Derbi Dirtboy 10 Manual de instrucciones

MINIMOTO 50 C.C.4T

WORKSHOP MANUAL

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 dismantling and

assembling the MINIMOTO 50 c.c. 4-stroke engine.

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

sub-dealers.

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

PREFACE

INDEX

NDEX

GENERAL INFORMATION

CARACTERISTICS

TIGHTENING TORQUES

MAINTENANCE

MAINETANCE CHART

ENGINE OIL

DISTRIBUTION

DISTRIBUTION - COMPRESSION

MOTOR

TRANSMISSION

CLUTCH

END GEAR SHAFT

STATOR-FLYWHEEL

REMOVING THEROCKER - ARMS COVER

CAM SHAFT

CYLINDER HEAD - VALVES

CYLINDER - PISTON - SMALL END

INSPECTING THE CYLINDER HEAD

DISTRIBUTION CHAIN VALVES

INSPECTING THE CAM SHAFT

REFITTING THE TIMING CHAIN

ASSEMBLING THE TIMING CHAIN TENSIONER

REFITTING PICK-UP

REFITTING CARTER

REFITTING CRANKSHAFT

REFITTING THE CRANKASE HALVES

OIL PUMP

CARBURETTOR

Pág. 4

Pág. 5-6

Pág. 7

Pág. 10

Pág. 10-11

Pág. 11

Pág. 13

Pág. 14

Pág. 15

Pág. 16

Pág. 17

Pág. 18

Pág. 19

Pág. 20-21

Pág. 21-28

Pág. 29

Pàg. 30-33

Pág. 34-36

Pág. 36-37

Pág. 37

Pág. 38

Pág. 39

Pág. 39-41

Pág. 42-43

Pág. 44-45

Pág. 46-47

RULES

This section describes the general safety rules and service recommendations to be observed.

SAFETY RULES

- Should it be necessary to run the engine in order to perform certain operations, please ensure the area is

adequately ventilated and, if required, use appropriate fume extractors; Never run the engine in an enclosed

space; exhaust gases are toxic.

- Petrol is extremely flammable and, under certain conditions, may be explosive. Do not smoke and do not

allow live flames or sparks in the work area.

SAFETY RULES

- Use genuine PIAGGIO spare parts and recommended lubricants. Use of non-genuine spare parts may

damage the engine.

- For operations requiring special tools, use only those specifically designed for this engine.

- Always replace seals, gaskets and split pins with new ones, when refitting new or old components.

- After removal, clean the components with a non-flammable or high flash-point solvent. Lubricate all contact

surfaces and inspect taper fit couplings, before refitting.

- After refitting, ensure all components have been correctly fitted and work properly.

- Use only metric-sized tools for removing, repairing and refitting operations. Metric screw fasteners, nuts

and bolts are not interchangeable or compatible with Imperial-sized fasteners. Use of Imperialsized tools or

fasteners may damage the engine.

- For engine repairs involving the electric system, carefully inspect the refitting of the connections.

GENERAL INFORMATION

RULES

SAFETY RULES

S US

CHARACTERISTICS

DIRTBOY 10

DIRTKID 12

ZEMMR4CC24 ¿AXXXXXX?

ZEMMS4CC64 ¿AXXXXXX?

CHASSIS CODE ENGINE CODE

C391M ¿XXXX?

CARACTERISTICS

CHASSIS,

WHEELS AND

BRAKES

DIMENSIONS

Frame Steel

Steel

Fork

Inner tube

Tyre

2,5 x 10”

3,00 x 10”

2,50 x 12”

3,00 x 10”

Front suspension 120mm travel

hydraulic fork

135mm travel

hydraulic fork

160mm mechanical disk.

90mm mechanical drum.

Front brake

Rear brake

Rear suspension 140mm travel pneumatic

shock absorbers.

160mm travel pneumatic

shock absorbers.

Total lenght 1290mm. 1430mm

Total width 590mm. 590mm

Distance between axles 905mm. 995mm

Seat height 610mm. 685mm

2,3L.

Fuel tank capacity

Weight 44Kg. 47Kg.

CARACTERISTICS

SPECIFICATION

Engine

CHARACTERISTICS

DESC. / QUANTITY

Displacement

Compression ratio

Carburettor Dell’orto

Recommended spark plug

Timing system

Valves play: induction

Valves play: exhaust

Lubrication

Fuel system

Transmission

Max. power

Engine oil

Grear-shaft teeth

Gearing retio

Four-stroke mono-cyl-inder

39 x 41,8 mm.

49,93 mm.

11,5 ÷12,5:1

PHVA

Champion RG 4 HC

overhead single camshaft, two valves, chain controlled on l.h. side.

0,10 mm. (en cold)

Engine lubrication by chain-driven lobe pump (in crankase) with gauze

strainer and centrifugal filter.

Gravity, unlead petrol (minimum octane number 95), through carbu-

rettor.

Automatic wet clutch and gear reducer.

3,3 Kw (4,6 CV ) 8500 rpm.

Capacity: ~ 600c.c.

1 / 4,1

Bore per stroke

SPECIFICATION DESC. / QUANTITY

Transmission Automatic wet clutch and gear reducer.

