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VESPA ET4 50, Workshop Manual

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VESPA ET4 50 Workshop Manual Download Page 154

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 - Replacement

5

003072

Clutch assembly - Wear check

6

001156

Reduction gearing cover - Replace-

ment

7

001155

Clutch bell housing - Replacement

Time

ET4 50

TIME - 154

Summary of Contents for ET4 50

Page 1: ...WORKSHOP MANUAL 633367 ET4 50 ...

Page 2: ... to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions models shown in this publication are available in all countries The availability of single versions should be checked at the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reproduction o...

Page 3: ...tions 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 these...

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: ...wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and split pins upon refitting After removal clea...

Page 8: ...n Desc Quantity Frame prefix ZAPC2610000001001 Engine prefix C261M Dimensions and mass DIMENSIONS AND MASS Specification Desc Quantity Total unloaded kerb weight 105 Kg Width 710 mm Length 1780 mm Wheelbase 1275 mm Height 1090 mm Characteristics ET4 50 CHAR 8 ...

Page 9: ...of 95 with carburettor Max power crankshaft 2 5 KW 3 4 CV at 6500 rpm Cooling system forced coolant circulation system Valve clearance cold engine intake 0 10 mm discharge 0 15 mm Transmission TRANSMISSION Specification Desc Quantity Transmission With automatic expandable pulley variator torque server V belt automatic clutch gear reduction unit Capacities CAPACITIES Specification Desc Quantity Fue...

Page 10: ...draulic linkage r h brake lever Rear brake Drum brake Ø 110 mm with mechanical linkage Wheels and tyres WHEELS AND TYRES Specification Desc Quantity Front tyre dimension 100 80 10 Rear tyre size 120 70 10 Front tyre pressure 1 3 bar Rear tyre pressure 1 8 2 bar Lightweight alloy wheels front 2 15 x 10 Light alloy rims rear rim 3 00 x 10 N B CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMP...

Page 11: ...per nut N B FOR INFORMATION ON SAFETY TIGHTENINGS REFER TO CHAPTER PRE CONSIGNMENT CHECKS FRONT BRAKE Name Torque in Nm Brake fluid pump hose fitting 8 12 Brake fluid pipe calliper fitting 20 25 Screw tightening calliper to the support 20 25 Brake disc screw 5 6 5 Oil bleed valve on the calliper 10 12 Handlebar pump 7 10 ENGINE ASSEMBLY Name Torque in Nm Spark plug 10 15 Nm Head cover screws 8 10 ...

Page 12: ...iven pulley shaft nut 40 to 44 Nm Hub oil drainage screw 3 5 Nm Rear hub cover screws 11 13 Wheel axle nut 115 125 Crankcase half union screw 8 10 When new stud bolts are assembled tighten them with 3 turns at 90 after the first tightening at 6 7 N m therefore 6 7 N m 90 90 90 in a crosswise manner Overhaul data Assembly clearances Cylinder piston assy PISTON AND CYLINDER MATING Name Initials Cyli...

Page 13: ...ylindre 3rd oversize Ø C 39 6 0 014 A 3 39 586 39 593 39 554 39 561 0 025 0 039 Cylindre 3rd oversize Ø C 39 6 0 014 B 3 39 593 39 600 39 561 39 568 0 025 0 039 Piston 3rd oversize Ø P 39 568 0 014 C 3 39 600 39 607 39 568 39 575 0 025 0 039 Piston 3rd oversize Ø P 39 568 0 014 D 3 39 607 39 614 39 575 39 582 0 025 0 039 Piston rings UPRATING TABLE Name Description Dimensions Initials Quantity 1 C...

Page 14: ...on side half shaft 14 0 0 005 A Flywheel side half shaft 16 0 0 005 B Connecting rod 14 8 0 05 0 C Spacing tool 45 00 assembly games D 0 15 0 30 E Slot packing system Shimming method for limiting the compression ra tio Rc 11 5 12 A MEASUREMENT A WITH PISTO AT T D C B MEASUREMENT A IS TO BE TAKEN WITHOUT ANY GASKET BETWEEN THE CRANKCASE AND THE CYLINDER C FIT THE GASKET SHOWN IN THE TABLE ACCORDING...

Page 15: ...f API GL3 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions brakes throttle control and odometer Oil for 4 stroke engines AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in creased adhesiveness AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP GREASE MU3 Grease for odometer transmission gear case Soap based...

