Gilera Runner RST 50 SP Service Station Manual Download Page 91

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Removing the crankshaft

- Install the specific tool on the half crankcase on

the transmission side using four M6 screws of an

adequate length.

- Remove 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

004499Y001

Bearing extractor bell

004499Y006

Bearing extractor ring

004499Y002

Bearing extractor screw

004499Y007

Half rings

- Using the specific tool remove any bearings left

on the half crankcase

Specific tooling

001467Y007

Driver for OD 54 mm bearing

001467Y006

Pliers to extract 20 mm bearings

Runner RST 50 SP

Engine

ENG - 91

Summary of Contents for Runner RST 50 SP

Page 1: ...SERVICE STATION MANUAL 639189 Runner RST 50 SP ...

Page 2: ...y changes 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 Repro...

Page 3: ...d the sections 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 obse...

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: ...ressed 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 u...

Page 8: ...rburettor DELL ORTO PHVA 17 5 ID CO adjustment 3 5 0 5 Engine idle speed 1800 to 2000 r p m Air filter Sponge impregnated with fuel mixture 50 SELENIA air filter oil and 50 unleaded petrol Starting system electric starter kickstarter Lubrication With blend and variable oil variable according to the engine revolutions and the throttle valve opening by means of a pump controlled by the driving shaft...

Page 9: ...fore dead centre 16 1 AT 4000 rpm Sparkplug One cylinder two stroke liquid cooled CHAMPION RN1C Battery 12V 4Ah Main fuse 7 5 A Generator In alternate current with three output sections Frame and suspensions FRAME Specification Desc Quantity Chassis type Welded tubular steel chassis with stamped sheet reinforce ments Front suspension Hydraulic fork with upside down rods Front fork stroke 73 mm Fro...

Page 10: ... ing that the steel blade is not warped and or does not guarantee the seal on its strike surface re place if necessary N B UPON REFITTING MAKE SURE TO CORRECTLY FIT THE TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMI NIUM COVERS 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...

Page 11: ...rew on brass copper aluminium and their alloys 6 5 M6 Ø 8 8 steel screw Iron steel 10 5 M7 Ø 8 8 steel screw on brass copper aluminium and their alloys 10 5 M7 Ø 8 8 steel screw Iron steel 17 M8 Ø 8 8 steel screw on brass copper aluminium and their alloys 16 M8 Ø 8 8 steel screw Iron steel 26 M10 Ø 8 8 steel screw Iron steel 52 M12 Ø 8 8 steel screw Iron steel 100 M14 Ø 8 8 steel screw Iron steel ...

Page 12: ...ng nut 10 11 Coolant bleed screw 1 2 Temperature sensor 6 8 Temperature sensor at the ECU 18 22 Crankcase closure screw 12 13 Transmission cover closing screw 12 13 Pick up screw 3 4 Stator screw 3 4 Suction connection screw 7 8 Starter screw 12 13 Mixer screw 3 5 Rear hub cap screw 12 13 Driving pulley nut 40 44 Driven pulley nut 40 44 Oil drain rear hub screw 3 5 Clutch nut 55 60 Mixer strip scr...

Page 13: ... 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 40 35 0 047 0 061 2nd oversize fitting N2 40 404 40 411 40 35 40 357 0 047 0 061 2nd oversize fitting O2 40 411 40 418 40 357 40 364 0 047 0 061 2nd oversize fitting P2 40 418 40 425 40 364 40 371 0 047 0 061 Piston ...

Page 14: ...uantity Rod small end Cat 3 Ø 17 0 011 0 007 Rod small end Cat 2 Ø 17 0 007 0 003 Rod small end Cat 1 Ø 17 0 003 0 001 Roller cas ing Cat 1 Ø 2 5 0 0 002 Roller cas ing Cat 2 Ø 2 5 0 002 0 004 Roller cas ing Cat 3 Ø 2 5 0 004 0 006 Roller cas ing Cat 1 Op tional Ø 2 5 0 001 0 003 Roller cas ing Cat 2 Op tional Ø 2 5 0 003 0 005 Roller cas ing Cat 3 Op tional Ø 2 5 0 005 0 007 Test probe 0 005 0 00...

Page 15: ...nd reset it on an adjusted surface Fit the tool on the top of the cylinder fixing it with two nuts to the stud bolts keeping to the torque wrench setting and take the piston to the dead centre position The thickness of the gasket to fit will change de pending on the value found Three gaskets are given with the following thick ness Specific tooling 020272Y Piston position check tool Locking torques...

Page 16: ...ITY TEC 2T Mixer oil synthetic oil for 2 stroke engines JASO FC ISO L EGD AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid AGIP GREASE SM 2 Grease for compensating ring NLGI 2 ISO L XBCHB2 DIN KF2K 20 Molybdenum disulphide grease and lithi um soap AGIP GREASE PV2 Grease for ...

