Derbi GP1 50 Open Workshop Manual.pdf

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W
ORKSHOP
MANUAL
GP1 50 cc
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.
1
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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3
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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4

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