PIAGGIO Ape TM Instructions Manual

for choosing one of its products. We have drawn up this booklet to show you all features of our product. Please read the booklet carefully before using your vehicle. It includes information, suggestions and warnings regarding your vehicle. You will also be informed of features, details and devices that will prove the excellence of your choice. We believe that if you follow our suggestions you will soon tune in with your vehicle and use it for a long time at full satisfaction. This booklet is an integral part of the vehicle, and upon sale, it should be transferred to the new owner. Ape TM - Ape TM Diesel Ed. 01_02/2012

procedures and regular checks that should be carried out on the vehicle at an Authorised PIAGGIO Dealer or Service Centre. The booklet also contains instructions for simple repairs. Any operations not specifically described in this booklet require the use of special tools and/or particular technical knowledge: to carry out these operations refer to any authorised PIAGGIO Dealer of Service Centre. Read this booklet carefully before using your vehicle. Follow the instructions contained in this booklet for your personal safety and to ensure long-lasting use of your vehicle. Failure to observe these instructions may cause personal injury or damage to the vehicle. 2

injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent dam- aging the environment. Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee. The signs indicated on this page are very important, they highlight the parts of the booklet that should be read with particular care. Each sign consists of a different graphic symbol, making it quick and easy to locate the various topics. 3

8 SAFE RIDING.............................................................................. 11 Safe drive.................................................................................. 12 Running-in period...................................................................... 12 VEHICLE USE.............................................................................. 13 Checks...................................................................................... 14 Before starting the engine......................................................... 18 Engine start up.......................................................................... 19 Stopping the engine.................................................................. 21 Starting difficulties..................................................................... 21 Gear position............................................................................. 22 Driving Tips............................................................................... 23 DOORS AND LOCKS.................................................................. 27 Keys.......................................................................................... 28 Door locking/unlocking by key............................................... 28 Front door windows................................................................... 29 Engine inspection port.............................................................. 30 SEATS AND SAFETY BELTS..................................................... 31 Using the safety belts................................................................ 32 Fasting the safety belt........................................................... 33 Adjusting the safety belt........................................................ 34 To release the safety belt...................................................... 34 INSTRUMENT PANEL AND CONTROLS................................... 35 Handlebars............................................................................ 36 Steering wheel....................................................................... 39 Controls..................................................................................... 43 Ignition switch........................................................................... 53 GAUGES AND WARNING LIGHTS............................................ 55 Instrument unit and indicators................................................... 56 AIR CONTROL SYSTEM............................................................. 57 Heating.................................................................................. 58 Heating and demisting........................................................... 59 Demisting.............................................................................. 59 MIRRORS AND WINDOW GLASSES......................................... 61 Adjusting the mirror............................................................... 62 Wipers and Brushes.................................................................. 62 INSIDE EQUIPMENT................................................................... 65 ELECTRICAL SYSTEM............................................................... 67 Fuel version.............................................................................. 68 Diesel version........................................................................... 68 EMERGENCY.............................................................................. 71 Wheel replacement................................................................... 72 Maintenance instructions....................................................... 72 MAINTENANCE........................................................................... 75 Check engine oil level........................................................... 76 Oil change and oil filter replacement..................................... 76 Checking the brake fluid level................................................... 79 Gear box oil level...................................................................... 81 Window washer fluid level......................................................... 83 Cooled fluid............................................................................... 83 Changing the engine cooling fluid......................................... 84 Checking and replacing the air cleaner element....................... 84 Replacing the fuel filter............................................................. 85 Air bleeding........................................................................... 86 Fuel exhaustion..................................................................... 86 Checking and replacing the pre-heating plugs.......................... 87 Fuses........................................................................................ 88 Exhaust circulation system (EGR)......................................... 91 Tyres......................................................................................... 91 Pressure................................................................................ 92 Periods of inactivity................................................................... 92 Troubleshooting / What to do if................................................. 98 SPARE PARTS AND ACCESSORIES........................................ 107 Warnings................................................................................... 108 TIPPER VERSION....................................................................... 109 5

Warnings for Loading and Unloading Operations..................... 111 Scheduled Maintenance........................................................... 114 Extraordinary Maintenance....................................................... 116 Trouble-Shooting...................................................................... 117 Warning Plate Symbols............................................................. 120 technical sheet for EC conformity declaration........................... 123 Preface.................................................................................. 123 Equipment Layout................................................................. 124 Analysis of Risks Connected with the Layout and Operation of the Equipment................................................................... 127 TECHNICAL DATA...................................................................... 135 Vehicle...................................................................................... 138 SCHEDULED MAINTENANCE - CHECKS................................. 149 Scheduled maintenance service............................................... 150 6

The identification codes consist of a prefix followed by a number punched on the chassis and on the engine, respectively. Always quote the serial numbers when ordering spare parts. The chassis identification number is located on the crossmember under the seat as shown in the figure. The frame identification code is: ZAPT1000000001001 01_02 Check that the chassis prefix and number punched on the vehicle correspond to that shown on the vehicle documents. The engine identification number is printed as shown in the figure. The first indicates the location of the plate on the diesel engine, while the second is on the gasoline engine. 01_03 The gasoline version engine identification initials are: ATM2M The diesel version engine identification initials are: LDW 422 8 1 Identification

MAY LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE. ETC.) 9 1 Identification

ENSURE THE SPARE WHEEL IS CORRECTLY SECURED TO THE SEAT THROUGH THE RETAINING STRAP, IN ORDER TO PREVENT IT FROM MOVING IN THE EVENT OF AN EMERGENCY STOP. Running-in period During the first 1000 km, do not twist the throttle fully open and avoid driving at constant speed over long stretches of roads. After the first 1000 km gradually increase speed until reaching the maximum performance. 12 2 Safe riding

Before using the vehicle, check: 1. That the oil and fuel (for fuel versions) tanks are filled. 2. The engine/transmission oil level (for diesel versions). 3. The brake fluid level. 4. That the tyre inflation pressure is correct. 5. Correct operation of side/taillights, headlights and turn indicators. 6. Front and rear brake operation. 7. Gearbox oil level (for petrol versions). 8. Electrolyte and battery charge check. 9. Check coolant (diesel version) CAUTION TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD. TYRE PRESSURE Front tyre pressure 2.5 atm Rear tyre pressure 4.5 atm Fuel tank 14 3 Vehicle use

To open: insert the supplied key and turn it anticlockwise. To close: put the filler cap back in position, turn the key clockwise and remove. For petrol versions, the recommended fuel is as follows: - unleaded petrol. For diesel versions, the recommended fuel is as follows: - diesel normally found on the market. To this purpose please note that at low temperatures the paraffin elements contained in diesel spontaneously dissociate, thereby decreasing fluidity. If it is not possible to use winter type diesel, mix diesel with a special additive in the amounts indicated on the container. The additive must be poured into the tank before the diesel and before the process described above since a late addition generates no effects. CAUTION • WHEN REFUELLING, KEEP THE CAP CLEAN FROM DUST AND DIRT. CAUTION BEFORE REFUELLING, STOP THE ENGINE. PETROL IS HIGHLY INFLAMMA- BLE. DO NOT DROP PETROL ON HOT ENGINE PARTS. DO NOT SMOKE. KEEP NAKED FLAMES AWAY: FIRE HAZARD. DO NOT INHALE PETROL FUMES. 15 3 Vehicle use