Page 17: ...INDEX OF TOPICS TOOLING TOOL ...

Page 18: ...eering 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 Tooling Runner RST 50 SP TOOL 18 ...

Page 19: ...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 Runner RST 50 SP Tooling TOOL 19 ...

Page 20: ...5Y 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 Tooling Runner RST 50 SP TOOL 20 ...

Page 21: ...sembly 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 Runner RST 50 SP Tooling TOOL 21 ...

Page 22: ...er 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 Tooling Runner RST 50 SP TOOL 22 ...

Page 23: ...Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger Runner RST 50 SP Tooling TOOL 23 ...

Page 24: ...ription 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 Tooling Runner RST 50 SP TOOL 24 ...

Page 25: ...Description 020456Y Ø 24 mm adaptor 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner 020625Y Kit for sampling gas from the exhaust manifold 494929Y Exhaust fumes analyser Runner RST 50 SP Tooling TOOL 25 ...

Page 26: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 27: ...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 checking...

Page 28: ... 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 brake tes...

Page 29: ...nt 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 made at a regime over 4000 rpm with stroboscopic gun The advance me...

Page 30: ...f defect replace the spark plug with one of the prescribed types Insert the sparkplug with the correct inclination screwing it all the way in then tighten it with the specific wrench to the correct torque Insert the cap onto the spark plug Refit the central door CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MO TOR IS COLD THE SPARK PLUG MUST BE REPLACED EVERY 5000 KM USE OF STARTERS NOT CONFORMI...

Page 31: ...EASE 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 OTHER MODELS ...

Page 32: ... 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 Oil for ai...

Page 33: ...as shown in the figure Turn the gas knob to the end stop a couple of times and check that the regulations are done correctly then tighten all the adjustments N B TO VERIFY THE CORRECT TIMING OF THE MIXER IT IS NECESSARY TO REMOVE THE AIR CONDUIT OF THE TRANSMISSION COVER CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN THE RESERVOIR BLEED THE MIXER AS FOLLOWS RE FILL THE OIL RESERVOIR WHEN ...

Page 34: ...nded products AGIP PERMANENT PLUS Coolant Monoethylene glycol antifreeze fluid CUNA NC 956 16 Braking system Level check Proceed as follows Rest the vehicle on its centre stand with the han dlebars perfectly horizontal Check the level of liquid with the related warning light A A certain lowering of the level is caused by wear on the pads Maintenance Runner RST 50 SP MAIN 34 ...

Page 35: ...N TOP UPS SHOULD ONLY BE CARRIED OUT WITH DOT 4 CLASSIFIED BRAKE FLUID CAUTION THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE THEREFORE WHEN TOPPING IT UP AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE THE BRAKING CIRCUIT FLUID IS HYGRO SCOPIC THAT IS IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE THIS WILL RES...

Page 36: ... 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 centre of vehicle headlamp and high er than 7 10 3 Otherwise regulate the headlight by adjusting the screw A after removing the front grille N B THE ABOVE PROCEDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO...

Page 37: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 38: ... 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 clogg...

Page 39: ...k 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 Correct...

Page 40: ...ble Cause Operation Secondary air reed blocking Replace Secondary air filter clogging Clean the filter and the 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 C...

Page 41: ...torcycle be careful not to invert the connections keep ing in mind that the black ground wire is connected 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 sho...

Page 42: ... quiet operation in the compression or release 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 ...

Page 43: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 44: ...ter 9 Remote control ignition 10 Ignition switch 11 STOP button on rear brake 12 STOP button on front brake 13 Horn 14 Horn button 15 Left rear direction indicator light 16 Rear optical unit A Parking light B Stop light 17 Turn indicator switch 18 Right rear direction indicator light Electrical system Runner RST 50 SP ELE SYS 44 ...

Page 45: ... light 22 Light switch 23 Fuel level transmitter 24 Water temperature probe 25 Instruments unit 26 Oil control light 27 Phonic wheel 28 Automatic starter 29 Starter control light Key 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 Runner RST 50 SP Electrical system ELE SYS 45 ...

Page 46: ...Ignition IGNITION 1 Electronic ignition device 2 Spark plug 3 Flywheel magneto 6 Key switch Electrical system Runner RST 50 SP ELE SYS 46 ...

Page 47: ...tage regulator 16 Rear optical unit A Parking light B Stop light 20 Front optical unit A Parking light B High beam headlight C Low beam headlight 22 Light switch 25 Instruments unit 28 Automatic starter 29 Starter control light Runner RST 50 SP Electrical system ELE SYS 47 ...

Page 48: ...age regulator 5 Main fuse 7 5 A 6 Key switch 7 Battery 8 Starter 9 Remote control ignition 10 Ignition switch 11 STOP button on rear brake 12 STOP button on front brake 16 Rear optical unit A Parking light B Stop light 26 Oil control light Electrical system Runner RST 50 SP ELE SYS 48 ...