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

Page 17: ...01467Y029 Bell for bearings O D 38 mm 004499Y Bearing extractor Fitted with 1 Bell 2 Sleeve 3 Screw 6 Ring 27 Half rings 34 Half rings 005095Y Engine support 008119Y009 Tube to assemble shafts and axles 020004Y Punch for removing fifth wheels from headstock ET4 50 Tooling TOOL 17 ...

Page 18: ...ench for steering tube ring nut 020074Y Tool to align crankshaft 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for driven pulley roller bearing 020265Y Bearing fitting base Tooling ET4 50 TOOL 18 ...

Page 19: ...ssemble piston on cylinder 020291y Valves assembly disassembly tool 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter ET4 50 Tooling TOOL 19 ...

Page 20: ...Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40 mm adaptor Tooling ET4 50 TOOL 20 ...

Page 21: ...Stores code Description 020359Y 42x47 mm adaptor 020360Y Adaptor 52 x 55 mm 020362Y 12 mm guide 020363Y 20 mm guide 020364Y 25 mm guide 020376Y Adaptor handle ET4 50 Tooling TOOL 21 ...

Page 22: ...2Y Tool to fit the start up sector spring 020439Y 17 mm guide 020444Y Test probe removal fitting tool 020448Y Pin lock fitting tool 020449Y Piston position check support 020450Y Camshaft fitting removal tool 020451Y Drive pulley stop wrench Tooling ET4 50 TOOL 22 ...

Page 23: ...tores code Description 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser ET4 50 Tooling TOOL 23 ...

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

Page 25: ...lacement Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyres condition and wear Check Tyre pressure check Vehicle and brake test road test AT 12000 OR 24 MONTHS AND AT 60000 KM 125 Action Engine oil replacement Hub oil level check Spark plug electrode gap check replacement Air filter clean Oil filter net filter clean Idle speed adjustment Throttle ...

Page 26: ... condition and wear Check Tyre pressure check Vehicle and brake test road test Refer to rules Refer to predelivery operations AT 36000 KM 175 Action Engine oil replacement Hub oil level check Spark plug electrode gap check replacement Air filter clean Oil filter net filter clean Idle speed adjustment Throttle lever adjustment Variable speed rollers check or replacement Driving belt replacement Odo...

Page 27: ...easing Steering adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid hoses replacement Brake fluid level check Transmission elements lubrication Emergency blockings Check Suspensions check Electrical system and battery check Headlight adjustment Tyres condition and wear Check Tyre pressure check Vehicle and brake test road test Refer to rules Refer to predeliver...

Page 28: ...tronic device 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...

Page 29: ...lug and if the insulator is chipped or damaged renew it Measure the spark plug gap with a feeler gauge If necessary adjust the gap by bending the outer electrode Make sure the washer is in good condition Fit the spark plug screwing it in first by hand and then tighten it to the prescribed torque with a plug spanner Characteristic Electrode gap 0 7 0 8 mm Spark plug Champion RG 4 PHP ET4 50 Mainten...

Page 30: ... products AGIP ROTRA 80W 90 rear oil hub SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Air filter After removing the lower part of the left hand side cover unscrew the four fixing screws and the two knobs which are exposed by overturning the sad dle and removing the helmet compartment re move the filter cover and then pull out the filter cartridge Cleaning Wash the filter ...

Page 31: ...650 cc of oil 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 top up by adding fresh oil taking care to never exceed the MAX level Recommended products AGIP CITY HI TEC 4T Oil to lubrica...

Page 32: ... silencer and the tube Insert the exhaust gas analyser probe into the tube 5 Connect the multimeter thermometer to the sump using an oil filler plug specially prepared for the insertion of the probe 6 Start the engine and before proceeding to tune up the idle speed ensure that the oil temperature is 70 80 C 7 Allow the idle speed to stabilize for about a mi nute 8 Without opening the throttle and ...

Page 33: ...494929Y Exhaust fumes analyser 020331Y Digital multimeter ET4 50 Maintenance MAIN 33 ...

Page 34: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 35: ...d Replace the head assembly Worn cylinder Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings Rear wheel spins at idle REAR WHEEL Possible Cause Operation Idling rpms too high Check the idling speed and if necessary adjust the C O Clutch fault Check the spring friction mass and the clutch bell Air filter housing not sealed Correctly refit the filter housing an...

