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WORKSHOP

MANUAL

Liberty 50 Catalyzed

The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any 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 each

model should be checked at the official Piaggio sales network.

"© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

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Summary of Contents for Liberty 50 Catalyzed

Page 1: ...WORKSHOP MANUAL 633112 Liberty 50 Catalyzed...

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 p...

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 spe...

Page 4: ......

Page 5: ...RACTERISTICS 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 DELIVER...

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

Page 7: ...eathe 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 r...

Page 8: ...c Compression ratio 10 3 1 Carburettor DELL ORTO PHVA 17 5 CO adjustment 3 5 0 5 Engine idle speed 1800 to 2000 r p m Air filter Sponge soaked in a mixture 50 SELENIA Air Filter Oil and 50 unleaded pe...

Page 9: ...RN3C Battery 12V 4Ah Main fuse 7 5 A Generator In alternate current with three output sections Frame and suspensions FRAME AND SUSPENSION Specification Desc Quantity Type of chassis Welded tubular ste...

Page 10: ...three slots found on that cap 2 Wash the polyurethane sponge with water and soap dry all components with compressed air and refit to place Refit the intake cap respecting the angle reference 3 Undo t...

Page 11: ...itting 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 coupli...

Page 12: ...on 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...

Page 13: ...smissions brake throttle control and mixer odom eter Oil for 2 stroke engines SAE 5W 40 API SL ACEA A3 JASO MA AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in crea...

Page 14: ...INDEX OF TOPICS TOOLING TOOL...

Page 15: ...ng seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y009 Driver for OD 42 mm bearings 001467Y013 Calliper to extract 15 mm bearings 001467Y014 Calliper to...

Page 16: ...iers for 11 mm bearings 002465Y Calliper for circlips 006029Y Punch for fitting fifth steering bearing on steering tube 020004Y Punch for removing steering bearings from headstock 020055Y Wrench for s...

Page 17: ...ption 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 Liberty 50 Catalyz...

Page 18: ...er spring fitting 020262Y Crankcase splitting plate 020265Y Bearing fitting base 020325Y Pliers for brake shoe springs 020329Y Mity Vac vacuum operated pump 020330Y Stroboscopic light to check timing...

Page 19: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger Liberty 50 Catalyzed Tooling TOOL 19...

Page 20: ...tion 020335Y Magnetic mounting for dial gauge 020350Y Electrical system check instrument 020357Y 32x35 mm Adaptor 020359Y 42x47 mm Adaptor 020376Y Adaptor handle 020412Y 15 mm guide Tooling Liberty 50...

Page 21: ...Stores code Description 020456Y 24 mm adaptor 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser Liberty 50 Catalyzed Tooling TOOL 21...

Page 22: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 23: ...fluid level check Electrical system and battery check Tyre pressure and wear check Vehicle test and brake test Road test AFTER 10000 KM 50000 KM 95 Action Hub oil change Spark plug electrode gap repla...

Page 24: ...ake levers greasing Brake pads check condition and wear Brake fluid level check Transmission lubrication Safety fasteners check Suspensions check Electrical system and battery check Headlight adjustme...

Page 25: ...Headlight adjustment Tyre pressure and wear check SAS box sponge cleaning Vehicle test and brake test Road test See regulations in the Adjusting the idle speed section See regulations in the Secondary...

Page 26: ...YING OUT THE ABOVE CHECKS CHECK THE CORRECT KEYING OF THE FLYWHEEL ON THE CRANKSHAFT Specific tooling 020330Y Stroboscopic light to check timing Spark plug Place the vehicle on its central stand Remov...

Page 27: ...been introduced This dipstick differs from the previous one in that it is 5 mm longer and has a cube on the lower end with a dot at the centre of two of its four side faces Such dot is the reference...

Page 28: ...removing the filter Cleaning Wash with water and neutral soap Dry with a clean cloth and short blasts of com pressed air Saturate with a 50 mixture of gasoline and oil Drip dry the filter and then sq...

Page 29: ...e reference mark on the mixer body as shown in the figure While doing this the engine must be fuelled with a 2 oil mixture 0 5 litre minimum if the reservoir is empty CAUTION IN CASE OF DISMANTLING OR...

Page 30: ...IDENTAL 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 OTHER WORDS...

Page 31: ...top cover see Bodywork Chapter and act upon screw A located behind the headlight as shown in the picture Before carrying out the adjustment operation check the tyres are inflated at the prescribed pre...

Page 32: ...sing the appropriate flux screw bring the engine up to 1800 100 rpm 9 Adjust the flux screw so to have a CO value equal to 3 5 0 5 10 Slowly twist the throttle grip until the engine reaches 4 000 rpm...

