Piaggio Typhoon 50 4t 4v (EN)

SERVICE STATION MANUAL 677691 EN

Typ ypho hoon on 50 4t 4v 4v

SERVICE STATION MANUAL

Typhoo Typh oon n 50 4t 4v 4v

The The descr escrip ipttions ions and and imag images es in this public blicat atio ion n are are given iven for illu illust stra rattive ive purp urposes oses only only and and are are not not bind bindin ing g. While the basic characteristics characteristics as described des cribed and illustrated in this this booklet remain remain unchanged, Piaggio P iaggio & C. S.p.A S .p.A.. reserves reserves the right, at any time time and without being required to to update this this publication beforehand, beforehand, to make make any changes to components, components, parts or accessories accessories,, which it considers considers necessary neces sary to improve 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 sales network. ©Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited. P iaggio iaggio & C. S.p.A. Viale Rinaldo Rinaldo Piag P iaggio gio,, 25 - 5602 56025 5 PONTE PO NTEDER DERA A (PI), (P I), Italy www.piaggio.com

SERVICE SERVICE STATION STA TION MA MANUA NUAL L Typhoo Typh oon n 50 4t 4v This This ser serv vice ice stat statio ion n man manu ual has bee been n dr drawn awn up up by by Piagg Piaggio & C. Spa to be be use used d by by the wor work kshop shops s of P iaggio dealers. It is assum assumed ed that the user of this m manual anual for maintaining maintaining and repairing Piaggio Piaggio vehicles has a basic basic knowledge of mechanical mechanical principles and vehicle repair ttechnique echnique procedures. Any significant significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.

key information information to make make the procedure easier easier to understand and carry out. N.B. P rovides key

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.

Safeguardin Safeguardin g the enviro nment 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

AINTENA NCE M AINTENANCE

MAIN

TROUBLESHOOTING

TROUBL

ELECTRICAL

ELE SYS

SYSTEM

ENGINE FROM VEHICLE

ENG VE

ENGINE

ENG

SUSPENSIONS

SUSP

B RAKING

SYSTEM

CHASSIS PRE-DELIVERY

BRAK SY SYS S CHAS PRE DE

INDEX OF TOPICS

CHARACTERISTICS

CHAR

Characteristics

Typho on 50 4t 4v 4v

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 ions ns per perform ormed on the vehic ehicle le..

Safety rules - If If work can only be done on the vehicle with the engine running, make make sure that the premises 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 - 6


Characteristics

Vehicl Ve hicl e ide identif ntif ication VEHICLE IDENTIFICATION Sp ec i f i c at i o n

Des c ./Qu an t i t y

Chassis prefix Engine prefix

ZAP C50 C37CM

Dimensions and mass

WEIGHTS AND DIMENSIONS Sp ec i f i c at i o n


Maximum length Overall width Max. height to the windshield Wheelbase Kerb weight

76.38 in (1940 mm) 28.35 in (720 mm) 44.69 in (1135 mm) 53.15 in (1350 mm) 242 lbs (110 Kg)

Engine DATI TECNICI MOTORE Sp ec i f i c at i o n


Motore Distribuzione Cilindrata Alesaggio per corsa Gioco Valvole

Monocilindrico 4 tempi, 4 valvole raffreddato ad aria monoalbero a camme in testa a 4 valvole 3,03 in³ (49,0 cc) 1,54 x 1,63 in (39 x 41,35 mm) aspirazione: 0,006 in (0,15 mm) scarico: 0,006 in (0,15 mm) Aut Automatic atic cont contin inuo uous us vari variat ator or Automatic centrifugal dry clutch

Trans Transm missio ission n Clutch

CHAR - 7


Characteristics

Sp ec i f i c at i o n


Lubrication Cooling E lectric Carburatore F uel Spark plug

Wet crankcase forced air circulation Starter and kick starter KE IHIN NCV Ø 20 Unleaded petrol 90 (M+R) /2 minimum octane NGK ER9EH-6N

