Gilera Stalker 50 Service Manual Download Page 91

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Removal

- Remove the front handlebar cover.

- Remove the rear handlebar cover.

- After removing the transmissions and discon-

necting the electrical terminals, remove the bolt

«A» and the handlebar

- 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 grease to protect

roller bearings; temperature range between -20 °

C and +120 °C; NLGI 2; ISO-L-XBCIB2

Locking torques (N*m)

Locking torque:

65 to 70 N•m

Front fork

Removal

- Remove the front brake calliper.

- Remove the odometer cable from the reduction

gear box.

- Remove the front mudguard.

- Remove the handlebar.

After removing the steering ring-nut using the spe-

cial tool, lean the vehicle on one side and extract

the steering tube.

Specific tooling

020055Y

Wrench for steering tube ring nut

Stalker 50

Suspensions

SUSP - 91

Summary of Contents for Stalker 50

Page 1: ...MANUALE STAZIONE DI SERVIZIO 638540 Stalker 50 ...

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: ...ne degli impianti e delle attrezzature necessarie ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici 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 specifi...

Page 4: ......

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

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

Page 7: ... you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings ...

Page 8: ...00 xxxx xxxxxxx Engine prefix C401M xxxx Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Overall length 1760 mm Overall width 720 mm Maximum height 810 mm Wheelbase 1230 mm Kerb weight 87 kg Characteristics Stalker 50 CHAR 8 ...

Page 9: ...l 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 with toothed belt Fuel supply With vacuum operated cock lead free gasoline with 95 octane minimum by means of the carburettor Cooling Forced air circulation Transmission TRANSMISSION Spe...

Page 10: ...AND SUSPENSIONS Specification Desc Quantity Chassis type Welded tubular steel chassis with stamped sheet reinforce ments Front suspension upside down hydraulic telescopic fork Front stroke 73 mm Front suspension stroke 58 mm Rear suspension With coaxial spring and hydraulic shock absorber Chassis to engine support with swinging arm Brakes BRAKES Specification Desc Quantity Front brake Disc D 190 m...

Page 11: ...EMBLY Name Torque in Nm Swinging arm engine pin safety locks 33 to 41 Nm Swinging arm frame pin safety locks 64 to 72 Nm Shock absorber frame nut safety locks 20 to 25 Nm Shock absorber engine pin safety locks 33 to 41 Nm Rear wheel axis safety locks 104 to 126 Nm Bolt holding stand to the engine 18 to 19 Nm FRONT SUSPENSION Name Torque in Nm Front wheel axle nut safety locks 45 to 50 Nm Wheel axl...

Page 12: ... on the engine 12 13 Overhaul data Assembly clearances Cylinder piston assy COUPLING BETWEEN PISTON AND CYLINDER Name Initials Cylinder Piston Play on fitting Standard coupling M 40 005 40 012 39 943 39 95 0 055 0 069 Standard coupling N 40 012 40 019 39 95 39 957 0 055 0 069 Standard coupling O 40 019 40 026 39 957 39 964 0 055 0 069 Standard coupling P 40 026 40 033 39 964 39 971 0 055 0 069 cou...

Page 13: ...scription Dimensions Initials Quantity Connecting rod 11 750 0 05 A clearance E 0 25 to 0 50 shoulder washer 0 5 0 03 G clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Half shaft transmission side 13 75 0 040 C clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Flywheel side half shaft 13 75 0 040 D clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Lining between the shoulders 40 64 H clearance E...

Page 14: ...ct Description Specifications AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the re quirements of API GL3 specifications AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in creased 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 spr...

Page 15: ... AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Stalker 50 Characteristics CHAR 15 ...

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

Page 17: ...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 Stalker 50 Tooling TOOL 17 ...

Page 18: ...traction 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 020055Y Wrench for steering tube ring nut 020150Y Air heater support Tooling Stalker 50 TOOL 18 ...

Page 19: ...Description 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020165Y Start up crown lock 020166Y Pin lock fitting tool Stalker 50 Tooling TOOL 19 ...

Page 20: ...1Y Starter spring fitting 020262Y Crankcase splitting strip 020265Y Bearing fitting base 020325Y Brake shoe spring calliper 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing Tooling Stalker 50 TOOL 20 ...

Page 21: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge Stalker 50 Tooling TOOL 21 ...

