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Gilera RCR 50, Manual

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Gilera RCR 50 Manual Download Page 33

Check the brake fluid reservoir level periodically. If necessary, refill it with the recom-
mended hydraulic liquid. Do not mix different types of liquid. Do not use the brake lever
with the reservoir open, otherwise, the liquid could be spilled spoiling all painted sur-
faces. Due to humidity absorption, it is advisable to change the liquid every two years.

CAUTION

TOP UPS SHOULD ONLY BE CARRIED OUT WITH DOT 4 CLASSIFIED BRAKE
FLUID.

DO NOT LET THE HIGHLY CORROSIVE BRAKE FLUID CONTACT PAINTED
PARTS. SHOULD THIS OCCUR, IMMEDIATELY WASH OFF WITH WATER.

WARNING

THE BRAKING CIRCUIT LIQUID IS HYGROSCOPIC, AND ABSORBS THE HU-
MIDITY OF SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKING FLUID
EXCEEDS A CERTAIN VALUE, IT WILL LEAD TO INEFFICIENT BRAKING. NEV-
ER USE BRAKING FLUID KEPT IN CONTAINERS THAT HAVE ALREADY BEEN
OPENED, OR PARTIALLY USED.

WARNING

IN NORMAL CLIMATIC CONDITIONS IT IS ADVISABLE TO REPLACE THE
ABOVE-MENTIONED FLUID EVERY 2 YEAR. NEVER USE BRAKE FLUID CON-
TAINED IN CONTAINERS WHICH ARE ALREADY OPEN OR PARTIALLY USED.

THE SYMBOL ON THE CONTAINER INDICATES THIS IS A SYNTHETIC BRAKE
FLUID AND NOT A MINERAL TYPE. USING MINERAL BRAKE FLUID CAUSES

33

3 Maintenance

Summary of Contents for RCR 50

Page 1: ...ns information tips and precautions for using your scooter It also describes features details and devices to assure you that you have made the right choice We believe that if you follow our suggestions you will soon get to know your new vehicle and it will serve you well for a long time to come This booklet forms an integral part of the scooter should the scooter be sold it must be transferred to ...

Page 2: ... checks that should be carried out on the vehicle at an Authorised PIAGGIO Dealer or Service Centre The booklet also contains instructions for simple repairs Any operations not specifically described in this manual require the use of special tools and or particular technical knowledge to carry out these operations refer to any authorised PIAGGIO Dealer or Service Centre 2 ...

Page 3: ...ent 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 The signs that you see on this page are very important They are used to highlight those parts of the booklet that should be read with particular care As you can see each sign consists of a different graphic symbol making ...

Page 4: ...4 ...

Page 5: ...ine 23 Precautions 23 Difficult start up 24 Stopping the engine 24 Stand 24 Safe driving 25 MAINTENANCE 27 Gearbox oil level 28 Gearing chain 29 Tyres 30 Spark plug dismantlement 30 Air filter cleaning 31 Cooling fluid level 32 Checking the brake oil level 32 Braking system fluid top up 34 Battery 34 Use of a new battery 35 Long periods of inactivity 36 Fuses 37 Front light group 38 Headlight adju...

Page 6: ...6 ...

Page 7: ...SMT RCR 50 Chap 01 Vehicle 7 ...

Page 8: ...01_01 8 1 Vehicle ...

Page 9: ...e speedometer indicates the motion speed in kilometres per hour 2 Odometer Total of covered kilometres The figure on the right side indicates the number of meters in hundreds 3 High beam warning light 4 Temperature indicator If the indicator is on the coolant temperature has exceeded 105º C 5 Turn indicator warning light 6 Oil reserve warning light This warning light turns on when there is an oil ...

Page 10: ...ed extractable key steering lock not on 3 Ignition disabled extractable key steering lock on Locking the steering wheel 01_04 In order to block the steering turn the handlebar completely to the left or right Fully insert the key and let it return to its original position turn it to position 3 and take it out Releasing the steering wheel 01_05 Insert the key press it and turn it clockwise Pull out ...

