, andafter one month charge the battery every twoweeks.

13-1

0 5 10 15 20 25 30 35

1,211,221,231,241,251,261,271,281,29

Temperature º C

Sp

ecif

ic G

ravi

ty

Normal

40

DENSITY OF THE ELECTROLYTE

- Check the level of the electrolyteperiodically and if the level is low,add distilled water.

- Check each cell with a densitometer.

- Density with fully charged battery at20ºC, 1.26 to 1.28.

- With values of lower than 1.26, char-ge the battery.

- Check that the density does not varyby more that 0.05 between the bat-tery cells.

- The density of the electrolyte varieswith the temperature: please refer tothe attached table.

Page 57: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

2 4 6 8 10 12 14 16

1,08

1,13

1,18

1,23

1,28

Time to charge in hours

Sp

ecif

ic G

ravi

ty a

t 20

°C

Red +

Black -

CHARGING THE BATTERY FORTHE FIRST TIME

- Before putting a new battery intoservice, carry out the following ope-rations:

- Cut or remove the seal from thebreather tube.

- Remove all the cell caps and fill thecells with electrolyte.

Specific gravity of the electrolyte:1.28 at 20ºC.

- Leave the battery to rest for onehour before charging.

- If the level of the electrolyte hasfallen, top up with fresh electrolyte.

- Connect the positive (+) terminal ofthe charger to the positive (+) termi-nal of the battery, and the negative(-) terminal of the charger to thenegative (-) terminal of the battery.

- Charging current: 0.4 A.

- Charging time: from 10 to 15 hours.

NORMAL IN-SERVICE BATTERYCHARGING

- Remove the battery from the machi-ne.

- Clean the battery with plenty ofwater, ensuring that the water doesnot penetrate into the cells of thebattery.

- Check the level of the electrolyteand top up with distilled water ifnecessary.

- Connect the positive (+) terminal ofthe charger to the positive (+) termi-nal of the battery, and the negative(-) terminal of the charger to thenegative (-) terminal of the battery.

- Charging current: 0.4 A.

- Determine the charging time withreference to the attached table.

13-2

CHECKING THE CHARGING OUTPUT

- Remove the saddle in order to gain access to thebattery.

- In order to carry out this check, it is necessary to usea fully-charged battery.

- Connect a voltmeter between the positive and nega-tive terminals of the battery.

- Start the engine and gradually increase the revolu-tions and read the regulated voltage.

Regulated voltage: 13.5 ± 0.5 V.

Page 58: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

RY

R/BY/G

- RED- YELLOW- RED / BLACK- YELLOW / GREEN

BATTERY 12V 4A

Y/GFUSE 8A.

R

YLIGHTS

MAGNETO

Y

Y

R/B

IGNITION SWITCH

ACCESSORIES

GROUND

DISCONTINUOUS REGULATOR RECTIFIER

L C +

L C +

GROUND

EARTH

TESTERCONNECTIONS

13 V.

C - A - C + DC

+-

10 13 V.

+-

10

BATTERY CHARGING SYSTEM - WIRING DIAGRAM

13-3

CHECKING THE AC / DC REGULA-TOR

- The regulator is checked with theengine running at 4,000 rpm, thelights on and the battery fully char-ged.

Page 59: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

30

87

85 86

STARTER MOTOR - In the event that the starter motor

does not turn, the following causesare possible:

- Main fuse, disconnected orblown.

- Battery discharged.

- Faulty starter relay.

- Replace the fuse and / or chargethe battery as necessary.

- If the starter motor still will not turn,proceed to check the electricalwiring and the starter push buttonon the handlebars, and the starterrelay in the following manner:

- Connect terminals 85 and 86 of therelay to the battery terminals(regardless of polarity).

- Connect terminals 30 and 87 of therelay to the ends of the tester pro-bes, having selected “continuity /ohms Ω“ (resistance measurement):

* Without disconnecting the tester pro-bes from the terminals 30 and 87 ofthe relay, disconnect one of the ter-minals 85 or 86 from the battery ter-minals:

- In the event that the sequenceshown in the above tables is notobserved, replace the relay.

14-1

READING OHMS RELAY(Ω) CONDITION

0 (closed cirduit) CORRECT

∞ (open circuit) FAULTY

READING OHMS RELAY(Ω) CONDITIONS

0 (closed circuit) FAULTY

∞ (open circuit) CORRECT

Page 60: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

CHECKING THE OIL LEVELAND FUEL LEVEL PILOTLIGHTS- Proceed according to the following

procedure:

- Turn on the ignition switch andcheck that the fuel reserve level andengine oil level pilot light verificationcheck comes into operation (appro-ximately 10 seconds) on the instru-ment panel (if this check does notoperate, check the condition of thebattery voltage, the main fuse, thecheck unit, and the electrical con-nection to these components).