The oil tank is provided with a light reserve indicator on the instrument panel. To top up, remove cap «B» and pour in new oil. CAUTION USING OTHER TYPES OF OIL CAN COMPROMISE ENGINE DURABILITY. Recommended products AGIP CITY TEC 2T Oil for 2-stroke petrol engines JASO FC, ISO-L-EGD Specifications 16 3 Vehicle use

RESERVE: 0.6 l 03_03 03_04 Removing the battery The battery is located under the seat. The latter can be easily tilted removing the two nuts «A» located at the two ends below the seat, as shown in the figure. If it is necessary to remove the battery from its housing (for replacing or charging it), disconnect the cables, remove nut «B» and release the battery from the locking bracket «C». CAUTION NEVER DISCONNECT THE BATTERY WHEN THE ENGINE IS RUNNING TO AVOID DAMAGING THE ELECTRICAL SYSTEM. BATTERY ELECTROLYTE CONTAINS SULPHURIC ACID: AVOID CONTACT WITH EYES, SKIN AND CLOTHES. IN THE EVENT OF ACCIDENTAL CONTACT, RINSE WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE WARNING USED BATTERIES ARE HARMFUL FOR THE ENVIRONMENT AND MUST BE COLLECTED AND DISPOSED OF IN COMPLIANCE WITH THE LAW. 17 3 Vehicle use

Make sure the terminals are fitted correctly. The battery is an electrical device that requires careful checks and diligent maintenance. CAUTION DO NOT INVERT THE POLARITIES: DANGER OF SHORT-CIRCUIT AND FAULTS IN THE ELECTRICAL DEVICES. Checking electrolyte level The electrolyte level must be checked frequently and must reach the maximum level. Top up exclusively with distilled water. If the battery requires topping up too frequently, check the electrical system - the bat- tery is probably working in overload conditions, which will lead to rapid deterioration. Before starting the engine - Ensure that the parking brake is released. - Ensure that the reverse gear control lever is forward or backward according to whether you want to move forward or in reverse. - Ensure that the gear control lever is in neutral position: position N for the handlebar version, central lever position for the steering wheel version. THIS PRELIMINARY OPERATION IS NOT REQUIRED IN THE STEERING WHEEL DIESEL VERSION. 18 3 Vehicle use

Engine ignition (gasoline version) Open the fuel cock «A» (turn it counter clockwise to open and clockwise to close). With cold engine, pull the starter lever «C» and insert the start key into the key switch, then turn it to position 2 and at the same time press the accelerator control. After start up, release the key that will automatically return to position 1. WARNING EXHAUST GASES ARE TOXIC. DO NOT START THE ENGINE IN A CLOSED PLACE. WHEN THE ENGINE IS ON, DO NOT HANDLE PARTS AND CONNECTIONS OF THE ELECTRIC SYSTEM, ESPECIALLY THE SPARK PLUG CABLE. 03_07 Engine start up (03_06, 03_07) Engine ignition (diesel version) Introduce the start key into the switch and move it to position 1. On the instrument panel, the glow plug preheat indicator will light up. The hotter the engine, the sooner the indicator will turn off. Then move the key to position 2 while pressing the acceler- ator control at the same time. After start up, release the key that will automatically return to position 1. 19 3 Vehicle use

PLACE. 03_08 Engine start up (03_07, 03_08) Starting off (versions with handlebar) With idle engine, pull the clutch lever «A» and turn the gear knob to the 1st gear (position 1 on the gear indicator «B »). To start off, release the clutch lever «A» smoothly and accelerate by turning the throttle twist grip «C». WARNING EXHAUST GASES ARE TOXIC. DO NOT START THE ENGINE IN A CLOSED PLACE. 03_09 Engine start up (03_08, 03_09) Start-up (handlebar versions) With idle engine, press the clutch pedal «A» and engage the first gear with the gearbox lever. Gently release the clutch pedal while gradually pressing the accelerator pedal «B». 20 3 Vehicle use

Stopping the engine (handlebar) Before stopping the engine, shift to neutral (position «N» on the gear indicator « B »). Then turn the ignition key to «A». Stopping the engine (steering wheel) Before stopping the engine, move the gearbox to neutral (central position), then turn the switch key to position «A». Starting difficulties Engine starting difficulties (gasoline version) Possible causes and suggested actions: - Carburettor flooded. Close the fuel cock, turn the start key to position "1"; with closed starter open the gas thoroughly and actuate the key switch, moving it to position "2"; open the fuel cock again and move the key switch to position "2". In any case, do not try starting for more than 5-6 times. - Dynamotor or battery inefficiency. Use an auxiliary battery with equivalent or slightly higher specifications with respect to the original battery. If you need to bump start the vehicle (by pushing or towing), follow these instructions: engage a high gear (2nd or 3rd), do not exceed 20 kph (even when freewheeling), release the clutch pedal or lever gradually. 21 3 Vehicle use

the engine even with the procedure described above, contact an Authorised PIAG- GIO Service Centre. CAUTION NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID POSSIBLE DAMAGE. WHEN DRIVING DOWNHILL, DO NOT EXCEED TOP SPEED OR THE ENGINE COULD BE DAMAGED BY PROLONGED OVERREV- VING. CAUTION • AFTER A LONG JOURNEY ALLOW THE ENGINE TO RUN AT IDLE SPEED FOR A FEW SECONDS BEFORE SWITCHING IT OFF. 03_10 Gear position (03_10, 03_11, 03_12) To reverse the vehicle, proceed as follows: 1. Stop the vehicle completely and turn the gear selector to neutral (position «N» on the gear indicator «B») while the engine is idling; 2. For gasoline versions, lift the reverse gear control lever from position «A» to position «B». 3. Diesel versions are not equipped with a reverse gear control lever. 4. Use the gear control lever to engage gears; («1stgear» for the gasoline version, «R» for the handlebar version), and gently release the clutch pedal while gradually pressing the accelerator pedal. 22 3 Vehicle use

procedures and move the reverse gear control lever to the «A» position (in the gas- oline version and in the handlebar version). Note: in the diesel handlebar version, once the reverse gear control lever has been moved to the «B» position, both the reverse gear and the «1st gear» can be used for vehicle parking manoeuvring; engagement of higher gears remains disabled until the reverse gear control lever is set to the «A» position. Driving Tips Follow these simple recommendations to use your vehicle every day, confidently and safely. Your ability and your mechanical knowledge form the basis of safe riding. Practice driving in a traffic-free area until you acquire a good knowledge of the vehicle. 1. Always drive within the limits of your ability, strictly following the road regulations of the country where you are driving. 23 3 Vehicle use

you. 3. Ensure nothing hinders the pedals stroke (mats, etc.) 4. Ensure that headlights are working properly. 5. To start the vehicle, with idle engine, engage the first gear and gently release the clutch lever, accelerating at the same time. 6. Reduce speed on badly surfaced roads and drive with caution. 7. Do not brake fully on wet, unsurfaced or slippery roads. 8. Do not shift down when the engine is running at high revs to avoid dangerous over- revving. 9. On a downhill, do not keep the gearbox to neutral position or the engine off, but decrease speed closing the accelerator. To facilitate the decrease of speed, use the brakes without pulling them for too long, to prevent dangerous overheating that would decrease their efficiency. Shift down to increase the engine brake effect. 10. For rapid pick-up, e.g. for overtaking, shift down a gear to employ all the required power. 11. When driving up demanding slopes, shift down to employ all the required power. 12. Check that the load is evenly distributed on the loading body, and do not exceed the provided loads (see chapter: "Technical data -performance") to prevent tilting while turning on a corner. ALWAYS DRIVE YOUR VEHICLE WITHIN THE LIMITS OF YOUR ABILITY. DRIV- ING WHILE DRUNK OR UNDER THE EFFECT OF DRUGS OR CERTAIN MEDI- CINES IS EXTREMELY DANGEROUS AND INFRINGES THE ROAD REGULA- TIONS. 24 3 Vehicle use