Page 49: ...AND LEVEL INDICATOR 3 Flywheel magneto 4 Voltage regulator 5 Main fuse 7 5 A 6 Key switch 7 Battery 23 Fuel level transmitter 24 Water temperature probe 25 Instruments unit 26 Oil control light 27 Phonic wheel Runner RST 50 SP Electrical system ELE SYS 49 ...

Page 50: ...ttery 13 Horn 14 Horn button 15 Left rear direction indicator light 17 Turn indicator switch 18 Right rear direction indicator light 19 Left front direction indicator light 21 Right front direction indicator light 25 Instruments unit Digital instrument panel instrument unit Electrical system Runner RST 50 SP ELE SYS 50 ...

Page 51: ...dometer O Clock P Coolant temperature indicator for liquid cooled vehicles S Fuel level indicator DIGITAL DISPLAY A Fuel level gauge B Coolant temperature gauge C Digital clock D Speedometer E Odometer F Partial odometer gauge G Total odometer gauge INSTRUMENT UNIT CONNECTOR INSTRUMENT UNIT CONNECTOR Specification Desc Quantity 1 Battery 2 permanent power supply 3 Ground lead Runner RST 50 SP Elec...

Page 52: ...g clean it with a metal brush remove the encrustations blast it with compressed air and if necessary replace it 2 Without removing the stator carry out the following checks 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 abnormalities ...

Page 53: ...rols 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 characteristic Stator green ground 1 Ω Stator Pick Up red ground approx 170 Ω Pick Up Voltage regulator check The malfunct...

Page 54: ... voltage tester to check that the voltage distributed at the connection between the grey cable and the black cable is included in the values indicated If there are abnormalities replace the stator If the checks made do not show abnormalities re place the regulator If replacing the regulator still does not restore prop er functioning make the controls on the connec tions of the electrics Specific t...

Page 55: ...G 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 to 2A Vol...

Page 56: ...nd 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 taillight are...

Page 57: ...S 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 MEDICAL ATT...

Page 58: ...ingle 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 distill...

Page 59: ...th 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 MAY SE...

Page 60: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 61: ...cylinder nut 9 11 Engine muffler screw 22 24 Removal of the engine from the vehicle Remove the rear mudguard by removing the three screws Remove the rear brake calliper by removing the two screws then remove the two supports of the brake tube and move the callipers toward the front of the vehicle to make subsequent removal oper ations easier Remove the carburettor cover by removing the 4 screws Ru...

Page 62: ...the engine crankcase Remove the air distribution intake cover by re moving the four screws Disconnect the transmission of the mixer com mand after removing the rubber plug on the trans mission crankcase cover Engine from vehicle Runner RST 50 SP ENG VE 62 ...

Page 63: ...ections of the start er Disconnect the transmission of the accelerator command by using the screw Disconnect the electrical connection of the ther mistor and the H V coil of the spark plug Remove the automatic starter by removing on the two screws Runner RST 50 SP Engine from vehicle ENG VE 63 ...

Page 64: ...om the oil tank Remove the clamp to disconnect the fuel line and the fuel pump control line Empty the cooling system and disconnect the supply and return lines using the respective clamps Engine from vehicle Runner RST 50 SP ENG VE 64 ...

Page 65: ...rber of the engine crankshaft Support the engine and remove the stud of the engine crankshaft at the swing arm Locking torques N m Swinging arm engine pin 33 41 Shock ab sorber engine bolt 33 41 Runner RST 50 SP Engine from vehicle ENG VE 65 ...

Page 66: ...INDEX OF TOPICS ENGINE ENG ...

Page 67: ...ismantle the dog gear from its seat slackening the tension that the toothed sector applies to it by means of the spring to do this it is necessary to rotate the toothed sector slightly see the figure CAUTION WHILE REMOVING THE TOOTHED SECTOR BE VERY CAREFUL OF THE SPRING TENSION IT COULD CONSTI TUTE A HAZARD FOR THE OPERATOR Remove the screws shown in the figure and re move the engine starting lev...

Page 68: ...en 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 bearing Refit the bearing with the aid of a bushing with the same diameter as the external ...

Page 69: ...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 scre...

Page 70: ...terial 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 mm Pin...

Page 71: ...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 there...

Page 72: ...d 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 bush...

Page 73: ...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 with ...

Page 74: ...ng 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 Characterist...

Page 75: ...K 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 tracks...

Page 76: ...anually move the 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 Reassemble the unit parts roller housing unit with bushing washer stationary half pulley belt cooling fan with intake w...

Page 77: ...tch 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 Removing the wheel axle bearings Remove the oil seal and the seeger ring Remove the bearing by pushing from the outside towards the inside of the gear compartment using the appropriate punch Specific tooling 020363Y 20 mm guide...

