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PIAGGIO Liberty 50 4tempi 2008, Workshop Manual, Page: 47 / 195

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PIAGGIO Liberty 50 4tempi 2008 Workshop Manual Download Page 47

Specification

Desc./Quantity

3

Light switch

4

Headlight bulb

12V-35/35W

5

High-beam warning light

12V - 1.2W

6

Rear light bulb

12V - 5W

7

Headlight warning light

12V - 1.2W

8

Front position light filament

12V - 5W

9

N°3 instrument lighting bulbs

12V - 1.2W

Battery recharge and starting

BATTERY RECHARGE AND STARTING SECTION

Specification

Desc./Quantity

1

Voltage regulator

2

Magneto flywheel

3

Automatic starter

4

Battery

12V-9Ah

5

Remote starter switch

6

Starter motor

7

Start up button

8

Brake light filament

12V-21W

9

Front and rear brake light button

10

Key switch

11

Main fuse

10A

Liberty 50 4tempi

Electrical system

ELE SYS - 47

Summary of Contents for Liberty 50 4tempi 2008

Page 1: ...WORKSHOP MANUAL 633104 Liberty 50 4tempi ...

Page 2: ...hanges 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 2008 PIAGGIO C S p A Pontedera All rights reserved Reproduc...

Page 3: ...he 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 observe...

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: ...the 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 The non original or non compliant spare parts may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and spli...

Page 8: ...ead camshaft driven by a chain to the left side Depression carburettor KEIHN CVK 18 CO adjustment 3 2 0 5 Engine idle 1900 2000 rpm Air filter Sponge soaked in a mixture 50 SELENIA Air Filter Oil and 50 unleaded petrol Starting system electric starter kick starter Lubrication Engine lubrication with lobe pump inside the crankcase con trolled by chain and double filter mesh and centrifugal Fuel sys...

Page 9: ...mended spark plug NGK CR 9EB CHAMPION RG 4HC Alternative spark plug DENSO U24ESR NB Battery 12V 9Ah Main fuse 10 A Generator single phase alternating current Frame and suspensions FRAME AND SUSPENSION Specification Desc Quantity Chassis type Welded tubular steel chassis with stamped sheet reinforce ments Front suspension mechanical telescopic steering tube Front suspension stroke 66 8 mm Trail 100...

Page 10: ...ondary air housing op erating principle for 50 4T engines is similar to that for 50 2T engines the only difference lies in how air is sucked in the external and the external side of the transmission compartment Air is taken in along tube A to the cylinder side and after been cleaned through the filter B gets into the reed valve C to be directed towards the head through a flexible pipe and then a r...

Page 11: ... to 28 Alternator flywheel nut 40 44 Nm Stator screws 3 to 4 Pick up screws 3 to 4 Oil pump bulkhead screw 4 to 5 Timing chain oil pump compartment cover screws 4 to 5 Nm Oil decantation labyrinth sheet screws 7 to 8 Oil pump crown screw 8 to 10 Screws fixing oil pump to the crankcase 5 to 6 Oil pump coupling screws 7 to 9 Nm Oil sump screws 8 to 10 Nm Inlet manifold screw 7 to 9 Carburettor manif...

Page 12: ...4 to 126 Stand bolt 20 25 Front mudguard fixing screw 4 6 FRONT SUSPENSION Name Torque in Nm Fork bottom screw 20 to 25 Front wheel axle 45 to 50 Odometer drive screw 6 7 FRONT BRAKE Name Torque in Nm Brake fluid pump hose joint 20 to 25 Brake fluid pipe calliper fitting 20 22 Calliper tightening screw 20 25 Disc tightening screw Apply LOCTITE 243 medium strength threadlock 8 to 12 Nm Oil bleeding...

Page 13: ...5 0 032 to 0 046 Piston 1st oversize D1 39 214 to 39 221 39 175 to 39 182 0 032 to 0 046 Cylinder 2nd oversize A2 39 393 to 39 400 39 354 to 39 361 0 032 to 0 046 Cylinder 2nd oversize B2 39 400 to 39 407 39 361 to 39 368 0 032 to 0 046 Piston 2nd oversize C2 39 407 to 39 414 39 368 to 39 375 0 032 to 0 046 Piston 2nd oversize D2 39 414 to 39 421 39 375 to 39 382 0 032 to 0 046 Cylinder 3rd oversi...

Page 14: ...smission side 14 0 0 005 A Flywheel side half shaft 16 0 0 005 B Connecting rod 14 8 0 05 0 C Spacer tool 45 00 Fits and clearan ces D 0 15 to 0 30 E Slot packing system N B MEASUREMENT A TO BE TAKEN IS A VALUE OF PISTON RE ENTRY IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER THE FURTHER THE PISTON GETS INSIDE THE CYLINDER THE ...

Page 15: ...se R I D A D R 2 10 b 2 R I Na 2 42 I A T A 2 I M D G class 2 UN 1950 Pag 9022 EM 25 89 eni i Ride PG 5W 40 Synthetic based lubricant for high per formance four stroke engines JASO MA MA2 API SL ACEA A3 AGIP BRAKE 4 Brake fluid Synthetic fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 MONTBLANC MOLYBDENUM GREASE Grease for driven pulley shaft adjusting ring and movable driven pulley ...

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

Page 17: ...or fitting steering seats 001467Y008 Pliers to extract 17 mm ø bearings 001467Y009 Bell for OD 42 mm bearings 004499Y Camshaft bearing extractor 005095Y Engine support 008119Y009 Tube to assemble shafts and axles Liberty 50 4tempi Tooling TOOL 17 ...

Page 18: ...h for removing steering bearings from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater mounting 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for Ø 17 mm roller bearing Tooling Liberty 50 4tempi TOOL 18 ...

Page 19: ...ng base 020288Y Fork to assemble piston on cylinder 020291Y Valve fitting removal tool 020306Y Punch for assembling valve seal rings 020329Y Mity Vac vacuum operated pump 020330Y Stroboscopic light to check timing Liberty 50 4tempi Tooling TOOL 19 ...

Page 20: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger Tooling Liberty 50 4tempi TOOL 20 ...

Page 21: ...20335Y Magnetic mounting for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40 mm Adaptor 020359Y 42x47 mm Adaptor 020360Y 52x55 mm Adaptor 020362Y 12 mm guide Liberty 50 4tempi Tooling TOOL 21 ...

Page 22: ...de Description 020363Y 20 mm guide 020364Y 25 mm guide 020376Y Adaptor handle 020431Y Valve oil seal extractor 020432Y Tool to fit the start up sector spring 020439Y 17 mm guide Tooling Liberty 50 4tempi TOOL 22 ...

Page 23: ...ting tool 020449Y Piston position check support 020450Y Camshaft fitting removal tool 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner Liberty 50 4tempi Tooling TOOL 23 ...

Page 24: ...Stores code Description 494929Y Exhaust fumes analyser Tooling Liberty 50 4tempi TOOL 24 ...

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

Page 26: ... C C Valve clearance I I I I I I Electrical system and battery I I I I I I I I I I I Cylinder ventila tion system I I Brake levers L L L L L L Brake oil level I I I I I I I I I I I Hub oil level R I R I R I R I R I R Engine oil R I R I R I R I R I R I R I R I R I R I R Brake Pads Shoes I I I I I I I I I I I Tyre pressure I I I I I I I I I I I Headlight A A A A A Vehicle road test I I I I I I I I I...