ORIGINAL STRUCTURE PARTS, RENDERS THE VEHICLE NO LONGER CON- FORMING TO THE APPROVED TYPE AND THEREFORE DANGEROUS FOR DRIVING SAFELY. 25 3 Vehicle use

«A»: key for the ignition and start-up switch, the door lock and the fuel tank cover. The code numbers, in fact, are the only way to identify the key for future copies. YOU SHOULD KEEP A DUPLICATED KEY AND ITS CORRESPONDING CODE IN ANY PLACE OTHER THAN THE VEHICLE. 04_02 Door locking/unlocking by key (04_02, 04_03) The doors are provided with antitheft device. To open turn the key clockwise and press button «A». To close turn the key anticlockwise. 28 4 Doors and locks

For the handlebar version, the release control «B» must be lifted, while for the steering wheel version it must be pushed rightwards. MAKE SURE IT IS SAFE TO OPEN THE DOORS BEFORE OPENING THEM. BE- FORE STARTING OFF, MAKE SURE THE DOORS ARE CLOSED AND LOCKED. THIS PRECAUTION WILL ENSURE THEY DO NOT OPEN ACCIDENTALLY WHICH WOULD BE A HAZARD FOR THE DRIVER 04_04 Front door windows (04_04) To open the windows, press the release lever while moving the handle downwards. (7 fixed positions are available). To close the windows, move the handle to "travel end top" position. 29 4 Doors and locks

Lower the rear side board and grip the handle «A» pulling it upwards to release the retain clips «B». On the vehicles with loading body in light alloy with tilting, to access the engine com- partment it is necessary to lower the side and rear boards and then tilt the loading body. Use the special safety bar to secure the loading body in tilted position. NEVER WORK UNDERNEATH THE LOADING BODY WHEN IT IS TILTED WITH- OUT HAVING FIRST SECURED THE SAFETY BAR. DANGER OF SERIOUS IN- JURY. 30 4 Doors and locks

Observe the following suggestions for using the seat belts correctly. Failure to follow these instructions may lead to severe injury in the event of an accident or sudden braking. Check the seat belts periodically to ensure proper functioning. If its operation appears faulty, have it checked at an Authorised PIAGGIO Service Centre imme- diately. Pregnant women: PIAGGIO recommends using the seat belt. The waist height seat belt length should adhere snugly to your body as low as possible (on the hips) and not at your waist. Ask your doctor for advice. Injured people: PIAGGIO recommends using the seat belt. Ask your doctor for ad- vice. WARNING THE SAFETY BELTS ARE DESIGNED TO EXERT THEIR ACTION ON THE BONE STRUCTURE OF YOUR BODY. THE DIFFERENT BELT SECTIONS SHOULD FIT SNUGLY TO THE PELVIS, THE CHEST AND SHOULDERS. DO NOT WEAR THE SECTION WHICH IS SUPPOSED TO FIT ON THE HIPS OVER THE ABDOMEN. SAFETY BELTS SHOULD BE ADJUSTED TO FIT SNUGLY AND SHOULD BE ADAPTED TO THE PERSON WEARING THEM, SO AS TO OFFER THE PROTEC- TION THEY ARE DESIGNED FOR. A LOOSE BELT WOULD CONSIDERABLY REDUCE PROTECTION TO THE PASSENGER WEARING IT. BE CAREFUL NOT TO DAMAGE BELTS WHEN CLOSING THE DOORS. DO NOT REMOVE BELTS FOR CLEANING. WASH THEM WITH WATER AND NEUTRAL SOAP, RINSE AND LET DRY IN A WARM PLACE. PAY SPECIAL ATTENTION NOT TO DAMAGE THE SEAT BELTS WITH CLEANING PRODUCTS, OIL, ABRASIVE DETERGENTS, CHEMICAL AGENTS OR BATTERY FLUIDS . 32 5 Seats and safety belts

BELT ASSEMBLY REPLACED, EVEN IF IT MAY NOT APPEAR DAMAGED. DO NOT WEAR A TWISTED SEAT BELT. DO NOT WEAR THE SEAT BELT WITH THE SHOULDER LENGTH UNDER YOUR ARM OR BEHIND YOUR BACK. DO NOT FASTEN THE SEAT BELT OVER HARD OR FRAGILE OBJECTS, SUCH AS GLASSES, JEWELLERY, PENS, KEYS. DO NOT WEAR THE SEAT BELT OVER VERY THICK CLOTHES, AS THIS MAY PREVENT IT FROM BEING POSITIONED CORRECTLY. DO NOT MODIFY OR DISASSEMBLE THE SEAT BELT ASSEM- BLY. AFTER AN ACCIDENT OF A CERTAIN SEVERITY, WE RECOMMEND THAT YOU HAVE THE SEAT BELT WHICH WAS BEING WORN REPLACED AT AN AU- THORISED PIAGGIO SERVICE CENTRE, EVEN IF IT DOES NOT APPEAR DAM- AGED. 05_01 Fasting the safety belt (05_01) Take the metal tongue from its housing. Insert the metal tongue in the buckle until it clicks. CAUTION TO GUARANTEE THE OPTIMAL PERFORMANCE OF THE SEAT BELT, AFTER HAVING INSERTED THE METAL TONGUE INTO THE BUCKLE, CHECK IT IS SE- CURELY BLOCKED AND THE SEAT BELT IS NOT TWISTED. 33 5 Seats and safety belts

Position the seat belt as low as possible on your hips and not at your waist. Adjust the seat belt so that you can slide your fist between the belt and your chest. Hold the anchoring at a right angle with respect to the belt and pull the belt to lengthen or shorten it. A: wrong B: right 05_03 To release the safety belt (05_03) Press the button. Insert the metal tongue in its housing when it is not in use. CAUTION TO PREVENT DAMAGING SEAT BELTS CHECK THEY DO NOT REMAIN PINCHED BETWEEN A DOOR AND THE CAR BODY, OR BEHIND THE SEAT BACK. 34 5 Seats and safety belts

2. Tachometer and odometer 3. Ashtray 4. Gear indicator 5. Clutch lever 6. Cigar lighter 7. Turn indicator selector 8. Reverse gear command lever 9. Key switch 10. Emergency or parking brake 11. Heater control lever (red) 12. Starter lever (only in the gasoline version) 13. Brake pedal 14. Headlight switch 15. Horn button 16. Accelerator control 17. Light indicators unit 18. Emergency light switch 19. Rear fog light switch 20. Windscreen wiper control switch 36 6 Instrument panel and controls

ApetmD 1. External light control switch 2. Tachometer and odometer 3. Ashtray 4. Gear indicator 5. Clutch lever 6. Cigar lighter 37 6 Instrument panel and controls