Page 78: ...he shaft toothed side as indicated in the figure Expel the driven pulley shaft with the aid of a press Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Inspecting the hub shaft Check that the three shafts exhibit no wear or deformation on the toothed surfaces at the bear ing housings and at the oil guards In case of anomalies replace the damaged com ponents Check th...

Page 79: ... or radial part on the bearing side N B FIT THE BALL BEARING WITH THE SHIELD FACING THE OIL SEAL Specific tooling 020151Y Air heater 020376Y Adaptor handle 020439Y 17 mm guide 020358Y 37x40 mm adaptor Refitting the wheel axle bearing Heat the half crankcase on the transmission side using a thermal gun After lubricating its outer strip insert the bearing with the special adapter with the aid of a h...

Page 80: ...5 screws and tighten them to the speci fied torque N B CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF RESIDUE FROM PREVI OUS GASKETS BEFORE APPLYING A NEW ONE Locking torques N m Locking torque 11 to 13 Nm Flywheel cover Removing the stator Remove the three stator fixings shown in the photo Remove the two pick up fixings shown in the photo Remove the stator with the wiring E...

Page 81: ... 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 Keeping the flywheel connector rubber clamp on the coolant inlet hose refit the flywheel cover paying attention in inserting the strap in the groove Tighten the 4 studs noting that the two longer golden screws are inserted in the 2 top holes and ar...

Page 82: ...figure Removing the flywheel magneto Lock the rotation of the flywheel using the calliper spanner Remove the nut CAUTION THE USE OF A CALLIPER SPANNER OTHER 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 Engine Runner RST 50 SP ENG 82 ...

Page 83: ...deformations visible on the Pick Up support N B A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING KNOCKING ETC Locking torques N m Flywheel nut 40 to 44 N m 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 PA...

Page 84: ...anner to remove the two clamping screws of the intake manifold Removing the cylinder head Remove the 4 screws shown in the figure Removing the cylinder piston assy Remove the cylinder holding the piston in order to prevent damage Engine Runner RST 50 SP ENG 84 ...

Page 85: ...THE ASSEMBLY POSITIONS OF THE LININGS TO PREVENT INVERTING THE POSITION IN CASE OF REUSE N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL Inspecting the small end Measure the internal diameter of the small end using an internal micrometer N B IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED...

Page 86: ... Calculate the piston pin coupling clearance Characteristic Wrist pin housing standard diameter 12 0 007 0 012 Wrist pin housing standard clearance 0 002 0 011 mm Measure the outer diameter of the piston per pendicular to the pin axis Take the measurement in the position shown in the figure To classify the cylinder piston fitting check the ap propriate table See also Cylinder piston assy Engine Ru...

Page 87: ...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 cylinder axis Measure the opening of the sealing rings using a thickness gauge as shown in the photograph If the values are higher than the values prescri be...

Page 88: ...ific tool with the aperture in the position shown on the tool as in the figure Place the wrist pin stop ring into position using a punch Specific tooling 020166Y Pin lock fitting tool Fit the wrist pin stop using the plug as shown in the figure Specific tooling 020166Y Pin lock fitting tool Engine Runner RST 50 SP ENG 88 ...

Page 89: ...gauge position Lock the tool by the nuts used to secure the head Turn the engine shaft to the dead centre position dial gauge rotation inversion point Measure the difference with the reset value Refer to the table to identify the thickness of the cylinder base gasket to use for refitting The correct identification of the thickness of the cylinder base gasket allows maintaining the correct compress...

Page 90: ...LLA Crankcase crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side Specific tooling 020163Y Crankcase splitting plate Engine Runner RST 50 SP ENG 90 ...

Page 91: ...ase 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 004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring 004499Y002 Bearing extractor screw 004499Y007 Half rings Using the specific tool remove any bearings left on the half cra...

Page 92: ...eck the temperature using a multimeter provi ded with thermal probe N B IF THE BEARINGS WERE IMMERSED INTO HOT OIL THEY WOULD BE IMMEDIATELY DAMAGED Place the crankshaft on the special support Alternately introduce the 2 bearings to insert them home If required use a specific pipe to ensure their in sertion N B THIS OPERATION SHOULD BE PERFORMED QUICKLY AND WITH PRECISE MOVES OTHERWISE START OVER ...

Page 93: ...e prescribed levels straighten the shaft by acting on the counterweights with a shim or tighten them in a clamp with an aluminium bushing as re quired Specific tooling 020335Y Magnetic support for dial gauge 020074Y Support base for checking crankshaft alignment Refitting the crankshaft Position the transmission side half crankcase on two wooden supports Using a thermal gun heat the bearing seat t...