Page 11: ...dicator move the lever A leftwards to activate the right turn indicator move the lever rightwards The lever automatically returns to the central position and the indicators remain on To turn off push the switch 01_07 Horn button 01_07 Push B to activate the horn 11 1 Vehicle ...

Page 12: ...nditions of the road Particularly if it is wet asphalt or with sand oil etc 01_09 Throttle grip 01_09 Placed on the right side of the handlebar When the hand grip B is turned towards the driver the carburettor valve will be opened 01_10 Front brake control 01_10 The front brake control E is placed on the right side of the handlebar Be particularly careful when using the front brake apply softly an...

Page 13: ...ushing the pedal upwards For downshifting pressing the pedal down CAUTION THE GEAR PEDAL MUST BE OPERATED BY RELEASING IT AFTER HAVING DISENGAGED THE CLUTCH AND REDUCING THE THROTTLE GRIP TO THE MINIMUM 01_12 Clutch control 01_12 The lever of the clutch grip A is placed on the left side of the handlebar When it is pulled completely towards the handlebar the clutch is disengaged and the engine tran...

Page 14: ...dal backwards with your foot CAUTION CHECK THE GEAR IS IN THE NEUTRAL POSITION BEFORE STARTING THE ENGINE 01_15 Manual starter control 01_15 The carburettor starter control 2 is on the right side of the carburettor so it is easily reached with the hand on the same side It has two positions Lever upwards Starting in cold conditions Lever downwards Starting in normal conditions CAUTION THE ONLY AIM ...

Page 15: ...k has a 1 litre capacity and a 0 25 litre reserve Use recommended oil only Recommended products AGIP CITY TEC 2T Mixer oil synthetic oil for 2 stroke engines JASO FC ISO L EGD 01_18 Opening the saddle 01_18 01_19 To dismantle the saddle insert the key in the lock of the tank cover 1 and while turning rightwards lift the cover After that dismantle the two nuts of the saddle re tainer 2 The oil tank...

Page 16: ...ITS TAG IN A SAFE PLACE AND NOT ON THE SCOOTER 01_21 Identification 01_21 01_22 The identification numbers consist of a prefix stamped on the chassis and on the en gine followed by a number They must be quoted when ordering spare parts We recommend that you check that the prefix and chassis number stamped on the vehicle correspond with those in the vehicle documents N B ALTERING THE IDENTIFICATION...

Page 17: ...01_22 17 1 Vehicle ...

Page 18: ...18 1 Vehicle ...

Page 19: ...SMT RCR 50 Chap 02 Use 19 ...

Page 20: ...he liquid level in the brake pump tanks are correct 8 that the transmission chain is tightened and properly lubricated 9 that the coolant level is correct CAUTION SHUT OFF THE ENGINE BEFORE REFUELLING WITH PETROL PETROL IS HIGHLY FLAMMABLE DO NOT LET PETROL SPILL FROM THE TANK OR WHILE REFUELLING Tyre pressure A different pressure from the one indicated may cause problems when riding the ve hicle ...

Page 21: ... only 2 2 Kg cm 220 kPa rider and passenger 02_01 Running in 02_01 DURING THE FIRST 1000 KM DO NOT RIDE THE SCOOTER OVER 80 OF ITS MAX SPEED AVOID OPENING THE ACCELERATOR COMPLETELY AND KEEP ING A CONSTANT SPEED FOR LONG STRETCHES AFTER THE FIRST 1000 KM INCREASE SPEED GRADUALLY UNTIL REACHING MAXIMUM PERFORMANCE N B THE DURABILITY AND THE EFFICIENCY OF YOUR SCOOTER DEPEND STRONGLY ON THE CARE REC...