8. Reverse gear command lever 9. Key switch 10. Emergency or parking brake 11. Heater control lever (red) 12. Airflow deflector lever: windscreen - floor heating 13. Brake pedal 14. Headlight switch 15. Horn button 16. Accelerator control 17. Light indicators unit 18. Heater fan switch 19. Rear fog light switch 20. Windscreen wiper control switch. 21. Emergency light switch 22. Body tilting button (where available). 38 6 Instrument panel and controls

Apetm 1. Steering wheel 2. Flashing light switch lever 3. Light and horn switch lever 4. Key switch 5. Clutch pedal 6. Brake pedal 39 6 Instrument panel and controls

8. External light control switch 9. Windscreen wiper control switch 10. Reverse gear control lever 11. Gearbox control lever 12. Emergency or parking brake 13. Heating control lever (red) 14. Starter lever (only gasoline version) (black) 15. Rear fog light switch 16. Cigar lighter 17. Emergency light switch 18. Ashtray 19. Light indicators unit 20. Tachometer and odometer 40 6 Instrument panel and controls

ApetmD 1. Steering wheel 2. Flashing light switch lever 3. Light and horn switch lever 4. Key switch 5. Clutch pedal 6. Brake pedal 41 6 Instrument panel and controls

8. External light control switch 9. Windscreen wiper control switch 10. Reverse gear control lever 11. Gearbox control lever 12. Emergency or parking brake 13. Heating control lever (red) 14. Airflow deflector lever: windscreen - floor heating 15. Rear fog light switch 16. Cigar lighter 17. Heater fan switch 18. Ashtray 19. Light indicators unit 20. Tachometer and odometer 21. Emergency light switch 22. Body tilting button (where available). 42 6 Instrument panel and controls

HANDLEBAR VERSION - GASOLINE External light control switch «A» 0 = Lights off; 1 = Front and rear side/taillights and instrument panel lights on; 2 = Headlights (high or dipped beams on). 43 6 Instrument panel and controls

0 = Disabled; 1 = Windscreen wiper enabled. 2 = Windscreen wiper + sprayer enabled. Light selector «A» 1 = High beams on. 2 = Dipped beams; THE SWITCH POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL SWITCH POSITION. 06_06 Horn button B = horn button. 44 6 Instrument panel and controls

0 = Lights off; S = Left turn indicators flashing; D = Right turn indicators flashing. Emergency light switch «B» 0 = Lights off; 1 = Direction indicators flashing 06_08 Rear fog light switch «A» 0 = Light off; 1 = Rear fog light on. STEERING WHEEL VERSION - GASOLINE Light and horn switch lever «A» With external light control switch «B» in position enabled. 45 6 Instrument panel and controls

2 = Dipped beams on; 3 = High beams on. To actuate the horn, press lever «A» upwards. THE LIGHT SWITCH LEVER POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL SWITCH POSITION. Flashing light switch lever «C» 0 = Lights off; S = Left turn indicators flashing; D = Right turn indicators flashing. External light control switch «A» 0 = Lights off; 1 = Lights on. Windscreen wiper control switch «B» 0 = Disabled; 1 = Windscreen wiper enabled. 2 = Windscreen wiper + sprayer enabled. Rear fog light switch «C» 0 = Light off; 46 6 Instrument panel and controls

Emergency light switch «D» 0 = Lights off; 1 = Direction indicators flashing 06_09 Cigar lighter«E» Press the lighter button and wait until it automatically returns to its initial position. The lighter is ready for use. Controls (06_09, 06_10, 06_11, 06_12, 06_13, 06_14) HANDLEBAR VERSION - DIESEL External light control switch «A» 0 = Lights off; 1 = Front and rear side/taillights and instrument panel lights on; 2 = Headlights (high or dipped beams on). 47 6 Instrument panel and controls

0 = Disabled; 1 = Windscreen wiper enabled. 2 = Windscreen wiper + sprayer enabled. Light selector «A» 1 = High beams on. 2 = Dipped beams; THE SWITCH POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL SWITCH POSITION. 06_11 Horn button B = horn button. 48 6 Instrument panel and controls

0 = Lights off; S = Left turn indicators flashing; D = Right turn indicators flashing. Rear fog light switch «A» 0 = Light off; 1 = Rear fog light on. Heater fan switch «B» 0 = Fan off 1 = First gear 2 = Second gear Emergency light switch «A» 0 = Lights off; 1 = Direction indicators flashing 49 6 Instrument panel and controls

0 = Body down 1 = Body up In order to improve safety and prevent unintentional operations, the lifting controls only becomes live after releasing the safety lever on the right hand side at the back of the cabin. Remember to bring the safety lever back onto the 'blocked' position once all tilting operations are completed. • THE BODY LIFTING OPERATIONS MUST BE CARRIED OUT WITH THE VEHICLE STOPPED AND THE EMERGENCY/PARKING BRAKE ACTI- VATED. STEERING WHEEL VERSION - DIESEL Light and horn switch lever «A» With external light control switch «B» in position enabled. 1 = Taillights on; 2 = Dipped beams on; 3 = High beams on. To actuate the horn, press lever «A» upwards. THE LIGHT SWITCH LEVER POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL SWITCH POSITION. Flashing light switch lever «C» 0 = Lights off; S = Left turn indicators flashing; 50 6 Instrument panel and controls

External light control switch «A» 0 = Lights off; 1 = Lights on. Windscreen wiper control switch «B» 0 = Disabled; 1 = Windscreen wiper enabled. 2 = Windscreen wiper + sprayer enabled. Rear fog light switch «C» 0 = Light off; 1 = Rear fog light on. Heater fan switch «D» 0 = Fan off 1 = First gear 2 = Second gear 51 6 Instrument panel and controls

lighter is ready for use. Emergency light switch «F» 0 = Lights off; 1 = Emergency light on. Body tilting button «G» 0 = Body down 1 = Body up 52 6 Instrument panel and controls

becomes live after releasing the safety lever on the right hand side at the back of the cabin. Remember to bring the safety lever back onto the 'blocked' position once all tilting operations are completed. • TIPPING ACTIONS OF THE PLATFORM MUST BE CARRIED OUT WHEN THE VEHICLE IS STOPPED AND THE HANDBRAKE ENGAGED. 06_16 Ignition switch (06_16, 06_17) According to the version (steering wheel or handlebar), the key switch is on the left of the steering wheel or on the front side, on the steering column cover. The key can turn to 3 different positions: 0 = Ignition off, key can be removed, steering locked. 1 = Running position - arrangement of utilities and external lights and start up of pre- heating glow plug (for diesel versions). 2 = Engine start up (after start up, the key automatically returns to the running position "1"). Locking the steering (antitheft): with the key switch set to 0, extract the key and turn the steering wheel leftwards (travel end). Unlocking the steering: insert the key and turn it to 1. Steering wheel lock (antitheft): with the key switch set to 0, extract the key and turn the steering wheel to lock it. Steering wheel release: insert the key and turn it to 1. 53 6 Instrument panel and controls