Page 33: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 34: ...Dirt Check the cap with filter is fitted to the transmission cover clean the speed variator replace the rollers if worn out Rear wheel spins at idle REAR WHEEL Possible Cause Operation Idling rpm too...

Page 35: ...ater in the carburettor Empty the tank through the appropriate bleed nipple Air filter dirty Clean or replace Defective floating valve Check the proper sliding of the float and the functioning of the...

Page 36: ...ngine without the clutch bell Check the cap with filter is fitted to the transmission cover Insufficient braking BRAKING SYSTEM MALFUNCTION Possible Cause Operation Poor braking The rear drum type bra...

Page 37: ...e is connected to the terminal marked Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries Steering and suspensions Rear wheel REAR WHEEL Possible Cause Operati...

Page 38: ...n of the ball bearings and relevant lock nuts the limit switch rubber buffers and the movement bushings Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from sus...

Page 39: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 40: ...t 3 Horn 4 Horn button 5 Turn signal switch 6 Headlight switch 7 Stop light switch on rear brake 8 Light bulb 9 Headlight bulb 10 RHS turn signal warning light 11 Headlamp warning light 12 High beam w...

Page 41: ...tage regulator 27 Starter relay 28 Rear RHS turn signal light 29 Taillight assembly 30 Stop and taillight bulb 31 Battery 32 Electronic ignition device CDI 33 Flywheel magneto 34 Starter motor 35 Fuse...

Page 42: ...nk Blue BlV Blue Green BRs White Pink Conceptual diagrams Ignition IGNITION Specification Desc Quantity 1 Electronic control unit 2 Magneto flywheel 3 Pick up 4 Key switch 5 Spark plug Electrical syst...

Page 43: ...e regulator 2 Magneto flywheel 3 Light switch 4 Rear light bulb 12V 5W 5 Headlight bulb 12V 35 35W 6 High beam warning light 12V 1 2W 7 N 3 instrument lighting bulbs 12V 1 2W 8 Taillight bulb 12V 5W 9...

Page 44: ...esc Quantity 1 Magneto flywheel 2 Voltage regulator 3 Automatic starter 4 Main fuse 7 5A 5 Brake light filament 12V 21W 6 Front and rear brake light button 7 Start up button 8 Starter motor 9 Remote s...

Page 45: ...ator 3 Key switch 4 Main fuse 7 5A 5 Brake light filament 12V 21W 6 Front and rear brake light button 7 Start up button 8 Starter motor 9 Remote starter switch 10 Battery 12V 4Ah 11 Low oil warning li...

Page 46: ...nspections 1 No load test the starter motor when unloaded must absorb no more than 10A with a supply volt age 12V and must rotate at 15 000 rpm 2 Load test when the starter motor is so braked that it...

Page 47: ...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 th...

Page 48: ...done the controls might be irretrievably dam aged Stator check Using a tester check the resistance between the brown earth and black earth terminal N B VALUES ARE STATED AT AMBIENT TEMPERATURE A CHEC...

Page 49: ...is present see fig ure If there is no voltage fit the negative prod directly on earth if voltage is measured check the regu lator s earth cables otherwise replace the regula tor because it is certain...

Page 50: ...ck that the wiring and devices following the ig nition switch are not shorted to earth Measure the resistance between contacts 3 White and 2 Black on the voltage regulator the connector must be discon...

Page 51: ...tween the white cable 3 and the black one 2 Turn the key 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...

Page 52: ...e mode Constant voltage equal to 14 40 14 70V Initial charge voltage equal to 0 3 0 5 for nominal capacity Duration of the charge 10 to 12 h recommended Minimum 6 h Maximum 24 h 3 Constant current bat...

Page 53: ...el the acid by adding distilled water Close and clean carefully 5 Once the above operations have been performed install the battery in the vehicle ensuring the connections between the wiring and the b...

Page 54: ...g the corresponding poles to and to 4 Cleaning the battery The battery should always be kept clean especially on its top side and the terminals should be coated with Vaseline WARNING Before recharging...

Page 55: ...igh 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 wa...

Page 56: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 57: ...cover Removal 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 Disassembling engine from frame Disconnect the...

Page 58: ...afety goggles when using hitting tools Removing the engine shock absorber pivot pin Remove the nut shown in the figure and then with draw the pin Reassembling engine to frame Perform the disassembly s...

Page 59: ...INDEX OF TOPICS ENGINE ENG...

Page 60: ...ssembly work in reverse and tighten the screws to the prescribed torque Locking torques N m Starter lever replacement 12 to 13 Nm Remove the seeger ring located on the exterior of the crankshaft Disma...