Page 22: ...s code Description 020350Y Electrical system check instrument 020357Y 32 x 35 mm adaptor 020359Y 42x47 mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide 020456Y Ø 24 mm adaptor Tooling Stalker 50 TOOL 22 ...

Page 23: ...Stores code Description 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner 020625Y Kit for sampling gas from the exhaust manifold Stalker 50 Tooling TOOL 23 ...

Page 24: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 25: ... I I I I I I I I I I Air filter C C C C C C C C C C Throttle control mixer A A A A A A Driving belt I R I R I R I R I R Spark plug I R I R I R I R I R Safety locks I I I I I I Driven pulley roller casing L L L L L Suspensions I I I I I Transmissions L L L L L Checking the spark advance Check to be made at over 4000 rpm with strobo scopic gun The advanced ignition measured must be 17 before the TDC...

Page 26: ...defects replace the spark plug with one of the specified type Engage the spark plug with the due inclination and screw it right down by hand then do it up with the wrench at the prescribed torque Put the hood on the sparking plug as far as it will go Refit the central flap 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 N...

Page 27: ...d notch starting from the lower end 4 Screw the dipstick back in checking that it is locked in place Recommended products AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Replacement Remove the oil filler cap A Unscrew the oil drainage cap B and drain out all the oil Screw in the drainage cap again and fill the hub with the prescribed oil Charac...

Page 28: ...t 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 air filter sponge Mineral oil with specific additives for increased ad hesiveness transmissions Odometer driving pinion connection Remove the odometer cable and grease with the recommended product Recommended ...

Page 29: ...ef erence mark on the mixer body as indicated in the figure Twist the throttle to the end of the stroke a couple of times and check that the adjustments have been made properly then lock 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...

Page 30: ...AND CLOTHING IN CASE OF ACCIDENTAL CONTACT WASH WITH WATER CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK CAUTION THE BRAKE FLUID IS HYGROSCOPIC IN OTH ER WORDS IT ABSORBS MOISTURE FROM THE SURROUNDING AIR IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE BRAKING WILL BE INEF FICIENT NEVER USE BRAKE LIQUID IN ...

Page 31: ...d check that the edge of the beam projected on the screen is not more than 9 10 of the height of the centre of the head light from the ground and not less than 7 10 3 If this is not the case remove the hook by turning the two screws then remove the cover on the shield back plate Adjust the headlight by turning screw A N B THE ABOVE PROCEDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM ...

Page 32: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 33: ... 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 cl...

Page 34: ...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 Corr...

Page 35: ...tch bell Insufficient braking BRAKING SYSTEM MALFUNCTION Possible Cause Operation Poor braking The rear drum type brake is adjusted by regulating the special adjustment on the wheel bearing in mind that with the control levers in the rest position the wheels must turn freely The braking action should begin when the brake levers are pressed by about a third Check the brake pad wear If it is not pos...

Page 36: ...s 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 or replace the rear shock absorbers in case of malfunction Tyres deflated or damaged Check the correct pres...

Page 37: ... 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 Check that there is no noise or seizing during the wh...

Page 38: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 39: ...ter motor 9 Starter remote control 10 Starter button 11 STOP button on rear brake 12 STOP button on front brake 13 Horn button 14 Horn 15 Left turn rear indicator lamp 16 Tail light stop light lamp 17 Turn indicator switch 18 Right turn rear indicator lamp 19 Left turn front indicator lamp Stalker 50 Electrical system ELE SYS 39 ...

Page 40: ... beam warning light 24 Fuel level transmitter 25 Automatic starter 26 Oil warning light control COLOUR CODES Or Orange Lb Light Blue Wh White Bl Blue Ye Yellow Gr Grey Br Brown Bl Black Pi Pink Re Red Gre Green Pu Purple Components arrangement Voltage regulator In order to access the voltage regulator it is nec essary to remove the shield back plate H V coil In order to access the H V coil it is n...

Page 41: ... to access the starter remote control it is necessary to remove the left side panel Conceptual diagrams Ignition LEGEND 1 Electronic ignition device 2 Spark plug 3 Magneto flywheel 6 Key switch Stalker 50 Electrical system ELE SYS 41 ...

Page 42: ...ront headlight assembly A Tail light B High beam low beam lamp 22 Light switch 23 Instrument panel A Flashing warning light B Instrument panel lamp and lights warning light C Fuel gauge D Low fuel warning light E Mixer oil warning light F High beam warning light 25 Automatic starter Electrical system Stalker 50 ELE SYS 42 ...

