Gilera Runner ST 200 (2005) manual

GILERA WOULD LIKE TO THANK YOU for choosing one of its products. We have prepared this manual to help you to get the very best from your scooter. Please read it carefully before riding the scooter for the first time. It contains information, tips and precautions for using your scooter. It also describes features, details and devices to assure you t[...]

The instructions given in this manual are intended to provide a clear, simple guide to using your scooter; this booklet also details routine maintenance procedures and regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre . The booklet also contains instructions for simple repairs. Any operations not spe[...]

Personal safety Failure to completely observe these instructions will result in serious risk of personal 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 se[...]

4[...]

INDEX VEHICLE ...................................................................................... 7 Dashboard ................................................................................ 9 Instruments ............................................................................... 9 Digital lcd display ........................................[...]

Scheduled maintenance table ................................................... 70 6[...]

Runner ST 125 - 200 Chap. 01 Vehicle 7[...]

01_01 8 1 Vehicle[...]

Dashboard (01_01) A = Rear brake control; B = Turn indicator switch; C = Horn button; D = Lights switch; E = Warning lights; F = Rpm indicator; G = Digital instrument panel; H = Start-up button; L = Throttle control; M = Front brake control; 01_02 Instruments (01_02) A = High-beam warning light; B = Engine oil pressure warning light; C = Turn indic[...]

N = Speedometer; O = Clock; P = Coolant temperature gauge S = Fuel gauge; 01_03 Digital lcd display (01_03) A= Fuel level gauge; B= Coolant temperature gauge; C= Digital clock; D= Speedometer; E= Odometer; F= Partial odometer gauge; G = Total odometer gauge; Setting the total and trip odometers Pushing the " MODE " button for less than a [...]

ON THE DISPLAY THE WORD "SET" WILL APPEAR FOR ONE SECOND CAUTION IT IS STRONGLY ADVISED NOT TO USE THE FUNCTIONS OF THE DIGITAL DISPLAY PANEL WHILE THE VEHICLE IS MOVING. Setting the hour/minutes function To set the clock push and hold the « CLOCK » button for longer than three seconds. The figures showing the hours start to flash. Set [...]

01_04 Key switch (01_04) LOCK = Ignition disabled, extractable key, steering lock engaged, seat cannot be opened. OFF = Ignition disabled, extractable key, steering lock disengaged, seat can be opened. ON = Ignition enabled, antitheft protection disconnected, non-extractable key, seat can be opened. To open the seat the key switch must be set to ei[...]

01_05 Switch direction indicators (01_05) To set the left turn indicators flashing, move lever « B » to the left; to set the right turn indicators flashing, move it to the right. The lever automatically returns to the central position and the indicators remain on. To turn the indicators off, press the lever towards the switch. 01_06 Horn button ([...]

01_08 Start-up button (01_08) Press the button « E » to start the engine, after pulling one of the two brake levers 01_09 01_10 The immobilizer system In order to enhance theft protection, the scooter is equipped with a « PIAGGIO IM- MOBILIZER » electronic engine locking device that is activated automatically when the starter key is removed. Up[...]

01_11 01_12 WARNING IT IS ADVISED THAT THE "CODE CARD" AND THE KEY WITH THE BROWN GRIP BE KEPT IN A SAFE PLACE (NOT ON THE VEHICLE). Immobilizerdevice enabled indicator led (01_12) The functioning of the « PIAGGIO IMMOBILIZER» system is shown by the flashing of the appropriate warning light « F », shown in the «Dashboard» section. I[...]

SHOULD THE VEHICLE CHANGE OWNERS, IT IS ABSOLUTELY NECESSARY THAT THE NEW OWNER GET POSSESSION OF THE KEY WITH THE BROWN GRIP (AS WELL AS ALL OTHER KEYS) AND THE «CODE CARD» Programming the immobilizer system In the following is described the procedure to follow to program the " PIAGGIO IM- MOBILIZER " system and/or enter other keys in [...]

BEEN CARRIED OUT, IT IS NECESSARY TO REPEAT THE PROCESS FROM THE BEGINNING. 01_13 Fuel tank (01_13) Tilt up the lock protection cover; Insert the key and turn it counter-clockwise, then pull out the cover. 01_14 Opening the saddle (01_14, 01_15) Push the key switch when it is in the « ON » or « OFF » position. 17 1 Vehicle[...]

