Piaggio Typhoon 50 2T MY 2010 (en)

MANUALE STAZIONE DI SERVIZIO 665497(IT)-665498(EN)-665499(FR)-677200 (DE)-677201(ES)-677202(NL)-677203(PT)-677204 (EL)

Typhoon 50 2T (MY2010)

MANUALE STAZIONE DI SERVIZIO


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 201 2010 0 - 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. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) www.piaggio.com

MANUALE STAZIONE DI SERVIZIO Typhoon 50 2T (MY2010) Questo manuale manuale per stazioni di servizio è stat s tato o realizzato da Piaggio P iaggio & C. Spa S pa per essere utilizzato dalle officine dei concessionari e sub-agenzie P iaggio-Gilera. S i presuppone che chi utilizz utilizza a questa pubblicazione pubblicazione per la manutenzione manutenzione e la riparazione dei veicoli P iaggio, abbia una conoscenza base dei principi della meccanica meccanica e dei procedimenti procedimenti inerenti inerenti la tecnica della riparazione dei veicoli. Le L e variazioni importan importanti ti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno verranno comunicate comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti riguardanti l'attrezzatura l'attrezzatura specifica e il catalogo degli attrezzi attrezzi specifici.

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


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 well ventilated, 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 spares 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. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. 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 electrical connections have been made properly, particularly the ground and battery connections.

CHAR - 7


Characteristics

Vehicle identification Chassis prefix LBMC501 Engine prefix C421M

Dimensions and mass WEIGHTS AND DIMENSIONS

CHAR - 8

Specification

Desc./Quantity

Maximum length Overall width Maximum height Wheelbase Kerb weight

1947 730 1130 mm 1355 99±5 Kg


Characteristics

Engine ENGINE Specification

Desc./Quantity

Engine type Bore x stroke Engine capacity Compression ratio carburettor CO adjustment Engine idle speed Air filter

S ingle cylinder 2-stroke 40 X 39.3 mm 49.38 cm³ 10.3:1 (±0.5) DE LL'ORTO P HVA 17.5 3.5% ±0.5 1800 ±100 rpm Sponge, soaked in a mixture (50% AGIP 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 crankshaft with toothed belt. With vacuum operated cock, lead-free gasoline (with 95 octane minimum) by means of the carburettor. F orced-circulation air cooling. 3.98 kW at 7500 rpm 5.20 Nm at 7000 rpm

Starting system Lubrication

F ue uel sy system Cooling Maximum power Maximum torque

Transmission TRANSMISSION Specification Trans Transm missio ission n

Desc./Quantity Wit With aut automatic atic exp expand andable able pull pulley ey varia ariattor, or, tor torq que serv server er,, VVbelt, automatic clutch, gear reduction unit.

CHAR - 9


Characteristics

Capacities CAPACITY Specification

Desc./Quantity In plastic, with a capacity of 7.0 litres (approximate value) including reserve ~1.5 litres In plastic, with a capacity of 1.5 lit. (including reserve ~0.500 lit). Quantity: ~80cc

F uel tank Oil mixer tank Rear hub oil

Electrical system ELECTRICAL SYSTEM Specification

Ignition type Ignition advance (before TDC) Spark plug electrode gap spark plug Battery Main fuse Alternator (permanent magnet type)

Desc./Quantity Cap Capacitive discharge electronic ignition, with incorporated HV coil F ixed 17° ±1 at 4,000 rpm 0.6 mm NGKR BR8ES CHAMPION RN2C (alternative) 12V-9Ah 10 A 88 W

Frame and suspensions CHASSIS AND SUSPENSION Specification

Chassis type F ront suspension Trai Traill F ront suspension stroke Rea Rear suspension

Desc./Quantity Welded tubular steel chassis with stamped sheet reinforcements hydraulic telescopic fork 73 mm 58 mm With coaxial spring and hydraulic shock absorber. Cha Chassis to engine support with swinging arm.

Brakes BRAKES Specification

Desc./Quantity

F ro ront brake

Disc D=220 mm with hydraulic control, operated by right brake lever on handlebars. Drum D=110 mm with expansion brake shoes, mechanically controlled by the left brake lever on the handlebars.

Rear brake

Wheels and tyres WHEELS AND TYRES Specification

F ront tyre F ront wheel rim Rear tyre Rear wheel rim F ront tyre pressure

CHAR - 10

Desc./Quantity Tubeless, 120/80-12" Die-cast aluminium alloy, 3.50x10" Tubeless, 120/80-12" Die-cast aluminium alloy, 3.50x10" 1.5 bar


Characteristics

Specification

Desc./Quantity

Rear tyre pressure Rear tyre pressure (rider and luggage)

1.8 bar 2.0 bar

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES

Carburettor 50cc Version Dell'Orto DELL'ORTO CARBURETTOR Specification

Desc./Quantity

Typ Type Diffuser diameter Regulation reference number Maximum nozzle: Maximum air nozzle (on the body): Tape Tapere red d pin pin stam stamped ped code code:: P in position (notches from above): Diffuser: Minimum nozzle: Minimum air nozzle (on the body): Secondary minimum air hole Initial minimum mix screw opening: Starter nozzle S tarter air nozzle (on the body): Stroke of starter pin: P etrol inlet hole

PHVA 17 17.5 RD Ø 17.5 8423 53 Ø 1.5 A22 A22 1 209 HA 32 F ree Ø 2.5 1 1/2 50 Ø 1.5 11 mm Ø 1.5

Tightening Torques ENGINE Name Ignition spark plug Cylinder head nuts (*) S tart-up lever screw F lywheel air duct screw Mixer clamping screws Nut fixing silencer to cylinder head Head intake manifold screw Rear brake cam tightening screw Engine-crankcase coupling screws Starter screws Silencer to crankcase fixing screws

Torque in Nm

18 Nm 10 ÷11 12-13 3 to 4 3 ÷4 16 to 18 11 to 13 11 to 13 11 to 13 11 to 13 24 to 27

(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.

TRANSMISSION Name

Torque in Nm

Drive pulley nut Trans Transm missio ission n cove coverr scre screw w Driven pulley shaft nut Rear hub cap screws Clutch unit nut on driven pulley

18 - 20 Nm +90° rotation 11 to 13 40 ÷44 24 to 27 40 ÷44

CHAR - 11


Characteristics

FLYWHEEL Name

Torque in Nm

F lywheel hood fixing screws F lywheel fan screws Stator screws (°) F lywheel nut P ick-up screw

3 ÷4 3 to 4 3 to 4 40 ÷44 3 to 4

(°) Apply LOCTITE 243 threadlock

STEERING ASSEMBLY Name

Torque in Nm

Upper steering ring nut Lower steering ring nut Handlebar fixing screw Mirror fastening spacer

30 to 36 10 - 13 (loosen by 90°) 45 to 50 25

CHASSIS ASSEMBLY Name Engine-swinging arm pin Centre stand screws on engine Chassis-side swinging arm retaining nut

Torque in Nm

45,5 18.5 to 19 52.5 Nm

FRONT SUSPENSION Name

Torque in Nm

F ront wheel axle nut (safety fasteners) Wheel axle clamp screw Lower leg screw Hydraulic cartridge stem nut

45 to 50 Nm 6 ÷7 Nm 15 to 20 N·m 15 to 18 Nm

FRONT BRAKE Name

Torque in Nm

Brake fluid hose-pump fitting Brake fluid pipe-calliper fitting Calliper to fork tightening screw Disc tightening screw Oil bleed screw P ump U bolt screw Brake pad fastening screw

20 to 25 20 to 25 20 to 25 8 to 12 8 to 12 8 15 to 20

REAR SUSPENSION Name

Torque in Nm

Rear wheel axle Shock absorber nut

115 22.5

FUEL TANK UNIT Name F uel tank to chassis fixing screw

Torque in Nm

10

SADDLE UNIT Name Saddle plate fixing nut

Torque in Nm

10

BODYWORK UNIT Name

Torque in Nm

Helmet compartment fixing screw Rear grab handle fixing screw Battery cover fixing screw F ront wheel housing to chassis fixing screw F ront wheel housing to leg shield back plate fixing screw

3 20.5 6 6 3

CHAR - 12


Characteristics

Name

Torque in Nm

F ront mudguard fixing screw F ootrest fixing screw Screw fixing leg shield back plate to chassis Leg shield back plate to leg shield fixing screw F ootrest spoiler fixing screw P assenger footrest protection fixing screw P assenger footrest to side body panel fixing screw Rear mudguard fixing screw Rear brake adjustment nut

