Gilera DNA 50 Workshop Manual Download Page 83

Page: 83 / 170

Removing the piston

- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.

-Push detail 2 into detail 1 until the stop and extract detail 2.

- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3

all the way in.

N.B.

REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM
THE REMOVAL OPERATIONS

Specific tooling

020166Y

Pin lock fitting tool

Locking torques (N*m)

Locking head nuts:

10 to 11 N·m

- Use new wrist pin snap rings.

- Use new cylinder base gasket.

- Before refitting carefully clean all the surfaces.

- Use oil to be mixed during the fitting of the piston

and the cylinder.

CAUTION

POSITION THE ARROW PRINTED ON THE PIS-
TON CROWN TOWARDS THE EXHAUST
OPENING.
THE WRIST PIN SNAP RINGS MUST BE POSI-
TIONED ON THE PISTON WITH THE SPECIFIC
TOOL

Recommended products

AGIP CITY TEC 2T

Oil

Recommended oil

DNA 50

Engine

ENG - 83

Summary of Contents for DNA 50

Page 1: ...WORKSHOP MANUAL 633507 DNA 50 ...

Page 2: ... to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions models shown in this publication are available in all countries The availability of single versions should be checked at the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reproduction o...

Page 3: ...tions of this manual relating to specific tools along with the specific tool catalogue N B Provides key information to make the procedure 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...

Page 4: ......

Page 5: ...S CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ... 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 Alw...

Page 8: ...esc Quantity Frame prefix ZAPC2700000001001 Engine prefix C271M Dimensions and mass DIMENSIONS AND MASS Specification Desc Quantity Maximum width 780 mm Maximum length 1970 mm Wheel base 1350 mm Saddle height 810 mm Dry weight 99 kg Characteristics DNA 50 CHAR 8 ...

Page 9: ...th variable capacity depending on the engine speed and opening of throttle valve petrol pump Intake By means of a compression valve on the casing Dellorto Carburettor PHVA 17 5 Lubrication Engine lubrication piston cylinder crankshaft main bearings with mixer oil Transmission TRANSMISSION Specification Desc Quantity Transmission With automatic expandable pulley variator torque server V belt automa...

Page 10: ...esc Quantity Chassis Double steel diagonal beam Front suspension Hydraulic telescopic fork Steer torque 123 mm Front suspension stroke 80 mm Rear suspension With coaxial spring and hydraulic shock absorber Chassis to engine support with swinging arm Max rear wheel travel 83 mm Brakes BRAKES Specification Desc Quantity Front brake 240 mm dia disc brake with hydraulic control activated from handleba...

Page 11: ...VERS CAUTION DURING THE OPERATION CHECK THE INTEGRITY AND SEAL OF THE TWO SLEEVES 3 IN RUBBER LOCATED AT THE ENDS OF THE SECONDARY AIR HOSE IF NEC ESSARY REPLACE THEM USING NEW CLAMPS TO FAS TEN Carburettor 50cc Version Dell Orto DELL ORTO CARBURETTOR Specification Desc Quantity Type PHVA 17 5 ID Diffuser diameter Ø 17 5 Reference number of adjustment 8439 Maximum nozzle 53 Maximum air nozzle on t...

Page 12: ...support fixing screw 7 to 10 Nm Brake fluid pump hose fitting 13 to 18 Nm Brake fluid tube calliper fitting 20 to 25 Nm Calliper tightening screw 20 to 25 Nm Disc tightening screw safety locks lock with LOCTITE THREADLOCK MEDIUM TYPE 243 6 7 Nm Oil bleed screw 7 to 10 Nm Calliper coupling screw 20 to 25 Nm REAR BRAKE Name Torque in Nm Fastening screws calliper to the crankcase 20 25 Brake reservoi...

Page 13: ... O 40 011 40 018 39 957 39 964 0 047 0 061 Standard fitting P 40 018 40 025 39 964 39 971 0 047 0 061 1st oversize fitting M1 40 197 40 204 40 143 40 15 0 047 0 061 1st oversize fitting N1 40 204 40 211 40 15 40 157 0 047 0 061 1st oversize fitting O1 40 211 40 218 40 157 40 164 0 047 0 061 1st oversize fitting P1 40 218 40 225 40 164 40 171 0 047 0 061 2nd oversize fitting M2 40 397 40 404 40 343...

Page 14: ... 25 to 0 50 clearance F 0 20 to 0 75 Lining between the shoulders 40 64 H clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Cage 11 800 0 35 B clearance F 0 20 to 0 75 Slot packing system Fit the cylinder without installing the basic gasket Apply a centimetre dial gauge on the special tool and zero it on the ground plane Fit the tool to the top of the cylinder fixing it with two nuts to the studbo...

Page 15: ...tic oil for 2 stroke engines JASO FC ISO L EGD AGIP GP 330 Grease for brake levers throttle White calcium complex soap based spray grease with NLGI 2 ISO L XBCIB2 AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based lithium grease containing NLGI 2 Molybdenum disulphide ISO L XBCHB2 DIN KF2K 20 AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid MONTBLANC MOLYBDENUM GREASE Grease ...

Page 16: ...INDEX OF TOPICS TOOLING TOOL ...

Page 17: ...g steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings 001467Y014 Pliers to extract ø 15 mm bearings DNA 50 Tooling TOOL 17 ...

Page 18: ...ings OD 39 mm 001467Y021 Extraction pliers for ø 11 mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer ing tube 020004Y Punch for removing fifth wheels from headstock 020209Y Spring hook Tooling DNA 50 TOOL 18 ...

Page 19: ...020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate DNA 50 Tooling TOOL 19 ...