Transmission TRANSMISSION Sp ec i f i c at i o n


Tran Transm smiss issio ion n

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 CAPACITY Sp ec i f i c at i o n


Fue Fuel tank capacity

~1.5 gal (including 0.4 gal reserve) ~7 litres (including 1.5 l reserve) ~0.0225 gal (~85 cc) ~0.225 gal (~850 cc)

Hub oil Engine oil

Electri Electri cal system ELECTRICAL COMPONENTS 1 2 3 4 5

Sp ec i f i c at i o n


Ignition advance S park plug Battery F uses Generator

reference in table NGK E R9E H-N 12V - 9Ah 1 15A - 1 10A - 1 7.5A single-phase alternating current

STATOR - PICKUP - Power: 120 W. - Resistance between BLUE cable and GROUND CONNECTION: 1 ohm. - Resistance between green cable and ground connection: approximately 170 Ohm.

CHAR - 8


Characteristics

- Prim P rimary ary resistance: 0.5 tto o 0.6 Ohm - Resistance between primary and ground connection: infinite - Resis R esistance tance between between primary primary and HV output: output: 3 to to 3.6 kOhm - Shielded cap: 5000 Ohm

Frame Frame and suspension s FRAME AND SUSPENSION Sp ec i f i c at i o n


F rame F ro ront suspension rear suspension

Tubular steel frame with sheet metal reinforcements Hydraulic telescopic fork; Ø 1,36 in (Ø 32) - 2.99 (76 mm) Hydraulic single shock absorber and spring adjustable to 4 positions at preloading; travel: 3.40 in (86.5 mm).

Brakes BRAKES Sp ec i f i c at i o n


F ront brake

Disc brake Ø 8.6 in (220 mm) with hydraulic control (lever on the far right of the handlebar) and floating calliper. Drum Ø 5.51 in (Ø 140 mm)

Rear brake

Wheels and tyres WHEELS AND TYRES Sp ec i f i c at i o n


Wheel rims F ront wheel rim Rear wheel rim Tyre Tyre type F ront tyre Rear tyre Sta Standard front tyre pressure [with passenger] Sta Standard rear tyre pressure [with passenger]

Die-cast aluminium alloy 3.00 x 14" 3.50 x 14 Wit Withou hout inne innerr tube ube (Tube (Tubele less) ss) 120/70 - 14" 55 P 120/70 - 14" 55 P 23 psi (1.6 bar) [29 psi (2.0 bar)] 29 psi (2.0 bar) [32 psi (2.2 bar)]

Tightening Torques ENGINE ENGINE A SSEMBL SSEMBLY Y Nam e

To r q u e i n N m

Ignition spark plug F loating head cover screws Head-cylinder stud bolt nuts Head Head nut nut tight ighten enin ing g (on (only ly for for stud stud bolt bolt rep replace lacem ment ent) S crews fixing head and cylinder to crankcase Chain tensioner pad screw Timing ing chai chain n tensio ensione nerr cent centra rall screw screw

7.4 - 11 lb ft (10 - 15 Nm) 4.4 - 5.2 lb ft (6 - 7 Nm) 4.4 - 5.2 lb ft +90° +90° (6 - 7 Nm +90° +90°) 4.4 - 5.2 5.2 lb lb ft ft +135° +135° +90° +90° (6 (6-7 Nm Nm +135° +135° +90° +90°) 5.9 - 7.4 lb ft (8 - 10 Nm) 3.7 - 5.2 lb ft (5 - 7 Nm) 3.7 3.7 - 4.4 4.4 lb ft (5 - 6 Nm) Nm)

