WORKSHOP MANUAL 633204
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WORKSHOP MANUAL
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The The descr escrip ipttion ions and and illu illust stra rattion ions given iven in this publica licattion ion are are not bind inding ing. Whil While e the basic asic spec specif ific icat atio ion ns as described and illustrat illustrated ed in this manual manual remain remain unchanged, unchanged, PIAG P IAGGI GIO-G O-GIL ILE ERA reserves reserves the right, right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing manufacturing or construct construction ion reasons. reasons. Not all versions/models shown in this publication are available in all countries. The availability of each model should be checked at the official Piaggio P iaggio sales network. network. "©Copyright "©Copyright 200 2008 8 - P IAGG IAGGIO IO & C. S.p.A. P onteder ontedera. a. All All rights rights reserved. Reprod R eproduct uction ion of this publicat publication ion in whole or in part is prohibited." PIAGGIO & C. S.p.A. - After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
WORKSHOP MANUAL Fly This This work orkshop shop manu anual has been een drawn awn up by Piagg Piaggio & C. Spa to be used sed by the work orkshop shops s of Piagg PiaggioioGilera Gilera dealers. This T his manual is addressed to Piaggio P iaggio service mechanics who are supposed to to have a basic knowledge of mechanics mechanics principles and of of vehicle fixing techniques and procedures. Any important important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with with the specific specific tool catalogue.
N.B. P rovides key key information information to make make the procedure easier easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment S ections marked wit with h this sym symbol bol indicate the correct use of the vehicle
to prevent damaging 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.
INDEX OF TOPICS
CHARACTERISTICS
CHAR
TOOLING
TOOL
MAINTENANCE
MAIN
TROUBLESHOOTING
TROUBL
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
ENGINE
ENG
SUSPENSIONS
SUSP
BRAKING SYSTEM CHASSIS PRE-DELIVERY TIME
BRAK SYS CHAS PRE DE TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
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Characteristics
Rules This This sect sectio ion n descr escrib ibes es gener eneral al saf safety ety rules les for for any any main aintenan enance ce oper operat atio ion ns per perfform ormed on the vehic ehicle le..
Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention. - The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it. - Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks. - Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.
Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - For F or removal, removal, overhaul and refit operations operations use use only tools with with metric metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been done properly, particularly the ground and battery battery connections.
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Characteristics
Vehicle identification VEHICLE IDENTIFICATION Specification
F rame prefix Engine prefix
Desc./Quantity ZAP M44100 ÷1001 C441M ÷1001
Dimensions and mass DIMENSIONS AND MASS
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Specification
Desc./Quantity
Dry weight Length Maximum height S eat height Width Wheelbase
97 Kg 1,880 1150 mm 785 735 1,340
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Characteristics
Engine ENGINE Specification
Engine type Bore x stroke Cubic capacity Compression ratio Carburettor CO adjustment Engine idle speed Air filter Starting system Lubrication
F ue uel supply Cooling system
Desc./Quantity Two-stroke, single cylinder P iaggio Hi-P ER2 40 X 39.3 mm 49.40 cc 10,3 :1 DE LL'ORTO P HVA 17.5 3.5% ±0.5 1800 to 2000 r.p.m. Sponge, soaked in a mixture (50% S ELENIA Air F ilter Oil and 50% unleaded petrol). electric starter/kick-starter With blend and variable oil variable according to the engine revolutions and the throttle valve opening by means of a pump controlled by the driving shaft with toothed belt. Gravity feed, with unleaded petrol (with a minimum octane rating of 95) with carburettor. forced coolant circulation system
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Characteristics
Transmission TRANSMISSION Specification Tran Transm smiss issio ion n
Desc./Quantity Wit With aut automatic atic expa expand ndab able le pull pulley ey vari variat ator or,, tor torqu que e serv server er,, VVbelt, automatic clutch, gear reduction unit.
Capacities CAPACITIES Specification
Desc./Quantity
Rear hub oil oil mixer tank F uel tank capacity
Quantity: approx. 85 cc P lastic, capacity ~1.2 l approx. 7.2 litres (of which 1.5 l is reserve)
Electrical system ELECTRICAL SYSTEM Specification Typ Type of igni ignittion ion
Ignition advance (before TDC) Recommended spark plug Battery Main fuse Generator
Desc./Quantity Capac Capacit itiv ive e disch dischar arge ge type elec electtroni ronic c igni ignittion, ion, with ith inco incorp rpor orat ated ed high voltage coil F ixed 17° ±1 CHAMP ION RN2C 12V-4Ah 7.5 A In alternate current with three output sections
Frame and suspensions FRAME AND SUSPENSIONS Specification
Desc./Quantity
Typ Type of chas chassis sis
Weld Welded ed tubul ubular ar stee steell chas chassis sis with ith stam stamped ped shee sheett rein reinfo forc rceements. Telescopic mechanical fork, 76mm travel. Single hydraulic shock absorber, 72.5-mm travel
F ront suspension Rear suspension
Brakes FRENI Specification
F ro ront brake Rear brake
Desc./Quantity Disc brake (Ø 200 mm) with hydraulic control (lever on the right end of the handlebar) and floating calliper. drum brake (Ø 140 mm) with mechanical linkage.(l.h. brake lever).