Page 20: ...ey assembly sheath 020165Y Start up crown lock 020166Y Pin lock fitting tool 020167Y Arrest key for impeller pump 020168Y Water seal punch mount on half crank case 020169Y Water pump crankshaft fitting and remov al spanner Tooling DNA 50 TOOL 20 ...

Page 21: ...Y Water pump mixer command gear ex tractor 020261Y Starter spring fitting 020262Y Crankcase splitting strip 020265Y Bearing fitting base 020325Y Brake shoe spring calliper 020329Y MityVac vacuum operated pump DNA 50 Tooling TOOL 21 ...

Page 22: ...Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger Tooling DNA 50 TOOL 22 ...

Page 23: ... Description 020335Y Magnetic support for dial gauge 020350Y Electrical system check instrument 020357Y 32 x 35 mm adaptor 020359Y 42x47 mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide DNA 50 Tooling TOOL 23 ...

Page 24: ...Stores code Description 020456Y Ø 24 mm adaptor 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner Tooling DNA 50 TOOL 24 ...

Page 25: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 26: ...vers greasing Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyre pressure and wear check Vehicle and brake test road test AT 10000 KM OR 24 MONTHS AND 50000 KM 95 Action Hub oil change Spark plug electrode gap replacement Air filter clean Idle speed adjustment Oil mixer throttle linkage adjustment Variable speed rollers replacement Driving belt che...

Page 27: ...cking Variable speed rollers replacement Mixer belt replacement Coolant level check Radiator external cleaning check Steering adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Vehicle and brak...

Page 28: ...placement Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check SAS box sponge cleaning Vehicle and brake test road test See the regulations of the Secondary air system section Checking the spark advance Check to be effected at 4000 rpm with strobo scopic gun The measured ...

Page 29: ...spark plug is defective replace it with the prescribed type Insert the spark plug with the correct inclination screw it down by hand then lock with a spanner to the prescribed torque Put the cap tightly back on the spark plug CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD THE SPARK PLUG MUST BE REPLACED EVERY 5000 KM USE OF STARTERS NOT CONFORMING OR SPARK PLUGS NOT THOSE DESCRIBED ...

Page 30: ...ANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY CAUSE SERIOUS DAMAGE CAUTION USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT FOR OIL REPLACEMENT CONTACT AN AUTHORISED SERVICE CENTRE WHICH IS EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY N B THE NOTCHES ON THE HUB OIL LEVEL DIPSTICK EX CEPT THOSE INDICATING THE MAXIMUM AND MINIMUM LEVELS REFER TO ...

Page 31: ...g Wash with water and neutral soap Dry with a clean cloth and short blasts of com pressed 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 products AGIP FILTER OIL...

Page 32: ...plate is aligned with the reference mark on the mixer body as shown in the figure Move the gas handle to the end of its stroke a few times and make sure the adjustments have been made correctly then lock all the adjusting screws CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN THE RESERVOIR BLEED THE MIXER AS FOLLOWS RE FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ...

Page 33: ...ing the two screws remove the gasket and top up using only the liquid specified without exceeding the maxi mum 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 CAU...

Page 34: ...vehicle in running order and with 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 scooter 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 not lower than 9 10 of the distance from the ground to the ce...

Page 35: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 36: ...rs if worn out Rear wheel spins at idle REAR WHEEL Possible Cause Operation Idling rpms too high Check the idling speed and if necessary adjust the C O Clutch fault Check the spring friction mass and the clutch bell Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged Starting difficulties DIFFICULTY STARTING Possible Cause Operation Carburettor nozzles ...

Page 37: ...e Tank breather hole obstructed Restore the proper tank aeration Engine tends to cut off at idle ENGINE STOP IDLING Possible Cause Operation Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air Starter that stays open Check electric wiring circuit continuity mechanical sliding and power supply Reed valve does not close Check replace the reed pack Wrong idling adjustment Co...

Page 38: ...e housing Blockage of the secondary air fitting on the muffler Remove the encrustations from the joint being careful not to let the debris fall into the muffler Transmission and brakes Clutch grabbing or performing inadequately CLUTCH Possible Cause Operation Tear or irregular functioning Check that the masses open and return normally Check that there is no grease on the masses Check that the clut...

Page 39: ...ected to the negative terminal while the red wire 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 Operation Faulty suspension Check that the rear shock absorber and or the front fork is are in good working order Replace or overhaul the front fork and...

Page 40: ...se pha ses of the fork and if necessary overhaul it Check that there is no noise or seizing during the wheel rotation if there is change the wheel bearing Components of the rear suspension damaged Check the absence of noise in the compression or release 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 Ch...

Page 41: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 42: ...otor 9 Starter relay 10 Starter button 11 Stoplight switch on rear brake 12 Stoplight switch on front brake 13 Turn signal switch 14 Low oil warning light sender 15 Automatic choke 16 Thermal switch 17 Antitheft LED pre wiring 18 Antitheft box pre wiring 19 Phonic wheel encoder 20 Fuel level sender Electrical system DNA 50 ELE SYS 42 ...

Page 43: ...rn signal light bulb B Low beam light bulb C High beam light bulb 25 Horn button 26 Horn 27 Dashboard assy A Low oil warning light B Dashboard light bulbs Ar Orange Az Sky Blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Conceptual diagrams DNA 50 Electrical system ELE SYS 43 ...

Page 44: ...Ignition 1 Electronic ignition device 2 Sparkplug 3 Magneto 6 Key switch Electrical system DNA 50 ELE SYS 44 ...