Page 94: ...Specific tooling 020163Y Crankcase splitting plate Refitting the crankcase halves Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the sur face using a suitable solvent e g trichloroethy lene Heat the flywheel side half crankcase with a ther mal gun Recommended products Loctite 510 Liquid sealant Gasket Keeping the half crankcase on the transmission side i...

Page 95: ...support for dial gauge Characteristic Axial clearance with warm crankcase 0 10 0 12 mm Axial clearance with cold crankcase 0 06 to 0 08 mm Limit value with cold crankcase 0 02 0 03 mm Lubrication Crankshaft oil seals Refitting Install a new flywheel side oil seal only with 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 ...

Page 96: ...nsmission side oil seal is recognised by the larger diameter Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Oil pump Removal Remove the 2 screws shown in the figure Remove the tube passage seal from the crank case shown in the figure Engine Runner RST 50 SP ENG 96 ...

Page 97: ... carburettor To determine the correct functioning of the pump the following 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 co...

Page 98: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 99: ...g screw of the wheel axle clamp and remove it Front wheel hub overhaul Remove the front wheel Keep the wheel level by means of two wooden wedges With the appropriate pliers and tool remove the wheel bearing on the side the rpm indicator detects movement as shown in the photograph Specific tooling 001467Y014 Pliers to extract ø 15 mm bearings 001467Y009 Driver for OD 42 mm bearings Runner RST 50 SP...

Page 100: ... a hot air gun heat the seat of the bearing on the brake calliper side With an appropriate tool remove the bearing on the brake disk side Insert the spacer bushing on the brake disk side Specific tooling 020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide With a hot air gun heat the seat of the bearing on the side the rpm indicator detects movement Insert the internal spacer with...

Page 101: ...lebar Check all components and replace faulty parts N B IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING TILT THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS Refitting When refitting tighten to the prescribed torque and apply the recommended grease to the threaded cone Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous calcium based gr...

Page 102: ...em and remove the stanchion heating it if necessary with the specified heater then remove sealing ring 2 and seeger 3 Using nut 4 remove the spring stem and bushing The damper is an integral part of the stem and cannot therefore be overhauled so if you need to work on the damper loss of fork oil carry out the operations mentioned above and replace the shock absorber stem unit When refitting tighte...

Page 103: ...he clean surface Lock the screw 4 Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Removing stanchion bracket Remove the dust guard 1 using a screwdriver to prise it out Remove the seeger 2 and remove the power pipe N B GREASE THE SPRINGS AND THE BUSHINGS BEFORE REFITTING WITH A SMALL QUANTITY OF GREASE AROUND 3 GR Recommended products AGIP GREASE ...

Page 104: ...N m Locking torque 50 to 60 Nm Steering column Removal Removing upper and lower frame housing Only remove the seats if it is strictly necessary Using the special tool remove the upper fifth wheel seat by putting the special tool into the lower part of the headstock as indicated in the figure By inserting the punch into the top of the tube remove the lower fifth wheel seat from the head stock Speci...

Page 105: ... properly Using the special tool remove the fifth wheel seat on the steering tube as shown in the photograph by applying small mallet blows Specific tooling 020004Y Punch for removing fifth wheels from headstock Always use a new fifth wheel seat on refitting Using the special tool refit the fifth wheel seat with the aid of a few mallet blows and bring it as far as the stop shown in the photo Speci...

Page 106: ...lso Handlebar Refitting Refit steering lock nut After locking the first ring nut in place lock the second ring nut using a specific tool Specific tooling 020055Y Wrench for steering tube ring nut Locking torques N m Locking torque 30 to 40 Nm Rear Removing the rear wheel Remove the wheel loosening the five clamps Suspensions Runner RST 50 SP SUSP 106 ...

Page 107: ...bag and remove the shock absorber chassis nut Then remove the shock absorber engine anchor bolt Refitting When refitting tighten the shock absorber frame anchorage nut and the shock absorber engine pin at the prescribed torque Locking torques N m Shock absorber frame nut torque 20 to 25 Nm Shock absorber engine pin torque 33 to 41 N m Centre stand Expulsion of kickstand bracket fastening pin Runne...

Page 108: ... 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 ATTACHMENTS AND THE PIN Replace complete kickstand 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 Runner RST 50 SP SUSP 108 ...

Page 109: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 110: ...ystem it is necessary to replace them Disconnect the oil line from the cal liper collecting the oil in a container Remove the two clamps highlighted in the diagram Overhaul Proceed as follows 1 remove the two male hexagonal screws 1 and take out the two pads 10 2 remove the two male hexagonal screws 2 and remove the reaction plate 3 3 take out the fixed plate 4 from the guide 4 remove the internal...

Page 111: ...ng the screws 2 insert the brake pad check spring 9 and then the pads fixing them with the corre sponding screws 1 5 place the calliper on the disc and lock it to the strut by tightening the fixing screws 6 fix the pipe joint on the calliper at the prescribed torque Functioning This is a floating type calliper It takes advantage of the action and reaction prin ciple to obtain the thrust for both p...