6 6 6 3 6 3 6 6 5

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

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

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

Piston rings SEALING RINGS Name

Compression ring Compression ring 1st oversize Compression ring 2nd Oversize

Description

CHAR - 13


Characteristics

Crankcase - crankshaft - connecting rod CRANKSHAFT - CONNECTING ROD AXIAL CLEARANCE Characteristic

Connecting rod thrust washer Tran Transm smiss issio ions nsid ide e half half-sh -shaf aftt F lywheel-side halfshaft Spacer tool Cage thrust washer Tran Transm smiss issio ions nsid ide e half half-sh -shaf aftt F lywheel-side halfshaft Spacer tool

CHAR - 14

Code

Value (mm)

Fitting clearance E (mm)

Fitting clearance F (mm)

A G C D H B G C D H

11.75 (+0;-0.05) 0.5±0.03 13.7 13.75 5 (-0. (-0.0 005;05;-0 0.04) .04) 13.65 (-0.005;-0.04) 40.46 11.8 (+0;-0.05) 0.5±0.03 13.7 13.75 5 (-0. (-0.0 005;05;-0 0.04) .04) 13.65 (-0.005;-0.04) 40.46

0.25 - 0.50 0.25 - 0.50 0.25 0.25 - 0.5 0.50 0 0.25 - 0.50 0.25 - 0.50 -

0.20 - 0.90 0.20 - 0.90 0.20 .20 - 0.9 0.90 0 0.20 - 0.90 0.20 - 0.90


Characteristics

Slot packing system - Fit F it the the cylinder without installing installing the basic gasket. - Apply A pply a centimetre centimetre dial gauge on the special speci al tool and zero it on the ground plane - Fit the tool to the top of the cylinder fixing it with two nuts to the studbolts and take the piston to the T.D.C. T.D.C. - The thickness of the gasket to fit will change depending on the value detected. For this purpose, there are three with different thicknesses

Specific tooling 020272Y Piston position check tool

SHIMMING SYSTEM Name

Measure A

Thickness

SHIMMING SHIMMING SHIMMING

2.80 ÷3.04 3.04 ÷3.24 3.25 ÷3.48

0.4 0.6 0.8

Products RECOMMENDED PRODUCTS TABLE Product AGIP ROTRA 80W-90

AGIP F ILTER OIL AGIP CITY TEC 2T AGIP GP GP 33 330 AGIP AGIP GREASE GREASE SM 2

AGIP BRAKE 4 MONTBLANC MOLYBDENUM GREASE AGIP GIP GRE GREA ASE PV2 PV2

Description

Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications 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 Grease for brake lever, gas White calcium complex soap-based spray grease grease with with NLGI 2; ISO-L IS O-L-XBC -XBCIB2 IB2 Gre Grease for th the C-r C-rin ing g of the to tone wh wheel Soa Soap-ba -based sed lilithium grease containing NLGI 2 Molybdenum disulphide; ISO-LXBCHB2, DIN KF2K-20 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.

Rear hub oil

CHAR - 15

INDEX OF TOPICS

TOOLING

TOOL


Tooli Toolin ng

TOOLS Stores code

Description

001330Y

Tool for fitting steering seats

001467Y 009

Driver for OD 42-mm bearings

001467Y 01 013

Calliper to extract ø 15-mm bearings

001467Y 017

Bell for bearings, OD 39 mm

001467Y02 Y021

Ext Extraction pliers for ø 11 mm bearings

001467Y 029

Bell for bearings, O.D. 38 mm

TOOL - 17 17


Tool Toolin ing g

TOOL - 18 18

Stores code

Description

002465Y

Calliper for circlips

004499Y 001

Bearing extractor bell

004499Y 002

Bearing extractor screw

004499Y 006

Bearing extractor ring

004499Y 007

Half rings

005095Y

E ngine support

006029Y

Pun Punch for fitting fifth steering bearing on steering tube


Tooli Toolin ng

Stores code

Description

020004Y

P un unch for removing steering bearings from headstock

020055Y

Wrench for steering tube ring nut

020074Y

Support base for checking crankshaft alignment

020150Y

Air heater mounting

020151Y

Air heater

020162Y

F lywheel extractor

TOOL - 19 19


Tool Toolin ing g

TOOL - 20 20

Stores code

Description

020163Y

Crankcase splitting plate

020164Y

Driven pulley assembly sheath

020165Y

Start-up sprocket lock

020166Y

P in lock fitting tool

020171Y

P unch for Ø 17 mm roller bearing

020201Y 020261Y

S pacer bushing driving tube S tarter spring fitting


Tooli Toolin ng

Stores code

Description

020265Y

Bearing fitting base

020325Y

P liers for brake-shoe springs

020329Y

Mity-Vac vacuum-operated pump

020330Y

S troboscopic light to check timing

020331Y

Digital multimeter

TOOL - 21 21


Tool Toolin ing g

TOOL - 22 22

Stores code

Description

020332Y

Digital rpm indicator

020334Y

Multiple battery charger

020335Y

Magnetic mounting for dial gauge

020340Y

Fly Flywheel and transmission oil seals fitting punch


Tooli Toolin ng

Stores code

Description

020350Y

Electrical system check instrument

020357Y 020358Y 020359Y

32x35-mm Adaptor 37x40-mm Adaptor 42x47-mm Adaptor

020360Y 020362Y 020363Y

Adaptor 52x54 mm 12 mm guide 20-mm guide

020364Y

25-mm guide

TOOL - 23 23


Tool Toolin ing g

TOOL - 24 24

Stores code

Description

020375Y

28 x 30 mm adaptor

020376Y

Adaptor handle

020412Y

15-mm guide

020439Y

17-mm guide

020444Y

Tool for fitting/ removing the driven pulley clutch

020451Y

S tarting ring gear lock


Tooli Toolin ng

Stores code

Description

020452Y

Tube for removing and refitting the driven pulley shaft

020456Y

Ø 24 mm adaptor

020477Y

37 mm adaptor

020483Y

30-mm guide

020565Y

F lywheel lock calliper spanner

020625Y

Kit for sampling gas from the exhaust manifold

TOOL - 25 25

INDEX OF TOPICS

MAINTENANCE

MAIN


Maintenance

Maintenance chart SCHEDULED MAINTENANCE TABLE I:

CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check level every 500 km ** Replace every 2 years *** Replace every 4 years

C:

Km x 1,000

S afety fasteners S park plug Trans Transm missio ission n cab cables les and and con controls rols Mixer belt Drive belt Air filter S AS filter box Rear brake shoes E lectrical system and battery Braking systems Light circuit Brake fluid ** E xhaust muffler/ silencer Mixer Hub oil Mixer oil* Rear brake cam pin Headlight Vehicle and brake test - test ride Brake pads E lectric starter gear pins Wheels/ tyres CVT rollers / S liding shoes Idle speed S uspension S teering Braking system pipes*** Mixer oil pipes F uel pipes ***

1

5

10

15

20

25

30

35

40

45

50

55

60

I I I

I R I

I R I

I R I

I R I

I R I

I R I

I R I

I R I

C

I C

C

C

I I I I I I I R I L

I I I I I I I R I L

I I I I I I I I I L

I I I I I I I I I L

I I I I I I I R I L

I I I I I I I R I L

I I I I I I I I I L

A I I

I I

I I

I I L I R A I I I I I


I I

I


I I

I


R C C I I I I I I I I I L A I I

I C

I I I I I I I I I L

R C C I I I I I I I I I L A I I

I R I R I C

I R I

C

I R I R I C

I R I R R C C I I I I I I I R I L A I I L I R A I I I I I

I I I I I R I

A I I I I

I I I I

I

I I I I

C

I

I I I I

R C C I I I I I I I R I L A I I L I R A I I I I I

I

I I I I

I

I I I I

I

I I I I

Carburettor Check the idle at the intervals indicated in the maintenance table. CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS, LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE.

•

Operate on the indicated screw until the pre-set idle speed is obtained.

Characteristic Idle speed

MAIN - 27

Maintenance

1800 ±100 rpm

Checking the spark advance -Check to be made at over 4000 rpm with stroboscopic gun. The The advanced ignition measured measured must be 17° before the TDC. - This T his value is correct when the the reference mark mark on the flywheel hood is aligned with the reference mark on the cooling fan and the phase shifter on the stroboscopic gun is set on 17°. N.B. IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER. CAUTION BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK THE CORRECT KEYING OF THE FLYWHEEL ON THE CRANKSHAFT.