Page 45: ... Key switch 7 Battery 15 Automatic choke 21 Blinker switch 22 Headlight switch 23 Taillight A Turn signal light bulb B Sidelight C Stoplight 24 Headlight A Turn signal light bulb B Low beam light bulb C High beam light bulb 27 Dashboard assy A Low oil warning light DNA 50 Electrical system ELE SYS 45 ...

Page 46: ...6 Key switch 7 Battery 8 Starter motor 9 Starter relay 10 Starter button 11 Stoplight switch on rear brake 12 Stoplight switch on front brake 14 Low oil warning light sender 23 Taillight A Turn signal light bulb B Sidelight C Stoplight 27 Dashboard assy A Low oil warning light Electrical system DNA 50 ELE SYS 46 ...

Page 47: ...lywheel magneto 4 Voltage regulator 5 Main 7 5 A fuse 6 Key switch 7 Battery 14 Low oil warning light sender 16 Thermal switch 19 Phonic wheel encoder 20 Fuel level sender 27 Dashboard assy A Low oil warning light B Dashboard light bulbs DNA 50 Electrical system ELE SYS 47 ...

Page 48: ...switch 7 Battery 13 Turn signal switch 23 Taillight A Turn signal light bulb B Sidelight C Stoplight 24 Headlight A Turn signal light bulb B Low beam light bulb C High beam light bulb 25 Horn button 26 Horn 27 Dashboard assy A Low oil warning light Electrical system DNA 50 ELE SYS 48 ...

Page 49: ...ater temperature signal 4 Spare 5 Earth 6 Phonic wheel signal 7 Oil level 8 Parking lights 9 Oil check 10 Phonic wheel supply 11 Under key positive 12 Battery positive 13 Phonic wheel earth 14 Left turn indicator 15 Right turn indicator 16 High beam lamp INSTRUMENT PANEL DNA 50 Electrical system ELE SYS 49 ...

Page 50: ...ressed air and if necessary replace it 2 Without removing the stator carry out the following checks CHECK ON THE PICK UP Specification Desc Quantity 1 Red and white cable 90 140 ohm After visually checking the electrical wiring perform measurements on the loading reel the pickup see chart and the continuity using the appropriate tester If checks on the loading reel pickup and continuity show abnor...

Page 51: ...ections and the devices making up the ignition circuit must be done with the engine off if this is not done the controls might be irreparably dam aged Stator check Using a tester check the resistance between the red ground and green ground terminal N B VALUES ARE STATED AT AMBIENT TEMPERATURE A CHECK WITH THE STATOR AT OPERATING TEMPERA TURE LEADS TO VALUES HIGHER THAN THOSE STATED Electric charac...

Page 52: ... disconnecting the regulator connector and with the vehicle running use a tester to measure the alter nate voltages between the connection of the grey blue wire and black wire make sure it is within the indicated values if not replace the stator If no irregularities occur during these checks re place the regulator If replacement of the regulator does not restore correct operation carry out the che...

Page 53: ...RE CARRYING OUT THE CHECKS ON THE REGU LATOR AND RELATIVE SYSTEM IT IS ALWAYS GOOD PRACTICE TO CHECK THAT THERE IS CONTINUITY BE TWEEN 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 Specific tooling 020331Y Digital multimeter Characteristic Distributed current 1 5...

Page 54: ... ground ca ble If these last two tests have a positive result replace the regulator because it is certainly not functioning properly Specific tooling 020331Y Digital multimeter Fuses The electrics are protected by a fuse located on the right side next to the battery well To replace it remove the transparent protection mounted on the fuse holder The ignition system front headlight and rear tailligh...

Page 55: ...S IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF Dry charge battery WARNING THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS IT CON TAINS SULPHURIC ACID AVOID CONTACT WITH THE EYES THE SKIN AND CLOTHING IF COMING INTO CONTACT WITH EYES OR SKIN WASH ABUNDANTLY WITH WATER FOR AP PROX 15 MIN AND SEEK IMMEDIATE MEDIC...

Page 56: ...33Y Single battery charger 020334Y Multiple battery charger 1 Hold the vertical tube 2 Look at the level 3 The float must be freed Battery maintenance The battery is an electrical device which requires careful monitoring and diligent maintenance The maintenance rules are 1 Check the level of the electrolyte The electrolyte level must be checked frequently and must reach the upper level Only use di...

Page 57: ...es with and with 4 Battery cleaning The battery should always be kept clean especially on its top side and the terminals should be coated with Vaseline WARNING BEFORE RECHARGING THE BATTERY REMOVE THE PLUGS OF EACH CELL KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING M...

Page 58: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 59: ...ecting the related hose to the engine 7 Disconnect the electrical system connection from the magneto choke thermistor and starter 8 Disconnect the accelerator and mixer control drives 9 Disconnect the mixer oil carburettor and vac uum pump hoses on the carburettor 10 Disconnect the HV lead from the spark plug 11 Remove the rear shock absorber set bolt from the engine 12 Unscrew the nut on the righ...

Page 60: ...Engine from vehicle DNA 50 ENG VE 60 ...

Page 61: ...INDEX OF TOPICS ENGINE ENG ...

Page 62: ...E CRANKCASE Kickstart Upon refitting apply the recommended grease to the bushing to the spring and along the toothed sector Use the special tool for the charging of 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 products AGIP GREASE MU3 Grease for odometer transmission gear case Soap ba...

Page 63: ...REFUL OF THE SPRING TENSION IT COULD CONSTI TUTE 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 DI AMETER EXTRACTOR CAN BE USED Refitting the driven pulley shaft...