Page 61: ...pulley shaft bearing Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing N B IN C...

Page 62: ...clutch bell is not worn or damaged Measure the inner diameter of the clutch bell Characteristic Clutch bell diameter standard value 107 0 2 0 mm Clutch bell diameter max value allowed after use 107 5...

Page 63: ...rial The masses must not show traces of lubricants otherwise check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE...

Page 64: ...e 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...

Page 65: ...ducts AGIP GREASE SM 2 Grease for the C ring of the tone wheel 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 re...

Page 66: ...362Y 12 mm guide 020171Y Punch for 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...

Page 67: ...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 spann...

Page 68: ...UD 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...

Page 69: ...e 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...

Page 70: ...move the 5 screws fixing the cover to the crankcase Remove the cover with the wheel axle and pull it out Remove the intermediate gear with the appropri ate shim washers Removing the wheel axle bearing...

Page 71: ...haft bearing Remove the seeger ring Heat the engine crankcase but do not direct the hot air towards the bearing Extract the driven pulley shaft together with the bearing with a few mallet blows Libert...

Page 72: ...distortion of the toothed surfaces the bearing housings and the oil seal housings If faults are found replace the damaged compo nents Check capacity A of the transmission gear wear deformations etc C...

Page 73: ...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 Refitting the wheel axle bea...

Page 74: ...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...

Page 75: ...move the four fixings shown 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 o...

Page 76: ...removal procedure in reverse tightening 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 C...

Page 77: ...162Y 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 Refitting the flywheel mag...

Page 78: ...e crankcase and lock the 2 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 Sta...

Page 79: ...the internal diameter of the small end using an internal micrometer N B IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE...

Page 80: ...lculate the piston pin coupling clearance Characteristic Wrist pin housing standard diameter 12 0 007 0 012 Wrist pin housing standard clearance 0 002 0 011 mm Measure the outer diameter of the piston...

Page 81: ...s perpendicularly to the cylinder axis Measure the opening of the sealing rings using a thickness gauge as shown in the photograph If the values are higher than the values prescri bed in the chart sub...

Page 82: ...o be mixed during the fitting of the piston and the cylinder CAUTION POSITION THE ARROW PRINTED ON THE PISTON CROWN TOWARDS THE EXHAUST OPENING THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON THE PISTO...

Page 83: ...Crankcase crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on...

Page 84: ...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...

Page 85: ...ial 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 ac...

Page 86: ...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 cancelled out Specific tool...

Page 87: ...tion 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 ma...

Page 88: ...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 se...

Page 89: ...tubes Close the fuel outlet pipe By means of the MITYVAC 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 vacu...

Page 90: ...acuum operated pump Characteristic Minimum flow rate 20 cc Completely empty the fuel tank Remove the petrol delivery pipe and the low pressure pipe Loosen the clip and remove the cock Clean the tank a...

Page 91: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 92: ...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 e...

Page 93: ...pper 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...

Page 94: ...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 Bre...

Page 95: ...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 batte...

Page 96: ...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 ATTACHMENT...

Page 97: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 98: ...coupling bolts Fit the pads and bleed air from the 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...

Page 99: ...e out the plungers inject shorts blasts of compressed air through the brake fluid pipe Check that the cylinders of the internal and external body of the calliper do not show scratches or signs of eros...

Page 100: ...OR 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 Screw tightening calliper to support 20 to 25 Calliper to tube con...

Page 101: ...emoval 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...

Page 102: ...N 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 I...

Page 103: ...t 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...

Page 104: ...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...

Page 105: ...INDEX OF TOPICS CHASSIS CHAS...

Page 106: ...hecking 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 u...

Page 107: ...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 Catalyzed Chassis CHAS...

Page 108: ...torques N m Mirror set screw 24 26 Rear handlebar cover Remove the front handlebar cover Unscrew the odometer transmission joint and slide it off Disconnect the instrument panel and electrical control...

Page 109: ...LB 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...

Page 110: ...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 joini...

Page 111: ...ade 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 tur...

Page 112: ...ing 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...

Page 113: ...THE LIGHT COVERS ROTATING THEM 30 ANTI CLOCKWISE Footrest Remove the shield back plate Remove the central frame cover Remove the passenger footrest by undoing its fixing screw Undo the screw of the f...

Page 114: ...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 Remov...

Page 115: ...ve the helmet compartment central cover Remove the battery and the fuse box Remove the fuel tank cap and the start up remote control switch Unscrew the rear fixing screw and lift the helmet compartmen...

Page 116: ...ral 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 remo...

Page 117: ...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...