Page 27: ...ice Two reference marks for the timing can be found on the flywheel cover as to find out with more precision the reference mark on the fan To check use a stroboscopic gun Tecnotest 130 P or similar type Start the engine and let it run at 1900 revs min act on the phase shifter to align the reference mark on the flywheel fan in between the two reference marks on the casing at the same time read the ...

Page 28: ...a tend to reduce the spark plug performance This results in difficulties for vehicles to reach the maximum speed and anomalous noises If the above situation should occur replace the spark plug before performing any other intervention Before installing the new spark plug blow with air to remove the silicone oil in excess Direct the jet of compressed air into the round groove between the threaded me...

Page 29: ...rk plug 1 Champion RG 4 HC Recommended spark plug NGK CR9EB Alternative spark plug DENSO U24ESR NB Locking torques N m Spark plug 10 to 15 Nm Hub oil Check Rest the vehicle on its centre stand on an even surface Unscrew the oil dipstick A dry it with a clean cloth and reinsert it screwing it in thoroughly Pull out the dipstick and check that the oil level is above the middle notch dipstick with 3 ...

Page 30: ...y with a clean cloth without wringing and with compressed air Soak with a 50 fuel oil mixture with selenia air filter oil Let the filter cartridge drip and then squeeze it between the hands without wringing Refit all components by following the reverse procedure to the removal CAUTION IF THE VEHICLE IS MOSTLY USED ON DUSTY ROADS THE AIR FILTER NEEDS TO BE CLEANED AT SHORTER INTERVALS THAN INDICATE...

Page 31: ...engine let it idle for about a minute and then switch it off Wait for at least ten minutes and then top up by adding oil to the MAX level Check Put the vehicle on the stand on level ground cold engine Check that the oil level is between the MIN and MAX marks on the sight The MAX reference mark corresponds to approx imately 850 cc of oil in the engine If the oil level is near or below the MIN mark ...

Page 32: ...el should always be below the MAX mark N B For the first top up or when servicing add 850 cm of engine oil for any other case add 650 cm and top up if required Recommended products eni i Ride PG 5W 40 Synthetic based lubricant for high performance four stroke engines JASO MA MA2 API SL ACEA A3 Locking torques N m Engine oil pre filter cover 25 to 28 Nm Checking the ignition timing Turn the flywhee...

Page 33: ...sening the counternut and using a screwdriver on the register screw as shown in the figure Characteristic Inlet with cold engine 0 10 mm Outlet with cold engine 0 15 mm Headlight adjustment Set the unladen vehicle on level even ground at a distance of 10 m from a flat wall or screen that is sufficiently darkened to be able to see the beam see figure Make sure that the vehicle axis is at right angl...

Page 34: ...ter clean and the spark plug in good con ditions 1 Warm up the engine by riding the vehicle for about 5 10 minutes as this is the time required for the choke device to disengage 2 Shut down the engine only for the time required to carry out operations 3 and 4 3 Remove the RH side fairing and the SAS box cover by loosening the 3 screws shown in the fig ure Interpose a plastic sheet between the seco...

Page 35: ...sparkplug Fit a compression testing pressure gauge in the sparkplug seat with a sparkplug fitting and tighten it Run the motor using the starter and with the carburetor fully open until the reading on the pressure gauge is stable If the pressure is normal remove the device and disassemble in the opposite order If the pressure readings are below those indicated check the engine rpm used for the tes...

Page 36: ...13 15 bar 630 rpm starting speed Locking torques N m Ignition spark plug 10 to 15 Nm Maintenance Liberty 50 4tempi MAIN 36 ...

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

Page 38: ...earance properly Valve seat distorted Replace the head unit Air filter blocked or dirty Dismantle the sponge wash with water and shampoo then soak it in a mixture of 50 petrol and 50 of specific oil Se lenia Air Filter Oil then hand dry without squeezing allow to drip dry and then reassemble Defective floating valve Check the proper sliding of the float and the functioning of the valve Rear wheel ...

Page 39: ...eplace the gaskets or restore the coupling seal Worn or broken piston rings or piston rings that have not been fitted properly Replace the piston cylinder unit or just the piston rings Worn valve seat Check and if necessary replace head assembly Insufficient lubrication pressure LOW LUBRICATION PRESSURE Possible Cause Operation By Pass remains open Check the By Pass and replace if required Careful...

Page 40: ...to the tank level with the carburettor inverted Loose nozzles Check the maximum and minimum nozzles are adequately fixed in their fittings Inefficient Starter Check electric wiring circuit continuity mechanical sliding and power supply Air filter blocked or dirty Dismantle the sponge wash with water and shampoo then soak it in a mixture of 50 petrol and 50 of specific oil Se lenia Air Filter Oil t...

Page 41: ...e piston sliding Check calliper and replace any damaged part Electrical system Battery BATTERY Possible Cause Operation Battery This is the device in the system that requires the most frequent attention and the most thorough maintenance If the vehicle is not used for some time 1 month or more the battery needs to be recharged periodically The battery runs down completely in the course of 3 months ...

Page 42: ...of the top and bottom ring nuts If irregu larities continue in turning the steering even after making the above adjustments check the seats in which the ball bearings rotate if they are recessed or if the balls are squashed replace them Faults in the suspension system If the front suspension is noisy check the efficiency of the front shock absorber the condition of the ball bearings and relevant l...

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

Page 44: ... button 4 Turn signal selector 5 High low beam selector 6 Rear brake stop button 7 Bulb 8 Bulb for front position light 9 Turn signal indicator lights Right 10 Instrument bulbs 11 Turn signal indicator lights Left 12 Fuel warning light Electrical system Liberty 50 4tempi ELE SYS 44 ...

Page 45: ...te taillight 26 Rear position and stop light bulb 27 Battery 28 Pick up 29 Magneto 30 Complete resistance 31 Starter motor 32 Fuse holder with 10A fuse 33 Rear left indicator 34 2 amber bulbs for indicator 35 Electronic ignition 36 Voltage regulator Wire color coding B White Mr Brown N Black GN Yellow Black Rs Pink R Red Vi Purple BN White Black BBl White Blue GV Yellow Green GrBl Gray Blue RBl Re...

Page 46: ...ick up 3 Key switch contacts 4 Electronic ignition device 5 Fuse 10 A 6 Voltage regulator 7 Battery 12V 9Ah Headlights and automatic starter section LIGHTS Specification Desc Quantity 1 Magneto flywheel 2 Voltage regulator Electrical system Liberty 50 4tempi ELE SYS 46 ...

Page 47: ... instrument lighting bulbs 12V 1 2W Battery recharge and starting BATTERY RECHARGE AND STARTING SECTION Specification Desc Quantity 1 Voltage regulator 2 Magneto flywheel 3 Automatic starter 4 Battery 12V 9Ah 5 Remote starter switch 6 Starter motor 7 Start up button 8 Brake light filament 12V 21W 9 Front and rear brake light button 10 Key switch 11 Main fuse 10A Liberty 50 4tempi Electrical system...

Page 48: ...ATORS Specification Desc Quantity 1 Voltage regulator 2 Fuel gauge 3 Fuel level sender 4 Low fuel warning light 12V 1 2W 5 Front and rear brake light button 6 Fuse 10 A 7 Battery 12V 9Ah 8 Brake light filament 12V 21W 9 Key switch contacts Electrical system Liberty 50 4tempi ELE SYS 48 ...

Page 49: ...2V 9Ah Checks and inspections 1 No load test the starter motor under no load must draw a maximum of 10 Amp with a supply voltage of 12V and must rotate at 15 000 rpm 2 Load test braking the starter motor so that it draws 47 Amp and with a supply voltage of 10V a torque of 0 2 N m must be obtained at 10 000 rpm minimum 3 Pick up test with the rotor locked and a supply voltage of 7V the current draw...