Page 64: ... the clutch bell is not worn or damaged Measure the inner diameter of the clutch bell Characteristic Clutch bell diameter standard value Ø 107 0 2 0 mm Clutch bell diameter max value allowed after use Ø 107 5 mm Eccentricity measured max 0 20 mm Removing the clutch Equip the tool with long pins screwed into position A from the outside insert the entire driven pulley in the tool and put the central...

Page 65: ...on material The masses must not show traces of lubricants otherwise check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EX HIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE AN OTHER 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 m...

Page 66: ...move 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 DRIVING BELT Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide Inspecting the driven fixed half pulley Check that there are no signs of wear on the work surface of the belt If ...

Page 67: ...mended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based lithium grease containing NLGI 2 Mo lybdenum 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 gr of grease This operation must be done through one of the holes inside the...

Page 68: ...ptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring Check that 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 XXXX Refitting the clutch Preassemble the driven pulley group with spring sheath and clutch Position the spring ...

Page 69: ...locking clutch unit on pulley 55 60 Nm Refitting the driven pulley Refit the driven pulley assembly the clutch bell and the nut using the specific tool Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Driven pulley shaft nut 40 to 44 Nm Drive belt Make sure the driving belt is not damaged and does not have cracks in the toothed grooves Check the width of the belt Charact...

Page 70: ... BREAK SUD DENLY 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 EVERY 20000 KM 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 t...

Page 71: ...e movable driven half pulley away by pulling it towards the clutch unit and insert 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 con tainer assembly with bushing limiting washer sta tionary half pulley cooling fan belt ...

Page 72: ... the hub cover Remove the transmission cover Remove the clutch assembly Discharge the rear hub oil Remove the 5 screws indicated in the figure Remove the hub cover with driven pulley shaft See also Refitting the clutch Removing the wheel axle Remove the intermediate gear and the complete gear wheel axle When removing the intermediate gear pay atten tion to the various shim adjustments Engine DNA 5...

Page 73: ...e the oil seal from the outside Remove the centring dowels and position the cover on a plane Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Position the special tube on the internal raceway of the bearing and from the shaft toothed side as indicated in th...

Page 74: ...itting the driven pulley shaft bearing Support the inner track of the bearing from the outside of the hub cover with the specific tool posi tioned under 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 Heat the hub cover and insert the bearing with the specific punch Fit the snap rin...

Page 75: ...andle 020363Y 20 mm guide 020359Y 42x47 mm adaptor Refitting the ub cover Refit the whole wheel axle Refit the intermediate gear paying attention to the two shim thicknesses Apply LOCTITE 510 for surfaces to the hub cov ers and refit the same with driven pulley shaft Refit the 5 screws and tighten them to the speci fied torque N B CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE ...

Page 76: ...in the inverse direction tightening the studs to the pre scribed torque THREAD THE CABLE OF THE STATOR INTO THE SPECIF IC HOUSING OF THE CRANKCASE AND MAKE SURE THAT IT IS LOCKED BY THE TAB OF THE RETURN LINE OF THE COOLING SYSTEM Locking torques N m Pick up screws 3 4 Stator screws 3 4 Refitting the flywheel cover Fit the rubber seal on the flywheel con nector and around the inlet coolant hose En...

Page 77: ... Tighten the 4 studs noting that the two longer golden screws are inserted in the 2 top holes and are also responsi ble for restraining the secondary air box Flywheel and starting Removing the starter motor Remove the central stand by unscrewing the 3 set screws of the engine support Remove the set screws indicated in the figure DNA 50 Engine ENG 77 ...

Page 78: ...ER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS 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 dis tortions that might cause rubbing on the stator and on the Pick Up Engine DNA 50 ENG 78 ...

Page 79: ... SUCH AS TO CAUSE PINGING KNOCKING ETC Locking torques N m Flywheel nut 40 to 44 N m Refitting the starter motor Fit a new O ring on the starter and lubricate it Fit the starter on the crankcase locking the two 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 motor screw...

Page 80: ...he 4 screws shown in the figure 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 Engine DNA 50 ENG 80 ...

Page 81: ...tic Rod small end standard diameter 17 0 011 0 001 Rod small end maximum allowable diameter 17 060 mm Inspecting the wrist pin Check the wrist pin external diameter using a mi crometer Characteristic Wrist pin standard diameter 12 0 005 0 001 mm Inspecting the piston Measure the bearings on the piston using a bore meter Calculate the piston pin coupling clearance Characteristic Wrist pin housing s...

Page 82: ...he cylinder with a bore meter according to the directions given in the figure Check that the fitting surface with the head is not dented or distorted To classify the cylinder piston fitting check the ap propriate table See also Cylinder piston assy Inspecting the piston rings Alternatively insert the two sealing rings in the cylinder Using the piston insert the seals perpendicularly to the cylinde...

Page 83: ...SE ORDER FROM THE REMOVAL OPERATIONS Specific tooling 020166Y Pin lock fitting tool Locking torques N m Locking head nuts 10 to 11 N m Use new wrist pin snap rings Use new cylinder base gasket Before refitting carefully clean all the surfaces Use oil to be mixed during the fitting of the piston and the cylinder CAUTION POSITION THE ARROW PRINTED ON THE PIS TON CROWN TOWARDS THE EXHAUST OPENING THE...

Page 84: ...ystem components CAUTION CHECK THE CORRECT REED UNIT SEAL NO LIGHT MUST PASS BETWEEN THE SUPPORT AND LAMELLA Crankcase crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners Engine DNA 50 ENG 84 ...

Page 85: ...e the crankshaft from the transmission side half crankcase Specific tooling 020163Y Crankcase splitting plate Removing the crankshaft bearings The bearings can stay on either the half crankcase or the crankshaft indifferently Using the special tool remove any bearings that have been left on the crankshaft N B The half rings must be inserted on the bearings with a few mal let blows Specific tooling...