Specific tooling 020330Y Stroboscopic light to check timing

Spark plug P lace the vehicle vehicle on its central stand - Remove the central cover by undoing the four clamping screws indicated in the figure;

MAIN - 28



Maintenance

- Undo the fixing screw (1) and remove the coil, leaving it connected to the system; - Disconnect Dis connect the the cap (2) of the spark plug HV wire; -Undo the spark plug using the socket wrench; - Examine the condition of the spark plug, check that the insulating material is whole and measure the distance between between the electrodes using using a feeler gauge. -Adjust the distance, if necessary, by bending the side electrode very carefully. In the case of defects, replace the spark plug with one of the specified type; - Engage the spark plug with the due inclination and screw it right down by hand, then do it up with the wrench at the prescribed torque; -Fit the cap on the spark plug as far as it will go; - Refit the central flap. CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5,000 KM. USE OF STARTERS NOT CONFORMING OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.

Characteristic spark plug

NGKR BR8ES CHAMPION RN2C (alternative)

Spark plug electrode gap

0.6 mm

Locking torques (N*m) Ignition spark plug 18 Nm

Hub oil

MAIN - 29

Maintenance

Check Do the following to check the correct level: - Ride a few kilometres until the regular working temperature is reached, then shut off the engine. - P ark the vehicle vehicle on level ground and rest it on the centre stand. - Unscrew the oil filler dipstick (A), dry it with a clean cloth and reinsert it. - Remove the dipstick and make sure that the oil level reaches the indicated reference notch. - Screw up the oil dipstick back in and make sure it is locked properly in place. CAUTION DO NOT RIDE THE MOTORCYCLE WITH INSUFFICIENT LUBRICATION OR WITH CONTAMINATED OR INCORRECT LUBRICANTS AS THIS ACCELERATES THE WEAR AND TEAR OF THE MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE.

Recommended Recommended products AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Replacement - Ride a few kilometres until the regular working temperature is reached, then shut off the engine. - P ark the vehicle vehicle on level ground and rest it on the centre stand. - Remove the oil dipstick (A). - Unscrew the oil drainage plug (B) and drain out all the oil. - Screw the oil drainage plug (B) back and fill up the hub with the required oil.

Characteristic Rear hub oil

Quantity: ~80cc

MAIN - 30



Maintenance

- Check the level. - Screw the oil filler dipstick (A) back into place completely.

Locking torques (N*m) Hub oil drainage cap 3 ÷ 5

Air filter -Rem -R emove ove the cap of the the purifier, unscrewing the six clamping screws and removing the filter. Cleaning:

-Wash with water and neutral soap. - Dry with a clean cloth and short blasts of compressed air. -Saturate with a 50% mixture of gasoline and oil. -Drip dry the filter and then squeeze it between the hands without wringing. -Let it dry and refit it again. CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.

Recommended Recommended products AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

FILTER BOX REMOVAL

- Undo the two screws indicated.

MAIN - 31

Maintenance

- Cut the tie.

transmissions P ut the the vehicle in gear and regulate the the idling by turning the adjustment screw on the carburettor. Adjust the control cables: Handlebar control: remove the front handlebar

cover and regulate the cable adjustment in such a way that it causes a minimum clearance on the throttle.

Carburettor control: remove the rubber hood and

regulate the cable adjustment in such a way that the sheath has a minimum clearance.

See also Carburettor

MAIN - 32



Maintenance

Oil mixer control: remove the cap on the trans-

mission cover and regulate the adjustment in such a way that with the throttle released, the reference mark on the rotating plate is lined up with the reference mark on the mixer body as indicated in the figure. Bring the throttle a couple of times to the end of the stroke and check that the adjustments have been made properly, then tighten them all up.

See also Carburettor CAUTION IN CASE OF DISMANTLING OF THE OIL RESERVOIR OR THE MIXER OR RUNNING OUT OF OIL IN THE RESERVOIR BLEED THE MIXER AS FOLLOWS: - FILL THE FUEL TANK WITH 3 LITER OF 2% MIXTURE MADE WITH THE RECOMMENDED OIL; - FILL THE OIL RESERVOIR; - WITH THE MIXER ON THE VEHICLE AND THE ENGINE OFF, DISCONNECT THE MIXER PIPE FROM THE CARBURETTOR AND LOOSEN THE BLEED SCREW (SHOWN IN THE FIGURE) UNTIL OIL STARTS FLOWING OUT; - TIGHTEN THE SCREW, START THE ENGINE AND WAIT UNTIL OIL COMES OUT FROM THE (PREVIOUSLY DISCONNECTED) DELIVERY PIPE TO THE CARBURETTOR; - RECONNECT THE DELIVERY PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH THE RELEVANT METAL CLIP.

MAIN - 33

Maintenance

Recommended Recommended products AGIP CITY TEC 2T Mixer oil

synthet synthetic ic oil for for 2-strok 2-stroke e engines: engines: J ASO AS O FC, F C, IS I SOL-EGD

See also Carburettor

Braking system Level check Proceed as follows: - Rest R est the vehicle on its centre centre stand with with the handlebars perfectly horizontal; - Check the fluid level through the corresponding sight glass. A certain lowering of the level is caused by wear on the brake pads.

Top-up Proceed as follows: - Undo the two screws and remove the cover with the seal. - Top-up using only the fluid specified, without exceeding the maximum level. CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.

MAIN - 34



Maintenance

NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS. N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGA RD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.

Recommended Recommended products AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

Headlight adjustment Proceed as follows: 1. P lace the vehicle in running order and with the the

tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen; 2. Turn on the headlight and check that the bor-

derline of the projected light beam on the screen is no higher than 9/10 or lower than 7/10 of the distance from the ground to the centre of the vehicle's headlamp; headlamp; 3. Otherwise, adjust the headlight by turning the

knobs of the body inside the wheel housing. - Tighten the screw (clockwise) to raise the light beam; - undo the screw (anticlockwise) to lower the light beam. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

CO check This This test est must be car carried ried out out aft after wash ashing ing all all car carburett ettor part arts accu accura rattely ely, the air air filt filter er must be clea clean n and the ignition spark plug in good condition.

MAIN - 35

Maintenance


- Warm up the vehicle at a speed of 45 Km/h for about 10 min., enough time for the automatic starter to exclude its circuit. - Switch off the vehicle for the time strictly necessary for carrying out the following operations. - Connect the exhaust gas analyser to the silencer. - Make sure the silencer and the exhaust gas analyser pipe are adequately connected and tight. - Start the engine. - Switch on the low beam light. - Wait until the idle speed stabilises for one minute. - Without operating the accelerator again and using the flow screw rev the engine at 1800 ±100 rpm. - Adjus Adjustt the the flow screw screw so that the "C "CO" value is is equal to 3.5%±0.5%. - Slowly operate the throttle accelerating the engine until it reaches 4000 rpm and then set throttle back to close position; check that the idle speed remains at the above set value; if not, repeat the procedure.

Specific tooling 020332Y Digital rpm indicator

SAS filters inspection and cleaning Undo the two fixing screws and remove the secondary air box cover. Detach the housing cover and remove the filtering element made of sponge. Wash the sponge with water and neutral soap, then dry with a clean cloth and short blasts of compressed air. While cleaning the filter, check the condition of the reed valve on the cover, and fit it back in place on the housing. Before closing the cover of the SAS housing, check the good condition condition of the sealing O O-ring; -ring; replace it if damaged or deformed. N.B. The reed valve can be inserted in only one direction on the SAS housing

MAIN - 36


Maintenance

MAIN - 37

INDEX OF TOPICS

TROUBLESHOOTING

TROUBL


Trou Troubl bles esh hoot ooting ing

This This sect sectio ion n makes akes it possi ossibl ble e to find ind what solu soluttion ions to to app apply when troub oublesh leshoo ootting ing. For each failure, a list of the possible causes and pertaining operations is given.