Page 50: ...rter motor is so braked that it absorbs 47A with supply voltage 10V tor que of 0 2 N m must be obtained at 10 000 rpm 3 Static torque test when the rotor is locked and the supply voltage is 7V the absorbed current must not exceed 130A and the torque must be at least 0 55 N m specifications Nominal voltage 12V Nominal power 0 25 kW Left turn seen from the pinion side Connection to the engine with p...

Page 51: ...s as follows After visually checking the electrical connections use a specific tester to measurement the stator winding and the pickup see table If any failure is found after checking the loading coil and the pick up replace the stator and the dam aged parts Disconnect the connector on the flywheel cover and measure the resistance between either con tact and the earthing Specific tooling 020331Y D...

Page 52: ...ATED Electric characteristic Stator Brown earth 170 Ω Pick Up Stator Black earth 1 Ω Stator Voltage regulator check A malfunction in the voltage regulator might cause the following problems depending on the type of fault 1 Bulbs burned out regulator in short circuit 2 Malfunction of the lighting system and the electric starter regulator interrupted 3 Battery not recharging 4 Turn indicators not wo...

Page 53: ...rectly to earth if voltage is detected with this operation check the earth wiring of the regulator otherwise replace the regulator be cause it is damaged As a last check the voltage supplied by the stator can be measured Disconnect the regulator connector and place a tester between the Grey Blue cable 4 and the earth in order to detect alternating voltages see figure Voltage supplied at 2 000 rpm ...

Page 54: ...ck that the upstream wiring and devices of the key switch are not in short circuit to earth Now measure the resistance between contact 3 White and contact 2 Black of the voltage regu lator with connector disconnected If the value measured is far from that indicated replace the regulator because it is in short circuit b Battery fails to recharge regulator interrupted To check if there is any failur...

Page 55: ...y switch to ON and check that the battery is getting voltage If no voltage is detected repeat the test now between the white cable and the earth if there is no voltage even after this op eration check the wiring and the contacts of the key switch and the battery If voltage in the battery is detected black cable check the regulator earth wiring If the above tests have positive results jump the cont...

Page 56: ...the key switch and the battery If voltage in the battery is detected black cable check the regulator earth wiring If the above tests have positive results jump the contacts 5 blue black and 3 white on the con nector set the key switch to ON and the turn indicator switch left and right to see when the lights are steadily on as they are powered directly from the battery If even after this operation ...

Page 57: ...GING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARG ING SO AS NOT TO DAMAGE THE BATTERY ITSELF 1 Hold the vertical tube 2 Look at the level 3 The float must be freed Dry charge battery WARNING Battery electrolyte is toxic and it may cause serious burns It contains sulphuric acid Avoid contact with eyes skin a...

Page 58: ...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 distilled water to restore this level If it is necessary to add water too frequently check the vehicle s electrical system the battery works overcharged and is subje...

Page 59: ...ames or sparks when charging Remove the battery from the vehicle disconnecting the negative terminal first CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE CAUTION DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BAT TERY USE DISTILLED WATER ONLY CAUTION TO ENSURE MAXIMU...

Page 60: ... beam warning light 12V 1 2W 3 Instrument panel lighting bulbs 12V 1 2W 4 Headlight warning light 12V 1 2W 5 Low fuel warning light 12V 1 2W 6 Right turn indicator warning light 12V 2W 7 Pre set warning light 8 Instrument panel lighting bulb 12V 2W Electrical system Liberty 50 4tempi ELE SYS 60 ...

Page 61: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 62: ...emoval of the engine from the vehicle Removing the engine connecting arm pivot pin Remove the nut shown in the figure and then with draw the pin Reassembling engine to frame Perform the disassembly steps in reverse order Observe the prescribed tightening torques Locking torques N m Engine swinging arm pin nut 33 to 41 Engine shock absorber 33 41N m Disassembling engine from frame Disconnect the ba...

Page 63: ...s Remove the throttle grip and mixer transmissions Disconnect the hoses petrol oil vacuum operated cock control WARNING Handle fuel with care CAUTION When installing the battery first attach the positive cable and then the negative cable WARNING Wear safety goggles when using hitting tools Liberty 50 4tempi Engine from vehicle ENG VE 63 ...

Page 64: ...INDEX OF TOPICS ENGINE ENG ...

Page 65: ...PPROPRIATE COUPLINGS TO REMOVE THE COVER Kickstart To remove the start up pinion push the starter lever to facilitate extracting the pinion Remove the kick start screw and lever Remove the Seeger ring and the washer indica ted in the figure Pull out the toothed sector WARNING THE SECTOR KEEPS THE SPRING SET BE CAREFUL SO AS NOT TO CAUSE ANY ACCIDENTS Air duct To remove the intake throat on the tra...

Page 66: ...ing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside N B WHEN REFITTING ALWAYS REPLACE THE BEARING WITH A NEW ONE CAUTION WHEN REMOVING REFITTING THE BEARING TAKE CARE NOT TO DAMAGE THE COVER PAINTED SURFACE Removing the driven pulley Lock the clutch housing with the specific tool Remove the nut the clutch housing and the whole of the...

Page 67: ...lutch Equip the tool with long pins screwed into position A from the outside insert the entire driven pulley in the tool and have the central screw make con tact CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW IS TIGHTENED UP TOO FAR Using a 34 mm socket wrench remove the clutch locking nut Loosen the central screw by undoing spring of the driven pulley unit Separate the components Specific...

Page 68: ...IT A CEN TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER 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 retaining collar Remove the collar with the aid of 2 screwdrivers Remove the three guide pins and the mobile half pulley Engine Liberty 50 4...

Page 69: ...s of the special tool N B PROPERLY SUPPORT THE HALF PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVE 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 are replace the half pulley Make sure the bearings do not show signs of un usual wear Measure the outsid...

Page 70: ...th a curved spout to lubricate the driven pulley unit with around 6 g of grease This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole This procedure is necessary to prevent the presence of grease beyond the O ring Recommended products AGIP GREASE SM 2 Gray black smooth textured lithium grease containing molybdenum di sulphide Refitting ...

Page 71: ...check the driven pulley unit N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL CONTACT SURFACE AND MUST NOT BE DIFFER ENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Minimum thickness permitted 1 mm Refitting the clutch Preassemble the driven pulley group with ...

Page 72: ...g clutch unit on pulley 55 to 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 drive belt is not damaged and does not have cracks in the toothed grooves Check the width of the belt Characterist...

Page 73: ...or deformation 2 Check the roller running tracks on the contact pulley there must not be signs of wear and check the condition of the contact surface of the belt on the half pulleys mobile and stationary 3 Check that the rollers do not show signs of marked facetting on the sliding surface and that the metallic insert does not come out of the plastic shell borders 4 Check the integrity of the slidi...

Page 74: ...it the components of the assembly roller housing assembly with bushing limiting washer stationary half pulley cooling fan belt with drive washer and nut With the specific tool tighten the lock nut to 20 Nm and then perform a final 90 locking in order to prevent the rotation of the driving pulley N B REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF...

Page 75: ...Seeger and the Kick start lever Recommended products AGIP GREASE MU3 Yellow brown lithium base medium fibre multipurpose grease ISO L X BCHA 3 DIN 51 825 K3K 20 Insert the pinion in its seating by pushing the starter lever Fit the intake throat and tighten the 3 screws Make sure the oil sump presents centring dowels and sealing gaskets Replace the cover tightening the 12 screws to the prescribed t...