Page 86: ...that acts on the bearing s inner track Specific tooling 020265Y Bearing fitting base Inspecting the crankshaft alignment With the specific tool shown check that the eccen tricity of the surfaces of diam A B C are within 0 03 mm reading limit on the dial gauge in addition check the eccentricity of diam D for which a maximum reading of 0 02 mm is permitted In the case where eccentricity is not much ...

Page 87: ...earing rea ches the end of stroke stop Let the temperature of the half crankcase settle at the temperature of the crankshaft Again install the special crankcase separation plate NOT installing the crankshaft protection During the assembly phase keep the central thrust screw loose Take the four clamping screws to the end of the stroke and loosen them again with the same angle e g 90 When the temper...

Page 88: ...t the flywheel side half crankcase with a clean precise movement Insert at least three clamping screws and tighten up rapidly Insert the other 5 screws and tighten them to the specified torque Locking torques N m crankcase coupling screws 11 13 Move the crankcase separation plate in a position back from the one indicated in the figure Install the special magnetic support with dial gauge at the end...

Page 89: ...the special tool s punch The flywheel side oil seal is recognised by its smaller diameter N B THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE WITH THE FITTED WRENCH Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Install a new transmission side oil seal using the special tool with adapter ring The transmission side oil seal is recognised by the larger diameter Specific to...

Page 90: ...figure Remove the tube passage seal from the crank case shown in the figure Refitting To refit perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure Engine DNA 50 ENG 90 ...

Page 91: ...lowing measurements can be made on the amounts distributed 1 Start up the engine bring it to normal operating temperature and then shut it off 2 Disconnect the fuel adduction line on the car burettor and insert it into a graduated tube 3 Start up the engine without the accelerator and keep it idle 4 After the engine is started count to 10 and then turn it off 5 Check that the quantity of fuel is n...

Page 92: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 93: ...ng the front wheel Loosen the wheel axle set screws A Unscrew and extract the wheel axle B Refitting the front wheel When reassembling be careful of the correct po sitioning of the odometer movement socket Locking torques N m Front wheel axle 45 50 Wheel axle clamp screw 6 7 Nm Handlebar DNA 50 Suspensions SUSP 93 ...

Page 94: ...front brake calliper using the two screws Remove the front wheel Remove the front bumper Loosen the four set screws of the fork leg to the plates and front cover indicated in the photo in or der to be able to remove the pump unit from below During disassembly be careful to support the cover only with the brackets anchored to the fork leg Suspensions DNA 50 SUSP 94 ...

Page 95: ...support screws on the fork legs Loosen the two pump unit set screws on the up per plate remove ring nut A and pull out the upper plate Remove ring nut B extract the rubber protection and the washer Remove the complete fork from the bottom being careful to support the cover only with the brackets anchored to the fork legs Use the extractor to remove the bearing from the seat in the chassis Remove t...

Page 96: ...range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Locking torques N m Locking torque 50 to 60 Nm Removing the rear wheel Use a screwdriver as a lever between the drum and the cover Straighten the split pin and remove the cap Remove the wheel acting on the central fixing point WARNING ALWAYS USE NEW SPLIT PINS FOR REFITTING Shock absorbers Removal To replace the shock absorber you just need to remov...

Page 97: ...in securing the stand to the bracket Remove the stand support bracket from the en gine Drill a 5 mm hole in the bracket so that the pin P can come out Assembly and caulking stand pin to the bracket Caulk the end of the pin P between the two punches shown in the figure After caulking it must be possible for the stand to turn freely N B UPON REFITTING USE NEW O RING AND PIN GREASE THE SPRING ATTACHM...

Page 98: ... Work on the screws shown in the figure When refitting secure to the prescribed torque Locking torques N m Stand screw torque 18 5 to 19 Nm Suspensions DNA 50 SUSP 98 ...

Page 99: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 100: ... male hexagonal screws 2 and remove the reaction plate 3 3 take out the fixed plate 4 from the guide 4 remove the internal elements from the floating body 5 with the help of short blows of com pressed air through the brake fluid pipe in order to facilitate the expulsion of pistons 6 5 Check that the plates and the body are whole and in good condition that the cylinder and the floating body of the ...

Page 101: ...btain the thrust for both pads The body and the reaction plate body work inte grally and can move axially with respect of the fixed plate that is integral to the strut The pistons forced by pressure to push the pad to the disk cause the reaction plate to push in turn the other pad towards the disc The brake pad lock spring 1 Pad fixing screws 2 Reaction plate fixing screws 3 Reaction plate 4 Fixed...

Page 102: ...the front wheel undoing the axle clamp ing Undo the five disc clamps Locking torques N m Disc tightening screw 8 10 Refitting When refitting position the disc correctly making sure that it rotates in the right direction Locking torques N m Disc tightening screw 8 12 Disc Inspection Checking the disc is important it must be perfectly clean with no sign of rust oil or grease or other dirt and must n...

Page 103: ...alue measured is greater re place the disc and repeat the check If the problem persists check and re place the wheel hub if necessary Specific tooling 020335Y Magnetic support for dial gauge Front brake pads Removal Proceed as follows Remove the front calliper Loosen the two pins shown in the figure that lock the two pads Remove the pads being careful with the pad spring clamp Check the thickness ...

Page 104: ...e of the special tool to the bleed screws When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system The operation is finished when just oil comes out of the bleed screws Do up the bleed screw When the operation is over tighten up the oil bleed screw to the prescribed torque N B IF AIR CONTINUES...