WARNING SHOULD THE STARTING DEVICE BE TAMPERED WITH (E.G. A THEFT AT- TEMPT) HAVE IT CHECKED AT THE EARLIEST OPPORTUNITY BY A DEALER OR AN AUTHORISED PIAGGIO SERVICE CENTRE BEFORE YOU START DRIV- ING AGAIN. WHEN YOU LEAVE THE VEHICLE, ALWAYS REMOVE THE KEY TO PREVENT SOMEBODY FROM ACCIDENTALLY ACTUATING THE CONTROLS. ENGAGE THE PARKING BRAKE AND THE FIRST OR REVERSE GEAR ACCORDING TO WHETHER THE VEHICLE IS UPHILL OR DOWNHILL. SUITABLY TURN THE STEERING WHEEL TO PREVENT BLOCKING THE ROAD IN CASE OF AN AC- CIDENTAL RELEASE OF THE EMERGENCY OR PARKING BRAKES. 54 6 Instrument panel and controls

A = Speedometer, odometer/mileometre. B = Preheat glow plug indicator (only on diesel versions - amber colour). C = Flashing lights on indicator (green colour). D = High beams on indicator (blue colour). E = Taillights on indicator (green colour). F = Rear fog light on indicator (amber colour). G = High water temperature indicator (only on diesel versions - red colour). H = Oil reserve indicator (for gasoline versions). Inadequate oil pressure indicator (for diesel versions). I = Fuel reserve indicator (amber colour). L = Battery charge voltage low indicator (red colour). 56 7 Gauges and Warning Lights

Lever «A» (with red grip): in position 1. Control bar «B»: in position 1 (travel end back) located below the driver's seat to allow opening diaphragm «C». Shuttering outlets «D» in position 1 (OPEN). The cabin heater can be disabled by the shuttering outlets «D» or directly by returning lever «A» to neutral position (position 2). 08_02 Heating (08_01, 08_02) Cabin heating controls (diesel): Lever «A» (with red grip): position 1, warm air. Lever «B»: position 1, warm air towards feet. Lever «B»: position 2, warm air towards the windscreen. 58 8 Air control system

Cabin defrosting/heating controls (gasoline): Control bar «B» in position 2 (travel end forward). Shuttering outlets «D» in position 1 (OPEN). 08_04 Heating and demisting (08_03, 08_04) Cabin defrosting/heating controls (diesel): Control bar «B» in position 2. 08_05 Demisting (08_05) Cabin defrosting controls (gasoline): Control bar «B» in position 2 (travel end forward). Shuttering outlets «D» in position 2 (CLOSED). The hot air flow is thus sent to the windscreen only, through the two outlets shown in the figure. 59 8 Air control system

Cabin heating controls (diesel): Control lever «B» in position 1. The hot air flow may be partitioned through the two outlets «D». 60 8 Air control system

Rear-view mirrors are adjusted by moving the mirror body manually until the ideal angle is obtained to guarantee full visibility. CAUTION NEVER ADJUST MIRRORS WHILE DRIVING AS YOU MAY LOSE CONTROL OF THE VEHICLE. Wipers and Brushes (9_02, 9_03) Blade • Clean regularly the rubber part with specific products. • Replace the blade if the rubber is misshapen or worn. In any case, blades should be replaced approximately once a year. Some simple recommendations can minimise the possibility of damage to the blade: • - If the temperature is below zero, make sure the rubber part is not frozen to the windscreen. If required, use a de-icing product to release the blade. • - Remove any snow from the windscreen: this will protect the blade and avoid overloading and overheating the electric motor. • Do not operate the windscreen wiper on a dry windscreen. DRIVING WITH A WORN WINDSCREEN WIPER BLADE CAN BE EXTREMELY DANGEROUS AS VISIBILITY IS DECREASED IN POOR WEATHER CONDITIONS. 62 9 Mirrors and Window Glasses

Replace the windscreen wiper blade as follows: • Lift the windscreen wiper arm "A" and position the blade so that it forms a right angle with the arm; • Press retainer tab "B" of the latching spring and extract the blade for arm "A"; • Fit a new blade. Insert the tab in its seat on the arm. Make sure it is locked. 9_03 Nozzles • If there is no jet of fluid, first of all check whether the windscreen washer reservoir is full. • Check whether the holes «A» are clogged. If so, open them with a pin. • Direct the windscreen washer nozzles so that the jets are directed towards the highest position of the blade stroke. 63 9 Mirrors and Window Glasses

by a dynamotor/battery unit, with a voltage regulator separated by the remote control switch unit, both installed under the seat in the compartment. The dynamotor acts as a generator-dynamo and as a starter motor: in particular, upon start-up, it absorbs current from the battery and operates as an electric motor. After starting the engine and reaching a certain speed, the dynamotor acts as a normal dynamo, charging the battery and powering the vehicle system. Electric characteristic Battery 12V-32Ah Diesel version The power for the lighting and indication system devices is provided in direct current by a special battery. The engine is equipped with an 18-pole rotor stator unit, three-phase, 330W MAX. The preheating device for starting the engine, which is fitted with a light indicator, controls the special preheat glow plug. FOR ESPECIALLY COLD AREAS, WE RECOMMEND INSTALLING A 12V-60AH BATTERY. WHEN INTERVENING ON THE ELECTRICAL SYSTEM, MAKE ESPECIALLY SURE THAT THE WIRES LEADING TO THE ELECTRONIC CONTROL UNIT ARE CORRECTLY CONNECTED AND RESPECT THE COLOUR CODING GIVEN ON THE CONTROL UNIT. Electric characteristic Battery 68 11 Electrical system

The tyre replacement operation and the use of jack require some precautions which are given below. WARNING SIGNAL THE PRESENCE OF THE VEHICLE AS PRESCRIBED BY THE HIGHWAY CODE IN FORCE. PLACE THE JACK IN THE POSITIONS SHOWN SO AS NOT TO DAMAGE ME- CHANICAL PARTS OR THE BODY WARNING WHENEVER POSSIBLE, REPLACE TYRES WITH THE VEHICLE ON LEVEL GROUND. IF THE GROUND IS SLOPING OR BADLY SURFACED, PUT WEDGES OR ANY OTHER SUITABLE MATERIAL UNDER THE WHEELS TO BLOCK THE VEHICLE. DO NOT GREASE BOLT THREADS BEFORE REFITTING: THEY COULD COME UNDONE SPONTANEOUSLY. NEVER TAMPER WITH THE INFLATION VALVE. DO NOT PLACE TOOLS BE- TWEEN RIM AND TYRE. Maintenance instructions They are located into the compartment, below the seat. 72 12 Emergency

JACK TO PERFORM REPAIRS UNDER THE VEHICLE. THE VEHICLE MAY FALL IF THE JACK IS NOT POSITIONED CORRECTLY CAUTION PERIODICALLY CHECK TYRE PRESSURE ACCORDING TO THE VALUES GIV- EN IN THE: «MAINTENANCE ». 73 12 Emergency

Engine oil level check (diesel version) To check the engine oil level, proceed as follows: 1. Check with engine off and vehicle on a flat surface; 2. Extract the level bar from the rear side of the vehicle and check that the level is between the MIN and MAX positions; 3. If a top up is required, add new oil by the filler located into the engine compartment; WARNING TOP UP USING OIL OF THE SAME TYPE ALREADY CONTAINED INTO THE EN- GINE. 13_02 Oil change and oil filter replacement (13_02, 13_03, 13_04) Replacing the engine oil (diesel version) To replace the engine oil proceed as follows: 1. Loosen the drainage cap «A» and drain the oil; 2. When drainage is complete, tighten cap «A», remove cap «B» and pour new oil by the filler; the oil level must always be between the MIN and MAX positions marked on bar «C»; 3. Periodically check the oil level; 76 13 Maintenance