Page 43: ...ge regulator 5 Main fuse 6 Key switch 7 Battery 8 Starter motor 9 Starter remote control 10 Starter button 11 STOP button on rear brake 12 STOP button on front brake 16 Tail light stop light lamp 26 Oil warning light control Stalker 50 Electrical system ELE SYS 43 ...

Page 44: ... 6 Key switch 7 Battery 23 Instrument panel A Flashing warning light B Instrument panel lamp and lights warning light C Fuel gauge D Low fuel warning light E Mixer oil warning light F High beam warning light 24 Fuel level transmitter 26 Oil warning light control Electrical system Stalker 50 ELE SYS 44 ...

Page 45: ...eft turn rear indicator lamp 17 Turn indicator switch 18 Right turn rear indicator lamp 19 Left turn front indicator lamp 21 Right turn front indicator lamp 23 Instrument panel A Flashing warning light B Instrument panel lamp and lights warning light C Fuel gauge D Low fuel warning light Stalker 50 Electrical system ELE SYS 45 ...

Page 46: ...ning light I High beam headlight warning light L Fuel gauge To remove the instrument loosen the three screws disconnect the odometer cable joint O and connectors M and N Checks and inspections Checks to be made in the case of ignition irregularities and or no spark on the spark plug 1 Check the condition of the spark plug clean it with a metal brush remove the encrustations blast it with compresse...

Page 47: ...tator otherwise replace the central unit Remember that disconnections due to replacement of the central unit must be done with the engine off Specific tooling 020331Y Digital multimeter CHECK ON THE PICK UP Specification Desc Quantity 1 Red and white cable 90 140 ohm RECHARGE COIL CHECK UP Specification Desc Quantity 1 Yellow and blue cable 800 1100 ohm CHECK CONTINUITY Specification Desc Quantity...

Page 48: ...TATED 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 malfunctioning of the voltage regulator might cause the following problems depending on the type of fault 1 The lighting system bulbs burn out 2 The lighting...

Page 49: ...age readings check that the voltage supplied between the con nection of the grey blue cable pin 2 and the black cable pin 6 is within the values indicated If faults are detected replace the stator If no faults are detected in the controls carried out replace the regulator If functioning is still not correct even when the reg ulator is replaced check the connections of the electrical system Specifi...

Page 50: ...ace the battery N B BEFORE 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...

Page 51: ...regulator s ground ca ble harness 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 electrical system is protected by a fuse con nected on the left hand side of the helmet com partment next to the battery For access it is necessary to remove the battery cover and the transparen...

Page 52: ...0 of the nominal capacity of the battery Duration of the charge 5 h WARNING WHEN THE BATTERY IS REALLY FLAT WELL BELOW 12 6V IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE IN THESE CONDITIONS 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 P...

Page 53: ...d install the battery in the vehicle ensuring that it is wired up properly WARNING ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE WITH CLOSED END NEAR THE POSITIVE TERMINAL WITH THE CORRE SPONDING LONG TUBE WITH OPEN END THAT YOU FIND FITTED TO THE VEHICLE TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY Specific tooling 020333Y Single battery ch...

Page 54: ...ingle or multiple battery charger placing the battery charger selector on the type of battery to be recharged The connections to the power supply must be made by connecting to the corresponding poles 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 PL...

Page 55: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 56: ...ator and mixer control transmissions 7 Disconnect the mixer oil fuel pipes and vacuum pump control on the carburettor 8 Disconnect the high voltage cable from the spark plug 9 Remove the bolt fixing the rear shock absorber from the engine 10 Undo the nut on the right hand side then re move the engine swinging arm fixing pin from the left hand side Locking torques N m Engine swinging arm bolt 33 41...

Page 57: ...Stalker 50 Engine from vehicle ENG VE 57 ...

Page 58: ...INDEX OF TOPICS ENGINE ENG ...

Page 59: ...or 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 based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Remove the screws shown in the figure and re move the engine start...

Page 60: ...earing 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 plate of the bear...

Page 61: ...he 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 s...

Page 62: ... 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 mm ...

Page 63: ...ve 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 th...

Page 64: ...nded 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 b...

Page 65: ...r 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 113 mm Refitting the clutch Preassemble the driven pulley group with spring sheath and clutch Position the spring w...

Page 66: ...cking 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 Character...