Page 22: ... AND BETTER PERFORMANCE IT IS NECESSARY NOT TO FORCE THE VEHICLE DURING THE 500 KM THE VEHICLE MUST HAVE A SUITABLE RUN IN PERIOD DURING WHICH THE FOLLOWING PRECAUTIONS MUST BE CONSIDERED AFTER STARTING THE ENGINE WARM IT UP PROGRESSIVELY WITHOUT MAXIMUM ACCELERATION WE RECOMMEND NOT TO EXCEED 3 4 OF THE THROTTLE GRIP OPENING FOR THE GEAR OR OVERCHARGE IN LONG STRETCHES DO NOT USE FULL SPEED CONSI...

Page 23: ...DO NOT KEEP MAXIMUM ACCELERATION FOR A LONG TIME USE THE EN GINE UP TO A 3 4 OF MAXIMUM PERFORMANCE PETROL WILL BE SAVED AND THE ENGINE LIFE WILL BE LONGER WHEN BRAKING STOP ACCELERATING BRAKE MODERATELY CONSIDERING THE TYPE OF ROAD ON ASPHALT TREATED DRY ROADS START BRAKING WITH THE FRONT BRAKE AND FIN ISH WITH BOTH ON WET ROADS OR WITH SAND OR SMALL STONES NEVER USE THE FRONT BRAKE AND KEEP MORE...

Page 24: ...hed put pressure on the rear wheel and release the clutch suddenly repeat the procedures as necessary 02_05 Stopping the engine 02_05 To stop the engine engage gear 1 in neutral position and turn the key switch anti clockwise Stand Check the stand is completely unfold before resting the vehicle so as to obtain an optimum resting PLEASE DO RIDE OFF WITH THE STAND UNFOLD 24 2 Use ...

Page 25: ...a good idea to apply the brakes from time to time Do not brake hard on a wet unsurfaced or slippery roads If you have to brake use both brakes in order to spread the braking action between both wheels For very steep slopes downshift gears to obtain a good traction Avoid resting the vehicle on the stand when starting off If you use the scooter on roads covered with sand mud snow mixed with salt etc...

Page 26: ...rate the clutch lever push the gear pedal on the left side of the scooter and position it in 1st gear Release the clutch gradually while accelerating progressively GEAR SHIFTING Release the accelerator pull the clutch and engage the desired gear release the clutch progressively and accelerate simultaneously To reduce speed downshift BRAKING Activate both brakes gradually downshift simultaneously 2...

Page 27: ...SMT RCR 50 Chap 03 Maintenance 27 ...

Page 28: ...ing If more oil is necessary use only oil with the same specifications as the one already in the engine CAUTION ENGINE OIL IS TOXIC DISPOSE IT PROPERLY Replacement Replace oil for the first time after 1 000 Km are covered and successively every 10 000 Km Replacement must be made with a warm engine Once the load cap 1 is removed unscrew also the drainage cap 2 on the crankcase central section and 3...

Page 29: ...nsion press using your finger on the corresponding fork pin the aver age of the chain must be between 30 and 45 millimetre TENSION ADJUSTMENT To keep the transmission chain clearance within the right values loosen nut A of the wheel pin screw the two adjustments B making the same number of turns for adjustment on the right as for the adjustment on the left so that the wheel is aligned Once the cha...

Page 30: ...LSO VEHICLE UNSTEADINESS LEADING TO DANGER WHEN RIDING THE TYRE MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS REQUIRED BY LAW 03_08 Spark plug dismantlement 03_08 Dismantle the spark plug periodically check electrodes and wear Use a thickness gauge and check that the distance between electrodes is correct Replace spark plugs using the recommended brands within the expirations indicated i...

Page 31: ...rew the 4 fixing screws of the air filter housing and take the filtering element out wash the sponge with water and a neutral shampoo dry with a clean cloth and short blasts of compressed air soak the sponge in a 50 petrol and Selenia Air Filter Oil solution remove it from the solution compress it with your hands without wringing out let it drain and reassemble Be extremely careful when reposition...