CAUTION RUNNING THE ENGINE WITH INSUFFICIENT LUBRICATION OR IMPROPER LU- BRICANTS ACCELERATES THE WEAR OF ALL MOVING PARTS AND MAY RESULT IN SERIOUS DAMAGES. CAUTION USED OIL IS HARMFUL TO THE ENVIRONMENT. WHEN REPLACING THE OIL, WE SUGGEST TO CONTACT A PIAGGIO AUTHORISED SERVICE POINTS EQUIPPED FOR DISPOSING SPENT OILS IN THE RESPECT OF NATURE AND IN COMPLIANCE WITH THE LAWS IN FORCE. Characteristic new oil: 2.8 litres 77 13 Maintenance

Engine oil cartridge replacement (Diesel version) To gain access to the oil cartridge proceed as follows: 1. Remove the engine inspection door (or lift the metal alloy plate); 2. Drain the engine crankcase; 3. Remove the filtering body «F»; 4. Lubricate the new cartridge seal and screw it in as far as it will go, and then tighten it by hand by half a turn; 5. Fill up with fresh oil, then start the engine whilst inspecting for oil leaks. WARNING TO PREVENT DAMAGING THE ENGINE, FILL THE FILTER WITH NEW OIL BE- FORE PROCEEDING TO THE REASSEMBLY. IN CASE OF REPLACEMENT OF THE FILTER, THE AMOUNT OF OIL CON- TAINED INTO THE CRANKCASE IS OF ABOUT 2.8 LITRES (THE TOTAL CIRCUIT CAPACITY IS 3.5 LITRES). WARNING USING NON-ORIGINAL SPARES SERIOUSLY IMPAIRS THE VEHICLE PER- FORMANCE AND LIFE. 78 13 Maintenance

LOW THE SPECIFIC ENVIRONMENT-RELATED REGULATIONS IN FORCE. 13_06 Checking the brake fluid level (13_06) Checking level (gasoline version) The rear brake fluid tank is located into the driver compartment, above the brake pedal. Check the level as follows: 1. Stop the vehicle on level ground; 2. Check the oil level is between 1 cm under the surface of cap «A» (MAX level) and 1 cm over the bottom of the reservoir (MIN level). If the oil is under the minimum level contact a PIAGGIO Dealer or Authorised Service Centre to have the brake system checked. Topping up brake fluid To fill the reservoir, unscrew cap «A» and top up. In normal climates, replace the fluid every 20,000 km or every 2 years. Qualified and skilled personnel is required for this operation. We recommend you go to a PIAGGIO Dealer or Authorised Service Centre. Recommended products AGIP DOT4 BRAKE FLUID Brake fluid 79 13 Maintenance

13_07 Checking the brake fluid level (13_06, 13_07) Level check (Diesel version) The rear brake fluid reservoir is located inside the vehicle, underneath the cover on the right-hand side of the instrument panel. To check the level, remove the two fixing screws and the cover, then follow the pro- cedure outlined in the previous paragraph. CAUTION ONLY USE DOT 4 CLASSIFIED BRAKE FLUIDS. CAUTION BRAKE FLUID IS HAZARDOUS: WASH WITH WATER IN THE EVENT OF ACCI- DENTAL CONTACT. CAUTION BRAKING CIRCUIT FLUID IS VERY CORROSIVE; AVOID CONTACT WITH PAIN- TED PARTS. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, I.E., IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKE FLUID EX- 80 13 Maintenance

USE BRAKE FLUID FROM PREVIOUSLY OPENED OR PARTLY-EMPTY CON- TAINERS. 13_08 13_09 Gear box oil level (13_08, 13_09, 13_10) To check the gearbox oil, proceed as follows: 1. Check with engine off and vehicle on a flat surface; 2. Loosen the two screws fixing the SAS to the support bracket and move the SAS so as to access the cap «A»; 3. Loosen the inspection cap «A», then check that the oil level is between the MIN and MAX references on the bar contained into the cap; 4. If you need to top up the level, extract the cap with the bar and restore the level; 5. Replace the SAS to the original position. TOP UP USING OIL OF THE SAME TYPE ALREADY CONTAINED INTO THE GEARBOX. 81 13 Maintenance

1. Remove the cap «A», loosen cap «B» and drain the oil; when drainage is complete, replace cap «B». 2. Pour some oil into the top hole and let the engine run for a few seconds; then, drain the crankcase again. 3. Refill with new oil, periodically checking the level with the bar until the mark MAX is reached. WARNING REPLACE THE OIL WHEN THE ENGINE IS WARM. • AN EXCESSIVE AMOUNT OF OIL CAN SPILL OUT AND DIRTY THE EN- GINE. WARNING • USED OIL CONTAINS SUBSTANCES HARMFUL TO THE ENVIRON- MENT. FOR OIL REPLACEMENT, CONTACT ANY AUTHORISED PIAG- GIO SERVICE CENTRE AS THEY ARE EQUIPPED WITH LAW-ABIDING ENVIRONMENTALLY- FRIENDLY OIL DISPOSAL SYSTEMS Recommended products AGIP ROTRA MP 80W-90 Oil with specifications SAE 80W-90, API GL-5 Gearbox oil Characteristic Oil amount for gasoline version: 82 13 Maintenance

13_11 Window washer fluid level (13_11) Topping up windscreen washer fluid The windscreen washer fluid reservoir is located inside the cab on the front right panel. To fill the reservoir, unscrew cap «A» and top up. Use a specific detergent. 13_12 Cooled fluid (13_12) Coolant top-ups (Diesel version) Loosen the filler cap on the expansion tank. Fill up the tank with coolant (permanent 50% water + ethyl glycol fluid recommended). The correct level is indicated on the expansion tank by the LEVEL reference mark. Circuit air-bleed: start the engine up and let it run at idle so to allow for any air bubble trapped inside the circuit to leave the cooling system. The coolant level will gradually decrease and then settle. Stop the engine and top-up the circuit as explained in the previous paragraph. After a few hours of normal use, check the level with the engine cold. Cooling circuit hose inspection (every 10,000 Km) 83 13 Maintenance

check that all fittings are properly sealed. If any of the hoses is worn, please contact your nearest Authorised Piaggio Service Centre to have it replaced. Changing the engine cooling fluid Drain the circuit completely and refill following the procedure given in the previous paragraphs. 13_13 13_14 Checking and replacing the air cleaner element (13_13, 13_14) Replacing the air filter (gasoline version) To replace the air filter, proceed as follows: 1. Lower the rear side and remove the engine cover; 2. Loosen the three knobs «A» fixing the filter cover, then remove the cover; 3. Remove the filtering element «B»; 4. Replace the filtering element and refit the cover. 84 13 Maintenance

13_16) Replacing the air filter (diesel version) To replace the air filter, proceed as follows: 1. Loosen the fixing know «A» and remove the filter box cover «B»; 2. Extract the filtering element «C» and replace it with a new one; 3. Refit the cover and tighten the knob «A». CAUTION THE FILTERING ELEMENT MUST BE REPOSITIONED INSIDE THE AIR-BOX PROPERLY, FOLLOWING THE REMOVAL OPERATIONS BUT IN REVERSE OR- DER. 13_17 Replacing the fuel filter (13_17) Replacing the diesel filter The diesel filter «A» can be removed by turning it anticlockwise. At the bottom of the cartridge there is the screw «B» for draining condensation water. To drain the condensation water, loosen the screw «B»; tighten it again when diesel without water comes out. 85 13 Maintenance