CHAR - 9


Characteristics

N am e

To r q u e i n N m

Camshaft pulley screw Rocking lever axle and camshaft bearing screw Rocker adjusting nuts Engine oil pre-filter cover Engine oil drainage cap F lywheel nut S tator screws P ick-up screws Oil pump bulkhead screw Timing ing chai chain/ n/oi oill pum pump com compart partm ment ent cove coverr screw screws s Oil decantation labyrinth sheet screws Oil pump sprocket gear screw Screws fixing oil pump to the crankcase Oil sump screws Inlet manifold screw Carburettor/manifold clamp screw S crews fixing cables to starter motor S tarter motor screws Trans Transm missio ission n cov cover scre screw ws S tart-up lever screw Crankcase cooling cover screw Clutch assembly nut Crankshaft pulley nut Driven pulley shaft nut Hub oil drainage screw Rear hub cap screws Crankcase half union screw

8.8 - 10.3 lb ft (12 - 14 Nm) 2.2 - 2.9 lb ft (3 - 4 Nm) 5.2 - 6.6 lb ft (7 - 9 Nm) 18.4 - 20.6 lb ft (25 - 28 Nm) 29.5 - 32.4 lb ft (40 - 44 Nm) 2.2 - 2.9 lb ft (3 - 4 Nm) 2.2 - 2.9 lb ft (3 - 4 Nm) 2.2 - 2.9 lb ft (3 - 4 Nm) 2.9 - 3.7 lb ft (4 - 5 Nm) 2.9 2.9 - 3.7 3.7 lb ft (4 - 5 Nm) Nm) 5.2 - 5.9 lb ft (7 - 8 Nm) 5.9 - 7.4 lb ft (8 - 10 Nm) 3.7 - 4.4 lb ft (5 - 6 Nm) 5.9 - 7.4 lb ft (8 - 10 Nm) 5.2 - 6.6 lb ft (7 - 9 Nm) 0.9 - 1.1 lb ft (1.2 - 1.5 Nm) 0.9 - 1.1 lb ft (1.2 - 1.5 Nm) 8.1 - 9.6 lb ft (11 - 13 Nm) 8.1 8.1 - 9.6 9.6 lb ft (11 (11 - 13 13 Nm) Nm) 8.1 - 9.6 lb ft (11 - 13 Nm) 1.5 - 1.8 lb ft (2 - 2.5 Nm) 40.5 - 44.2 lb ft (55 - 60 Nm) 13.3 - 14.8 lb ft +90° (18 - 20 Nm +90°) 29.5 - 32.4 lb ft (40 - 44 Nm) 2.2 - 3.7 lb ft (3 - 5 Nm) 8.1 - 9.6 lb ft (11 - 13 Nm) 5.9 - 7.4 lb ft (8 - 10 Nm)

STEERING STEERING ASSEMBLY A SSEMBLY N am e

To r q u e i n N m

Steering upper ring nut Steering lower ring nut Headstock handlebar

27.7 lb ft (37.5 Nm) 9.6 lb ft (13 Nm) 38.7 lb ft (52.5 Nm)

CHASSIS ASSEMBL ASSEMBLY Y N am e

To r q u e i n N m

E ngine side swinging arm Chassis side swinging arm P assenger handle Centre stand pin Saddle plate fixing nut Mirror fixing spacer Chassis fuel tank retainer screws Handlebar brake pump

31.3 lb ft (42.5 Nm) 31.3 lb ft (42.5 Nm) 15.1 lb ft (20.5 Nm) 31.3 lb ft (42.5 Nm) 7.4 lb ft (10 Nm) 18.4 lb ft (25 Nm) 7.4 lb ft (10 Nm) 5.9 lb ft (8 Nm)

FRONT SUSPENSION N am e

To r q u e i n N m

P late fork stanchions Sleeve fork stanchions F ront wheel axle hub F ork wheel axle

29.5 lb ft (40 Nm) 22.1 lb ft (30 Nm) 7.3 lb ft (10 Nm) 34.3 lb ft (46.5 Nm)

REAR SUSPENSION N am e

To r q u e i n N m

Shock absorber upper part S hock absorber lower part Rear wheel hub

27.3 lb ft (37 Nm) 27.3 lb ft (37 Nm) 87.8 lb ft (115 Nm)