Wheels and tyres WHEELS AND TYRES Specification F ront wheel rim F ront tyre
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Desc./Quantity Die-cast aluminium alloy 3.50 x 12" Tubeless, 120/70-12"
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Specification
Desc./Quantity
Rear wheel rim Rear tyre F ront tyre pressure Rear tyre pressure Rear wheel pressure (rider and passenger):
Die-cast aluminium alloy: 3.00"x12" Tubeless, 120/70 - 12" 1.8 bar 2 bar 2.3 bar
Secondary air Follow these steps to clean the sponge filters of the secondary air system: 1) Remove the snap-on plastic cover (1) on the transmission cover using a small screwdriver as a lever on the retaining tongues in order to insert inse rt one of the three slots found on that cap. 2) Wash the polyurethane sponge with water and soap, dry all components components with compressed air and refit to place. Refit the intake cap respecting the angle reference. 3) Undo the two fix fixing ing screws (2) on the aluminium cover of the secondary air housing in order to reach the polyurethane sponge inside that housing; clean as indicated in point 2) and refit all elements after checking the steel tab is not deformed and/or does not guarantee correct tightness at its fitting; replace if necessary. N.B. UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMINIUM COVERS. CAUTION WHILE CARRYING OUT OPERATION 3), ALWAYS CHECK THE TWO RUBBER COUPLINGS (3) ON ONE END OF THE SECONDARY AIR PIPE FOR CORRECT TIGHTNESS AND CONTINUITY; IF NECESSARY, REPLACE THEM AND USE NEW CLAMPS TO FIX THEM.
Carburettor 50cc Version
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Characteristics
Dell'Orto DELLORTO CARBURETTOR Specification
Desc./Quantity
Typ Type Diffuser diameter Regulation reference number Maximum nozzle: Maximum air nozzle (on the body): Taper Tapered ed pin pin stam stamped ped code code:: P in position (notches from above): Diffuser: Minimum nozzle: Minimum air nozzle (on the body): Initial minimum mix screw opening: S tarter jet S tarter air nozzle (on the body): Stroke of starter pin: Gasoline inlet hole
PHVA 17. 17.5 5 RD Ø 17.5 8423 53 Ø 1.5 A22 A22 1 209 HA 32 F ree 1 1/2 50 Ø 1.5 11 mm Ø 1.5
Tightening Torques FRONT BRAKE Name
Torque in Nm
Brake fluid pump - hose fitting Brake fluid pipe-calliper fitting Calliper tightening screw Disc tightening screw Oil bleed screw
16 ÷20 Nm 19 ÷24 24 ÷27 8 ÷10 7 ÷10
FRONT SUSPENSION Name
Torque in Nm
Lower fork fixing screw F ront wheel axle nut
15 ÷20 45 - 50
STEERING ASSEMBLY Name Upper steering ring nut Steering lower ring nut Handlebar fixing screw
Torque in Nm
35 ÷40 8 ÷10 50 ÷55
ENGINE ASSEMBLY Name
Torque in Nm
Clutch bell nut (**) Clutch lock ring nut Nut locking driving pulley on crankshaft (**) S tart-up lever screw F lywheel nut (**) F lywheel fan screws Half-crank case joint bolts Bolts holding exhaust pipe to the crankcase Screws holding the filter box to the crank case Head nuts S tarter screws Ignition spark plug Hub oil drainage cap Oil hub level dipstick Rear hub cap screws Trans Transm missio ission n cov cover scre screw ws Inlet manifold screws
40 ÷44 55 ÷60 40 ÷44 Nm 12 ÷13 40 ÷44 3 ÷4 12 ÷13 22 ÷24 4 ÷5 10 ÷11 12 ÷13 25 ÷30 3 ÷5 Manual 12 ÷13 12 ÷13 ÷13 8 ÷9
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Characteristics
Name
Torque in Nm
F lywheel hood fixing screws Cylinder hood fixing screws S tator clamping screws P ick-Up clamping screw Mixer clamping screws S crew fixing brake lever to the journal on the engine
1 ÷2 3.5 ÷5 3 ÷4 4 ÷5 3 ÷4 12 ÷13
CHASSIS Name
Torque in Nm
S winging arm - engine pin* F rame/swing-arm bolt (*) S hock absorber - chassis nut (*) shock absorber - engine pin (*) Rear wheel axle (*) Centre-stand mounting bracket bolt Centre-stand mounting bracket screw Side stand fixing screw Side stand bracket fixing screw
33 ÷41 64÷72 20 to 25 Nm 33 to 41 N·m 104÷126 N·m 25÷30 N·m 20÷25 N·m 12 ÷20 15 ÷20