Page 112: ...per fitting 19 24 Refitting Refit the pincer on the support and tighten the screws at the prescribed torque Refit the tube complete with fitting with new copper gaskets Bleed the air from the system Locking torques N m Brake fluid tube calliper 20 25 Nm Fastening screws calliper to the crankcase 20 25 Oil bleed screw 7 to 10 Nm Front brake disc Removal Remove the front wheel loosening the axle cla...

Page 113: ...n the wheel is fitted properly The protrusion measured near the external edge of the disc must be less than 0 1 mm If a value is measured other than the specified value remove the front wheel Front Rear Suspension chapter and check the protrusion of the disc Maxi mum permissible out of true is 0 1 mm If the value measured is greater re place the disc and repeat the check If the problem persists ch...

Page 114: ...the callipers Screw the two pad lock pins to the correct torque and apply the recommended product Fit the calliper on its support tightening the two screws to the prescribed torque N B IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT TING GENTLY EXPAND THE PADS Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Locking ...

Page 115: ... THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS CAUTION DURING THE OPERATIONS THE VEHICLE MUST BE ON THE STAND AND LEVEL N B DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP WARNING BRAKING CIRCUIT FLUID IS HYGROSCOPIC IT ABSORBS HUMIDITY FROM THE SUR ROUNDING AIR IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EXCEEDS A GIVEN ...

Page 116: ...m Oil bleed screw 8 12 Front brake pump After removing the front and rear handlebar covers act on the two stand fixing points see the figure Disconnect the tube collecting the brake oil 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 Runner...

Page 117: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 118: ...um 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 Remove the rpm sensor coolant delivery hose clamp Remove the transmission cover Remove the mixer Position the...

Page 119: ... the crankcase in the area around the water pump bearings as shown in the picture Using the special tool loosen the impeller shaft turning the spanner clockwise left handed thread As the thread is fully disengaged extract the shaft using pliers Specific tooling 020169Y Water pump crankshaft fitting and re moval spanner Runner RST 50 SP Cooling system COOL SYS 119 ...

Page 120: ...eplace shaft and bearings Carefully clean oil seal and bearing housings Use a new oil seal to refit Position the new oil seal on the special tool with the main lip facing the bearings as shown in the picture Lubricate the oil seal and push it home using the special tool as shown in the picture Specific tooling 020168Y Water seal punch mount on half crankcase Cooling system Runner RST 50 SP COOL SY...

Page 121: ...ame turn anticlock wise for tightening Turn it rapidly to the end of the threading Should 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 m...

Page 122: ... thermostat is completely open 3 Replace the thermostat if not working properly CAUTION TO EXECUTE THE TEST CORRECTLY MAKE SURE NEI THER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER 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...

Page 123: ...Runner RST 50 SP Cooling system COOL SYS 123 ...

Page 124: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 125: ...ews indicated in the figure After disconnecting the wiring remove the rear handlebar See also Front handlebar cover Headlight assy Remove the front shield Remove the 2 screws indicated in the photograph at the back of the shield then disconnect the wiring and remove the headlight assembly See also Legshield Runner RST 50 SP Chassis CHAS 125 ...

Page 126: ... screws indicated in the photograph Remove the filling hole unit of the fuel tank by loosening the 3 screws A indicated in the pho tograph and the metal clamp Remove the screw B indicated in the photo graph then remove the chassis central cover by pulling it upwards To fit repeat the procedure in reverse order being careful to replace the metal clamp of the fuel tank filling hole Chassis Runner RS...

Page 127: ...he photograph from the front wheel compartment Lever on the plastic parts creating enough space to remove the 4 screws 2 per side A indicated in the photograph Remove the front shield after disconnecting the wiring of the front headlight assembly and of the taillights Assembly following the procedure in reverse or der See also Front central cover Runner RST 50 SP Chassis CHAS 127 ...

Page 128: ...hield and back shield Insert a small awl in the groove shown in the photo and pry up until the clamp is removed Remove the lock body To fit repeat the procedure in the reverse direc tion See also Legshield Knee guard Removing the ignition key switch when on lock Remove the shield Remove the switch of the key switch Make a hole on the block using a drill as shown in the figure Insert the wheel cyli...

Page 129: ...Knee guard Legshield Front wheel housing Remove the front fork Unscrew the central stud of the wheel well at the frame Disconnect the brake pipe to the pump and pull it out Remove the odometer transmission Taillight assy Remove the two screws and take out the whole unit Runner RST 50 SP Chassis CHAS 129 ...

Page 130: ...ng A Remove the 4 screws indicated in the figure and take out the casing Fairing B Remove fairing A Remove the passenger handles Remove the rear light assembly Remove the license plate holder undoing the 4 screws indicated in the figure Remove the screw of the rear wheel compart ment Remove the 2 screws indicated in the figure Chassis Runner RST 50 SP CHAS 130 ...