FRONT FRONT AND REAR BRAK E

CHAR - 10

N am e

To r q u e i n N m

Brake disc F ront brake calliper to fork Brake pad fastening screw

6.6* lb ft (9* Nm) 18.8 lb ft (25.5 Nm) 11-14.7 lb ft (15-20 Nm)


Characteristics

Nam e

To r q u e i n N m

Rear brake adjustment nut Brake fluid hose-pump fitting Oil bleed screw

3.69 lb ft (5 Nm) 14.75 - 18.44 lb ft (20-25 Nm) 5.9 - 8.8 lb ft (8-12 Nm)

*with Loctite 243

Overhaul data

As sem bl y c l earanc earan c es Cylinder - pist on assy.

COUPLING BETWEEN PISTON AND CYLINDER Nam e

In i t i al s

Cy l i n d er

Pi s t o n

Pl ay o n f i t t i n g

Cylinder

A

Cylinder

B

P iston

C

P iston

D

Cylinder 1st oversize

A1

Cylinder 1st oversize

B1

P iston 1st oversize

C1

P iston 1st oversize

D1

Cylinder 2nd oversize

A2

Cylinder 2nd oversize

B2

1.535157 - 1.535433 in (38.993 - 39.000 mm) 1.535433 - 1.535709 in (39.000 - 39.007 mm) 1.535709 - 1.535984 in (39.007 - 39.014 mm) 1.535984 - 1.536260 in (39.014 - 39.021 mm) 1.543031 - 1.543307 in (39.193 - 39.200 mm) 1.543307 - 1.543583 in (39.200 - 39.207 mm) 1.543583 - 1.543858 in (39.207 - 39.214 mm) 1.543858 - 1.544134 in (39.214 - 39.221 mm) 1.550906 - 1.551181 in (39.393 - 39.400 mm) 1.551181 - 1.551457 in (39.400 - 39.407 mm)



CHAR - 11


Characteristics

Nam e

In i t i al s

Cy l i n d er

Pi s t o n

Pl ay o n f i t t i n g

P iston 2nd oversize

C2

P iston 2nd oversize

D2

Cylinder 3rd oversize

A3

Cylinder 3rd oversize

B3

P iston 3rd oversize

C3

P iston 3rd oversize

D3

1.551457 - 1.551732 in (39.407 - 39.414 mm) 1.551732 - 1.552008 in (39.414 - 39.421 mm) 1.558780 - 1.559055 in (39.593 - 39.600 mm) 1.559055 - 1.559331 in (39.600 - 39.607 mm) 1.559331 - 1.559006 in (39.607 - 39.614 mm) 1.559006 - 1.559882 in (39.614 - 39.621 mm)

1.549921 - 1.550197 in (39.368 - 39.375 mm) 1.5590197 - 1.550472 in (39.375 - 39.382 mm) 1.557244 - 1.557520 in (39.554 - 39.561 mm) 1.557520 - 1.557795 in (39.561 - 39.568 mm) 1.557795 - 1.558071 in (39.568 - 39.575 mm) 1.558071 - 1558346 in (39.575 - 39.582 mm)

0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm)

N.B.

THE PISTON MUST MUST BE INSTAL LED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALL ED WITH THE WORD «TOP» OR THE THE STAMPED MARK FACING UPWARDS.

- Measure the outer diameter of the gudgeon pin.

Characteristic Pin outside diameter

0.511811 +0 -0.000157 in (13 +0 -0.004 mm) Minimum admissible di ame ameter ter gudgeon pin

0.511417 in (12.990 mm)

- Measure Measure the diameter diameter of the bearings on the piston.

Characteristic Pin seat diameter

0.511811 +0.000197 +0.000394 in (13 +0.005 +0.010 mm)

- Calculate the piston pin coupling clearance. N.B.

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS

Characteristic Standard clearance

0.000197 - 0.000551 in (0.005 - 0.014 mm) - Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston. N.B.

CHAR - 12

Piaggio Typhoon 50 4t 4v (EN)

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