Page 67: ...REAK 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 tra...

Page 68: ...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 wi...

Page 69: ...he 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 Stalker 50 Eng...

Page 70: ...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 the ...

Page 71: ...ting 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 ring ...

Page 72: ...dle 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 OF...

Page 73: ...n in the figure Remove the fan cover Remove the oil piping retention band from the hood Remove the 2 screws shown in the figure Cooling fan Remove the cooling fan by acting on the three fixings indicated in the figure Stalker 50 Engine ENG 73 ...

Page 74: ...the retainers to the specified torque N B THE PICK UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM BLY Locking torques N m Pick up screws 3 4 Stator screws 3 4 Flywheel and starting Removing the starter motor Remove the center stand by unscrew ing the four clamping screws two per side of the engine block R e...

Page 75: ... 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 Stalker 50 Engine ENG 75 ...

Page 76: ...UCH 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 screws ...

Page 77: ... 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 Stalker 50 Engine ENG 77 ...

Page 78: ...c 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 sta...

Page 79: ... 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 cylinder ...

Page 80: ... 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 W...

Page 81: ...tem 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 Stalker 50 Engine ENG 81 ...

Page 82: ...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 0...

Page 83: ...e 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 above prescribed levels straighten the shaft by acting on the counterweights with a...

Page 84: ...rature 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 temperature has settled preload the thrust screw of the tool manually until the ball bear ing clearance is...

Page 85: ...apidly 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 of the crankshaft Check the axial clearance of the crankcase If this is not within the maximum limit allowed re peat t...

Page 86: ...OT 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 tooling 020340Y Flywheel and transmission oil seals fitting punch Oil pump Removal Remove the 2 screws shown in the figure Engine...

Page 87: ...the two tubes Close the fuel outlet pipe By means of the MITIVAC pump apply 0 1 bar of suction to the tap Make sure that the suction is kept stable and that and that there are no fuel leaks Reconnect the suction pipe to the manifold Position the fuel pipe with the outlet at the point of the tap Turn the engine by using the starter for five sec onds with the carburettor at minimum Take up the fuel ...

Page 88: ... MityVac vacuum operated pump Characteristic Minimum flow rate 20 cc Completely empty the gas tank Remove the petrol delivery tube and the suction tube Loosen the clip and remove the tap Clean the tank and the filter of the tap with a spe cific solvent Refit the tap making sure that there is an O Ring Turn the tap to the direction it had before it was removed and block the clip N B THE FILTER CAN ...

Page 89: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 90: ...heel Support the vehicle in such a way that the front wheel is raised Using two 18 mm hexagonal wrenches remove the front wheel axle Refitting the front wheel When refitting pay attention in repositioning the odometer drive correctly Locking torques N m Wheel fixing nut 40 to 50 N m Handlebar Suspensions Stalker 50 SUSP 90 ...

Page 91: ...ed grease to the threaded cone Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Locking torques N m Locking torque 65 to 70 N m Front fork Removal Remove the front brake calliper Remove the odometer cable from the reduction gear box Remove the fro...

Page 92: ...ve screw 1 fixing the screw to the stem 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 abs...

Page 93: ...mmended product to the clean surface Lock the screw 4 Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Refitting Lubricate the seats and the balls with the grease recommended Lock at the prescribed torque and turn the key anticlockwise by 90 to 100 Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GREASE PV2 Greas...

Page 94: ...y inserting the punch into the top of the tube remove the lower fifth wheel seat from the head stock Specific tooling 020004Y Punch for removing fifth wheels from headstock Refitting Refitting the lower and upper seat on the frame Using the special tool refit the upper and lower bearing seats on the headstock Specific tooling 001330Y Tool for fitting steering seats Steering bearing Removal Overhau...

Page 95: ...tting 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 Specific tooling 006029Y Punch for fitting fifth wheel seat on steering tube Removing steering lock nut Remove the handlebar Remove the bearing of steering ring nut using the specific tool Specific tooling 020055Y Wrench for steering tube ring nut See also H...

Page 96: ... acting on the central fixing point WARNING ALWAYS USE NEW SPLIT PINS FOR REFITTING Removal To replace the shock absorber you just need to remove the battery access flap to get and remove the shock absorber frame anchorage nut Then remove the shock absorber engine anchorage nut Refitting When refitting tighten the shock absorber frame anchorage nut and the shock absorber engine pin at the prescrib...