Page 131: ...he fairing by pulling it upwards Air filter Remove 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 Runner RST 50 SP Chassis CHAS 131 ...

Page 132: ...le of the saddle opening de vice Remove the 5 screws indicated in the figure lo cated on the front part of the helmet compartment Remove the 2 screws indicated in the figure lo cated on the rear part of the helmet compartment Remove the screw indicated in the figure located on the rear wheel compartment and then remove the helmet compartment See also Seat Side fairings Chassis Runner RST 50 SP CHA...

Page 133: ...n the figure Lift the chassis very gently being careful with the cables affixed to it Disconnect the electrical connections and the fuel tank pipes when extracting the chassis N B this operation should be preferably be carried out with the tank empty See also Frame central cover Helmet bay Side fairings Front mudguard Loosen the four screws fixing the fender to the fork Runner RST 50 SP Chassis CH...

Page 134: ...photograph Remove the cap momentarily to disconnect it from the shield back plate by pulling it downwards Disconnect the expansion tank from the support anchored to the chassis Prepare a container to collect the coolant Remove the coolant in top and return bottom pipes Assembly following the procedure in reverse or der See also Legshield Mixture oil tank Remove the helmet compartment Disconnect th...

Page 135: ...coperchio batteria installare la batteria rispettando le polarità come mostrato in foto Lower cover Remove the footrests Remove the 4 screws 2 per side indicated in the photograph of the front wheel compartment Remove the two bottom screws 1 per side of the shield back plate then lever the plastic parts to reach the screws A indicated in the photo graph Remove the lower cover Runner RST 50 SP Chas...

Page 136: ...Chassis Runner RST 50 SP CHAS 136 ...

Page 137: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 138: ...dlebar 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 Instrument p...

Page 139: ...D 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 REACH OF...

Page 140: ... 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 and any...

Page 141: ...INDEX OF TOPICS TIME TIME ...

Page 142: ...s 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 Runner RST 50 SP TIME 142 ...

Page 143: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement Runner RST 50 SP Time TIME 143 ...

Page 144: ...RANKSHAFT 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 Runner RST 50 SP TIME 144 ...

Page 145: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder piston Replacement 2 001107 Cylinder piston Inspection clean ing Runner RST 50 SP Time TIME 145 ...

Page 146: ...ake 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 Runner RST 50 SP TIME 146 ...

Page 147: ... 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 Runner RST 50 SP Time TIME 147 ...

Page 148: ...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 Runner RST 50 SP TIME 148 ...

Page 149: ...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 Runner RST 50 SP Time TIME 149 ...

Page 150: ...de Action Duration 1 001011 Driving belt Replacement 2 001066 driving pulley Replacement 3 001006 rear view pulley Service 4 001177 Variator rollers shoes Replace ment 5 001086 Driving half pulley replace Time Runner RST 50 SP TIME 150 ...

Page 151: ...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 Runner RST 50 SP Time TIME 151 ...

Page 152: ... 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 Runner RST 50 SP TIME 152 ...

Page 153: ...tion 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 6 001017 Start up pinion Replacement Runner RST 50 SP Time TIME 153 ...

Page 154: ...ywheel magneto FLYWHEEL MAGNETO Code Action Duration 1 001058 Flywheel Replacement 2 001067 Stator Replacement 3 001173 Rotor Replacement 4 001087 Flywheel cover Replacement Time Runner RST 50 SP TIME 154 ...

Page 155: ...tor Replacement 2 003058 Carburettor Adjustment 3 001008 Carburettor Inspection 4 001178 Disc pack Replacement 5 001081 Automatic choke Replacement 6 007020 Carburettor heating tubing replace ment 7 001013 Intake manifold Replacement Runner RST 50 SP Time TIME 155 ...

Page 156: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 001136 Exhaust emissions Adjustment Time Runner RST 50 SP TIME 156 ...

Page 157: ...r 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 Runner RST 50 SP Time TIME 157 ...

Page 158: ...Frame CHASSIS Code Action Duration 1 004001 Frame replace 2 004116 Rear frame Replacement 3 004015 Footrest Replacement Time Runner RST 50 SP TIME 158 ...

Page 159: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 004171 Stand support plate Replacement Runner RST 50 SP Time TIME 159 ...

Page 160: ... spoiler FRONT SHIELD Code Action Duration 1 004064 Front shield Replacement 2 004053 Spoiler Replacement 3 004182 Side cover Replacement 4 004149 Shield central cover Replacement Time Runner RST 50 SP TIME 160 ...

Page 161: ...over Replacement 2 004068 Passenger handgrip Replacement 3 004012 Rear fairings Removal and refitting 4 004129 Rear fairing Replacement 5 004085 Fairing 1 Replacement 6 004036 Lower chassis cover Replacement 7 004159 Plates Stickers Replacement Runner RST 50 SP Time TIME 161 ...