Page 32: ...R TO AVOID BURNS DO NOT UNSCREW THE EXPANSION TANK CAP WHILE THE ENGINE IS STILL HOT The cooling circuit approximate capacity is 1 100 cc SYSTEM CHECK Check the manifold conditions If during scooter normal use the temperature indicator lights up stop the engine and wait so the coolant becomes cool After that with cold engine check the coolant level and refill if necessary Never take the expansion ...

Page 33: ...AINTED PARTS SHOULD THIS OCCUR IMMEDIATELY WASH OFF WITH WATER WARNING THE BRAKING CIRCUIT LIQUID IS HYGROSCOPIC AND ABSORBS THE HU MIDITY OF SURROUNDING AIR IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE IT WILL LEAD TO INEFFICIENT BRAKING NEV ER USE BRAKING FLUID KEPT IN CONTAINERS THAT HAVE ALREADY BEEN OPENED OR PARTIALLY USED WARNING IN NORMAL CLIMATIC CONDITIONS IT IS ADVISABLE...

Page 34: ... insert the key on the tank cover lock turn the key rightwards and lift the cover Dismantle the two fixing wing nuts of the saddle and extract them the battery compartment is under the saddle The battery is the electrical device that requires the most frequent inspections and diligent maintenance The main points of maintenance to be observed are as follows Check the electrolyte level this must be ...

Page 35: ...TERY MAXIMUM INTENSITY MUST NOT EX CEED 0 5 1 A OTHERWISE THE BATTERY WOULD BE SERIOUSLY DAM AGED BATTERIES CONTAIN VERY ENVIRONMENTAL DANGEROUS SUBSTANCES FOR BATTERY REPLACEMENT CONTACT AN AUTHORISED PIAGGIO GILERA SERVICE CENTRE AS THEY ARE EQUIPPED FOR THE DISPOSAL IN AN EN VIRONMENTALLY FRIENDLY AND LEGAL WAY Use of a new battery Replace the battery it must be done using the same capacity and...

Page 36: ...der Store the vehicle with the battery removed The battery must be clean com pletely charged and stored in a dry and well ventilated area Recharge at least once every two months CAUTION THE CHARGE MUST BE MADE WITH A CURRENT EQUAL TO 1 10 OF THE RAT ED CAPACITY OF THE BATTERY AND FOR NOT LONGER THAN 8 HOURS TAKE THE VEHICLE TO AN AUTHORISED PIAGGIO GILERA SERVICE CENTRE FOR THIS OPERATION WHEN REF...

Page 37: ...battery positive cable Before replacing a blown fuse find and solve the problem that caused it to blow Do not substitute the fuse with any alternative form of conductor BULBS Front headlamp bulbs 12V 35 35 W Type Twin filament light stop bulb 12 V 21 5 W Type Twin filament Turn indicators bulb 12 V 10 W 37 3 Maintenance ...

Page 38: ... m distance in a darkened area with the vehicle in perpendicular position to the screen Start the engine and pull the throttle to 1 3 of its stroke and turn the headlamp on Select low beam light the maximum demarcation limit between the dark and the light area must result in a height inferior to a 8 10 height from the ground to the centre of the headlight The front headlight pointing must be done ...

Page 39: ... the transparent plastic The bulbs have a bayonet coupling to remove them press gently and twist anticlock wise about 30 and then withdraw it 03_19 Rear optical unit 03_19 To access the rear light bulbs unscrew the transparent plastic retainers B and the bulb is completely accessible 39 3 Maintenance ...

Page 40: ...ion Do not alter this adjustment Adjusting the idle speed This operation must be made with warm engine in neutral position and with no ac celeration Twist the adjustment screw at minimum towards the inside or outside until the engine idle speed is set at a point in which the engine is about to stop but functioning normally For any other carburettor adjustment contact an Authorised Service Centre P...