Page 97: ...can come out Fitting and caulking the 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 ATTACHMENTS AND THE PIN Replace complete stand Work on the screws shown in the figure When refitting secure to the prescribed torque Locking t...

Page 98: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 99: ...ghted in the diagram Overhaul Disconnect the oil line from the calliper and collect the brake fluid in a suitable container Remove the brake calliper from the fork Exerting leverage on the floating body remove the external brake pad then the internal one and lastly the reten tion spring Remove the piston and make sure that there is no scoring or erosion If there is replace the pincer CAUTION ALL T...

Page 100: ...ling rings must be immersed in the op erating liquid the use of the PRF1 protection is tolerated CAUTION RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS AFTER WASHING THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH Locking torques N m Calliper coupling screw 20 to 25 Nm Oil bleed screw 7 to 10 Nm Refitting Refit the pincer on the support and tighte...

Page 101: ... thick ness of the disc as shown in the pho tograph Characteristic Standard thickness 4 02 01mm Using the appropriate tool measure how much the disc protrudes when 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 pr...

Page 102: ...g 020335Y Magnetic support for dial gauge Front brake pads Removal Remove the brake calliper from the fork Exert leverage on the floating body and remove the outer pad Then remove the internal pad by ex erting pressure on the retention spring The pads must be replaced if the friction material lining is less than 1 5 mm Braking system Stalker 50 BRAK SYS 102 ...

Page 103: ...Refitting Follow the steps in the opposite order from the re moval making sure the retention spring is inserted properly Fill Stalker 50 Braking system BRAK SYS 103 ...

Page 104: ... FOR 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 GI...

Page 105: ...o 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 Rear drum brake Drum brake adjustment Regulate the point where the rear drum brake in tervenes using the adjustment indicated...

Page 106: ...l do the following 1 Remove the shoe spring with the special tool 2 Remove the shoe with the aid of a lever 3 Refit the new shoes giving a few taps with the mallet 4 Fasten the spring using the special tool Braking system Stalker 50 BRAK SYS 106 ...

Page 107: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 108: ...gure Disconnect the joint of the odometer cable Disconnect the two electrical connections Front handlebar cover Remove the instrument panel Remove the four screws indicated in the figure Prise upwards at the lateral fittings and separate the front cover from the rear cover Disconnect the cable harness of the tail light For installation reverse the removal sequence paying attention to the correct a...

Page 109: ... pay attention to the correct con nection of the cables to the lamp support LEGEND Bl black Vi violet Br brown Frame central cover Remove the 3 fixing screws located under the saddle as shown in the fig ure Remove the cover by pulling it off the lower fittings For installation reverse the removal sequence Stalker 50 Chassis CHAS 109 ...

Page 110: ...hield from its seat and disconnect the turn indicators and front headlight connectors For installation reverse the removal sequence paying attention to the correct assembly of the lower fittings During assembly pay attention to the correct con nection of the cables to the lamp support LEGEND Bl black Vi violet Br brown Chassis Stalker 50 CHAS 110 ...

Page 111: ...hield back plate down For installation reverse the removal sequence paying attention to the correct assembly of the lower fittings Taillight assy To replace the bulbs it is sufficient to remove the two screws shown in the figure and to then pull off the glass of the rear headlight During assembly pay attention to correctly install the glass of the turn indicators Stalker 50 Chassis CHAS 111 ...

Page 112: ...ted in the figure and remove the footrest by pri sing at the fittings Side fairings Remove the rear spoiler by loosening the 4 retaining screws Remove the central chassis cover Remove the 8 retaining screws 4 each side indicated in the figure Chassis Stalker 50 CHAS 112 ...

Page 113: ...els Remove the 3 screws indicated in the figure Disconnect the electrical connection of the tail light assembly and then pull off the mudguard During assembly position the connectors in the correct housings Stalker 50 Chassis CHAS 113 ...

Page 114: ...ve the five screws and pull off the helmet compartment For installation reverse the removal sequence Fuel tank Remove the side panels Remove the rear mudguard Disconnect the fuel hose and the vac uum hose for the fuel valve Disconnect the electric cable harness of the fuel gauge Remove the three screws indicated in the figure and the tank down from the chassis Chassis Stalker 50 CHAS 114 ...

Page 115: ...se paying atten tion to collect the oil remaining in the tank in a suitable container Disconnect the electric cable harness from the oil level sensor Remove the 2 fixing screws of the oil tank For installation reverse the removal sequence Stalker 50 Chassis CHAS 115 ...