01_15 01_16 01_17 Identification (01_16, 01_17) The identification numbers consist of a prefix stamped on the chassis and on the en- gine, followed by a number. They should always be given when requesting spare parts. We recommend that you check that the prefix and chassis number stamped on the vehicle correspond with those in the vehicle documents[...]

Runner ST 125 - 200 Chap. 02 Use 19[...]

Checks Before using the vehicle, check: 1 . There is enough fuel in the fuel tank. 2 . The correct fluid level for front and rear brakes. 3 . That tyres are properly inflated. 4 . The correct functioning of tail lights, headlamp, turn indicators, stop light and license plate light. 5 . The correct functioning of front and rear brakes. 6 . The oil l[...]

02_02 CAUTION THE USE OF OILS AND SPARK PLUGS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE OF THE ENGINE. CAUTION IF ONLY THE FIRST AND THE LAST SEGMENTS OF THE FUEL LEVEL INDICA- TOR FLASH, CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE TO CHECK THE INDICATOR. WARNING DO NOT RIDE WITH THE FUEL TANK ALMOST EMPTY, LACK OF FUEL CAN DAMAGE THE CATA[...]

TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS SET FORTH BY LAW. Characteristic Front wheel pressure: 1.7 bar Rear tyre pressure: 2 bar Rear tyre pressure (rider and luggage) 2.2 bar 02_03 Running in (02_03) WARNING DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80% OF ITS MAXIMUM SPEED. AVOID TWISTING THE THROTTLE GRIP FULLY [...]

02_04 Starting up the engine (02_04) The vehicle is equipped with an automatic transmission system with a speed variator and centrifugal clutch. For this reason, the throttle must be slightly untwisted while the engine is being started; to start-off from stationary position, progressively twist the throttle grip. The vehicle is equipped with a fuel[...]

CAUTION NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID POSSIBLE DAMAGE. BE CAREFUL NEVER TO EXCEED THE MAXIMUM SPEED WHILE RUNNING DOWNHILL, IN ORDER TO AVOID DAMAGING THE ENGINE. IN ANY CASE, IN ORDER TO PRESERVE THE ENGINE FROM PROLONGED EX- CESSIVE REVOLUTIONS, THE REVOLUTION LIMITER WILL BE ACTIVATED IF THE ENGINE SPEED EXCEEDS T[...]

a) Switch off all services and users, start up the vehicle with the auxiliary battery and make the engine run slightly above idle to ensure deep battery charge; then turn off the engine. b) Turn off everything and turn the scooters' key switch to " OFF ." c) Connect the positive terminal (+) of the discharged battery to the positive [...]

Catalytic silencer CAUTION TAMPERING WITH THE CATALYTIC MUFFLER MAY CAUSE SEVERE DAMAGE TO THE ENGINE . CAUTION WHEN PARKING THE VEHICLE, DUE TO THE HIGH TEMPERATURES THE CAT- ALYTIC CONVERTER CAN REACH, ALWAYS BE CAREFUL THAT THE MUF- FLER DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS, TO AVOID SERIOUS BURNS. CAUTION DO NOT SWITCH OFF THE EN[...]

friction of the clutch parts on the clutch bell. It is therefore recommended to avoid conditions of prolonged clutch slippage leading to clutch overheating (for example, as well as the situation described above, riding uphill fully laden on steep slopes or start- ing off on slopes greater than 25%, etc.): 1. Do not continue riding in such condition[...]

6. Avoid starting off by mounting the scooter while it is still resting on its stand. In any case, the rear wheel should not be turning when in comes into contact with the ground, in order to avoid abrupt departures. 7. If the vehicle is used on roads covered with sand, mud, snow mixed with salt, etc., clean the brake disc frequently with mild dete[...]

02_06 Air conveyors (02_06) The vehicle is equipped with 2 air vents designed to draw hot air coming from the radiator to the rider, to make riding in winter or in low-temperature conditions more comfortable. To open or close the air vents use the control " A " located on one of the wings. 29 2 Use[...]

30 2 Use[...]

Runner ST 125 - 200 Chap. 03 Maintenance 31[...]

03_01 03_02 03_03 Engine oil level In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all four-stroke engines, a loss of efficiency in oil perform- ance and consumption should be considered normal. Consumpt[...]

03_04 or while turning a corner, it will be necessary to take your vehicle to an Author- ised Piaggio Service Centre. Engine oil change (03_03, 03_04) The engine oil and cartridge filter, " C ", must be replaced after the first km, and every 6.000 km thereafter, by an Authorised Piaggio Service Centre . The engine should be emptied by dra[...]