- Disconnect the connector spade ofthe corresponding sensor, and shortthe end that plugs into the electricalwiring circuit with a tail of electriccable, then turn on the ignitionswitch, and the pilot light for thereserve with the bridged sensorshould remain on: if this is not thecase, there is a fault in the electricalwiring in the circuit for this pilot light.

Fuel level sensor:

Oil level sensor:

- Take a couple of ends of cable andconnect them to the terminals of thebattery of the machine, and put abulb in one of them. Disconnect thespade connector of the sensor to bechecked, and connect the ends tothe cables. Then remove the sensorto be checked from its socket(taking care in the case of the fuelsensor, because it is located at thebottom of the tank, which should beemptied before carrying out this

15-1

COLOUR YELLOW /OF CABLE GREEN

BLUE / FUEL RESERVEWHITE LIT

COLOUR YELLOW /CABLE GREEN

BLUE / OIL RESERVEBLACK LIT test). Hold the sensor in a vertical position, out of the

tank for about 1 minute, after which time the pilotlamp should come on. If the pilot light does not lightup, it is faulty, and should be replaced.

- Reinstall the sensors and the electrical connectionsproperly, fill the fuel tank and the oil reservoir, thenturn on the ignition key. Check that the reserve tankpilot light operating test runs (about 10 seconds).Keep the ignition key switched on for about 1 minu-te, and after that time the oil and fuel reserve pilotlights should go off and stay off. If this does notoccur, it indicates that the pilot light is faulty and inthis case should be replaced.

Page 61: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

STRIPPING DOWN THEMAGNETO ALTERNATOR

- Remove the gear shift lever and themagneto alternator cover, which aresituated on the left hand side of theengine.

- Block the magneto from rotating bymeans of special immobilising tool(part number 00G05300011), andproceed to slacken off the magnetonut, which secures it to the cranks-haft.

- Insert special extractor tool (partnumber 00F05300021) and with-draw the magneto.

- Extract the stator coil assembly, byfirst slackening off and then remo-ving the screws securing theassembly to the base. Finally,extract the base plate, which issecured to the crankcase with screws.

16-1

Page 62: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

G/B Y/G

IGNITIONSWITCH

G

R

W

SPARK PLUG

G

G

MAGNETO

HIGH TENSION COIL

GREENREDWHITE

G/B -Y/G -

G -W -R -

GREEN/BLACKYELLOW/GREENGREENWHITERED

STRIPPING DOWN THEMAGNETO ALTERNATOR- Disconnect the magneto spade con-

nector located on the left hand sideof the frame.

- Proceed to static checks on theassembly as detailed below, using amultimeter (tester), connected so asto measure continuity / resistance(ohms: (), and selecting an appro-priate scale in accordance with themagnitude of the values to be mea-sured.

Checking the lighting coil:

16-2

COLOUR YELLOWCABLE

WHITE 0,3 a 0,9 Ω ± 10%

Page 63: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

Checking the magneto supply coil:

Checking the pick-up coil:

Checking the secondary high ten-sion coil (without spark plug cap):

- Checking the spark plug cap: dis-connect the spark plug cap from thesecondary cable and measure theresistance reading between theends of the connector: the readingshould be equal to:

5.0 kΩ ± 15%

- In ignition systems with the HALLsensor, use the following procedureto carry out this check (please referto the diagram below):

- Using the machine’s own batteryand a few ends of electric cable,connect the terminals of the batterydirect to the following magnetocables:

- Connect a tester, selecting theappropriate scale for continuity /ohms (Ω), and connecting the pro-bes as in the table below:

16-3

COLOUR GREENCABLE

EARTH 610 Ω ± 10%

COLOUR REDCABLE

EARTH 80 Ω ± 10%

COLOUR THICKCABLE BLACK

EARTH 3,4 kΩ ± 15%

BATTERY COLOURTERMINAL MAGNETO CABLE

POSITIVE BROWN

NEGATIVE WHITE

TESTER COLOURPROBE MAGNETO CABLE

POSITIVE (RED) BLUE

NEGATIVE (BLACK) WHITE

Page 64: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

-+

Battery12V

White

Brown

Blue

Magneto- Rotate the magneto rotor by hand,taking it through one complete revo-lution of 360º, and observe whetherthe tester shows a very high resis-tance reading throughout the grea-ter part of the revolution (open cir-cuit), and gives a very low reading(closed circuit / continuity) during avery short part of the revolution. Ifthis does not occur, this is a sign ofa fault and the magneto should bereplaced.

- In the event of a fault, the entirefaulty component as identif iedthrough the procedures indicatedabove should be replaced.

- Proceed to re-assemble the unit,taking special care to check thecondition of the key at the end ofthe crankshaft. If it shows any signsof damage, it should be replaced.

- In order to be able to synchronisethe ignition timing correctly, whenassembling the coil base plate ontothe engine crankcase, take care toensure that the reference mark onthe magneto coil base plate is alig-ned with the centre of the arrow onthe crankcase.