Page 105: ...LY DRY THE CALLIPER AND DE GREASE THE DISC SHOULD THERE BE OIL ON IT Specific tooling 020329Y MityVac vacuum operated pump Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Locking torques N m Oil bleed screw 8 12 Front brake pump Drain the brake fluid from the circuit using the bleed screw located on the calliper and operating the brake lever until more fluid comes out Rem...

Page 106: ...mes out Remove the handlebar pump using the two stand set screws indicated in the figure disconnect the hose and put the brake fluid in a container On refitting perform the operation in reverse Tighten the hydraulic line to the prescribed torque and bleed the system Locking torques N m Brake fluid pump hose fitting 20 25 Nm Braking system DNA 50 BRAK SYS 106 ...

Page 107: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 108: ... 5 Turn off the engine restore the level of liquid to the maximum level then close the expan sion tank 6 Heat up the engine to normal operating tem perature in order to eliminate any air forma tion in the main lines 7 Stop the engine and let it cool then check that the level of coolant in the expansion tank to the maximum refill it Water pump overhaul Ensure the shaft is not abnormally worn and th...

Page 109: ...hould this operation prove difficult do not carry on instead start over by reheating the crankcase N B FAILURE TO OBSERVE THIS RULE MAY RESULT IN DAM AGE TO THE THREAD OF THE COPPER INSERT ON THE IMPELLER OR SEPARATION OF THIS FROM THE IMPEL LER ITSELF Specific tooling 020169Y Water pump crankshaft fitting and re moval spanner Using the air heater warm up the water pump bearing housing without dir...

Page 110: ...NG THE TOOL PAY ATTENTION NOT TO OVERLOAD THE PLASTIC IMPELLER Specific tooling 020167Y Arrest key for impeller pump Remove the mixer water pump drive belt with the two sprockets Remove the split ring from the shaft together with the bearings Remove the steel washer Using the air heater warm up the crankcase in the area around the water pump bearings as shown in the picture Cooling system DNA 50 C...

Page 111: ...Thermostat Removal Detach the coolant hose from the head partially draining the system Remove the cylinder head Remove the two fixing screws and hence the thermostat Check 1 Visually check that the thermostat is not dam aged 2 Fill a metallic container with approx 1 litre of water Immerge the thermostat and keep it in the centre of the bowl Immerge the multimeter temperature probe and keep it clos...

Page 112: ...INER Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check Opening start temperature 60 2 C Refitting Refit the thermostat onto the head fol lowing the removal operations in the reverse order and paying attention in inserting the groove on the thermostat on the reference on the head Cooling system DNA 50 COOL SYS 112 ...

Page 113: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 114: ...in the figure Remove the rubber caps and disconnect the con nectors from the bulbs Remove the headlamp unit set screws and pull the unit out from the top Taillight assy Remove the two screws and take out the whole unit Chassis DNA 50 CHAS 114 ...

Page 115: ...screws indicated in the photo and then the side panels Front side panels Remove the screws shown in the photo and then disconnect the joint between the side panels and the lower central cover When reassembling be sure to screw the shortest threaded screw in position A DNA 50 Chassis CHAS 115 ...

Page 116: ...emove the protective crankcase of the carbu rettor by removing the four screws Remove the two screws shown in the photo then disconnect the air manifold at the carburettor and remove it When refitting be careful to correctly install the air manifold into the air filter housing Rear mudguard Rimuovere il carter di protezione carburatore agendo sulle quattro viti Rimuovere il parafango agendo sulle ...

Page 117: ...s inside the helmet com partment indicated in the photo Remove the saddle opening drives on both sides using the two screws indicated in the photo Remove the five screws connecting the two com partment guards indicated in the photo Remove the fuel cap separate the two guards enough to let the fuel intake pipe pass and then remove the compartment from the top DNA 50 Chassis CHAS 117 ...

Page 118: ... photo Disconnect the three hoses A towards the engine unit then remove the fuel pump using the two screws B indicated in the photo Remove the two expansion tank support screws remove the two radiator set screws and without draining the cooling system pull the radiator out from the bottom and the expansion tank from the chassis unit Remove the fuel level connector Chassis DNA 50 CHAS 118 ...

Page 119: ...ure to secure the split ter block support with the left front set screws of the tank Radiator fan Remove the front side panels and the lower cen tral covering Drain the coolant and then disconnect the four hoses A Remove the two screws B and pull the radiator out of its seat on the lower bracket DNA 50 Chassis CHAS 119 ...

Page 120: ...ainer Mixture oil tank Remove the saddle remove the battery cover disconnect the mix oil level connector and unscrew the screw shown in the photo Pull the tank out from the top collect the oil in a container and disconnect the oil supply hose Battery Remove the saddle unscrew the screw indicated in the photo and remove the cover Chassis DNA 50 CHAS 120 ...

Page 121: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 122: ...m Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam low beam position and parking lights and the respective warning lights Adjusting the headlights according to the regulations currently in force Rear light parking light stop light Front and rear stop light switches Turn indicators and their warning lights Instrum...

Page 123: ...ES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GAS KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO EN SURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REA...

Page 124: ...NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Throttle travel check Others Check documentation Check the frame and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirrors an...

Page 125: ...INDEX OF TOPICS TIME TIME ...

Page 126: ...ion is devoted to the time necessary to carry out repairs The description and code for each operation is in dicated Engine ENGINE Code Action Duration 1 001001 Engine to chassis Replacement Time DNA 50 TIME 126 ...

Page 127: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement DNA 50 Time TIME 127 ...

Page 128: ...aft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001118 Main bearings Replacement 3 001099 Oil seal flywheel side Replacement 4 001100 Oil seal clutch side Replacement Time DNA 50 TIME 128 ...