Page 76: ...l it out Remove the intermediate gear with the appropri ate shim washers Removing the wheel axle bearings Remove the oil seal and the seeger ring Fix the hub cover properly to avoid damaging the sealing surface with the housing Remove the wheel axle bearing using the specific tool Specific tooling 020363Y 20 mm guide 020376Y Adaptor handle 020477Y 37 mm adaptor Engine Liberty 50 4tempi ENG 76 ...

Page 77: ...ct the driven pulley shaft together with the bearing with a few mallet blows Remove the bearing off the driven pulley shaft using the specific tool and a press N B USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALL ER INTERNAL DIAMETER Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Liberty 50 4tempi Engine ENG 77 ...

Page 78: ...ing the hub cover Check that the fitting surface is not dented or dis torted If faults are found replace the hub cover Refitting the wheel axle bearing Support the hub cover on a wooden surface Heat up the hub cover using the thermal gun Preassemble the bearing on the specific punch using grease and then insert the bearing in its seating Refit the seeger ring and the oil seal using the 42 x 47 mm ...

Page 79: ...cap so that it does not interfere with the wheel axle gear when placing the transmission shaft Refitting the ub cover Apply product recommended for surfaces on the hub cap and refit cap on the crankcase Fit the 5 screws and tighten them to the specified 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 Recommen...

Page 80: ... it Remove the 4 front coupling screws 1 of them is a knob and the side fixing screw at the crankcase base Remove the 4 side screws Extract the 3 covers Remove the cover sealing gaskets on the head For refitting repeat the removal steps but in re verse order CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR N B WHEN REFITTING THE COVER TAKE CARE NOT TO DAM AGE THE STATOR WIRING Engine...

Page 81: ...xing screws indicated in the figure Remove the stator and its wiring Refitting the stator Refit the stator and flywheel carrying out the re moval procedure in reverse tightening the retain ers 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 COV ER ASSEMBLY Locking torques N m Pick up...

Page 82: ...he power wiring 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 Liberty 50 4tempi ENG 82 ...

Page 83: ...ause rubbing on the stator and the Pick Up Check that the stator winding its ferromagnetic support and the pick up are in good conditions Starter gear rim Check the toothing is level and in good conditions Intermediate gear Check that the keying toothing on the crown and the starter motor are in good conditions Check that the Bendix opens and returns ade quately Liberty 50 4tempi Engine ENG 83 ...

Page 84: ...c tooling 020565Y Flywheel lock calliper spanner Locking torques N m Flywheel nut 52 to 58 Refitting the starter motor Install the starter motor in its seating in the crank case Tighten the screw on the head side but do not lock it screw the second screw inserting the earth cable black then tighten the 2 screws at the pre scribed torque Tighten the locking screw of the positive cable red on the si...

Page 85: ...emove the cover unit See also Cooling hood Removing the timing system drive Temporarily loosen the tensioner central screw and remove it together with the spring Unscrew the 2 retainers indicated in the figure and remove the chain tightener support being careful to recover the sealing gasket N B SHOULD THE GASKET NOT BE IN GOOD CONDITIONS REPLACE IT AFTER CAREFULLY CLEANING THE FAYING SURFACE IN O...

Page 86: ...emove the chain lower guiding pad remove the head by pulling it upwards N B IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE DIRECTION OF RO TATION IS MAINTAINED See also Removing the driving pulley Removing the rocker arms cover Removal Removing the cam shaft Remove the bearing clamping screw indicated in the figure Remove the entire camshaft with bearing using the specific tool show...

Page 87: ...KE AND DISCHARGE ENDS Removing the cylinder head Remove the cooling covers the timing control the camshaft and the rocking levers Remove the spark plug Remove the 2 side fixings shown in the figure Loosen the 4 head cylinder fastening nuts in two or three stages and in criss cross fashion Remove the head the two alignment dowels and the gasket N B IF NEEDED THE HEAD MAY BE REMOVED WITH THE CAMSHAF...

Page 88: ... 020431Y Valve oil seal extractor Removing the cylinder piston assy Remove the cylinder paying attention to the 2 cylinder centring dowels in the housing Remove the cylinder base gasket To avoid damaging the piston keep it fixed while removing the cylinder Remove the two stop rings the wrist pin and the piston Remove the 3 piston rings from the piston N B BE CAREFUL NOT TO DAMAGE THE PISTON RINGS ...

Page 89: ...mall end 13 0 025 0 015mm Inspecting the wrist pin Measure the outer diameter of the gudgeon pin Characteristic Standard diameter gudgeon pin 13 0 0 004mm Minimum admissible diameter gudgeon pin 12 990 mm Inspecting the piston Calculate the piston pin coupling clearance Fitting clearance Pin coupling clearance 13 0 010 0 005mm 0 005 to 0 014 mm Measure the outside diameter of the piston perpendicu...

Page 90: ...ameter at three different points according to the directions shown in the figure Check that the coupling surface with the head is not worn or misshapen Pistons and cylinders are classified into catego ries based on their diameter The coupling is car ried out in pairs A A B B C C D D Characteristic Maximum allowable run out 0 001 in 0 05 mm The cylinder rectifying operation should be car ried out w...

Page 91: ...figure of the sealing rings using a thickness gauge If any measurements are greater than specified replace the piston rings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES AND BETWEEN THE PISTON AND THE CYLINDER IS AS SPECIFIED IN ANY CASE NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING C...

Page 92: ... the gaskets match cylinders with different heights Fibre gaskets with cylinder 56 45 mm high Fibre gaskets with cylinder 57 15 mm high In order to carry out the revision both gaskets should be present on the spare parts All pin piston cylinder units supplied with the spare parts present cylinders 57 15 mm high Provisionally fit the piston into the cylinder without any base gasket Fit a dial gauge...

Page 93: ...05 Base gasket thickness 0 4 Value measured 0 30 0 05 Base gasket thickness 0 5 N B MEASUREMENT A TO BE TAKEN IS A VALUE OF PISTON RE ENTRY IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER THE FURTHER THE PISTON GETS INSIDE THE CYLINDER THE THINNER THE HEAD GASKET TO BE APPLIED SHOULD BE TO RECOVER THE COMPRESSION RATIO AND VICE ...

Page 94: ...Engine Liberty 50 4tempi ENG 94 ...

Page 95: ...S ARE MADE OF CONE SHAPED CONTACT SECTION TO THE CYLINDER AS A RESULT IT IS IMPOR TANT TO RESPECT THE FITTING INSTRUCTION TO AS SEMBLY THE RINGS WITH THE T MARK FACING UPWARDS Alternately insert the three sealing rings into the cylinder in the area where it retains its original di ameter Using the piston insert the rings perpen dicularly to the cylinder axis Measure the opening see figure of the s...

Page 96: ...ork to assemble piston on cylinder If the four cylinder stud bolts should be replaced in this kind of engine it is necessary to tighten the head nuts strictly following the procedure below The procedure is different from that indicated in the vehicle manuals Head nuts tightening only for stud bolts replacement 6 7 N m 90 90 90 The 45 rotation reduction of the key is necessary to avoid stud bolt st...

Page 97: ...er slider are not worn out Ensure that the camshaft drive pulley the chain assembly and the sprocket wheel are not worn If sings of wear are found replace the parts if the chain pinion or pulley are worn replace the whole assembly Remove the central screw and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found ...

Page 98: ... Inspecting the valve housings Remove any carbon formation from the valve guides Measure the inside diameter of each valve guide Take the measurement at three different heights in the rocker arm push direction Characteristic Discharge guide Standard diameter 5 0 0 012mm Discharge guide Wear limit 5 022 mm Intake guide Standard diameter 5 0 0 012mm Intake guide Wear limit 5 022 mm If the width of t...