TECHNICAL DATA

TIGHTENING TORQUES

ENGINE ASSEMBLY

NAME

Spark plug:

TORQUE IN Nm

Head-cylinder stud nut

Head-cylinder / crankcase fixing screw

Chain-tensioning pad screw

Timing chain tensioner screw

Timing chain tensioner central screw

Camshaft pulley screw

Rocker-arm shaft and camshaft bearing screw

Rocker-arm adjusting nuts

Engine oil pre-filter cap

Oil drain cap

Flywheel nut (electric starter version)

Stator screws

Pick-up screw

Mounting bracket / crankcase (flywheel side) fixing screws

Head cover screw

Oil pump /crankcase fixing screws

Intake manifold fixing screws

Carburettor manifold clamp screw

Starter motor fixing screw

Flywheel cover fixing screw

Transmission cover fixing screw

Oil conveying plate fixing screws

(half-crankcase transmission side)

Half-crankcase joining screws

When installing new studs, proceed as follows

10 ÷ 15 Nm

6 ÷ 7 + 135º+90º Nm for first fitting,

6 ÷ 7 90º+90º Nm for refitting/locking

8 ÷ 10 Nm

5 ÷ 7 Nm

8 ÷ 10 Nm

5 ÷ 6 Nm

12 ÷ 14 Nm

3 ÷ 4 Nm

7 ÷ 9 Nm

25 ÷ 28 Nm

40 ÷ 44 Nm

2 ÷ 3 Nm

8 ÷ 10 Nm

2 ÷ 3 Nm

7 ÷ 9 Nm

1,5 Nm

11 ÷ 13 Nm

2,5 ÷ 3 Nm

8 ÷ 10 Nm

6 ÷ 7 Nm + 135º + 90º

following a diagonally crosswie sequence.

ENGINE ASSEMBLY

MAINTENANCE

MAINTENANCE CHART

ACTION FREQUENCY

Engine Oil - Level Check/Top up

Spark plug/electrode gap - Check

Air Filter - Cleaning

Idle speed / Fuel - Adjust

Acceleration command - Adjustment

Clutch - Check

Oil filter - Clean

Engine oil - Replacement

Engine Oil - Level Check/Topup

Spark plug/electrode gap - Check

Idle speed / Fuel - Change

Oil filter - Clean

Oil filter - Replacement

Air Filter - Cleaning

Valve clearance” Check

Idle speed / Fuel - Adjust

Acceleration command -Adjustment

Clutch - Check

Eletrical system - Check

Every 3 month

Every 6 month

Every engine oil replacement

At 5 hours or 1 month

Engine oil - Replacement At 20 hours or 6 month

Engine oil - Replacement

Idle speed / Fuel - Change

Oil filter - Replacement

Valve clearance - Check

At 40 hours or 12 month

Clutch - Replacement

Eletrical system - Check

At 40 hours or 12 month

Engine oil - Replacement At 60 hours or 18 month

MAINTENANCE CHART

SPARK PLUG

The spark plug inspection must be carried out with the engine cold and as described below:

- Detach the spark plug cap at the end of the HT cable.

- The spark plug must be unscrewed using the supplied box spanner.

- Carefully inspect the insulator; replace if dented or damaged.

- Measure the spark gap using a suitable thickness gauge and, if necessary, adjust it by carefully bending

the outer electrode.

- Ensure the seal washer is in good conditions.

- Refit the spark plug by screwing it in carefully by hand, and then locking it with the supplied box spanner.

CHARACTERISTICS

Recommended spark plug

Champion RG 4 HC

MAINTENANCE

MAINTENANCE CHART

ACTION FREQUENCY

Engine oil - Replacement

Idle speed / Fuel - Change

Filtro aceite - Sustitución

Valve clearance - Check

At 80 hours or 24 month

Clutch - Replacement

Eletrical system - Check

At 80 hours or 24 month

At 40 hours or 12 month

Engine oil - Replacement At 100 hours or 30 month

Engine oil - Replacement

Idle speed / Fuel - Change

Oil filter - Replacement

Valve clearance - Check

At 120 hours or 36 month

Clutch - Replacement

Eletrical system - Check

At 120 hours or 36 month

SPARK PLUG

MAINTENANCE CHART

ELECTRICAL CHARACTERISTICS

Distance between electrodes

0.8 ÷ 0.9 mm

Locking torques (N*m)

Spark plug: 10 ÷ 15Nm

INE

REPLACEMENT

Renew the oil when the engine is hot. Place a container

under the oil sump and remove the oil drain plug. After

draining the oil, clean the gauze strainer with a suitable

solvent and then blow it with compressed air. To gain access

to the gauze strainer, remove plug «A» (see figure). Refit the

strainer and tighten the oil plug with the prescribed torque

using a new O-ring.

MAINTENANCE

MAGNETIC FLYWHEEL RESISTANCE

YELLOW EARTH

RED 55 ± 10%

EARTH Infinite

Infinite

BROWN EARTH

BLACK 100 ± 10%

EARTH 100 ± 10%

0-1

MAGNETIC FLYWHEEL RESISTANCE

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