Engine Poor performance POOR PERFORMANCE Possible Cause Defective fuel cock or vacuum hose damaged. Car Carburettor nozzles zzles clog clogg ged or dirt irty F ue uel filter on the tank outlet fitting dirty or clogged Excess of scales in the combustion chamber Lack Lack of com compressi essio on: we wear of the pis pistton rin ring gs or or cy cylin linder Silencer Silencer clogg clogged ed due due to excessiv excessive e encrust encrustat ation ions s Air filter blocked or dirty. Star Startter ine inefficie icien nt (st (stays on on)

Clutch slipping Def Defect ective ive mobile ile pu pulle lley sli slid ding ing Drive belt worn Rol Roller wear; Pre Presen sence of oil; Di Dirt

Operation Rep Replace the cock or the control hose. Dism Disma antle, le, wa wash with ith sol solv vent and dr dry wit with h com compresse ressed d air air Clean the fitting filter Remove the encrustations Che Check the wo worn part arts an and rep repla lace ce them Replace Replace the the silen silencer cer and and check check the the carb carbur urat ation ion and and mix mixer er tim timer er Clean according to the procedure Chec Check k the mech echanic anical al slid slidin ing g, con continu inuity ity of the cir circuit cuit,, the presence of power and electrical wiring Check the centrifugal brake shoe assembly and /or clutch housing and replace if necessary Chec Check k the pa parts, chan chang ge th the fa faulty lty part arts an and lub lubrica icate on only the sliding seat of the driven pulley with specific grease. Replace Cle Clean the spe speed variator, re replace the ro rollers if if worn out

Rear wheel spins at idle REAR WHEEL Possible Cause Idling rpm too high Clutch fault Air Air filte lter housin sing not sea sealed led

Operation Check the idling speed and, if necessary, adjust the C.O. Check the spring/friction mass and the clutch housing Cor Correctly refit the fifilter housin sing and replace it it if it is damaged

Starting difficulties DIFFICULTY STARTING Possible Cause Car Carburettor nozzles zzles clog clogg ged or dirt irty Defective fuel cock or vacuum hose damaged. Ine Inefficient Sta Starter

F la lat battery

Eng Engine flflooded

Alt Altered fuel characteristics Defectiv Defective e spark plug plug or with with incor incorrect rect electrode electrode gap gap

Operation Dism Disma antle, le, wa wash with ith sol solv vent and dr dry wit with h com compresse ressed d air air Rep Replace the cock or the control hose. Che Check: electric wiring, circuit continuity, mechanical sli sliding and power supply Check the state of the battery. If it shows signs of sulphation replace it and bring the new battery into service charging it for eight hours at a current of 1/10 of the capacity of the battery itself Sta Start the vehicle keeping the throttle fully open alternately making the engine run for approx. five seconds and stopping for other five seconds. If however it does not start, remove the spark plug, the engine over with the throttle open being careful to keep the cap in contact with the spark plug and the spark plug grounded but away from its hole. Refit a dry spark plug and start the vehicle. Drain off the fuel no longer up to sta standard; then, refill Remove Remove the the encrusta encrustatio tion, n, restor restore e the the pluggap or replace replace being being sure to use the types of spark plug recommended at all times.

TROUBL - 39 39


Trou Troub blesh leshoo ootting ing

Possible Cause

Operation

Int Intake ake joi joint nt crac cracke ked d or or wit with h a bad seal seal

Bear in mind that many problems engines have, derive from the use of the wrong spark plug Repla Replace ce the int intake ake joi join nt and and che check ck its its tig tight htne ness ss on on the the cran crank kcase and on the carburettor Replace

P urifier-carburettor fitting damaged

Excessive oil consumption/Exhaust smoke EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST Possible Cause Excess of scales in the combustion chamber

Operation Remove the encrustations

Engine tends to cut-off at full throttle ENGINE STOP FULL THROTTLE Possible Cause Max Maximum nozzl ozzle e dir dirtty - lean lean mixt ixture Dirty carburettor Water in the carburettor Air filter dirty Defective flfloating valve

Tank Tank brea breatther her hole ole obst obstru ruct cted ed

Operation Wash Wash the noz nozzl zle e wit with h sol solv vent and dr dry wit with h com compresse ressed d air air Wash the carburettor with solvent and dry with compressed air Empty the tank through the appropriate bleed nipple. Clean or replace Che Check the pr proper sli sliding of the flfloat and the functioning of the valve Rest Restore ore the prope roperr rese reserv rvoi oirr aera aerattion ion

Engine tends to cut-off at idle ENGINE STOP IDLING Possible Cause Minimum nozzle dirty Sta Starter th that st stays op open

Reed valve does not close Wrong idling adjustm stment Spa Spark pl plug de defective or or fa faulty

Operation Wash the nozzle with solvent and dry with compressed air Che Check: el electric wi wiring, ci circuit continuity, mechanical sl sliding and power supply Check / replace the reed pack Cor Correctly adjust the engine idling and check the level of the C.O. Rep Replace th the sp spark plu plug g wit with h on one wit with th the sp specifi ified de degree an and check the plug gap

Excessive exhaust noise INCREASED NOISINESS Possible Cause Secon Seconda dary ry metal etal air air pip pipe e det deter erio iora ratted

Operation Check Check the seal seal of the pip pipin ing g on on the cran crank kcase case and and on on the the housousing, check the piping between the housing and the silencer. Good condition condition ofthe missing secondary air circuitcomponent components s Check the individual component components s and the piping, check the precision of the fitting. Replace the damaged components

High fuel consumption HIGH FUEL CONSUMPTION CONSUMPTION

TROUBL - 40 40

Possible Cause

Operation

Air filter blocked or dirty.

Clean according to the procedure



Possible Cause

Operation

Ine Inefficient Sta Starter

Che Check: electric wiring, circuit continuity, mechanical sli sliding and power supply

SAS malfunctions SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE SILENCER Possible Cause Secondary air reed blocking Secondary air filter clogging Blockage Blockage of the the secondary secondary air fittin fitting g on the the silencer silencer

Operation

Replace Clean the filter and the housing Remove Remove the the encru encrustat stations ions from fromthe the joint joint being being careful careful not not to let the debris fall into the silencer

Transmission and brakes Clutch grabbing or performing inadequately CLUTCH Possible Cause Sli Slippage or irregular functioning

Operation Che Check that the masse sses open and return normally Check that there is no grease on the masses Check that the clutch masses' contact surface with the clutch housing is mainly in the middle with characteristics equivalent on the three masses Check that the clutch housing is not scored or worn abnormally Never operate the engine without the clutch housing

Insufficient braking BRAKING SYSTEM MALFUNCTION Possible Cause INSU INSUFFI FFICI CIEN ENT T BRAKI BRAKIN NG

Air bub bubble bles s inside inside the the hyd hydrau raulic lic brak braking ing system system Fluid Fluid leak leakag age e in hydr hydrau aulic lic brak brakin ing g syst system em The The brake rake flui fluid d has has los lostt its its pro prope pert rtie ies s Defective sliding of the cables in their sheathes Brake noise

Operation The The re rear (d (drum type) br brake is is ad adjusted by regulating the sp special adjustment (on the wheel) bearing bea ring in mind that, with the control levers in the rest position, the wheels must turn freely. The The braki raking ng act action ion shou should ld beg begin when hen the brak brake e lev levers ers are are pressed by about a third. Check the brake pad wear. If it is not possible to remove any problems by simply adjusting the transmissions, check the brake pads and front brake disc, the brake shoes and the rear drum. If you encounter excessive wear or scoring, make the necessary replacements. Carefull Carefully y blee bleed d the the hyd hydrau raulic lic bra brakin king g syste system m, (ther (there e must must be no flexible movement of the brake lever). Elastic Elastic fit fittings, ings, pist piston on seals seals or or bra brake ke pum pump bre break akdo down wn,, rep repla lace ce Repla Replace ce the fron frontt brak brake e flu fluid and and top up to the corr correc ectt leve levell in in the pump Lubricate or substitute Check the wear of the brake pads and/or shoes

Brakes overheating BRAKE OVERHEAT Possible Cause Defective piston sliding

Operation Check calliper and replace any damaged part.

TROUBL - 41 41


Trou Troub blesh leshoo ootting ing

Possible Cause

Operation

Bra Brake disc or drum deformed

Usi Using a di dial ga gauge, ch check the planarity of the di disk with the wheel correctly fitted or the concentricity of the rear drum.

Electrical system Battery BATTERY Possible Cause

Operation

Battery

The battery is the electrical device in the system that requires the most most frequent inspec inspections tions and thorough maintenance. If I f the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 5 to 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keeping in mind that the black ground cable is connected to the negative terminal while the red cable is connected to the terminal marked +. Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries.