AS THEY ARE EQUIPPED TO DISPOSE OF SPENT OILS IN AN ENVIRONMEN- TALLY FRIENDLY AND LEGAL WAY. CAUTION USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE OF THE ENGINE. Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil Characteristic Engine oil Capacity: 1.1 lt. dry; 1.0 l oil filter chan[...]

03_06 03_07 CAUTION USING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH THE WRONG LUBRICANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY CAUSE SERIOUS DAMAGE. CAUTION USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOR OIL REPLACEMENT, CONTACT AN AUTHORISED SERVICE CENTRE, WHICH IS EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIR[...]

03_08 Tyres (03_08) CAUTION TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD. INCOR- RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID- ING DANGEROUS. TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS SET FORTH BY LAW. WARNING THE WHEELS FITTED WITH TYRES SHOULD ALWAYS BE BALANCED. RIDING THE VEHICLE WITH VERY LOW TYRE PRESS[...]

03_09 03_10 03_11 Spark plug dismantlement (03_09, 03_10, 03_11) Remove one of the two sides of the footrest, unscrewing the four fastening screws, one of which is under the passenger footrest. Detach the spark plug shielded cap and remove the plug with the box-spanner sup- plied. To reinstall it, screw in the spark plug by hand, setting it at the [...]

CHAMPION RG 6 YC NGK CR 8 EB Spark plug: electrode distance 0.7 mm ÷ 0.8 mm 03_12 Removing the air filter (03_12) Proceed as follows: - Loosen the 9 clamping screws and remove the air filter cover; - Remove the filter element and clean it with water and shampoo; then dry it with a clean cloth and slight blows of compressed air. Finally, immerse it[...]

Mineral oil with specific additives for increased adhesiveness 03_13 Secondary air system (03_13) In order to reduce polluting emissions, the vehicle is furnished with a catalytic con- verter in the muffler. To facilitate the catalytic process, a further quantity of previously filtered air is brought in through the exhaust duct on the head by the s[...]

03_15 a) Put the vehicle in vertical position on its centre stand. b) Remove the expansion tank cap " A " by turning it anticlockwise. The fluid level can be visually checked once the front shield central cover has been removed. If the fluid is near the minimum level, proceed with the top-up operation to be carried out when the engine is [...]

CAUTION IF THE FIRST AND THE LAST SEGMENTS OF THE COOLANT LEVEL INDICA- TOR FLASH, CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE TO CHECK THE INDICATOR. IF THE FIRST AND THE LAST SEGMENTS OF THE COOLANT LEVEL TEMPER- ATURE INDICATOR FLASH WHEN RIDING IN EXTREMELY LOW TEMPERA- TURE CONDITIONS -TEMPERATURE BELOW 15º C - JUST SWITCH OFF THE ENGINE AND[...]

03_17 attention not to tilt the vehicle in order to keep the brake fluid reservoir in horizontal position when checking the fluid level. CAUTION TOP UPS SHOULD ONLY BE CARRIED OUT WITH DOT 4 CLASSIFIED BRAKE FLUID. CAUTION THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE. THEREFORE, WHEN TOPPING IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINT[...]

03_18 03_19 03_20 Battery (03_18) The saddle should be lifted in order to reach the battery. Loosen the four clamping screws " A " fitted on the cover. To remove the battery disconnect the positive and negative cables from the vehicle's system. The battery is the electrical device that requires the most frequent inspections and dilig[...]

Long periods of inactivity Battery performance will decrease if the vehicle is not used for a long time. This is the result of the natural phenomenon of battery discharging plus residual absorption by vehicle components with constant power consumption. Poor battery performance may also be due to environmental conditions and the cleanness of the pol[...]

WARNING SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENT REGULATIONS. 03_21 03_22 Fuses (03_21, 03_22) The electrical system is protected by 4 fuses fitted on the side of the battery. If a fuse blows again after it has been replaced, contact an Authorised Piaggio Service Centr[...]

FUSE TABLE Fuse No. 1 Position on fuse box: 1 Capacity : 20A Protected circuits: System protection main fuse Location : battery compartment Fuse No. 2 Position on fuse box: 2 Capacity : 7.5 A Protected circuits: High- and low- beam light bulbs. Location : battery compartment Fuse No. 3 Position on fuse box: 3 Capacity : 7.5 A Protected circuits: St[...]