- Re-assemble the magneto coil unitonto the magneto coil base plate,using special immobilising tool (partreference number 00G05300011) toprevent the part from rotating.Check that the magnet in the inte-rior shows no signs of breakage orof damage: in the event that dama-ge is found, it should be replaced.Tighten the securing screws to therecommended torque setting. Thesetting of the ignition timing doesnot require any maintenance.Ensure that the electrical cables inthe unit are correctly routed to avoidany possible chafing, which couldlead to later damage and failures.

16-4

Page 65: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

ELECTRICAL WIRING DIAGRAM GPR 50 RACING

OrangeGrünSchwarzBraunWeiBGrauGelbBlauRotRosaViolett

OrangeVertNoirMarronBlancGrisJauneBlauRougeRosaViolet

OrangeGreenBlackBrownWhiteGrayYellowBlueRedPinkViolet

ArancioVerdeNeroMarroneBiancoGrigioGialloAzzurroRossoRosaViola

NaranjaVerdeNegroMarronBlancoGrisAmarilloAzulRojoRosaVioleta

OGRB

BRWGYBLRPVI

D F UK I E

17-1

Page 66: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

17-2

ELECTRICAL WIRING DIAGRAM SENDA R DRD

OrangeGrünSchwarzBraunWeiBGrauGelbBlauRotRosaViolett

OrangeVertNoirMarronBlancGrisJauneBlauRougeRosaViolet

OrangeGreenBlackBrownWhiteGrayYellowBlueRedPinkViolet

ArancioVerdeNeroMarroneBiancoGrigioGialloAzzurroRossoRosaViola

NaranjaVerdeNegroMarronBlancoGrisAmarilloAzulRojoRosaVioleta

OGRB

BRWGYBLRPVI

D F UK I E

Page 67: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

17-3

ELECTRICAL WIRING DIAGRAM SENDA R X-TREME USA

OrangeGrünSchwarzBraunWeiBGrauGelbBlauRotRosaViolett

OrangeVertNoirMarronBlancGrisJauneBlauRougeRosaViolet

OrangeGreenBlackBrownWhiteGrayYellowBlueRedPinkViolet

ArancioVerdeNeroMarroneBiancoGrigioGialloAzzurroRossoRosaViola

NaranjaVerdeNegroMarronBlancoGrisAmarilloAzulRojoRosaVioleta

OGRB

BRWGYBLRPVI

D F UK I E

Page 68: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

17-4

ELECTRICAL WIRING DIAGRAM SENDA R X-TREME WVTA

OrangeGrünSchwarzBraunWeiBGrauGelbBlauRotRosaViolett

OrangeVertNoirMarronBlancGrisJauneBlauRougeRosaViolet

OrangeGreenBlackBrownWhiteGrayYellowBlueRedPinkViolet

ArancioVerdeNeroMarroneBiancoGrigioGialloAzzurroRossoRosaViola

NaranjaVerdeNegroMarronBlancoGrisAmarilloAzulRojoRosaVioleta

OGRB

BRWGYBLRPVI

D F UK I E

Page 69: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

17-5

ELECTRICAL WIRING DIAGRAM SENDA SM DRD

OrangeGrünSchwarzBraunWeiBGrauGelbBlauRotRosaViolett

OrangeVertNoirMarronBlancGrisJauneBlauRougeRosaViolet

OrangeGreenBlackBrownWhiteGrayYellowBlueRedPinkViolet

ArancioVerdeNeroMarroneBiancoGrigioGialloAzzurroRossoRosaViola

NaranjaVerdeNegroMarronBlancoGrisAmarilloAzulRojoRosaVioleta

OGRB

BRWGYBLRPVI

D F UK I E

Page 70: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

17-6

ELECTRICAL WIRING DIAGRAM SENDA SM X-TREME USA

OrangeGrünSchwarzBraunWeiBGrauGelbBlauRotRosaViolett

OrangeVertNoirMarronBlancGrisJauneBlauRougeRosaViolet

OrangeGreenBlackBrownWhiteGrayYellowBlueRedPinkViolet

ArancioVerdeNeroMarroneBiancoGrigioGialloAzzurroRossoRosaViola

NaranjaVerdeNegroMarronBlancoGrisAmarilloAzulRojoRosaVioleta

OGRB

BRWGYBLRPVI

D F UK I E

Page 71: Derby 6 Speed Manual de Reparatie Www.manualedereparatie.info

17-7

ELECTRICAL WIRING DIAGRAM SENDA SM X-TREME WVTA

OrangeGrünSchwarzBraunWeiBGrauGelbBlauRotRosaViolett

OrangeVertNoirMarronBlancGrisJauneBlauRougeRosaViolet

OrangeGreenBlackBrownWhiteGrayYellowBlueRedPinkViolet

ArancioVerdeNeroMarroneBiancoGrigioGialloAzzurroRossoRosaViola

NaranjaVerdeNegroMarronBlancoGrisAmarilloAzulRojoRosaVioleta

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