Steering and suspensions Rear wheel POOR ROAD HOLDING Possible Cause Fau Faulty suspension

Operation Che Check that the rear shock absorber and/or the front fork is/are in good working order. Replace or overhaul the front fork and/ or replace the rear shock absorbers in case of malfunction Tyre Tyres s def defla latted or dam damaged aged Check Check the corr correc ectt pres pressu sure re of the tyres res and and the cond condit itio ion n of the tread. Inflate to the correct pressure or replace. Loosen the anchorage points of the front and/or rear suspen- Check the tightness between the frame, swinging arm and ension unit. gine and the fixing of the wheels to the hub and/or the axle. Check the correct tightening of the steering ring nut.

Heavy steering STEERING HARDENING Possible Cause Torqu Torque e not conf confor orm ming ing

Operation Check Check the tight ightenin ening g of the top and and bot bottom ring ring nut nuts. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.

Excessive steering play EXCESSIVE STEERING CLEARANCE

TROUBL - 42 42

Possible Cause

Operation

Exc Excessiv sive steering clearance

Che Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.



Noisy suspension NOISY SUSPENSION Possible Cause Compon Componen ents ts of of the the front front suspen suspension sion dam damaged. aged.

Compo Compone nent nts s of the the rea rearr suspe suspensi nsion on dam damaged aged..

Operation Check the the quie quiett oper operat ation ion in the the compressio pression n or or relea release se phaphases of the fork and if necessary overhaul it. C heck that there there is no noise or seizing during the wheel rotation; if there is, change the wheel bearing. Check Check the the abse absenc nce e of noi noise se in the the com compressi pression on or or relea release se of the suspension, if necessary check the proper tightness to the swinging arm unit and the absence of rust or replace the entire shock absorber. Check that there is no noise or seizing during the wheel rotation; if there is noise or seizing overhaul the final reduction assembly.

Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause

Operation

Sho Shock absorbers malfunctioning Hydraulic cartridge in the fork damaged.

Rep Replace the complete shock absorption unit Replace the hydraulic cartridge

TROUBL - 43 43

INDEX OF TOPICS

ELECTRICAL SYSTEM

ELE SYS


Electrical system

Key

1. Multiple connectors 2. Horn 3. Horn button 4. Oil level warning light 5. Instrument panel lighting bulbs 6. High beam warning light 7. Turn indicator warning light 8. Fuel level instrument 9. Instrument panel 10. Fuel F uel level transmit transmitter ter 11. Light switch 12. Key switch 13. Turn indicator switch 14. Starter button 15. Front stop switch 16. Rear stop switch 17. Rear left turn indicator 18. Rear light 19. License plate light ELE SY S - 45 45

Electrical system

20. Rear right turn indicator 21. Start-up relay 22. Starter motor 23. Battery 24. Main fuse 25. Ignition coil 26. Spark plug 27. Pick-up 28. Generator 29. Regulator 30. Automatic starter 31.Oil reserve warning light 32. Front right turn indicator 33. High beam light 34. Daylight running light 35. Low beam light 36. Front left turn indicator 37. Front F ront headlamp headlamp 38. Low fuel warning light 39. Ground point on chassis 40. License plate cables 41. Heater control device 42. Heater Key Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yello Y ellow w Gr:Grey Ma:Brown Ne: Black Ro: Pin P ink k Rs: Red Ve: Green Vi: Purple

ELE SYS S YS - 46 46



Electrical system

Components arrangement

1. Instrument panel - To reach the connector, re-

move the front handlebar cover.

2. Ignition switch 3. Regulator 4. Turn indicators

Remove the leg shield back plate to reach it.

ELE SY S - 47 47

Electrical system

5. Horn - Remove the leg shield back plate to re-

move it.

6. Ignition coil - Remove the rear central cover to

reach it.

7. Pick-Up/Current generator - The connector is

located on the right-hand side of the engine.

8. Starter motor - The T he starter motor motor is located located un-

der the engine.




Electrical system

9. Automatic starter - Heater - To reach the con-

nector, remove the helmet compartment inspection lid.

10. Start-up solenoid- Remove the side fairings

to reach it.

11. Fuel level transmitter - Located on the fuel

tank.

12. Mixer oil reserve indicator - Remove the side

fairings to reach it.

ELE SY S - 49 49

Electrical system

13. Battery - 14. Main fuse - Remove the specific

cover under the saddle to reach it.

Ground points - On the vehicle there is a chassis ground point, beneath the rear central cover.

- On O n the engine there there is a ground point fixed under under the starter motor. remove the centre stand together with its support to reach it.

Conceptual diagrams




Electrical system

Ignition

Key

1. Multiple connectors 12. Key switch 23. Battery 24. Main fuse 25. Ignition coil 26. Spark plug 27. Pick-up 28. Generator 39. Ground point on chassis

ELE SY S - 51 51

Electrical system

Battery recharge and starting

Key

1. Multiple connectors 12. Key switch 14. Starter button 15. Front stop switch 16. Rear stop switch 18. Rear light 21. Start-up relay 22. Starter motor 23. Battery 24. Main fuse 28. Generator 29. Regulator 39. Ground point on chassis




Electrical system

Level indicators and enable signals section

Key

1. Multiple connectors 4. Oil level warning light 8. Fuel level instrument 10. Fuel F uel level transmit transmitter ter 12. Key switch 23. Battery 24. Main fuse 29. Regulator 31.Oil reserve warning light 38. Low fuel warning light 39. Ground point on chassis

ELE SY S - 53 53


Electrical system

Instruments and warning lights control board A=High beam warning light; B =Oil pressure warning light; C=Turn indicator warning light; D=Low fuel warning light; E =Odometer; F=Rpm indicator; G=Fuel gauge

LIGHT BULBS TABLE Specification

1

High/low beam light bulb

2

F ront side light bulb

3

Inst Instrrument ent panel anel bulb, lb, in indicat icator warnin rning g lig lights, mixer ixer oil reserve and high beams

4

F ront turn indicator light bulb

5

Rear turn indicator light bulb

6

Stop light/rear daylight running light bulb

7

License plate bulb


Desc./Quantity Type: Halogen (H8) Power : 12V - 35W Quantity: 2 Type: All glass Power: 12V 3W Quantity: 2 Type: All glass Power: 12V - 1.2W Quantity: 5 Type : SPHERICAL (amber colour) Power : 12V - 10W Quantity: 1 RHS +1 LHS Type : SPHERICAL (amber colour) Power : 12V - 10W Quantity: 1 RHS +1 LHS GLA SS (twin-fila (twin-filam ment) ent) Type: ALL GLASS Power: 12V - 21/5W Quantity: 1 Type: All glass Power: 12V - 3W Quantity: 1


Electrical system

Devices and accessories

Key

1. Multiple connectors 2. Horn 3. Horn button 12. Key switch 23. Battery 24. Main fuse 29. Regulator 30. Automatic starter 39. Ground point on chassis 41. Heater control device 42. Heater

ELE SY S - 55 55

Electrical system

Lights and turn indicators

Key

1. Multiple connectors 5. Instrument panel lighting bulbs 6. High beam warning light 7. Turn indicator warning light 9. Instrument panel 11. Light switch 13. Turn indicator switch 15. Front stop switch 16. Rear stop switch 17. Rear left turn indicator 18. Rear light 19. License plate light 29. Regulator 32. Front right turn indicator 33. High beam light 34. Daylight running light 35. Low beam light




Electrical system

36. Front left turn indicator 37. Front headlamp 40. License plate cables

Checks and inspections Checks to be made in the case of ignition irregularities and/or no spark on the spark plug

1. Check the condition condition of the the spark plug (clean it with with a metal metal brush, brush, remove the the encrustations, encrustations, blast blas t it with compressed air and, if necessary, replace it). 2. Without removing removing the the stator, stator, carry out the following checks: After visually checking the electrical wiring, perform measurement measurements s on the loading reel, the pickup (see (s ee chart) and the continuity using the appropriate tester. If checks on the loading reel, pickup and continuity show abnormalities, replace the stator; otherwise replace the central unit. Remember that the engine must be off to disconnect and replace the control unit.

Specific tooling 020331Y Digital multimeter

CHECK ON THE PICK UP 1

Specification

Desc./Quantity

Red and white cable

90±140 ohm

RECHARGE COIL CHECK UP 1

Specification Y ellow and blue cable

Desc./Quantity

800±1100 ohm

ELE SY S - 57 57


Electrical system

CHECK CONTINUITY 1 2

Specification

Desc./Quantity

White cable-frame White cable-engine

Continuity Continuity

Ignition circuit All All the control operations of the system systemthat require the disconnection of cables (checks of the connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged.