Page 118: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 119: ...ndlebar lock nut Lower steering ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam low beam position and parking lights and the respective warning lig...

Page 120: ...ND SEEK IMMEDIATE MEDICAL ATTENTION IF IT ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP TH...

Page 121: ...CEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioni...

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

Page 123: ...d 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 from frame removal and re fitting Liberty 50 C...

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

Page 125: ...KSHAFT Code Action Duration 1 001118 Main bearings Replacement 2 001100 Clutch side oil seal Replacement 3 001099 Flywheel side oil seal Replacement 4 001117 Crankshaft Replacement Liberty 50 Catalyze...

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

Page 127: ...EAD Code Action Duration 1 001097 Cooling hood Replacement 2 001093 Spark plug Replacement 3 001126 Head Replacement 4 001013 Intake manifold Replacement 5 001178 Disc pack Replacement Liberty 50 Cata...

Page 128: ...lley DRIVEN PULLEY CLUTCH Code Action Duration 1 001012 Driven pulley overhaul 2 001110 Driven pulley Replacement 3 001022 Clutch Replacement 4 001155 Clutch bell Replacement Time Liberty 50 Catalyzed...

Page 129: ...Oil pump OIL PUMP Code Action Duration 1 001028 Mix movement gear socket Re placement 2 001019 Mixer belt replacement 3 001018 Mixer Replacement Liberty 50 Catalyzed Time TIME 129...

Page 130: ...PULLEY Code Action Duration 1 001066 Driving pulley Removal and refitting 2 001086 Driving half pulley replace 3 001011 Driving belt Replacement 4 001177 CVT rollers sliders Replacement Time Liberty...

Page 131: ...ver TRANSMISSION COVER Code Action Duration 1 001087 Flywheel cover Replacement 2 001135 Transmission cover bearing Re placement 3 001096 Transmission crankcase cover Re placement Liberty 50 Catalyzed...

Page 132: ...l magneto FLYWHEEL FAN Code Action Duration 1 001109 Cooling fan Replacement 2 001173 Rotor Replacement 3 001067 Stator Fitting and Refitting 4 001058 Flywheel Replacement Time Liberty 50 Catalyzed TI...

Page 133: ...BURATOR Code Action Duration 1 001008 Carburettor Inspection 2 001063 Carburettor Replacement 3 007020 Carburettor heating tubing replace ment 4 001081 Automatic choke Replacement Liberty 50 Catalyzed...

Page 134: ...eplacement 3 001136 Exhaust emissions Adjustment Silencer fixing Please take note that starting from chassis serial number ZAPM3810000003971 the two M8 x 50 silencer fixing flaged head screws have bee...

Page 135: ...leaner AIR CLEANER Code Action Duration 1 004122 Air cleaner carburettor fitting Re placement 2 001014 Air filter Replacement cleaning 3 001015 Air filter box Replacement Liberty 50 Catalyzed Time TIM...

Page 136: ...Centre stand STAND Code Action Duration 1 004001 Frame replace 2 004004 Stand Replacement 3 001053 Stand bolt Replacement Time Liberty 50 Catalyzed TIME 136...

Page 137: ...placement 2 004149 Shield central cover Replacement 3 004064 Front shield front section Removal and refitting 4 004015 Footrest Disassembly and reas sembly 5 004053 Spoiler Replacement 6 004079 Rear f...

Page 138: ...love box remote opening linkage Replacement 2 004065 Knee guard Removal and refitting 3 004131 Rear rack mounting bracket Re placement 4 004082 Glove box packing Replacement 5 004081 Glove comparment...

Page 139: ...entral cover CENTRAL COVER Code Action Duration 1 004059 Spark plug inspection flap Replace ment 2 004106 Undersaddle band Replacement 3 004085 Fairing 1 Replacement Liberty 50 Catalyzed Time TIME 139...

Page 140: ...Underseat compartment HELMET COMPARTMENT Code Action Duration 1 004136 License plate holder support Re placement 2 005048 number plate holder Replacement Time Liberty 50 Catalyzed TIME 140...

Page 141: ...8 Fuel tank cap Replacement 2 005010 Fuel tank float Replacement 3 004109 Fuel tank breather Replacement 4 004005 Fuel tank Replacement 5 004007 Mixture cock Replacement 6 004112 Cock carburettor hose...

Page 142: ...RVOIR Code Action Duration 1 005018 Oil reservoir float Replacement 2 004017 Oil reservoir Replacement 3 004095 Oil reservoir cock Replacement 4 004091 Oil reservoir hose Replacement Time Liberty 50 C...

Page 143: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and Refitting Liberty 50 Catalyzed Time TIME 143...