Page 99: ...lve with a new one Characteristic Valve standard length Intake 70 1 mm Valve standard length Exhaust 69 2 mm Fitting clearance Max clearance allowed Intake 0 052 mm Max clearance allowed drainage 0 062 mm If no faults are found during the above checks you can use the same valves For best sealing results it is advisable to grind the valves Grind the valves gently with a fine grained lapping compoun...

Page 100: ...g rings one at a time Specific tooling 020306Y Punch for assembling valve seal rings Fit the valves the springs and the upper caps Using the appropriate tool compress the springs and insert the cotters in their seats Inspecting the cam shaft Inspect the camshaft for signs of abnormal wear on the cams Characteristic Standard diameter Bearing A Ø 12 0 002 0 010 mm Standard diameter Bearing B Ø 16 0 ...

Page 101: ...height Intake 25 935 mm Standard height Discharge 25 935 mm Fitting clearance Maximum admissible axial clearance 0 5 mm Check there are no signs of scoring or wear on the rocking lever bolt Measure the diameter A Measure the internal diameter of each rocking lever level B Check there are no signs of wear on the slider from contact with the cam and on the jointed adjustment plate In case of anomali...

Page 102: ...20450Y Camshaft fitting removal tool Locking torques N m Head cylinder stud bolt nuts 6 to 7 135 90 Nm first fitting upon refitting tighten again at 6 to 7 90 90 Nm Loosen the rocking lever registers Fit the pin the intake rocking lever and the dis charge rocking lever Lubricate the 2 rocking levers through the holes N B IF A BEARING SEPARATES FROM THE CAMSHAFT IT IS ESSENTIAL TO FIT A NEW BEARING...

Page 103: ...nsert the timing chain pads in their correspond ing seatings the screw and the spacer as indica ted in the figure Tighten to the prescribed torque and check the tensioner pad moves adequately Insert the timing pinion in driving shaft with the chamfered side facing the insertion towards the main bearing Loop the timing chain around the sprocket on the crankshaft Locking torques N m Chain tensioner ...

Page 104: ...shaft pulley screw 12 to 14 Head cover screw 8 to 10 Nm Set the tensioner cursor in the rest position Fit the chain tensioner on the cylinder using a new gasket and tight the two screws to the prescribed torque Insert the spring with the central screw and tighten it to the prescribed torque Fit the spark plug Characteristic Recommended spark plug NGK CR 9EB CHAMPION RG 4HC Alternative spark plug D...

Page 105: ...e carburettor on the inlet manifold and lock the clamp Fit the secondary air pipe and fix it with the ap propriate clamp N B FIT THE CARBURETTOR THROUGH THE SUPPLEMENT ON THE MANIFOLD Locking torques N m Inlet manifold screw 7 to 9 Nm Crankcase crankshaft First remove the following units Driving pulley Driven pulley Final reduction greasing Oil pump Flywheel with stator Cylinder piston head unit S...

Page 106: ...MPURITIES LEAK OUT A CENTRIFUGAL OIL FILTER S LIFE IS THE SAME AS THE ENGINE S AND IS MAINTENANCE FREE Check the axial clearance on the connecting rod Fitting clearance Standard connecting rod axial clearance 0 15 to 0 30 mm Max connecting rod clearance 0 5 mm Check the correct radial clearance of the con necting rod by holding the driving shaft with your hands and with a dial gauge fitted to the ...

Page 107: ... extractor ring 004499Y034 Bearing extractor part Refitting the crankshaft bearings Support the crankcase on a surface and place it with the driving shaft axle in a vertical position Warm the crankcase at 120 C with a thermal gun and support Fit the punch with guide and adaptor place the bearing on the punch using grease to keep it from falling Insert the bearing in the crankcase if needed use a m...

Page 108: ...ent in the 4 points indicated in figure N B IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC TED TRY STRAIGHTENING THE CRANKSHAFT BY IN SERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE DED IF EVEN AFTER THIS OPERATION THE VALUES ARE NOT THOSE ADMITTED REPLACE THE CRANKSHAFT Characteristic Off line maximum admitted A 0 15 mm Off line maximum admitted B 0 02 mm Off li...

Page 109: ...it the 10 screws and tighten them to the pre scribed torque N B WHEN FITTING THE HALF CASING AND THE CRANK SHAFT TAKE CARE NO TO DAMAGE THE SHAFT THREA DED TANGS Recommended products Loctite 510 Liquid sealant Gasket Locking torques N m Half casing joint bolts 8 to 10 Nm Fit a new O Ring on the mesh oil filter and on the filling cap lubricate the rings Insert the filter on the engine and lock the ...

Page 110: ...Refitting Apply engine oil on the oil seal and it seating on the crankcase From the outside and using the specific punch place the oil seal fully down until it reaches the bottom of the seating in the crankcase N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE QUENCE IN INADEQUATE OIL SEAL Fit a new oil seal on the outer rim with the help of the specific...

Page 111: ...g screws in the figure and re move the cover over the pump control crown gear Block the rotation of the oil pump control gear with a screwdriver inserted through one of its pump holes Remove the central screw and the belleville washer Remove the chain with the crown gear Remove the crankshaft control pinion Remove the oil pump by undoing the 2 screws indicated in the figure Remove the oil pump sea...

Page 112: ...tor outer rotor with a thickness gauge in the position shown in the picture Characteristic Admissible maximum clearance 1 0 15 mm Measure the distance between the outer rotor and the pump body see figure Characteristic Admissible maximum clearance 2 0 20 mm Check the axial clearance of the rotors using a trued bar as reference as shown in the figure N B MAKE SURE THE TRUED BAR IS POSITIONED PROPER...

Page 113: ...ibed torque Fit the pulley on the pump the central screw to the specified torque and the belleville washer Check that there is no seizing and or friction dur ing the pulley rotation N B FIT THE CUP WASHER SO THAT ITS OUTER CURVED RIM TOUCHES THE PULLEY Locking torques N m Central screw 12 to 14 Nm Cover screws 0 7 to 0 9 Nm Oil pump screws 5 6 Removing the oil sump Remove the oil filling cap the t...

Page 114: ...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 vacuum pipe to the manifold Position the fuel pipe with the outlet at the point of the tap Turn the engine by using the starter motor for five seconds with the carburettor at minimum Take up the fuel by means of a graded burette N B THE MEASUREMENT MAY BE FALSIFIED ...

Page 115: ...ine re move the two clamps anchoring the carburettor to the inlet manifold and the air intake coupling to the filter Remove the fuel supply pipe Disconnect the starter connection Detach the accelerator cable with the sheath that connects the plate and the support Remove the carburettor Remove the protection the bracket and the start er undoing the screw shown in the figure CAUTION THE CARBURETTOR ...

Page 116: ...VER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Remove the 3 fixing screws and the chamber with the gasket Remove the chamber components following the procedure below Undo the 2 screws fixing the intake pump dia phragm cover Remove the cover being careful with the spring below then remove the spring take out the rubber protection and the diaphragm together with the pipe O Ring Engine ...

Page 117: ... jet together with the ball spring Remove the screw indicated in the figure fixing the float pin Remove the float and the plunger Remove the maximum nozzle Remove diffuser Remove the minimum nozzle Liberty 50 4tempi Engine ENG 117 ...

Page 118: ...N DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PIN SEATING STARTER NOZZLE THROTTLE VALVE CONTROL VALVE SHAFT DO NOT REMOVE THROTTLE SHAFT CONNECTION SCREWS THE FIXING SCREWS ARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT Refitting the carburettor Before refitting wash the carburettor body accu rately with a degreasing solvent and compr...