Stator check - Using U sing a tester, check the resistance resis tance between between the the stator wiring. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE LEADS TO VALUES HIGHER THAN THOSE STATED.

Electric characteristic Stator: Grey ÷ Ground

~1 ohm Stator: White ÷ Ground

~1 ohm Stator: Green - Ground

~1Kohm Stator: Blue ÷ Yellow

~1 ohm Pick-Up: Red - Ground

~170 Ω (Pick-Up)

Voltage regulator check A malfunction in the voltage regulator might cause the following problems depending on the type of fault: 1. The lighting system bulbs burn out. 2. The lighting system bulbs stop working.



Electrical system

3. The battery overcharges (the main fuse blows). 4. Non-recharging of the battery. 5. Non functioning of the turn indicators. Measures FAULT 1

Replace the regulator because it is certainly inefficient. FAULT 2

Check the efficiency of the bulbs. With the vehicle in gear, check the battery voltage on the green cables of the light switch. If there is no voltage check the presence of voltage between the yellow-black cable on the regulator and ground. If there is voltage here, the fault needs to be sought in the wiring from the regulator to the light switch or the correct supply of voltage to the stator is to be checked: without disconnecting the regulator connector and with the vehicle in gear, using the tester for alternate voltage readings check that the voltage supplied between the connection of the yellow-grey cable (pin 2) and the blue cable (pin 6) is within the values indicated. If faults are detected, replace the stator. If no faults are detected in the controls controls carried out, replace the regulator. If functioning is still not correct even when the regulator is replaced, check the connections of the electrical system. system.


Characteristic Voltage distributed at 3000 rpms

25 to 30V FAULT 3

After checking that there are no short circuits in the system towards the earth, replace the regulator because it is certainly inefficient and replace it with a protective fuse. Following the replacement, measure the current and the recharging voltage on the battery end. ELE SY S - 59 59

Electrical system

FAULT 4

P ut the the vehicle in gear and check when the tester tester for the detection of alternate voltages put between the blue cable connection and the yellow cable connection on the stator, the voltage distributed by the generator is within the values indicated. In the case of malfunction, check the continuity of the stator or continue with the tests. Insert an ammeter between the stator (blue cable) and the battery and check, with the tester, that the current is properly distributed at 3000 rpm and the battery is kept between 12 and 13V as indicated. If the values detected are lower than those specified, replace the regulator; otherwise replace the battery. N.B. BEFORE CARRYING OUT THE CHECKS ON THE REGULATOR AND RELATIVE SYSTEM, IT IS ALWAYS GOOD PRACTICE TO CHECK THAT THERE IS CONTINUITY BETWEEN THE BLACK CABLE AND THE GROUND. N.B. TO KEEP THE BATTERY BETWEEN 12 AND 13V, CAUSING CURRENT ABSORPTION BY THE SYSTEM, A 12V - 35W BULB CONNECTED BETWEEN THE + BATTERY AND GROUND CAN BE USED.


Characteristic Distributed current

1.5 to 2A Voltage distributed at 3000 rpms

25 to 30V FAULT 5

If the turn indicators do not work, do the following: •

With the engine off, remove the regulator connector, and insert the ends of the tester between contact 5 and the ground.

•

Move the ignition switch to ON and check there is battery voltage. If no voltage is detected, check the wiring




Electrical system

and the contacts on the ignition switch and on the battery. •

Repeat the same procedure with the ends of the tester inserted between contact 5 (+) and 6 (-) and check the presence presence of the battery voltage voltage with the ignition switch at on. If this does not happen, check the regulator's regulator's ground cable.

•

If these last two tests have a positive result replace the regulator because it is certainly not functioning properly.


Turn signals system check WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

Check that bulb operates properly. Check continuity of the Blue-Black cable between the regulator and the turn indicators switch. Check that the turn indicator switch works properly. Check continuity of the Red and Blue cables which connect the switch to the bulbs.

Fuses The The elec electtrica ricall syst system em is protec otectted by a fuse conconnected on the left-hand side of the helmet compartment next to the battery. For access it is necessary to remove the battery cover and the transparent transparent protection protection over the fuse block. The T he ignition system, headlight and the rear tail light are not fuse-protected. CAUTION BEFORE REPLACING THE BLOWN FUSE, SEARCH AND SOLVE THE PROBLEM THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).

Characteristic ELE SY S - 61 61

Electrical system


Fuse

10 A

Sealed battery Commissioning sealed batteries

INSTRUCTIONS FOR REFR ESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check

Before installing the battery on the vehicle, check the open circuit voltage with a standard tester. - If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge. - If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 2) Constant voltage battery charge mode

-Cons -C onstant tant voltage equal to 14.40÷14.70V -Initial -Initial charge charge voltage equal to 0.3÷0.5 for nominal capacity capacity -Duration of the charge: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode

-Charge current equal to 1/10 of the nominal capacity of the battery -Duration of the charge: 5 h WARNING

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Dry-charge battery If available WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.



Electrical system

BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN Commissioning dry-charged batteries:

1) - Remove the short closed tube and the plugs, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1.26, corres corresponding ponding to 30 Bé Bé at a minimumtemtemperature of 15°C. until the upper level is reached. 2) - Leave L eave to rest for at least 2 hours; then, restore the level with sulphuric acid. 3) - Within the following 24 hours, recharge using the specific battery battery charger (single) (single) or (multiple) (multiple) at a density of about 1/10 of the battery nominal capacity until fully charged; check that the acid density is about 27, corresponding to 31 Be, and that these values are stabilised. 4) - Once the charge is over, level the acid (by adding distilled water ). ). Close Close and clean carefully. 5) Once the above operations have been performed, install the battery on the vehicle ensuring that it is wired up properly. 1 Hold the vertical tube 2 Look at the level 3 The float must be freed WARNING - ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Battery maintenance

The The batt attery ery is an elec electtrical ical devic evice e which ich req requires ires car careful eful monit onitor orin ing g and and car carefu eful main aintenan enance ce.. The The maintenance rules are: 1) Check the level of the electrolyte

ELE SY S - 63 63

Electrical system


The The elec electtroly olyte lev level must be chec check ked frequ equent ently and and must reac reach h the upper pper lev level. el. Only Only use dist istille illed d water, to restore this level. If water topping is required too often, check the vehicle electrical system: the battery works overcharged and is subject to quick wear. 2)Load status check

After topping-up topping-up the electrolyte level, check its density using an appropriate densitometer densitometer (see figure). When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the vehicle is not used for a given time time (1 month month or more) it will be necessary neces sary to periodically recharge the battery. The The batt attery ery run runs down own com complet letely ely in the cou course of three ree mont onths. If it is neces ecessa sarry to refit efit the batt attery ery in the vehicle, be careful careful not to reverse the connections, connections , remembering that that the the ground wire (black) marked (-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign. 3) Recharging the battery

Remove the battery from the vehicle disconnecting the negative terminal first. Regular bench charging must be carried out with the specific battery charger, (single) or (multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connecting the corresponding poles (+to+and - to -). 4) Cleaning the battery

The The batt attery ery shou should ld alw always ays be kept ept clea clean n, esp especia eciall lly y on its its top sid side, and and the term erminal inals s shou should ld be coat coated ed with Vaseline. CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VEHICLE OR EVEN CAUSE A FIRE. CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER. CAUTION

TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE. LACK OF PROPER CHARGING OF THE BATTERY BEFORE FIRST USE AT L OW ELECTROLYTE LEVEL, CAN LEAD TO PREMATURE BATTERY LIFE.

Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger

Battery installation If available VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)



Electrical system

WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN 1) Battery preparation

Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.

2) Electrolyte preparation.

Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing sealing of the container or

the container container itself because inside there is sulfuric s ulfuric acid. 3) Procedure for filling the battery with acid.

P osition the electrolyte electrolyte container upside down with with the six areas sealed in line with the six battery battery filler holes. P ush the container down with with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow

of electrolyte from pausing or stopping. 4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container

two or three times. Do not remove the container from the battery. ELE SY S - 65 65

Electrical system


5) Take out the container.

Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point. 6) Battery closing.

Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note: To To do this, is, do not use shar sharp p obje object cts s tha thatt cou could damage age the clos closin ing g str strip, ip, use glov gloves es to protec otectt

your hands and do not bring your face close to the battery. The The filli illing ng proces ocess s is is now now com complet lete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. P lace the battery battery down for 1 to 2 hours prior prior to the charging from the battery. battery. 7) Recharging the new battery

With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before B efore installing the battery on the vehicle, it must be fully charged and then must be recharged. If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle.

The The dry char charg ge batt attery ery MF lik like the com complet letely ely loaloaded YTX, must have a no-load voltage between 12.8 - 13.15 V Bring the battery to full charge, using the 020648Y 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect connect the clamps of the battery charger to the the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).



Electrical system

d - Press P ress the red button, button, as shown in figure.

e - P ress the "MF "MF"" black button button to to activate activate the batbattery recharge Maintenance Free as shown in figure.

f - Check the ignition of the green LED indicated with a red arrow in figure.

g - The activation activation cycle of the new battery battery lasts for 30 minutes after the ignition of the recharge LED has taken place

ELE SY S - 67 67

Electrical system


h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.


INDEX OF TOPICS

ENGINE FROM VEHICLE

ENG VE

Engine from vehicle

Exhaust assy. Removal - P osition the vehicle vehicle on centre stand. - Undo and remove the two screws that fix the exhaust manifold to the engine. CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS, LET THE ENGINE AND THE SILENCER TO COOL OFF AT AMBIENT TEMPERATURE TO AVOID POTENTIAL BURNS.

Locking torques (N*m) Screws fixing silencer to cylinder head 16 to 18

- Remove the clamp on the SAS box pipe. - Undo and remove the screws indicated. - Remove the silencer. CAUTION UPON REFITTING, REPLACE THE GASKET BETWEEN THE EXHAUST MANIFOLD AND THE SILENCER WITH A NEW ONE.

Locking torques (N*m) Screws fixing silencer to the crankcase 24 to 27

Removal of the engine from the vehicle •

Rest the vehicle on its stand.

•

Remove the side panels

•

Slide off the tube from the spark plug.

•

Disconnect the alternator connector.

•

Release the starter motor cable, by cutting the indicated clamp.

•

Disconnect the power connector and the ground cable from the starter motor.

ENG VE - 70 70



•

Engine from vehicle

Remove the air duct pipe from the carburettor cover.

•

Remove the carburettor cover.

•

Remove the fuel pipes.

•

Undo the screw and remove from the carburettor the gas cable.

ENG VE - 71 71

Engine from vehicle

•

Disconnect the automatic starter and the heater connectors.

•

Removing emoving the lower m mixer ixer oil reservoir pipe.

•

Remove the mixer control cable.

ENG VE - 72 72



•

Engine from vehicle

Undo the rear brake set screw and the indicated screw and then free the engine from the rear brake transmission.

CAUTION

SUPPORT THE VEHICLE ADEQUATELY.

Locking torques (N*m) Rear brake adjustment nut 5 •

Undo the shock absorber lower screw.

Locking torques (N*m) Shock absorber nut 22.5

•

Remove the entire silencer assembly.

•

Undo and remove the engine-rod fulcrum nut.

•

Operating on the chassis, lift the vehicle rear part.

•

Slide off the engine-rod fulcrum pin.

•

Slide off the engine towards the back.

Locking torques (N*m) Engine-swinging arm pin 42.5

ENG VE - 73 73

INDEX OF TOPICS

ENGINE

ENG


Engine

Automatic transmission Transmission cover - Loosen L oosen the 14 screws screws and remove th the e transmistransmission cover with the aid of a mallet. N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PU LLEY AND THE BEARING HOUSED ON THE CRANKCASE.

- To refit tighten the screws to the prescribed tightening torque.

Locking torques (N*m) Transmission cover screws 11 ÷ 13

Kickstart - Remove the screws shown in the figure and remove the engine starting lever. - For F or the assembly, work in reverse and tighten the the screws to the prescribed torque..

Locking torques (N*m) Start-up lever screw 12-13

- Upon refitting, apply the recommended grease to the bushing, to the spring and along the toothed sector. - Use Use the special tool for the the charging of the the spring, as shown in the figure. - Refit the seeger ring after checking that it is in good condition.

Specific tooling 020261Y Starter spring fitting

Recommended Recommended products

ENG - 75

Engine


AGIP GREASE MU3 Grease for odometer transmission gear case

Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20

- Remove the seeger ring located on the exterior of the crankshaft. - Dismantle the dog gear from its seat, slackening the tension that the toothed sector applies to it by means of the spring; to do this, it is necessary to rotate the toothed sector slightly (see the figure). CAUTION WHILE REMOVING THE TOOTHED SECTOR, BE VERY CAREFUL OF THE SPRING TENSION: IT COULD CONSTITUTE A HAZARD FOR THE OPERATOR.

Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing. N.B. IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DIAMETER EXTRACTOR CAN BE USED.

Refitting the driven pulley shaft bearing -Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside. N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE. CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED SURFACE.

ENG - 76


Engine

Removing the driven pulley - Lock the clutch housing with the specific tool. - Remove the nut, the clutch housing and the whole of the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.

Specific tooling 020565Y Flywheel lock calliper spanner

Inspecting the clutch drum - Check C heck that the the clutch housing is not worn or damdamaged. - Measure Measure the inner diameter of the clutch housing.

Characteristic clutch housing diameter/standard value

Ø 107+0.2 +0 mm clutch housing diameter/max. value allowed after use

Ø 107.5 mm Eccentricity measured /max.

0.20 mm

Removing the clutch - Equip E quip the tool tool with long pins s screwed crewed into position «A» from the outside, insert insert the entire driven pulley in the tool and have the central screw make contact. CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCR EW IS TIGHTENED UP TOO FAR.

ENG - 77

Engine

- Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw by undoing spring of the driven pulley unit - Separate the components.

Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch

Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic Check minimum thickness

1 mm

Pin retaining collar - Rem R emove ove the collar with the the aid of 2 screwdriv screwdrivers. ers.

ENG - 78



Engine

- Rem R emove ove the three three guide pins and the mobile mobile half pulley.

Removing the driven half-pulley bearing - Remove the roller bearing with the special extractor inserted from the bottom of the fixed halfpulley. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLIERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEAL RING.

Specific tooling 001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring. - Expel the ball bearing from the side of the clutch housing by means of the special tool. N.B. PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVE BELT

Specific tooling 020376Y Adaptor handle 020363Y 20-mm guide

Inspecting the driven fixed half-pulley - Check C heck that there there are no signs signs of wear on the work work surface of the belt. If there are, replace the halfpulley.. - Make sure the bearings do not show signs of unusual wear. - Measure Measure the external diameter of the pulley bushbushing.

Characteristic ENG - 79

Engine


Stationary driven half-pulley/Standard diameter

Ø 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diameter admitted after use

Ø 33.96 mm

Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two Orings. - Measure the inside diameter of the mobile halfpulley bushing.

Characteristic Mobile driven half-pulley/ Maximum diameter allowed

Ø 34.08 mm - Check the belt contact surfaces. - Insert the new oil seal and O-rings on the mobile half-pulley. - Fitting the half-pulley on the bushing.

Recommended Recommended products AGIP GREASE SM 2 Grease for the C-ring of the tone wheel

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 - Make sure the pins and collar are not worn, reassemble the pins and collar. - Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended Recommended products AGIP GREASE SM 2 Grease for the C-ring of the tone wheel

Soap-based lithium lithium grease containing containing NLGI 2 Molybdenu Molybdenum m disulphide; disulphide; ISO-L IS O-L-XB -XBC CHB2, DIN DI N KF K F2K-20

ENG - 80


Engine

Refitting the driven half-pulley bearing - Fit a new ball bearing with the specific tool. - Fit the ball bearing retention snap ring. - Fit F it the new roller bearing with with the wording wording visible from the outside. CAUTION PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT DAMAGE TO THE THREADED END WHILE THE BEARIN GS ARE BEING FITTED.

Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller bearing

Inspecting the clutch spring - Check C heck that the the contrast spring of the driven pulley does not show signs of deformation - Measure the free length of the spring

Characteristic Standard length

118 mm Minimum length allowed after use

113 mm

Refitting the clutch - P reassemble the driv driven en pulley group wit with h spring, sheath and clutch. - P osition the spring with with the sheath - Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded shank.