Bleed air once the injection system has been emptied for checking due to running out of fuel. To this purpose, repeatedly actuate the lever controlling the hand pump, until you feel a resistance during the pumping phase. Normally, a totally empty system is filled with about 40 pumping actions. 13_19 Fuel exhaustion (13_19) Running out of fuel (diesel version) If you run out of fuel, refuel and then actuate the lever controlling the hand pump, as described for the air bleeding, until you feel a certain resistance during the pumping phase. Then, start the engine according to the standard procedure. If you feel a certain resistance in the pumping and the stroke of the hand pump control lever is not complete, turn the driving shaft by another revolution to return the mark «D» at the reference «E». Actuate the hand pump again until the injection system is totally bled. N.B. IN CASE OF AIR BLEEDING AND OF RUNNING OUT OF FUEL, IN ORDER TO OBTAIN THE MAXIMUM CAPACITY OF THE HAND PUMP IT IS NECESSARY TO TURN THE DRIVING SHAFT UNTIL THE MARK «D» PUNCHED ON THE CLUTCH BOX MATCHES THE REFERENCE «E» (TDC) OF THE CRANKCASE. 86 13 Maintenance

Access the spark plugs as follows: 1. remove the plate releasing the three fixing clamps; 2. disconnect the high voltage wire cap «A» from the spark plug «B»; 3. remove the spark plug using the provided tool; 4. when refitting, place the spark plug in place at the correct slant and screw it by hand. Use the tool for locking only; 5. insert cap «A» fully on the spark plug and refit the rear washer. THE SPARK PLUG SHOULD BE REMOVED ONLY WHEN THE ENGINE IS COLD. CHANGE THE SPARK PLUG EVERY 4,000 KM. USING SPARK PLUGS WITH DIFFERENT VALUE WITH RESPECT TO THE PRESCRIPTIONS OR WITH IN- CORRECT THREADING CAN SEVERELY DAMAGE THE ENGINE. Characteristic Recommended spark plugs: BOSCH W3AC CHAMPION RL78C NGK BR8HS 87 13 Maintenance

The electrical system is protected by six 8A fuses located underneath the instrument panel, to the left of the steering column. To the left of the fuse-box are two fuses: 15A fuse «G» protecting the cigarette lighter, and 15A fuse «I» guarding the heater fan. Van versions are also fitted with an 8A fuse located underneath the right-hand side seat and protecting the van lighting circuit. The vehicle is also protected by the main fuse «H» located underneath the passenger seat. 13_22 13_23 The function of general fuse «H» varies according to the version: - Gasoline = 40 A Safeguarding all services with the exception of the start-up power circuit. - Diesel = 40 A Safeguarding the preheating and charging circuits. Next to the main fuse, on the tipper version, is an additional 80A fuse safeguarding the body tilting system. The six 8 A fuses safeguard different circuits depending on the vehicle's version. BEFORE REPLACING THE BLOWN FUSE, TRY TO ELIMINATE THE FAULT THAT CAUSED IT TO BLOW. NEVER ATTEMPT TO REPLACE A FUSE USING A DIFFERENT MATERIAL (I.E. A PIECE OF ELECTRIC WIRE) OR A HIGHER AMP FUSE. 88 13 Maintenance

LIGHTS) WE POINT OUT THAT INCORRECT DERIVATIONS ON THE ELECTRIC CONNECTIONS MAY CAUSE DAMAGE TO THE INSTALLATION. Handlebar gasoline version A. Dipped beams (left and right), rear fog light circuit. B. High beams (left and right), high beams indicator. C. Emergency (key OFF), windscreen wiper, horn, glass bowl. D. Emergency (key ON), flashing lights, indicator circuits (recharge, oil reserve, fuel reserve, tilting), stop lights, reverse gear lights. E. Instrument lighting, light indicator, number plate lighting, taillights (left rear and front), cigar lighter lighting. F. Taillights (right rear and front). Steering wheel gasoline version A. Emergency (key OFF), windscreen wiper, horn, glass bowl. B. Emergency (key ON), flashing lights, indicator circuits (recharge, oil reserve, fuel reserve, tilting), stop lights, reverse gear lights. C. Right dipped beam. D. Left dipped beam, rear fog light circuit. E. Instrument lighting, light indicator, number plate lighting, taillights (left rear and front), cigar lighter lighting. F. Taillights (right rear and front). 89 13 Maintenance

A. Emergency (key OFF), windscreen wiper, horn, glass bowl. B. Emergency (key ON), flashing lights, indicator circuits (recharge, oil pressure, oil temperature, fuel reserve, preheating, tilting), stop lights, reverse gear lights, solenoid valve, preheating (power circuit excluded). C. Right dipped beam. D. Left dipped beam, rear fog light circuit. E. Instrument lighting, light indicator, number plate lighting, taillights (left rear and front), cigarette lighter lighting. F. Taillights (right rear and front). Handlebar diesel version A. Dipped beams (left and right), rear fog light circuit. B. High beams (left and right), high beams indicator. C. Emergency (key OFF), windscreen wiper, horn, glass bowl. D. Emergency (key ON), flashing lights, indicator circuits (recharge, oil pressure, oil temperature, fuel reserve, tilting, preheating), stop lights, reverse gear lights. E. Instrument lighting, light indicator, number plate lighting, taillights (left rear and front), cigarette lighter lighting. F. Taillights (right rear and front). 90 13 Maintenance

Secondary air box - SAS (gasoline version) Remove the two screws «A» of the aluminium SAS cover, without extracting the metal pipe from the cover/sleeve. Remove the plastic cover and the plate, pull the sponge out and wash with soap and water. Dry with compressed air before reassembling. Reinstall the plate into the seat on the two plastic and aluminium covers. Replace the box sealing O-Ring housed in the cover seat at every disassembly. TURN TO AN AUTHORISED PIAGGIO SERVICE CENTRE FOR THIS OPERA- TION. 13_25 Tyres (13_25) • Periodically check the inflation pressure of each tyre. • Tyres feature wear indicators; replace tyres as soon as these indicators be- come visible on the tyre tread. • Also check that there are no cuts on the sides of the tyres or irregular tread wear; in such cases, contact an authorised service centre for the replace- ment. Characteristic TYRES 4.50 - 10'' 91 13 Maintenance

2.5 atm Rear tyre pressure 4.5 atm Pressure ACCORDING TO THE PROVISIONS OF THE REGULATIONS IN FORCE, THE TYRE TREADS MUST BE OVER 1.6 MM THICK. CHECK TYRE PRESSURE WHEN COLD. INCORRECT TYRE INFLATION PRES- SURE WILL CAUSE UNEVEN THREAD WEAR AND MAKE DRIVING DANGER- OUS.THE TYRE MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS SET FORTH BY LAW. Periods of inactivity Prolonged inactivity If the vehicle is not to be used for long periods, the battery must be charged periodically (when not in use, the battery will discharge over a period of about three months). If the battery is removed, make sure you connect the leads correctly at the time of in- stallation Perform the following operations: 1. Clean the vehicle; 92 13 Maintenance