Overhaul data Assembly clearances Cylinder - piston assy. COUPLING BETWEEN PISTON AND CYLINDER Name S tandard coupling S tandard coupling S tandard coupling S tandard coupling coupling 1st oversize coupling 1st oversize coupling 1st oversize coupling 1st oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize
Initials
M N O P M1 N1 O1 P1 M2 N2 O2 P2
Cylinder 40.005 - 40.012 40.012 - 40.019 40.019 - 40.026 40.026 - 40.033 40.205 - 40.212 40.212 - 40.219 40.219 - 40.226 40.226 - 40.233 40.405 - 40.412 40.412 - 40.419 40.419 - 40.426 40.426 - 40.433
Piston 39.943 - 39.95 39.95 - 39.957 39.957 - 39.964 39.964 - 39.971 40.143 - 40.15 40.15 - 40.157 40.157 - 40.164 40.164 - 40.171 40.343 - 40.35 40.35 - 40.357 40.357 - 40.364 40.364 - 40.371
Play on fitting
0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069 0.055 - 0.069
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Characteristics
Piston rings SEALING RING Name
Description
Compression ring Compression ring 1st oversize Compression ring 2nd Oversize
Dimensions
Initials
Quantity
40 40.2
A A
0.10 to 0.25 0.10 to 0.25
40.4
A
0.10 to 0.25
Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD Name Connecting rod
Description
Dimensions
Initials
11.750-0.05
A
shoulder washer
0.5 ±0.03
G
Half-shaft, transmission side
13.75+0.040
C
F lywheel-side half-shaft
13.75+0.040
D
Lining between the shoulders
40.64
H
Cage
11.800-0.35
B
Slot packing system This This type of engi engin nes fores oresee ees s th the use of one one size size of basi basic c gask askets. ets. CHAR - 14
Quantity clearance E =0.25 to 0.50 clearance E =0.25 to 0.50 - clearance F = 0.20 to 0.75 clearance E =0.25 to 0.50 - clearance F = 0.20 to 0.75 clearance E =0.25 to 0.50 - clearance F = 0.20 to 0.75 clearance E =0.25 to 0.50 - clearance F = 0.20 to 0.75 clearance F =0.20 to 0.75
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Characteristics
For 25 km/h engine type versions, use 2 gaskets between cylinder and crankcase.
Products RECOMMENDED PRODUCTS TABLE Product AGIP ROTRA 80W-90
AGIP AGIP CIT CITY Y HI HI TEC TEC 4T 4T
AGIP F ILTER OIL AGIP CITY TEC 2T AGIP BRAKE 4 MONTBLANC MOLYBDENUM GREASE AGIP GIP GRE GREA ASE PV2 PV2
AGIP AGIP GREA GREASE SE SM SM 2
AGIP GP GP 33 330
Description
Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Oil Oil to to lubricate flexible transmissio sions Oil for 2-stroke 2-stroke engine engines: s: SAE S AE 5W-40, 5W-40, AP I (brake, throttle control and mixer, odomSL, ACEA A3, A3, J ASO MA eter) Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness Mixer oil synthetic oil for 2-stroke engines: J ASO FC, ISO-L-EGD Brake fluid F MVSS DOT 4 Synthetic fluid Grease for driven pulley shaft adjusting Grease with Molybdenum disulphide ring and movable driven pulley housing Gre Grease for steering bearings, pin seats White anhydrous-calcium anhydrous-calcium based grease and swinging arm to protect roller bearings; temperature range between -20 C and +120 C; with NLGI 2; ISO-L-XBCIB2. Gre Grease for odometer transmissi ssion gear Lithium grease with NLGI 2 molybdenum case disulphide; ISO-L-XBCHB2, DIN KF2K-20 Grease for brake control levers, throttle, White calcium complex soap-based stand spray grease grease with with NLGI 2; ISO-L IS O-L-XBC -XBCIB2 IB2
Rear hub oil
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INDEX OF TOPICS
TOOLING
TOOL
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Tooli Toolin ng
TOOLS Stores code
Description
001330Y
Tool for fitting steering seats
001467Y 006
P liers to extract 20 mm bearings
001467Y 007
Driver for OD 54 mm bearing
001467Y 009
Driver for OD 42-mm bearings
001467Y 01 013
P liliers to extract ø 15-mm bearings
001467Y 01 014
P liliers to extract ø 15-mm bearings
TOOL - 17 17
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Tool Toolin ing g
TOOL - 18 18
Stores code
Description
001467Y 017
Bell for bearings, OD 39 mm
001467Y02 Y021
Ext Extraction pliers for ø 11 mm bearings
002465Y
P liers for circlips
006029Y
Pun Punch for fitting fifth wheel seat on steering tube
020004Y
P un unch for removing fifth wheels from headstock
020055Y
Wrench for steering tube ring nut
020150Y
Air heater mounting