Page 116: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 117: ... the turn indicators pro ceed as follows Take the turn indicators out of the package To facilitate removing the supporting grilles re move the glass of the rear light unit Remove the supporting grille of the turn indicators Slide the cable harness of the turn indicators into its fitting Stalker 50 Pre delivery PRE DE 117 ...

Page 118: ... screw as indicated in the pho tograph Refit the glass of the rear light unit Aesthetic inspection Appearance check Paintwork Fitting of plastics Scratches Dirt Tightening torques inspection Lock check Safety locks clamping screws Safety locks Pre delivery Stalker 50 PRE DE 118 ...

Page 119: ... ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE WARNING BEFORE RECHARGING THE BATTERY REMOVE THE CAPS OF EACH CELL KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED REMOVE THE BATTERY FROM THE SCOOTER DISCONNECTING THE NEGATIVE TERMINAL FIRST CAUTI...

Page 120: ...em fluid level Rear hub oil level Engine oil level Road test Test ride Cold start Instrument operations Response to the throttle control Stability on acceleration and braking Rear and front brake efficiency Rear and front suspension efficiency Abnormal noise Static test Static control after the test ride Starting when warm Starter operation Minimum hold turning the handlebar Uniform turning of the...

Page 121: ...h 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 accessories Stalker 50 Pre delivery PRE DE 121 ...

Page 122: ...INDEX OF TOPICS TIME TIME ...

Page 123: ...n 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 Stalker 50 Time TIME 123 ...

Page 124: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement Time Stalker 50 TIME 124 ...

Page 125: ...t 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 Stalker 50 Time TIME 125 ...

Page 126: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder piston Replacement 2 001107 Cylinder piston Inspection clean ing Time Stalker 50 TIME 126 ...

Page 127: ... Code Action Duration 1 001013 Intake manifold Replacement 2 001093 Spark plug Replacement 3 001126 Head Replacement 4 001097 Cooling hood Replacement 5 001178 Disc pack Replacement 6 001087 Flywheel cover Replacement Stalker 50 Time TIME 127 ...

Page 128: ...ven 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 Time Stalker 50 TIME 128 ...

Page 129: ...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 Stalker 50 Time TIME 129 ...

Page 130: ...AL 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 Time Stalker 50 TIME 130 ...

Page 131: ...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 Stalker 50 Time TIME 131 ...

Page 132: ... COVER Code Action Duration 1 001096 Transmission crankcase cover Re placement 2 001131 Transmission air intake Replace ment 3 001135 Transmission cover bearing Re placement 4 004179 Stand buffer Replacement Time Stalker 50 TIME 132 ...

Page 133: ...TER 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 Stalker 50 Time TIME 133 ...

Page 134: ...Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001058 Flywheel Replacement 2 001067 Stator Replacement 3 001173 Rotor Replacement 4 001109 Cooling fan Replacement Time Stalker 50 TIME 134 ...

Page 135: ...Brake shoes BRAKE SHOES Code Action Duration 1 002002 Rear brake shoe s Replacement Stalker 50 Time TIME 135 ...

Page 136: ...Carburettor CARBURETTOR INSPECTION Code Action Duration 1 001081 Automatic choke Replacement 2 001008 Carburettor Inspection Time Stalker 50 TIME 136 ...

Page 137: ...ttor Replacement 2 003058 Carburettor Adjustment 3 004177 Heating hood Replacement Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 001136 Exhaust emissions Adjustment Stalker 50 Time TIME 137 ...

Page 138: ...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 Stalker 50 TIME 138 ...

Page 139: ...ion 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 Stalker 50 Time TIME 139 ...

Page 140: ...d spoiler FRONT SHIELD Code Action Duration 1 004064 Front shield Replacement 2 004065 Front shield rear section Replace ment 3 004178 Footrest Replacement 4 004053 Spoiler Replacement Time Stalker 50 TIME 140 ...

Page 141: ...rings REAR COVERS Code Action Duration 1 xxxx Rear spoiler Replacement 2 004085 Fairing 1 Replacement 3 004012 Rear side panels 2 Replacement 4 xxxxx Lower cover side panel Replace ment Stalker 50 Time TIME 141 ...

Page 142: ...Underseat compartment CENTRAL FRAME COVER Code Action Duration 1 004011 Central chassis cover Replacement Time Stalker 50 TIME 142 ...