Page 119: ...ly small and is oriented to the throttle valve Check that the carburettor body has the closing ball for the idle circuit pipe Check that the coupling surfaces the chamber and the diaphragm are not dented Check that the depression valve housing pipe is not scratched Check that the throttle valve and the shaft do not show abnormal wear Check that the plunger seat does not show abnormal wear Replace ...

Page 120: ...e no fuel infiltrations Replace it in case of failures Fit the float together with the pin and rod in its position and lock it with its screw N B INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY Insert the ball in the corresponding accelerating pump Fit the spring Fit the accelerating pump nozzle WARNING WHEN REFITTING PAY SPECIAL ATTENTION TO THE COMPONENTS AS THEY ARE SMALL Check the di...

Page 121: ...l as shown in the figure Blow air in to the tank and then assembly it and its gasket on the carburettor body with the 3 fixing screws N B ALWAYS USE NEW RINGS AND GASKETS FOR REFIT TING WARNING THE SCREW IN THE TANK BOTTOM IS A BLEEDING ONE AND CONSEQUENTLY IT ONLY REQUIRES CLEANING Insert the diaphragm into the throttle valve Insert the tapered pin together with the plastic support and the contra...

Page 122: ...ional de pending on the ambient temperature Measure the protrusion of the piston as shown in the figure and check its corresponding value Make sure that the starter is adjusted for the am bient temperature Characteristic Protrusion value 11 mm ambient temperature 24 C The starter should disconnect progressively by means of electric heating Check the starter resistance when adjusted to the ambient ...

Page 123: ...ing values are dif ferent from the ones prescribed replace the start er Characteristic Battery 12V 9Ah max protrusion 15 mm max time 15 min Fit the starter the support bracket and the pro tection with the screw indicated in the figure Insert rubber pipes for chamber ventilation Insert the O Ring the washer the spring and the idle flow screw in their seats Liberty 50 4tempi Engine ENG 123 ...

Page 124: ...rance and complying timing spark plug should be in optimum conditions air filter clean and sealed and the exhaust system tight Warm up the engine by running it at least 10 mi nutes at a speed as close as possible to the max imum one Connect the vehicle to the exhaust fumes analy ser inserting the probe into a sealed extension pipe placed at the muffler exit end N B THE EXTENSION TUBE IS INDISPENSA...

Page 125: ... lean mix If the adjustment of the flow screw causes a rpm increase readjust the revs again and if necessary the flow screw to reach stable values Characteristic CO adjustment 3 2 0 5 When the oil temperature the numbers of revs and the percentage of carbon monoxide are respected the idle carburation is considered correct Further information can be drawn from the analyser carbon dioxide percentage...

Page 126: ...on failure or incorrect timing or a clogged or unsealed exhaust valve If it is difficult to adjust CO values check accurately That the automatic starter is efficient That the tapered pin housing is efficient Tank level adjustments Engine Liberty 50 4tempi ENG 126 ...

Page 127: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 128: ...N THE AREAS MARKED WITH THE ASTERISK Handlebar Removal Disassembling the handlebar Remove the handlebar cover before carrying out this operation After removing the transmissions and discon necting the electrical terminals remove the termi nal fixing the handlebar to the steering Check all components and replace faulty parts N B IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING TILT THE HAND...

Page 129: ... the lower screw 1 Remove the upper screw 2 Add 30 cc 1 Fork PG oil SAE 20W oil for forks Refit all components Locking torques N m Upper screw tightening torque 20 to 25 Nm Lower screw tightening torque 20 to 25 Nm Steering column Refitting Lower and upper seating on the chassis LOWER AND UPPER SEATING ON THE CHASSIS Titolo Durata Valore Testo Breve 4000 car Indirizzo Immagine Lower and upper seat...

Page 130: ...ring tube making sure mudflaps have been removed and the calliper dis connected Lower and upper races from frame To remove the bearing seats from the chassis use the appropriate tool as shown in the figure N B To remove the lower seating of the lower bearing just use a screwdriver as a lever between the seating and the shell LOWER AND UPPER SEATING FROM THE CHASSIS Titolo Durata Valore Testo Breve...

Page 131: ...OR DER TO AVOID BACKSLASH BETWEEN THE CAP AND THE WHEEL AXLE Locking torques N m Rear wheel axle 104 to 126 Shock absorbers Removal Absorber To replace the shock absorber remove the rear cover and battery access flap to get and remove the shock absorber chassis anchoring nut Then remove the shock absorber engine anchorage nut When refitting tighten the shock absorber chas sis anchoring nut and the...

Page 132: ...E NEW O RING AND PIN GREASE THE SPRING ATTACHMENTS AND THE PIN Changing the complete stand 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 Expelling stand pivot pin from bracket Remove the stand support bracket from the en gine Drill a 5 mm hole in the bracket so that the pin P can come out Suspensions Liber...

Page 133: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 134: ...he system see previous paragraphs Position the caliper on the disc and fasten it to the support tightening the bolts Secure the tube connection to the caliper with the required torque Before reassembly the parts must be perfectly clean and bear no traces of oil diesel fuel grease etc They must therefore be washed thor oughly in denatured alcohol before proceeding Immerse the seals in brake fluid t...

Page 135: ...ake fluid pipe Check that the cylinders of the internal and external body of the calliper do not show scratches or signs of erosion otherwise replace the entire calliper CAUTION ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED Refitting Insert the following parts into the calliper half bod ies sealing rings 1 2 pistons 3 fit O ring seal 4 in one of the pump bodies C...

Page 136: ...WASHING THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH Locking torques N m Screw tightening calliper to support 20 to 25 Calliper to tube connection 8 12 Nm 1 DUST GUARDS 2 SEALING RINGS 3 PLUNGERS 4 O RING GASKET Front brake disc Removal Remove the front wheel loosening the axle clamp Remove the six fastenings of the disc Refitting When refitting position the disc corre...

Page 137: ...s Removal To facilitate this operation remove the two calliper fixings With the calliper detached from its support but still connected to the brake fluid line remove the plastic cover by prising it with a screwdriver Remove the outside circlip from the brake pad pin the leaf spring and the pads Renew the pads when friction facing thickness is less than 1 5 mm Refitting To reassemble perform the ab...

Page 138: ...ION 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 AB SORBS HUMIDITY FROM THE SURROUNDING AIR IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX CEEDS A GIVEN VALUE BRAKING EFFICIENCY WILL BE REDUCED THEREFORE ALWAYS USE FLUID FROM SE...

Page 139: ...ke fluid pump hose fitting 20 25 Nm Removal Bleed the circuit and drain the brake fluid through the bleeding screw located on the calliper and ac tuate the brake lever until no more fluid flows out Remove the oil pump from the handlebar remove the brake lever and then remove the wheel cylin der 1 Tank cap screw 2 Tank cover 3 Diaphragm 4 Bellows 5 Sealing ring 6 Piston 7 Gasket 8 Spring CAUTION TH...

Page 140: ...ts must be perfectly clean and free of traces of oil diesel fuel grease etc They should be washed thoroughly in denatured alcohol before proceeding Reinstall the individual parts in the reverse order to the removal paying attention to the correct po sitioning of the rubber parts in order to ensure leak tightness 1 Tank cap screw 2 Tank cover 3 Diaphragm 4 Bellows 5 Sealing ring 6 Piston 7 Gasket 8...