L IGHT BULBS TABLE Low-beam bulb Type : H8 Power : 12V - 35W Quantity : 1 High-beam light bulb Type : H8 Power : 12V - 35W Quantity : 1 Front tail light bulb Type: All glass Power: 12V - 3W Quantity: 2 Front turn indicator bulb Type: Spherical Power: 12V - 10W Quantity: 1 RHS + 1 LHS Rear turn indicator light bulb Type: Spherical Power: 12V - 10W Q[...]

Power : 12V - 3W Quantity : 2 03_23 03_24 Front light group (03_23, 03_24, 03_25) In order to reach the headlamp bulb remove the snap-on Gilera shield by inserting the blade of a small screwdriver in the corresponding lateral notch, paying attention not to scratch the paint. Then loosen the screw underneath and lift up the front shield centre cover[...]

03_25 03_26 03_27 STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE ve- hicle IS USED. 49 3 Maintenance[...]

03_28 Front direction indicators (03_28) To replace the front turn signal bulbs loosen the locking screws that fasten the bulb and then remove the rubber cap to be able to take off the bulb socket; gently turn the bulb around 30º and remove it. Follow the process in reverse order to refit. 03_29 03_30 Rear optical unit (03_29, 03_30, 03_31, 03_32)[...]

03_31 03_32 03_33 Rear turn indicators (03_33) Loosen the screws fitted on the back of the turn indicator and remove the glass. Hold the bulb gently and make a 30º anticlockwise turn; then remove it from the sup- port and replace it. 51 3 Maintenance[...]

03_34 Number plate light (03_34) Loosen the locking screws fitted on the license plate light support and remove it. Remove the rubber bulb socket from its housing; then remove the bulb and replace it. 03_35 Rear-view mirrors (03_35) The mirrors can be set to the desired position by adjusting the mirror frame. The mirrors must be adjusted so that th[...]

03_37 CAUTION WHEN ADJUSTING IDLE SPEED, PAY SPECIAL ATTENTION NOT TO TOUCH THE CATALYTIC MUFFLER TO AVOID BURNS. CAUTION IDLE SPEED MUST BE ADJUSTED WHEN THE ENGINE IS VERY HOT. BEFORE THIS OPERATION, MAKE SURE THAT THE THROTTLE GRIP HAS THE RECOM- MENDED BACKLASH. IF BACKLASH IN THE THROTTLE GRIP TRANSMISSION NEEDS ADJUSTING TAKE YOUR VEHICLE TO [...]

03_39 GION OF 1.5 MM, BOTH PADS MUST BE CHANGED. THIS OPERATION MUST BE CARRIED OUT AT AN AUTHORISED PIAGGIO-GILERA SERVICE CENTRE. AFTER REPLACING THE BRAKE PADS DO NOT USE THE VEHICLE BEFORE HAVING USED THE BRAKE LEVER SEVERAL TIMES IN ORDER TO ALLOW THE PADS TO SETTLE AND THE LEVER STROKE TO BE SET TO THE CORRECT POSITION. CAUTION THE BRAKING AC[...]

03_41 Periods of inactivity (03_41) We recommend carrying out the following operations: 1. General cleaning of the vehicle. 2. With the engine off and the piston at the bottom dead centre position, remove the spark plug , and pour 1÷ 2 cm³ of recommended oil through its opening. Press the engine start pedal 3 or 4 times letting the engine perform[...]

WARNING NEVER WASH THE VEHICLE UNDER DIRECT SUNLIGHT, ESPECIALLY IN SUM- MER WHEN THE BODYWORK IS STILL HOT, AS THE CAR SHAMPOO MAY DRY BEFORE BEING RINSED OFF, AND COULD DAMAGE THE PAINTWORK. NEVER USE RAGS SOAKED IN PETROL OR DIESEL OIL TO CLEAN THE PAINTED OR PLASTIC SURFACES, TO PREVENT THEM LOSING THEIR SHINE AND ME- CHANICAL CHARACTERISTICS. [...]

START-UP PROBLEMS No fuel in tank Refuelling Filters, jets or carburettor dirty or clogged. Contact an Authorised Service Centre. Battery flat Charge the battery (max. current equal to 1/10 of the battery capacity). In case of emergency try starting up with an auxiliary battery as described in the chapter "USE." As a final step, replace t[...]