Page 143: ...OMPARTMENT Code Action Duration 1 004016 Helmet compartment Replacement 2 005046 Battery cover Replacement Mudguard REAR MUDGUARD Code Action Duration 1 004009 Rear mudguard Replacement Stalker 50 Time TIME 143 ...

Page 144: ...el tank FUEL TANK Code Action Duration 1 004005 Fuel tank Replacement 2 005010 Tank float Replacement 3 004072 Fuel filter Replacement 4 004112 Cock carburettor hose Replace ment Time Stalker 50 TIME 144 ...

Page 145: ...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 Stalker 50 Time TIME 145 ...

Page 146: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorbers Replace ment Time Stalker 50 TIME 146 ...

Page 147: ...n 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 Stalker 50 Time TIME 147 ...

Page 148: ...Handlebar components HANDLEBAR COMPONENTS Code Action Duration 1 002071 Left hand grip Replacement 2 002037 Brake or clutch lever Replacement 3 005017 Stop switch Replacement Time Stalker 50 TIME 148 ...

Page 149: ...ode Action Duration 1 004066 Driving mirror Replacement 2 003001 Handlebar Replacement 3 005017 Stop switch Replacement 4 002037 Brake or clutch lever Replacement 5 002059 Right hand grip Replacement Stalker 50 Time TIME 149 ...

Page 150: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine frame swinging arm fitting Replacement Time Stalker 50 TIME 150 ...

Page 151: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement Stalker 50 Time TIME 151 ...

Page 152: ...EBAR 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 5 005076 Clock Cell Replacement Time Stalker 50 TIME 152 ...

Page 153: ...n Duration 1 005067 Front turn indicator bulb Replace ment 2 005008 Front headlamp bulbs Replacement 3 005002 Front headlamp Replacement 4 005091 Turn indicator glass Replacement 5 005012 Front turn indicator Replacement Stalker 50 Time TIME 153 ...

Page 154: ...or bulb Replace ment 3 005091 Turn indicator glass Replacement 4 005028 Rear light assembly glass Replace ment 5 005066 Rear light bulbs Replacement 6 004136 License plate support Replacement 7 004056 Upper rear light cover Replacement 8 005048 Licence plate holder Replacement Time Stalker 50 TIME 154 ...

Page 155: ...ensor Re placement 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 ...

Page 156: ...Rear wheel REAR WHEEL Code Action Duration 1 001071 Rear wheel rim Replacement 2 001016 Rear wheel Replacement 3 004126 Rear wheel tyre Replacement Time Stalker 50 TIME 156 ...

Page 157: ...1 005007 Battery Replacement 2 005024 Battery fuse Replacement 3 005025 Fuse holder Replacement 4 005011 Start up remote control switch Re placement 5 xxxxxx Turn indicator assembly Replace ment 6 xxxxxxx Diode Replacement Stalker 50 Time TIME 157 ...

Page 158: ...RICAL SYSTEM Code Action Duration 1 001023 Control unit Replacement 2 001094 Spark plug cap Replacement 3 005001 Electrical system Replacement 4 005009 Voltage regulator Replacement Time Stalker 50 TIME 158 ...

Page 159: ...orn 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 9 005077 Emergency stop switch Replace ment Stalker 50 Time TIME 159 ...

Page 160: ...on 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 Stalker 50 TIME 160 ...

Page 161: ...REAR BRAKE TRANSMISSION AND ODOMETER Code Action Duration 1 002051 Odometer transmission assembly Replacement 2 002053 Rear brake transmission complete Replacement Stalker 50 Time TIME 161 ...

Page 162: ...ront 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 Stalker 50 TIME 162 ...

Page 163: ...3 Brake fluid reservoir Replacement 2 002052 Front brake transmission Replace ment 3 002025 Brake piping Replacement 4 002021 Front brake piping Replacement 5 002039 Front brake calliper Replacement 6 002024 Front brake pump replace Stalker 50 Time TIME 163 ...

Page 164: ...105 135 C Carburettor 10 136 E Engine stop F Fuel 34 87 114 144 Fuses 51 H Headlight 31 109 Hub oil 26 I Identification 8 Instrument panel 108 152 M Maintenance 7 25 O Odometer S Saddle Spark plug 26 T Tank 114 115 144 145 Transmission 9 35 59 132 Tyres 10 ...

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