Page 41: ...icult procedures As the discs are wet on rainy days the recovery of the braking power is excellent and efficient braking of the front and rear brakes is ensured This is thanks to the pads high pressure specifications Front and rear disc brake 03_22 03_23 03_24 Brake disc The disc surface must be completely free of oil Use alcohol and a soft cloth for clean ing Brake pads If the brake squeals may b...

Page 42: ...e reservoir exceeds the Minimum when the peephole is partially full the level has decreased to the Minimum when it is completely empty the level is inferior to the Minimum Worn brake pads may cause the decrease of the brake liquid level Should the level be below the minimum the Customer is advised to contact an Authorised Piaggio Gilera Service Centre for a thorough check of the braking system To ...

Page 43: ...e vehicle coat the unpainted metal parts with antirust grease keep the wheels off the ground by resting the chassis on two wooden sup ports 4 For the battery follow the standards listed in the booklet 5 Drain the petrol from the carburettor tank through the bleed tap CAUTION THE CHARGE MUST BE MADE WITH A CURRENT EQUAL TO 1 10 OF THE RAT ED CAPACITY OF THE BATTERY AND FOR NOT LONGER THAN 8 HOURS T...

Page 44: ... sponge for bodywork soaked in lots of water and shampoo 2 4 of car shampoo in water Then rinse abundantly with water and dry with a shammy cloth For the motor exterior use petroleum a brush and clean rags Petroleum can damage paintwork Remember that any polishing with silicon wax must always be preceded by washing CAUTION DETERGENTS POLLUTE WATER THEREFORE THE VEHICLE SHOULD BE WASHED IN AN AREA ...

Page 45: ...ot rub emphatically Rinse with warm water and dry Once the cleaning is complete dry the components completely to avoid water spots Finishing with protection paint Apply the protective paint as soon as the first rusting signs appear To obtain optimum finishing we recommend using a small brush and shaking the paint before its use Ensure the surface is clean and dry Apply where impairment signs are s...

Page 46: ...ed by specialised technician Check the electrodes adjustment at 0 5 0 6 mm Clean the electrodes with pure petrol and a metallic brush Check if there is any fracture or crack in the isolating spark plug and replace if necessary If the spark plug is in good condition take your vehicle to an Authorised Piaggio Gilera Service Centre Flooded engine Accelerate and try to start even pushing make the engi...

Page 47: ...ised Piaggio Gilera Service Centre THE ENGINE TENDS TO STOP WITH MAXIMUM ACCELERATION Check that the throttle valve is not dirty or rusted Check that the spark plug is not dirty or faulty that the fuel is supplied normally the washers are leak tight Contact an Authorised Piaggio Gilera Service Centre IRREGULAR ENGINE EXHAUST BLASTS DURING ACCELERATION OR SLOPES Check that the throttle valve is not...

Page 48: ...justment Air in the braking system Contact an Authorised Piaggio Gilera Service Centre FAULTY SUSPENSION Oil leak silent block wearing at the end of the stroke wearing in shock absorber retainers Contact an Authorised Piaggio Gilera Service Centre ENGINE DOES NOT ACCELERATE OR WORK REGULARLY AT LOW RPM NOISY ENGINE FUNCTIONING ENGINE DOES NOT ACCELERATE OR WORK REGULARLY AT LOW RPM noisy engine fu...

Page 49: ...malfunctioning gear spontaneous disengagement malfunctioning of controls or steering 49 3 Maintenance ...

Page 50: ...50 3 Maintenance ...

Page 51: ...SMT RCR 50 Chap 04 Technical data 51 ...

Page 52: ...04_01 52 4 Technical data ...

Page 53: ...oil 2T through pump and variable capacity Transmission With oil coated gear for transmissions Fuel Unleaded petrol Carburettor Dell Orto PHVA 17 5 with manual starter Clutch Oil coated multiple disk Main transmission At rectified gears Ratio 21 78 Inlet Reed direct on the crankcase Gearbox At 6 speeds with selector fork and distribution drum operated by external control Speeds First Speed 11 34 Se...