HIGH CONSUMPTION AND LOW PERFORMANCE Air filter blocked or dirty. Clean with water and shampoo and impregnate with petrol and specific oil (section «Removing the air filter») INSUFFICIENT BRAKING Greasy disc. Worn pads. Contact an Authorised Piaggio- Gilera Service Centre . Air in the brake assembly. Contact an Authorised Piaggio- Gilera Service [...]

STAND DOES NOT RETURN TO POSITION Presence of dirt Clean and grease STARTER LEVER DOES NOT RETURN TO CORRECT POSITION Presence of dirt Clean and grease 59 3 Maintenance[...]

60 3 Maintenance[...]

Runner ST 125 - 200 Chap. 04 Technical data 61[...]

04_01 62 4 Technical data[...]

ENGINE TECHNICAL DATA Engine single-cylinder, four-stroke Bore x stroke (125) 57 x 48.6 mm Cubic capacity (125) 124 cm³ Compression ratio (125) 11.5 - 12.5 1 Bore x stroke (200) 72 x 48.6 mm Cubic capacity (200) 197 cm³ Compression ratio (200) 11 ÷ 12 : 1 Timing system single overhead camshaft driven by a chain on the left-hand side, 4 valves, t[...]

Spark plug (125) Champion RG 4 HC NGK CR 8 EB Spark plug (200) CHAMPION RG 6 YC NGK CR 8 EB Air Filter Sponge, impregnated with mixture (50% SELENIA Air Filter Oil and 50% unleaded petrol). Fuel supply Unleaded petrol; carburettor and electrical pump. Carburettor KEIHIN CVK 30 Idle speed ~ 1650 ± 100 rpm Engine oil Capacity: 1.1 lt. dry; 1.0 l oil[...]

Wheelbase 1340 mm Fuel tank Plastic, 8.5 l tank (estimated value) including the fuel reserve ~ 1.7 l Front suspension hydraulic double-acting telescopic fork with 35 mm stems Front brake Ø 240 mm disc brake (vehicle LHS), with hydraulic control activated by handlebar right lever. Front tyre Tubeless 120/70-14'' 55P Rear suspension With c[...]

Maximum load Driver + passenger + baggage (180 Kg) 04_02 Kit equipment (04_02) Wrenches: socket wrench (16 mm); a double ended screwdriver, a shock absorber wrench. The tools are stored under the seat in an appropriate container. 66 4 Technical data[...]

Runner ST 125 - 200 Chap. 05 Spare parts and accessories 67[...]

05_01 Warnings (05_01) CAUTION WE STRONGLY RECOMMEND USING ORIGINAL PIAGGIO-GILERA SPARE PARTS, THE ONLY PARTS THAT GUARANTEE THE SAME QUALITY LEVEL AS THE ORIGINAL PARTS ASSEMBLED ON THE VEHICLE. IT SHOULD BE REMEMBERED THAT USING NON-ORIGINAL SPARE PARTS CAUSES YOUR WARRANTY RIGHTS TO EXPIRE. CAUTION PIAGGIO-GILERA MARKETS ITS OWN LINE OF ACCESSO[...]

Runner ST 125 - 200 Chap. 06 Programmed maintenance 69[...]

06_01 Scheduled maintenance table (06_01) Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been suggested, which are included in the summary table on the following page. Any minor faults shoul[...]

km x 1,000 1 6 12 18 24 30 36 42 48 54 60 Coolant ** I I I I I I I I I I Engine oil * R R R R R R R R R R R Hub oil R I I I R I I I R I I Headlight aiming adjustment A A A A A Brake pads I I I I I I I I I I I Sliding blocks / variable speed rollers I I I R I I I R I I Tyre pressure and wear I I I I I I I I I I I Vehicle road test I I I I I I I I I [...]

RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications AGIP CITY HI TEC 4T Four-stroke engine oil Lubricating oil for flexible shafts (throttle control) AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increa[...]

TABLE OF CONTENTS A Air filter: 38 B Battery: 43 Brake: 41 , 53 D Disc brake: 53 Display: 10 E Engine oil: 32 , 33 F Fuel: 17 Fuses: 45 H Headlight: 48 Horn: 13 Hub oil: 34 I Identification: 18 Immobilizer: 14 , 16 K Key switch: 12 Keys: 14 L Light switch: 13 M Maintenance: 31 , 69 , 70 Mirrors: 52 S Saddle: 17 Scheduled maintenance: 70 Spark plug:[...]

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it [...]