Page 129: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder piston Replacement 2 001107 Cylinder piston Inspection clean ing DNA 50 Time TIME 129 ...

Page 130: ... Intake manifold Replacement 2 001056 Head gasket change 3 001057 Thermostat Replacement 4 001093 Spark plug Replacement 5 001126 Head Replacement 6 007010 Bleed valve Replacement 7 001178 Disc pack Replacement 8 001083 Thermistor Replacement Time DNA 50 TIME 130 ...

Page 131: ...riven pulley DRIVEN PULLEY Code Action Duration 1 001110 Driven pulley Replacement 2 001022 Clutch Replacement 3 001155 Clutch bell housing Replacement 4 001012 Driven pulley Service DNA 50 Time TIME 131 ...

Page 132: ...Oil pump OIL MIX PUMP Code Action Duration 1 001018 Mixer Replacement 2 001019 Mixer belt replacement 3 001028 Mix movement gear socket Re placement Time DNA 50 TIME 132 ...

Page 133: ...INAL REDUCTION GEAR Code Action Duration 1 001010 Geared reduction unit Service 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 004125 Rear wheel axle Replacement DNA 50 Time TIME 133 ...

Page 134: ...e Action Duration 1 001011 Driving belt Replacement 2 001066 driving pulley Replacement 3 001017 Starter sprocket wheel Replace ment 4 001086 Driving half pulley replace 5 001177 Variator rollers shoes Replace ment Time DNA 50 TIME 134 ...

Page 135: ...tion 1 001096 Transmission crankcase cover Re placement 2 001131 Transmission air intake Replace ment 3 001132 Transmission air inlet pipe Replace ment 4 001135 Transmission cover bearing Re placement 5 004179 Stand buffer Replacement DNA 50 Time TIME 135 ...

Page 136: ...Water pump WATER PUMP Code Action Duration 1 001113 Water pump Replacement 2 001062 Water pump command shaft Re placement 3 007019 Connection water pump pipe return pipe Replacement Time DNA 50 TIME 136 ...

Page 137: ...ARTER Code Action Duration 1 001020 Starter motor Replacement 2 001021 Kick starter Inspection 3 001084 Starter lever Replacement 4 008008 Starter spring pack Replacement 5 005045 Starter motor cable harness Re placement DNA 50 Time TIME 137 ...

Page 138: ...Flywheel magneto FLYWHEEL MAGNETO Code Action Duration 1 001058 Flywheel Replacement 2 001067 Stator Replacement 3 001173 Rotor Replacement 4 001087 Flywheel cover Replacement Time DNA 50 TIME 138 ...

Page 139: ...Brake shoes BRAKE SHOES Code Action Duration 1 002002 Rear brake shoe s Replacement DNA 50 Time TIME 139 ...

Page 140: ...Carburettor CARBURETTOR Code Action Duration 1 001063 Carburettor Replacement 2 007020 Carburettor heating tubing replace ment 3 003058 Carburettor Adjustment Time DNA 50 TIME 140 ...

Page 141: ...CARBURETTOR INSPECTION Code Action Duration 1 001081 Automatic choke Replacement 2 001008 Carburettor Inspection Exhaust pipe DNA 50 Time TIME 141 ...

Page 142: ...1095 Muffler guard Replacement 3 001136 Exhaust emissions Adjustment Air cleaner AIR FILTER Code Action Duration 1 001014 Air filter Replacement cleaning 2 001015 Air filter box Replacement 3 004122 Air cleaner carburettor fitting Re placement Time DNA 50 TIME 142 ...

Page 143: ...ction Duration 1 001053 Stand bolt Replacement 2 004004 Stand Replacement 3 004001 Frame replace 4 004015 Footrest Replacement 5 004171 Stand support plate Replacement 6 004143 Footrest support replace DNA 50 Time TIME 143 ...

Page 144: ... Code Action Duration 1 004065 Front shield rear section Replace ment 2 004064 Front shield Replacement 3 003087 Wheel housing Replacement 4 004167 Grill radiator cover Replacement 5 004176 Air vent Replacement Time DNA 50 TIME 144 ...

Page 145: ...Side fairings CENTRAL COVER Code Action Duration 1 004053 Spoiler Replacement 2 004178 Footrest Replacement 3 004011 Central chassis cover Replacement DNA 50 Time TIME 145 ...

Page 146: ...derseat compartment HELMET COMPARTMENT Code Action Duration 1 004059 Spark plug inspection flap Replace ment 2 004016 Helmet compartment Replacement 3 005046 Battery cover Replacement Time DNA 50 TIME 146 ...

Page 147: ...ction Duration 1 005022 Rear turn indicators Replacement 2 005068 Rear turn indicator bulb Replace ment 3 005005 Taillight Replacement 4 005023 Rear tail light support Replacement 5 005091 Turn indicator glass Replacement DNA 50 Time TIME 147 ...

Page 148: ...Mudguard MUDGUARDS Code Action Duration 1 004009 Rear mudguard Replacement 2 004052 Bumper Replacement 3 004002 Front mudguard Replacement Time DNA 50 TIME 148 ...

Page 149: ... tank Replacement 2 005010 Tank float Replacement 3 004011 Central chassis cover Replacement 4 004072 Fuel filter Replacement 5 004110 Fuel tank hose Replacement 6 004168 Fuel tank cap Replacement 7 004170 Tank filler neck Replacement DNA 50 Time TIME 149 ...

Page 150: ...l OIL TANK Code Action Duration 1 004017 Oil reservoir Replacement 2 005018 Oil reservoir float Replacement 3 004095 Oil reservoir cock Replacement 4 004091 Oil reservoir hose Replacement Time DNA 50 TIME 150 ...