3. Lift the vehicle from the ground, resting the wheels on wooden supports; 4. Drain the fuel tank. Cover the unpainted metal parts with rustproof grease; 5. For the battery, follow the procedures indicated in the «Maintenance» section. FOR THE GASOLINE VERSION WITH ENGINE ON AND AT LOW SPEED, POUR 30 CC OF SAE 40 OIL THROUGH THE CARBURETTOR CHOKE. NO START-UP (GASOLINE VERSION) Connectors to the spark plug disconnected Restore connection DIFFICULTIES WHEN STARTING (GASOLINE VERSION) Fuel tank empty Refuel Clogged or dirty filters, jets or carburettor Contact an Authorised PIAGGIO Service Centre Starter control lever in lowered position Move it to lifted position 93 13 Maintenance

Connectors to the glow plug disconnected, or inefficient glow plug Restore the connection or replace the preheating glow plug No fuel in tank Refuel Air into the injection system Bleed the air Water in the diesel Drain the water and replace the filter, if required, then bleed the air Injector dirty or faulty Contact an Authorised PIAGGIO Service Centre IGNITION FAILURE (GASOLINE VERSION) No spark on spark plug Check whether the electrodes are clean (clean with white spirit and wire brush or sandpaper). Check spark plug insulation: if cracked or broken, replace the spark plug. If the spark plug is in good conditions, contact an Authorised PIAGGIO Service Centre. CAUSE: HIGH VOLTAGE. THIS INSPECTION SHOULD BE CARRIED OUT BY A SKILLED MECHANIC. 94 13 Maintenance

Spark plug seat threading damaged; head bolts insufficiently torqued, piston seals worn Contact an Authorised PIAGGIO Service Centre HIGH FUEL CONSUMPTION AND POOR PERFORMANCE (GASOLINE VERSION) Air filter blocked or dirty Replace the air filter ENGINE IRREGULAR OPERATION (DIESEL VERSION) Injector faulty Contact an Authorised PIAGGIO Service Centre Air into the injection system Bleed the air Diesel filter clogged Replace the filter and bleed the air POOR PERFORMANCE (DIESEL VERSION) Injector faulty Contact an Authorised PIAGGIO Service Centre Diesel filter clogged Replace the filter and bleed the air 95 13 Maintenance

Injector faulty Contact an Authorised PIAGGIO Service Centre Delayed injection Contact an Authorised PIAGGIO Service Centre BLACK FUMES UPON EXHAUST (DIESEL VERSION) Air filter clogged Replace the air filter Wrong injection pump calibration Contact an Authorised PIAGGIO Service Centre Injector faulty Contact an Authorised PIAGGIO Service Centre THE ENGINE KNOCKS Injection advanced Contact an Authorised PIAGGIO Service Centre Injector faulty Contact an Authorised PIAGGIO Service Centre 96 13 Maintenance

loading; stroke end bumpers worn. Contact an Authorised PIAGGIO Service Centre TRANSMISSION IS NOT SMOOTH Gearbox failure Contact an Authorised PIAGGIO Service Centre Gearcase noise Contact an Authorised PIAGGIO Service Centre POOR BRAKING ACTION Drums greasy, brake shoes worn Contact an Authorised PIAGGIO Service Centre Air into the circuit pipes Bleed the air Shoe self-adjustment device faulty Contact an Authorised PIAGGIO Service Centre Irregular friction material wear Contact an Authorised PIAGGIO Service Centre Oil leaks from the circuit Contact an Authorised PIAGGIO Service Centre Air in the brake circuit Bleed the air Contact an authorised PIAGGIO service centre. 97 13 Maintenance

Faulty controls (switches) or lights and indicators Contact an Authorised PIAGGIO Service Centre Battery inefficient Contact an Authorised PIAGGIO Service Centre 13_26 Troubleshooting / What to do if... (13_26) Idle adjustment Adjust the idle speed as follows: 1. Release the three clamps and remove the plate. 2. Start the engine and take it to its normal operating temperature, i.e., 5 minutes run at a medium speed. 3. Turn the gas valve travel end adjustment knob «A» to approach the minimum stop limit of engine spontaneous stop. 4. Then, adjust the mixture flow adjustment screw «B» to reach the highest rpm num- ber. If the rpm number reached is excessive, decrease it by knob «A» to reach a regular minimum speed. If this is problematic, go to a PIAGGIO Dealer or Authorised Service Centre. THE IDLE ADJUSTMENT MUST BE PERFORMED WITH HOT ENGINE AND AC- TIVE CATALYTIC CONVERTER. BEFORE PROCEEDING, CHECK THAT THERE IS NO PLAY ON THE THROTTLE CONTROL. IF REQUIRED, GO TO A PIAGGIO DEALER OR AUTHORISED SERVICE CENTRE TO HAVE THE THROTTLE CON- TROL PLAY ADJUSTED. 98 13 Maintenance

ESSARY TO ADJUST EXHAUST EMISSIONS (CO). THIS OPERATION MUST BE PERFORMED AT AN AUTHORISED PIAGGIO SERVICE CENTRE. Characteristic Idle adjustment (approx. 1250 - 1450 rpm) 13_27 Troubleshooting / What to do if... (13_26, 13_27) Brakes adjustment The brake shoes are provided with a self-adjustment device that automatically re- stores the proper clearance between blocks and drums, regardless of the friction material wear, so it is not necessary to perform manual adjustments. The brake drums are provided with hole with screw cap «A» through which it is pos- sible to inspect the wear of the friction material: In case of excessive wear, replace the brake shoes. For this operation, turn to a Concessionaire or to an Authorised PIAGGIO Service Centre. 13_28 Troubleshooting / What to do if... (13_27, 13_28) Parking brake Pull the lever to engage parking brake. Lift the lever slightly to release the brake, press the button with the thumb and lower the lever completely. • BEFORE SETTING OFF ENSURE THE PARKING BRAKE IS FULLY RE- LEASED AND THE WARNING LIGHT IS OFF. SHOULD THE PARKING BRAKE BE PARTIALLY PULLED, THIS WOULD CAUSE THE BRAKES 99 13 Maintenance

EARLY WEAR OF THE FRICTION MATERIAL. WHEN PARKING THE VEHICLE ON HILL ROADS, ALWAYS PULL THE PARKING BRAKE LEVER FULLY AND MOVE INTO THE LOWEST GEAR OPPOSITE THE DIRECTION FACED BY THE VEHICLE. IN ADDITION, POSITION WEDGES BE- HIND THE WHEELS. • TO IMPROVE SAFETY AND AVOID ACCIDENTAL ACTIVATIONS, WE SUGGEST YOU ALWAYS PULL THE PARKING BRAKE BEFORE, OP- ERATING THE LIFTING/LOWERING BODY CONTROL. 13_29 Troubleshooting / What to do if... (13_28, 13_29) Air bleeding from the braking system In case of anomalies of the brake performance, accompanied by idle pumping, have the system drained by the Concessionaires or Authorised PIAGGIO Service Cen- tres. IN FACT, THE BRAKE FLUID IS HIGHLY CORROSIVE AND IT MUST BE DIS- POSED ACCORDING TO PRECISE REGULATIONS. MOREOVER, ANY INTER- VENTION TO THE BRAKING SYSTEM MUST BE CARRIED OUT ONLY BY QUALIFIED PERSONNEL. 100 13 Maintenance