Page 162: ... PORTACASCO Code Action Duration 1 004016 Helmet compartment Replacement 2 005046 Battery cover Replacement 3 004071 Battery compartment replacement 4 004059 Spark plug inspection flap Replace ment Time Runner RST 50 SP TIME 162 ...

Page 163: ...rd PARAFANGHI Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement 3 003044 Shock absorber cover Replace ment 4 004052 Bumper Replacement Runner RST 50 SP Time TIME 163 ...

Page 164: ...ration 1 004005 Fuel tank Replacement 2 004007 Fuel valve Replacement 3 005010 Tank float Replacement 4 004170 Tank filler neck Replacement 5 004110 Fuel tank hose Replacement 6 004109 Fuel tank breather Replacement Time Runner RST 50 SP TIME 164 ...

Page 165: ... 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 Runner RST 50 SP Time TIME 165 ...

Page 166: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorbers Replace ment Time Runner RST 50 SP TIME 166 ...

Page 167: ...earings 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 Runner RST 50 SP Time TIME 167 ...

Page 168: ...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 Time Runner RST...

Page 169: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine frame swinging arm fitting Replacement Runner RST 50 SP Time TIME 169 ...

Page 170: ...Seat SELLA Code Action Duration 1 004003 Saddle Replacement 2 004054 Seat lock hook Replacement 3 002083 Saddle opening transmission Re placement Time Runner RST 50 SP TIME 170 ...

Page 171: ...BRIO Code Action Duration 1 004019 Handlebar rear section Replace ment 2 004018 Handlebar front section Replace ment 3 005014 Odometer Replacement 4 005078 Odometer glass Replacement 5 004117 Top fairing Replacement Runner RST 50 SP Time TIME 171 ...

Page 172: ...t bulbs Replacement 3 005068 Rear turn indicator bulb Replace ment 4 005022 Rear turn indicators Replacement 5 005002 Front headlamp Replacement 6 005008 Front headlamp bulbs Replacement 7 005012 Front turn indicator Replacement 8 005067 Front turn indicator bulb Replace ment Time Runner RST 50 SP TIME 172 ...

Page 173: ...acement 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 indicate wi...

Page 174: ...e 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 Time Runner RST 50 SP TIME 174 ...

Page 175: ...NTE Code Action Duration 1 004073 Fuel pump Replacement 2 004137 Pump carburettor hose Replace ment 3 004086 Petrol pump depression tube Re placement 4 004089 Tank petrol pump pipe Replace ment Runner RST 50 SP Time TIME 175 ...

Page 176: ...09 Voltage regulator Replacement 3 001023 Control unit Replacement 4 001094 Spark plug cap Replacement 5 005003 Horn Replacement 6 005011 Start up remote control switch Re placement 7 005052 Fuse 1 Replacement 8 005054 Fuse block 1 Replacement 9 005007 Battery Replacement Time Runner RST 50 SP TIME 176 ...

Page 177: ...er button Replacement 2 005040 Horn button Replacement 3 005016 Key switch Replacement 4 004096 Lock series Replacement 5 004010 Antitheft lock replace 6 005006 Light switch or turn indicators Re placement 7 005039 Headlight switch Replacement Runner RST 50 SP Time TIME 177 ...

Page 178: ...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 Time Runner RST 50 SP TIME 178 ...

Page 179: ...ation 1 004056 Upper rear light cover Replacement 2 004136 License plate support Replacement 3 004183 Cover for engine components Re placement 4 004181 Lower cover Replacement 5 005048 Licence plate holder Replacement Runner RST 50 SP Time TIME 179 ...

Page 180: ...t 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 Time Runner RST 50 SP TIME 180 ...

Page 181: ...radiator Replace ment 2 007003 Delivery line and coolant return Re placement 3 007001 Expansion tank Replacement 4 007024 Expansion tank cap Replacement 5 007013 Expansion tank radiator connecting hose Replacement 6 001052 Coolant and air bleed Replacement Runner RST 50 SP Time TIME 181 ...

Page 182: ...3 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 Time Runner RST 50 SP TIME 182 ...

Page 183: ...6 178 C Carburettor 10 155 E Engine stop F Fuel 39 97 133 134 164 175 Fuses 56 H Headlight 36 125 Hub oil 30 I Identification 8 Instrument panel 50 171 M Maintenance 7 27 S Shock absorbers 107 Spark plug 30 Stand T Tank 133 134 164 165 Transmission 9 40 67 151 Tyres 10 ...

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Summary of Contents for Runner RST 50 SP

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Gilera Runner RST 50 SP, Service Station Manual, Page: 91 / 183

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Summary of Contents for Runner RST 50 SP

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