Page 141: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 142: ...r checking the typeapproval specifications it was concluded that the strap on the saddle is redun dant Please note that the passenger saddle comes without strap since last May The design number remains unchanged Side fairings Remove the shield back plate Undo the 4 fixing screws and remove the bumper band Chassis Liberty 50 4tempi CHAS 142 ...

Page 143: ...ee also Knee guard Rear rack Operating from the rear and using a screwdriver remove the plastic cap of the central screw cover Remove the central and the 2 side screws Liberty 50 4tempi Chassis CHAS 143 ...

Page 144: ... torques N m Mirror set screw 24 to 26 Rear handlebar cover Remove the front handlebar cover Unscrew the odometer transmission joint and slide it off Disconnect the instrument panel and electrical controls connections Cut the clamp retaining the front brake pipes to the instrument panel Remove the screw fixing the instrument panel to the handlebar See also Front handlebar cover Chassis Liberty 50 ...

Page 145: ...BULB HOLDER THE LATTER CAN BE REMOVED BY ROTATING IT 30 ANTICLOCKWISE THE CLOCK IS POWERED BY A BATTERY TYPE See also Rear handlebar cover Front handlebar cover Remove the 2 screws in the rear handlebar cover and the screw under the headlamp Pull up and detach the front handlebar cover disconnect the headlight assembly connections Liberty 50 4tempi Chassis CHAS 145 ...

Page 146: ...LB JUST SLIDE IT OFF THE RUBBER BULB HOLDER See also Front handlebar cover Frame central cover Remove the rear luggage rack Remove the saddle Remove the spark plug access cover unscrew the 2 screws joining the helmet compartment clamp with the footrest Unscrew the 2 side screws placed on the bumper rings Remove the cover by holding it from the rear part and disconnect the turn indicator light conn...

Page 147: ...e and op erating carefully from the right side Undo the screw underneath and slide the cover upwards Undo the front screw fixing the shield Undo the 2 lower screws and remove the shield once the turn indicator connections have been dis connected See also Knee guard Footrest Removal Liberty 50 4tempi Chassis CHAS 147 ...

Page 148: ...e the spring with a pair of pliers Take out the lock block See also 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 cylinder with the key and with the anchoring tab facing down halfway on the lock body taking care that the insertion phase of the key is orien...

Page 149: ... THE LIGHT COVERS ROTATING THEM 30 ANTI CLOCKWISE Footrest Remove the leg shield back plate Remove the central frame cover Remove the passenger footrest by undoing its fixing screw Undo the screw of the footrest lock and remove the tab Remove the 2 outer rubber covers of the footrest fixing screws and undo them Pull the footrest upwards paying attention to the lower hooks See also Knee guard Frame...

Page 150: ...he cover to reach the filter sponge To disassemble the filter housing unscrew the 2 bottom screws and disconnect the manifold con nections the carburettor and the external air in take Rear mudguard Remove the 3 retainers on the left side 2 of which also fix the air filter housing Remove the fixing screw on the cooling cap side Remove the mudguard making it come out on the muffler side Chassis Libe...

Page 151: ...the fuel tank cap and the start up remote control switch Unscrew the rear fixing screw and lift the helmet compartment See also Frame central cover spoiler Remove the footrest Undo the 2 front retainers and then remove the spoiler from the bottom See also Footrest Liberty 50 4tempi Chassis CHAS 151 ...

Page 152: ...al cover Front mudguard With the front wheel mounted remove the fork from the vehicle Unscrew the 3 fixing screws and remove them Slide off the odometer transmission and the brake pipes and then remove the mudguard N B Note ON REASSEMBLY TAKE CARE TO CORRECTLY PO SITION THE 2 METAL CABLE GROMMETS IN ORDER TO PREVENT ANY RUBBING AGAINST THE WHEEL Chassis Liberty 50 4tempi CHAS 152 ...

Page 153: ...g the inner shield fairing glove box assy Remove the two screws from inside the glove box Remove the two screws at the lower part of the inner shield fairing Remove the two screws located behind the front grille Liberty 50 4tempi Chassis CHAS 153 ...

Page 154: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 155: ...Handlebar lock nut Lower steering ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam lights low beam lights tail and parking lights and their 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 Instrume...

Page 156: ... MEDICAL ATTENTION IF IT ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REACH OF CH...

Page 157: ... INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Throttle travel check Others Check documentation Check the chassis and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirrors and any accessories Liberty 50...

Page 158: ...INDEX OF TOPICS TIME TIME ...

Page 159: ...2 003060 Rear brake transmission Adjust ment 3 002051 Odometer transmission assembly Replacement 4 002049 Odometer cable Replacement This section is dedicated to the time necessary to carry out repairs The description and code for each operation is in dicated Liberty 50 4tempi Time TIME 159 ...

Page 160: ... ENGINE Code Action Duration 1 001001 Engine from chassis Removal and refit 2 001127 Engine Complete service 3 003064 Engine oil change 4 003057 Engine fixing Nuts tightening 4 Time Liberty 50 4tempi TIME 160 ...

Page 161: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement Crankshaft Liberty 50 4tempi Time TIME 161 ...

Page 162: ...aul 3 001099 Oil seal flywheel side Replacement 4 001100 Clutch side oil seal Replacement 5 001118 Main bearings Replacement Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder Piston Inspection Clean ing Time Liberty 50 4tempi TIME 162 ...

Page 163: ...lves Replacement 3 001126 Head Replacement Rocker arms support assy CAMSHAFT SUPPORT Code Action Duration 1 003056 Head cylinder Nuts tightening 2 001049 Valve clearance Adjustment 3 001148 Valve rocking levers Replace ment 4 001044 Camshaft Re placement Liberty 50 4tempi Time TIME 163 ...

Page 164: ...89 Head cover Replacement Driven pulley DRIVEN PULLEY CLUTCH Code Action Duration 1 001110 Driven pulley Replacement 2 001012 Driven pulley overhaul 3 003065 Gear casing oil Replacement 4 001022 Clutch Re placement 5 003072 Clutch assembly Wear check 6 001156 Reduction gear ing cover Re placement 7 001155 clutch housing Replacement Time Liberty 50 4tempi TIME 164 ...

Page 165: ...2 001112 Oil pump change 3 001042 Oil pump overhaul 4 001121 Chain cover oil seal Replacement 5 001122 Oil pump chain Replacement 6 001125 Chain guide pads Replacement 7 001130 Oil sump change 8 001129 Chain tensioner Service and Re placement Liberty 50 4tempi Time TIME 165 ...

Page 166: ...Final gear assy REDUCTION GEAR Code Action Duration 1 001010 Geared reduction unit Service 2 004125 Rear wheel axle Replacement Time Liberty 50 4tempi TIME 166 ...

Page 167: ...RIVING PULLEY Code Action Duration 1 001006 Driving pulley Overhaul 2 001086 Driving half pulley Replacement 3 001066 Driving pulley Removal and refitting 4 001011 Drive belt Replacement Liberty 50 4tempi Time TIME 167 ...

Page 168: ...Action Duration 1 001096 Transmission crankcase cover Re placement 2 001132 Transmission air intake pipe Re placement 3 001131 Transmission air intake Replace ment 4 001135 Transmission cover bearing Re placement Time Liberty 50 4tempi TIME 168 ...

Page 169: ...ion 1 001020 Starter motor change 2 001017 Starter sprocket wheel replace 3 005045 Starter motor with cables unit Re plac 4 001084 Starter lever Replacement 5 008008 Starter spring pack Replacement 6 001021 Kick starter Inspection Liberty 50 4tempi Time TIME 169 ...