Page 151: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorbers Replace ment DNA 50 Time TIME 151 ...

Page 152: ...umn bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheel Replacement 2 003073 Steering clearance Adjustment 3 004119 Bearing upper steering fifth wheel Replacement Time DNA 50 TIME 152 ...

Page 153: ...nt 5 003059 Counterweight Replacement 6 002024 Front brake pump replace 7 002037 Brake or clutch lever Replacement 8 002047 Front brake fluid and air bleeding system Replacement 9 003061 Accelerator transmission Adjust ment 10 004066 Driving mirror Replacement 11 002071 Left hand grip Replacement 12 002067 Rear brake pump Replacement 13 002080 Rear brake oil bleeding system Re placement DNA 50 Tim...

Page 154: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine frame swinging arm fitting Replacement Time DNA 50 TIME 154 ...

Page 155: ...Seat SEAT Code Action Duration 1 004003 Saddle Replacement 2 004054 Seat lock hook Replacement 3 002083 Saddle opening transmission Re placement DNA 50 Time TIME 155 ...

Page 156: ...NT UNIT AND HANDLEBAR COVER Code Action Duration 1 005014 Odometer Replacement 2 004018 Handlebar front section Replace ment 3 004019 Handlebar rear section Replace ment 4 005078 Odometer glass Replacement Time DNA 50 TIME 156 ...

Page 157: ...FRONT LIGHT Code Action Duration 1 005067 Front turn indicator bulb Replace ment 2 005008 Front headlamp bulbs Replacement 3 005002 Front headlamp Replacement 4 005012 Front turn indicator Replacement DNA 50 Time TIME 157 ...

Page 158: ... Replacement Grease tone wheel or drive Please take note that the code has been intro duced 900001 Tone wheel drive greasing 15 Never mistake the codes 002011 movement sen sor replacement and 005089 tone wheel replace ment in the event of noise of the indicated components The grease recommended is TUTE LA MRM 2 soap based lithium grease with Mo lybdenum disulphide In the following points we indica...

Page 159: ...L Code Action Duration 1 001071 Rear wheel rim Replacement 2 001016 Rear wheel Replacement 3 002070 Rear brake disc Replacement 4 004126 Rear wheel tyre Replacement 5 002028 Rear wheel hub Replacement DNA 50 Time TIME 159 ...

Page 160: ...Fuel pump FUEL PUMP Code Action Duration 1 004073 Fuel pump Replacement 2 004137 Pump carburettor hose Replace ment 3 004086 Petrol pump depression tube Re placement Time DNA 50 TIME 160 ...

Page 161: ...c devices BATTERY Code Action Duration 1 005007 Battery Replacement 2 005024 Battery fuse Replacement 3 005025 Fuse holder Replacement 4 005011 Start up remote control switch Re placement DNA 50 Time TIME 161 ...

Page 162: ...23 Control unit Replacement 2 001094 Spark plug cap Replacement 3 005001 Electrical system Replacement 4 005009 Voltage regulator Replacement 5 005136 Resistance Replacement 6 005044 Front lights cable unit Replacement Time DNA 50 TIME 162 ...

Page 163: ...on Replacement 2 005040 Horn button Replacement 3 005016 Key switch Replacement 4 004096 Lock series Replacement 5 004010 Antitheft lock replace 6 005003 Horn Replacement 7 005006 Light switch or turn indicators Re placement 8 005039 Headlight switch Replacement DNA 50 Time TIME 163 ...

Page 164: ...tion 1 002012 Splitter Replacement 2 002058 Mix splitter transmission complete Replacement 3 002057 Carburettor splitter transmission complete Replacement 4 002054 Throttle or splitter transmission com plete Replacement Time DNA 50 TIME 164 ...

Page 165: ...2007 Front brake pads Replacement 2 002021 Front brake piping Replacement 3 002039 Front brake calliper Replacement 4 002002 Rear brake pads Replacement 5 002020 Rear brake disc piping Replace ment 6 002048 Rear brake calliper Replacement DNA 50 Time TIME 165 ...

Page 166: ...S Code Action Duration 1 004159 Plates Stickers Replacement 2 004056 Upper rear light cover Replacement 3 004036 Lower chassis cover Replacement 4 004085 Fairing 1 Replacement 5 004129 Rear fairing Replacement Time DNA 50 TIME 166 ...

Page 167: ...Front suspension FORK Code Action Duration 1 003010 Front suspension Service 2 003051 Complete fork replace 3 003048 Fork oil seal Replacement 4 003041 Fork stanchion Replacement DNA 50 Time TIME 167 ...

Page 168: ...002 Water cooling radiator Replace ment 3 001052 Coolant and air bleed Replacement 4 007024 Expansion tank cap Replacement 5 007013 Expansion tank radiator connecting hose Replacement 6 007003 Delivery line and coolant return Re placement 7 001170 Air deflector Replacement Time DNA 50 TIME 168 ...

Page 169: ...001163 Muffler secondary air connection Replacement 2 001165 Secondary air reed Replacement 3 001164 Crankcase secondary air connection Replacement 4 001161 Secondary air filter Replacement Cleaning 5 001162 Secondary air housing Replace ment DNA 50 Time TIME 169 ...

Page 170: ...05 106 139 165 C Carburettor 11 140 E Engine stop F Fuel 37 91 118 149 160 Fuses 54 H Headlight 34 114 Hub oil 29 I Identification 8 Instrument panel 49 156 M Maintenance 7 26 S Shock absorbers 96 Spark plug 29 T Tank 118 120 149 150 Transmission 9 38 62 135 Tyres 10 ...

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Gilera DNA 50, Workshop Manual

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