ENG - 81

Engine


- Reass R eassem emble ble the nut securing the clutch and tighttighten to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCKET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE NUT IN CONTACT WITH THE CLUTCH

Locking torques (N*m) Nut locking clutch unit on pulley 55 to 60 Nm

Refitting the driven pulley -Refit -R efit the the driven pulley ass assemb embly, ly, the clutch housing and the nut, using the specific tool.

Specific tooling 020565Y Flywheel lock calliper spanner

Locking torques (N*m) Clutch unit nut on driven pulley 40 ÷ 44

Drive-belt - Make sure the drive belt is not damaged and does not show abnormal wear. - Replace as indicated in the scheduled maintenance table.

Removing the driving pulley - Lock L ock the driving pulley using the appropriate appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.

Specific tooling 020451Y Starting ring gear lock

ENG - 82


Engine

Mixer gears and belt - Remove the mixer oil pump. - Remove gear and belt. CAUTION PAY PARTICULAR ATTENTION TO NOT TOUCHING OR BENDING THE BELT BECAUSE THIS COULD BREAK SUDDENLY DURING OPERATION. CAUTION ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET INTO THE INNER BUSHING OF THE MIXER CONTROL GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON THE CRANKCASE PIN. N.B. REPLACE THE BELT AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE.

See also Lubrication

Inspecting the rollers case 1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation. 2) Check the roller running tracks on the contact pulley; there must not be signs of wear and check the condition of the contact surface of the belt on the half-pulleys (m (mobile and stationary). stationary). 3) Check that the rollers do not show signs of marked facetting on the sliding surface and that the metallic insert does not come out of the plastic shell borders. 4) Check the integrity of the sliding shoes of the contact plate. - Check that the internal bushing shown in the figure is not abnormally worn and measure inside diameter «A». - Measure Measure outside diameter diameter «B» of the pulley sliding bushing shown in the figure. CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING.

Characteristic Driving pulley / Maximum diameter:

ENG - 83

Engine

20.12 mm Driving pulley/ Standard diameter:

20.021 mm Driving pulley bushing/ Diameter maximum:

XXX mm Driving pulley bushing/ Standard diameter:

20 -0.020/-0.041mm

Refitting the driving pulley - Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert ins ert the belt observing the direction of rotation of the first fitting. N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE.

- Refit the components of the assembly (roller housing assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive, washer and nut). - With the specific tool, tighten the lock nut to 20 Nm and then perform a final 90° locking in order to prevent the rotation of the driving pulley. N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UTMOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN ORDER TO AVOID WRONG TIGHTENING AND CONSEQUENTLY DAMAGING THE CRANKSHAFT KNURLING.

Specific tooling 020451Y Starting ring gear lock

Locking torques (N*m) Drive pulley nut 18 - 20 Nm + 90° rotation

End gear

ENG - 84



Engine

Removing the hub cover - Drain the rear hub oil - Remove driven pulley - Remove the rear brake shoes - Remove the 5 screws fixing the cover to the crankcase - Remove the cover with the wheel axle and pull it out out - Remove the intermediate gear with the appropriate shim washers

Removing the wheel axle bearings - Remove the oil seal and the seeger ring. - Fix the hub cover properly to avoid damaging the sealing surface with the housing - Rem R emove ove the wheel wheel axle bearing us using ing the specific tool

Specific tooling 020363Y 20-mm guide 020376Y Adaptor handle 020477Y 37 mm adaptor

ENG - 85

Engine

Removing the driven pulley shaft bearing - Remove the seeger ring - Heat the engine crankcase but do not direct the hot air towards the bearing - Extract the driven pulley shaft together with the bearing with a few mallet blows

- Remove the bearing off the driven pulley shaft using the specific tool and a press N.B. USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALLER INTERNAL DIAMETER

Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft

ENG - 86



Engine

Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - If faults are found, replace the damaged components. - Check capacity ( A ) of the transmission gear (wear, deformations, deformations, etc.) - Check the pulley shaft seating: Superficial wear ( B ) may indicate irregularities in the crankcase seatings or in the pulley shaft capacities

Inspecting the hub cover - Check C heck that the fitting fitting surface is not dented dented or disdistorted. - If faults are found, replace the hub cover.

Refitting the driven pulley shaft bearing - Support the inner track of the bearing from the outside of the hub cover with the the specific specific tool posipositioned under the the press and insert the driven pulley axle. - Refit the oil seal flush with the cover.

Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft

ENG - 87

Engine

• Heat the hub cover and insert the bearing with the specific punch. • Fit the snap ring with the concave or radial part on the bearing side. N.B. FIT THE BALL BEARING WITH THE SHIELD FACING THE OIL SEAL.

Specific tooling 020151Y Air heater 020376Y Adaptor handle 020439Y 17-mm guide 020358Y 37x40-mm Adaptor

Refitting the wheel axle bearing - Support the hub cover on a wooden surface - Heat up the hub cover using the thermal gun. - Preassemble P reassemble the bearing bearing on the the specific punch using grease and then insert the bearing in its seating - Refit R efit the the seeger ring and the oil seal seal using using the 42 42 x 47 mm adaptor N.B. POSITION THE OIL SEAL WITH THE SEALING LIP FACING THE HUB INTERNAL SIDE

Specific tooling 020150Y Air heater mounting 020151Y Air heater 020376Y Adaptor handle 020363Y 20-mm guide 020359Y 42x47-mm Adaptor

ENG - 88



Engine

Refitting the hub bearings - Remove the wheel axle on the cover and pay attention not to damage the sealing lip of the oil seal - Apply a thin layer of grease on the two shim washers of the intermediate intermediate gear and and fit one on the cap so that it does not interfere with the wheel axle gear when placing the transmission shaft

Refitting the ub cover - Apply product recommended for surfaces on the hub cap and refit cap on the crankcase - Fit the 5 screws and tighten them to the specified torque. N.B. CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF RESIDUE FROM PREVIOUS GASKETS BEFORE APPLYING A NEW ONE.

Recommended Recommended products Loctite 510 Liquid sealant

Gasket

Locking torques (N*m) Hub cover screws 24 - 27

Flywheel cover Cooling hood - Remove the four fixings shown in the figure. - Remove the fan cover

ENG - 89

Engine


- Remove the oil piping retention band from the hood - Remove the 2 screws shown in the picture

Cooling fan - Remove the cooling fan by acting on the three fixings indicated in the figure.

Removing the stator - Remove the three stator fixings shown in the photo - Remove the two pick-up fixings shown in the photo - Remove the stator with the wiring

Refitting the stator - Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque. torque. N.B.

THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE T HE FAN COVER ASSEMBLY.

Locking torques (N*m) ENG - 90


Engine

Pick-up screws 3 to 4 Stator screws 3 to 4

Flywheel and starting Removing the starter motor •

Remove the centre stand by unscrewing the four clamping screws (two per side) of the engine block

•

Remove the two clamps shown in the figure

Removing the flywheel magneto - Lock L ock the rotation rotation of the flywheel using the calliper call iper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS

ENG - 91

Engine

- Extract the flywheel with the extractor.

Specific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor

Inspecting the flywheel components - Check the condition of the flywheel and any distortions that might cause rubbing on the stator and on the Pick-Up.

Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly. - Lock the flywheel nut at the prescribed torque - Check the Pick-Up air gap. - The air gap may not be modified in the fitting of the Pick-Up. - Other O ther values derive from deform deformations ations visible on the Pick-Up support. N.B. A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING, KNOCKING ETC.

Locking torques (N*m) Flywheel nut 40 to 44 N.m

ENG - 92



Engine

Refitting the starter motor - Fit a new O-ring on the starter and lubricate it. - Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque. N.B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS.

Locking torques (N*m) Starter screws 11 to 13

Cylinder assy. and timing system Removing the intake manifold Use an anti-tampering TORX spanner to remove the two clamping screws of the intake manifold

Removing the cylinder head Remove the 4 screws shown in the figure

ENG - 93

Engine

Removing the cylinder - piston assy. Remove the cylinder very carefully

Remove the snap rings and remove the pin CAUTION AFTER EACH REMOVAL OPERATION REPLACE THE PIN RETENTION SNAP RINGS

Inspecting the small end - Measure the internal diameter of the connecting rod small end using an internal micrometer. N.B. IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER".

Characteristic Rod small end: standard diameter

17 +0.011-0.001 Rod small end: maximum allowable diameter

17.060 mm

ENG - 94


Piaggio Typhoon 50 2T MY 2010 (en)

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