Page 54: ...A 12V Ignition advance TDC 1 2 mm Spark plug NGK B8 ES VEHICLE TECHNICAL DATA Chassis diagonal twin spar frame Front suspension Hydraulic fork and centred axle Rear suspension Swinging with hydraulic progressive shock absorber Front wheel brake Hydraulic disc Ø 240 mm RCR Ø 260 mm SMT Rear wheel brake Hydraulic Ø 180 mm disc Front tyre 80 90 x 21 RCR 100 80 x 17 SMT 54 4 Technical data ...

Page 55: ...ear tyre 110 80 x 18 RCR 130 70 x 17 SMT Fuel Tank Capacity 7 l Reserve 1 3 l Oil mixer tank Capacity 1 l Reserve 0 25 l Total length 2030 mm Wheelbase 1 355 mm Maximum length 780 mm 55 4 Technical data ...

Page 56: ...56 4 Technical data ...

Page 57: ...SMT RCR 50 Chap 05 Spare parts and accessories 57 ...

Page 58: ...58 5 Spare parts and accessories ...

Page 59: ...SMT RCR 50 Chap 06 Programmed maintenance 59 ...

Page 60: ...n chain greasing Tension transmission chain check Safety locks check Front fork Check Electrical system and battery check Wheel Check Tyres pressure Check Fuel and oil hoses Check Vehicle and brake test road test Engine oil change Spark plug electrode gap check Carburettor Adjustment Clutch control lever Adjustment 60 6 Programmed maintenance ...

Page 61: ...mission chain check Front fork Check Electrical system and battery check Tyre condition and wear Check Tyres pressure Check Fuel and oil hoses Check Vehicle and brake test road test Engine oil Check Spark plug electrode gap replacement Carburettor Adjustment Clutch control lever Adjustment AT 10 000 20 000 40 000 50 000 KM Coolant Change Air filter clean 61 6 Programmed maintenance ...

Page 62: ...ks check Front fork Replacement Rear shock absorber Check Electrical system and battery check Headlight adjustment Tyre condition and wear Check Wheel Check Tyres pressure Check Oil filter Replacement Fuel and oil hoses Replacement Vehicle and brake test road test Engine oil change Spark plug electrode gap replacement Carburettor Adjustment Clutch control lever Adjustment 62 6 Programmed maintenan...

Page 63: ...smission chain check Front fork Check Electrical system and battery check Tyre condition and wear Check Tyres pressure Check Fuel and oil hoses Check Vehicle and brake test road test Engine oil Check Spark plug electrode gap replacement Carburettor Adjustment Clutch control lever Adjustment Cylinder head and cylinder Cleaning Complete piston Replacement 63 6 Programmed maintenance ...

Page 64: ...ific additives for increased adhesiveness AGIP CITY TEC 2T Mixer oil synthetic 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 BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm White anhydrous calcium based gre...

Page 65: ...ation between FL Selenia and Piaggio Engineering the Selenia Moto Rider products give the Piaggio Gilera scooters protection and safety in every operating situation A broad range of lubricants and functional fluids to satisfy the demands of every mo torcyclist tested on the Piaggio Gilera engines from the moment they leave the production line and selected to maximise reliability and performance Th...

Page 66: ...66 6 Programmed maintenance ...

Page 67: ...1 D Disc brake 41 F Fuel 15 Fuses 37 H Headlight 38 Horn 11 I Identification 16 Instrument panel 9 K Key switch 10 Keys 16 M Maintenance 27 59 S Saddle 15 Spark plug 30 Stand 24 Start up 14 T Tank 15 Technical Data 51 Turn indicators 40 Tyre pressure 20 Tyres 30 67 ...

Page 68: ...s or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication are available in all Countries The availability of single versions should be checked at the official Piaggio sales network Copyright 2005 PIAGGIO C S p A Pontedera All rights reserved Reproduction of this publication in whol...

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