Page 170: ... Code Action Duration 1 001067 Stator Fitting and Refitting 2 001058 Flywheel Replacement 3 001102 Net oil filter change Cleaning 4 001109 Cooling fan Replacement 5 001087 Flywheel cover Replacement Time Liberty 50 4tempi TIME 170 ...

Page 171: ... Replacement 3 001095 Muffler guard Replacement Silencer fixing Please take note that starting from chassis serial number ZAPM3810000003971 the two M8 x 50 silencer fixing flaged head screws have been replaced by two M8 x 50 internal hexagonal cylindrical head screws Liberty 50 4tempi Time TIME 171 ...

Page 172: ...Air cleaner AIR FILTER Code Action Duration 1 001014 Air filter Replacement Cleaning 2 001015 Air filter box Replacement Time Liberty 50 4tempi TIME 172 ...

Page 173: ...Frame CHASSIS Code Action Duration 1 004004 Stand Replacement 2 001053 Stand bolt Replacement 3 004001 Chassis Replacement Liberty 50 4tempi Time TIME 173 ...

Page 174: ...r Replacement 2 004064 Front shield front section Removal and refitting 3 004015 Footrest Disassembly and reas sembly 4 004053 Spoiler Replacement 5 006006 Steering head tube cover Painting 6 006012 Front shield front section Painting 7 006027 Spoiler Painting Time Liberty 50 4tempi TIME 174 ...

Page 175: ...Rear cover FRONT FOOTBOARD Code Action Duration 1 004081 Glove comparment door Replace ment 2 004065 Front shield rear section Replace ment Liberty 50 4tempi Time TIME 175 ...

Page 176: ... Action Duration 1 004106 Undersaddle band Replacement 2 004059 Spark plug inspection flap Replace ment 3 006035 Undersaddle band Painting 4 006032 Door Painting 5 004085 Fairing 1 Replacement Mudguard Time Liberty 50 4tempi TIME 176 ...

Page 177: ...rettor hose Replace ment 5 004007 Fuel valve Replacement Rear shock absorber In order to unify the licensed vehicles starting from frame C28200 10346 a new frame dis no 576680 has been introduced instead of the old dis no 576823 At the same time a new steering tube dis no 597419 a new front hydraulic brake hose dis no 597286 a new front shock absorber dis no 597470 and a new stand dis no 582894 ha...

Page 178: ...ion 1 003007 Rear shock ab sorber Disas sembly and reas sembly Steering column bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering bearing Replacement 2 003073 Steering clearance Adjustment Time Liberty 50 4tempi TIME 178 ...

Page 179: ...ndlebar front section Replace ment 2 004019 Handlebar rear section Replace ment 3 005014 Odometer Replacement 4 006013 Handlebar front part Painting 5 005038 Instrument panel warning light bulbs Replacement 6 005078 Speedometer glass Replacement Liberty 50 4tempi Time TIME 179 ...

Page 180: ... 003067 Front brake fluid Renewal 4 003061 Accelerator transmission adjust 5 002060 Complete throttle control Replace ment 6 002047 Front brake fluid and air bleeding system Replacement 7 002024 Front brake pump Removal and Re fitting 8 002063 Accelerator transmission Replace ment 9 005017 Stop switch Replacement Time Liberty 50 4tempi TIME 180 ...

Page 181: ...andlebar Removal and refitting 4 004066 Driving mirror Replacement Swing arm We inform you that starting from frame C15000 160199 a new frame side swinging arm pin locknut part no 231370 has replaced old part no 232108 Also the locknut tightening torque has been in creased from 33 41 Nm to 64 72 N m Liberty 50 4tempi Time TIME 181 ...

Page 182: ... Duration 1 001072 Engine frame connection swing arm Replacement Seat SADDLE CARRIER Code Action Duration 1 004003 Saddle Replacement 2 004008 Carrier Replacement 3 006002 Luggage rack Painting Time Liberty 50 4tempi TIME 182 ...

Page 183: ...light bulbs Replacement 2 005002 Front headlamp Replacement 3 005012 Front turning indicators Replace ment 4 005067 Front turning indicator bulb replace ment 5 005044 Front lights cable unit replace 6 004020 Headlight frame Replacement Liberty 50 4tempi Time TIME 183 ...

Page 184: ...05 Taillight change 2 005022 Rear turning indicators Replace ment 3 005066 Rear light bulbs Replacement 4 005068 Rear turning indicator bulb Re placement 5 005028 Rear optical unit glass Replace ment Front wheel Time Liberty 50 4tempi TIME 184 ...

Page 185: ...placement Tone wheel or drive greasing 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 the area t...

Page 186: ...de Action Duration 1 001016 Rear wheel Replacement 2 004126 Rear wheel tyre Replacement 3 003063 Tyres pressure Check 4 006018 Wheel rim Paintwork 5 001071 Front wheel rim Removal and Re fitting Time Liberty 50 4tempi TIME 186 ...

Page 187: ...LECTRICAL DEVICES Code Action Duration 1 005009 Voltage regulator Replacement 2 001094 Spark plug cap Replacement 3 001023 CPU Replacement 4 005001 Electrical system Removal and re fitting Liberty 50 4tempi Time TIME 187 ...

Page 188: ... hand switch Replacement 3 005039 Lights switch Replacement 4 005040 Horn button Replacement 5 005041 Starting device push button Re placement 6 005003 Electric horn Replacement 7 005016 Key switch Replacement 8 004096 Locks series Replacement 9 004010 Antitheft lock Replacement Time Liberty 50 4tempi TIME 188 ...

Page 189: ...ECTRICAL DEVICES Code Action Duration 1 005007 Battery change 2 005011 Start up solenoid Replacement 3 005024 Battery fuse Replacement 4 005025 Battery fuse box Replacement Liberty 50 4tempi Time TIME 189 ...

Page 190: ... Duration 1 002039 Front brake caliper Removal and refitting 2 002040 Front brake caliper Overhaul 3 002021 Front brake hose Remov and Re fitt 4 003070 Front brake pads Wear check 5 002007 Front brake pads Replacement Time Liberty 50 4tempi TIME 190 ...

Page 191: ...oes Check for wear 2 002002 Rear brake pads shoes Wear check Front mudguard FRONT AND REAR MUDGUARD Code Action Duration 1 004009 Rear mudguard Replacement 2 004002 Front mudguard Replacement 3 006003 Paragraph Painting Helmet bay Liberty 50 4tempi Time TIME 191 ...

Page 192: ...ame C28200 10346 a new frame dis no 576680 has been introduced instead of the old dis no 576823 At the same time a new steering tube dis no 597419 a new front hydraulic brake hose dis no 597286 a new rear shock absorber dis no 597470 and a new stand dis no 562694 have been introduced FRONT SUSPENSION Code Action Duration 1 003010 Front suspension Service 2 003051 Fork assembly Replacement Time Lib...

Page 193: ...4 Crankcase secondary air connection Replacement 2 001161 Secondary air filter Replacement Cleaning 3 001162 Secondary air housing Replace ment 4 001163 Silencer secondary air connection Replacement 5 001165 Secondary air reed Replacement Liberty 50 4tempi Time TIME 193 ...

Page 194: ... 115 118 Checks 49 E Electric 187 Engine oil 31 F Fuel 40 114 152 177 H Headlight 33 146 Horn Hub oil 29 I Identification 8 Instrument panel 145 M Maintenance 7 26 Mirrors 144 O Odometer Oil filter 32 R Recommended products S Saddle Shock absorbers 131 Spark plug 28 Suspension 192 ...

Page 195: ...T Tank 152 177 Transmission 9 40 65 75 168 Turn indicators Tyres 10 V Vehicle 8 62 ...

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