Page 144: ...g column bearings STEERING FIFTH WHEELS Code Action Duration 1 003051 Complete fork Replacement 2 003002 Steering bearing Replacement 3 003073 Steering clearance Adjustment Time Liberty 50 Catalyzed T...

Page 145: ...Rear handlebar covers Replace ment 2 004018 Handlebar front section Replace ment 3 005078 Odometer glass Replacement 4 005076 Clock Cell Replacement 5 005014 Odometer Replacement 6 005038 Instrument...

Page 146: ...ment 4 003001 Handlebar Replacement 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 002054 Throttle or splitter transmission com plete Replacement 8 002060 Complete...

Page 147: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine chassis connection swinging arm Replacement Liberty 50 Catalyzed Time TIME 147...

Page 148: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004008 Luggage rack Replacement 3 004062 Luggage rack cover Replacement Time Liberty 50 Catalyzed TIME 148...

Page 149: ...AMP Code Action Duration 1 005002 Front headlamp Replacement 2 005012 Front turning indicators Replace ment 3 005067 Front turn indicator bulb Replace ment 4 005008 Front headlamp bulbs replace Libert...

Page 150: ...05022 Rear turn signal light Replacement 2 005068 Rear turning indicator bulb Re placement 3 005005 Taillight change 4 005066 Rear light bulbs Replacement 5 005028 Rear light assembly glass Replace me...

Page 151: ...brake disc Replacement Grease tone wheel or drive Please take note that the code has been intro duced 900001 Tone wheel drive greasing 15 Never mistake the codes 002011 movement sen sor replacement an...

Page 152: ...Rear wheel REAR WHEEL Code Action Duration 1 004126 Rear wheel tyre Replacement 2 001071 Rear wheel rim Removal and Refit ting 3 001016 Rear wheel Replacement Time Liberty 50 Catalyzed TIME 152...

Page 153: ...0 Starter motor Replacement 2 005045 Starter motor cable assembly Re placement 3 001017 Start up pinion Replacement 4 001021 Kick starter Inspection 5 008008 Starter spring pack Replacement 6 001084 S...

Page 154: ...ic devices ELECTRICAL DEVICES Code Action Duration 1 005007 Battery change 2 005011 Starter relay Replacement 3 005052 Fuse 1 Replacement 4 005054 Fuse block 1 Replacement Time Liberty 50 Catalyzed TI...

Page 155: ...n Duration 1 005001 Electrical system Replacement 2 005009 Voltage regulator Replacement 3 001094 Spark plug cap Replacement 4 001023 Control unit Replacement 5 005114 Electrical system Service Libert...

Page 156: ...acement 2 005006 Light switch or turn indicators re place 3 005040 Horn button Replacement 4 005003 Horn Replacement 5 005041 Starting device push button Re placement 6 005016 Key switch Replacement 7...

Page 157: ...Splitter Replacement 3 002057 Carburettor splitter transmission complete Replacement 4 002058 Mix splitter transmission complete Replacement 5 002053 Rear brake transmission complete Replacement 6 00...

Page 158: ...on 1 002021 Front brake hose Remov and Re fitt 2 002007 Front brake shoes pads Remov and Refitt 3 002039 Front brake calliper Removal and Refitting 4 002047 Front brake fluid and air bleed sys tem Rep...

Page 159: ...FRONT BRAKE CALIPER Code Action Duration 1 002002 Rear brake pads shoes Wear check Front mudguard Liberty 50 Catalyzed Time TIME 159...

Page 160: ...eplacement 2 004009 Rear mudguard Replacement Steering column STEERING Code Action Duration 1 003048 Fork oil seal Replacement 2 003076 Fork sheath Replacement 3 003079 Fork stem Replacement 4 003010...

Page 161: ...Helmet bay HELMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment Removal and Refitting 2 005046 Battery cover change Liberty 50 Catalyzed Time TIME 161...

Page 162: ...EEL AXLE Code Action Duration 1 001156 Gear reduction unit cover Replace ment 2 004125 Rear wheel axle Replacement 3 001010 Geared reduction unit Service 4 003065 Gear box oil Replacement Time Liberty...

Page 163: ...rankcase 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 00...

Page 164: ...10 25 133 Checks 46 E Electric 153 154 Engine stop F Fuel 36 89 116 141 H Headlight 31 110 Horn Hub oil 27 I Identification 8 Instrument panel 109 M Maintenance 7 23 Mirrors 108 O Odometer R Recommend...

Page 165: ...T Tank 116 141 142 Transmission 9 36 60 131 Turn indicators Tyres 10 V Vehicle 8 57...

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