Page 36: ...e the proper tank aeration Level in tank too low Restore the correct level in the tank the float must be parallel to the upper cover contact plane that is the throttle valve mem brane cover Engine tends to cut off at idle ENGINE TENDS TO STOP WHEN IDLING Possible Cause Operation Air calibrated holes in carburettor blocked Dismantle wash with solvent and dry with compressed air Defective floating v...

Page 37: ...r bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system there must be no flexible movement of the brake lever Brake disc or drum deformed Use a dial gauge to check the levelness of the disk with the wheel correctly fitted and the concentricity of the rear drum check the brake disc screws are locked Fluid leakage in hydraulic braking system Elastic fittings piston...

Page 38: ...n Steering hardening Check the tightening of the top and bottom ring nuts If irregu larities in turning the steering continue even after making the above adjustments check the seats on which the ball bearings rotate replace them if they are recessed or if the balls are flat tened Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation Excessive steering backlash Check the tig...

Page 39: ...Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the damper ET4 50 Troubleshooting TROUBL 39 ...

Page 40: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 41: ...igh beam warning light bulb 12V 1 2W instrument lighting bulb 12V 1 2W lights on warning light bulb 12 Rear stop light switch 13 Starter remote control 14 Voltage regulator 15 Battery 12V 9Ah 16 Rear turn indicator bulbs Two 12V 10W spherical 17 Front direction indicator lights N 2 12V 10W spherical 18 Brake light button on rear brake 12V 21 5W 19 Magneto flywheel 20 Pick up 21 Automatic starter 2...

Page 42: ...e Black CAUTION SHOULD ANY INTERVENTIONS TO THE ELECTRIC SYSTEM BE REQUIRED MAKE SURE THAT THE LEADS TO THE ELECTRONIC IGNITION DEVICE ARE PROPERLY CONNECTED ACCORD ING TO POLARITY AND TO THE LEAD COLOURS Conceptual diagrams Ignition IGNITION SECTION Specification Desc Quantity 1 Electronic ignition device 2 Key switch contacts 3 Voltage regulator 4 Magneto flywheel 5 Pick up 6 Main fuse 10A 7 Bat...

Page 43: ... 35 35W 6 High beam warning light 12V 1 2W 7 Parking light bulb 12V 5W 8 2 Instrument lighting bulbs 12V 1 2W 9 1 Instrument panel lighting bulb 12V 2W 10 Lights on warning 1 light bulb 12V 1 2W 11 Rear light bulb 1 light bulb 12V 5 21W 12 Electronic ignition device 13 Automatic starter 14 Light switch 15 Light switch 16 Battery 12V 9Ah ET4 50 Electrical system ELE SYS 43 ...

Page 44: ...ion Desc Quantity 1 Magneto flywheel 2 Starter motor 3 Main fuse 10A 4 Battery 12V 9Ah 5 Key switch contacts 6 Voltage regulator 7 Electronic ignition device 8 Starter remote control 9 Starter button 10 Front and rear brake light button Electrical system ET4 50 ELE SYS 44 ...

Page 45: ...Y SWITCHES Specification Desc Quantity 1 Voltage regulator 2 Fuel gauge 3 Fuel level sending unit 4 Low fuel warning light 5 Front and rear brake light button 6 Horn 12V 7 Horn button 8 Brake light filament 12V 21W ET4 50 Electrical system ELE SYS 45 ...

Page 46: ...lights TURN SIGNAL LIGHTS Specification Desc Quantity 1 Turn indicator switch 2 Voltage regulator 3 4 Turn indicator bulbs 12V 10W 4 Two 2 turn signal warning light bulbs 12V 2W Electrical system ET4 50 ELE SYS 46 ...

Page 47: ... 2W 7 Right turn indicator warning light 12V 2W 8 Dashboard light bulbs 12V 2W 9 Available warning light Checks and inspections In case the cause of ignition failure or malfunction cannot be easily identified at sight first of all re place the control unit by another one in operating conditions Remember that the engine must be off to discon nect and replace the control unit If after replacement th...

Page 48: ... the connector on the flywheel housing and measure the resistance between each of the two contacts and the earth Specific tooling 020331Y Digital multimeter PICK UP CHECK Specification Desc Quantity 1 1 Brown cable and earth 170 Ω STATOR WINDING CHECK Specification Desc Quantity 1 1 Black cable and earth 1 Ω Ignition circuit All the control operations of the system that require the disconnection o...

Page 49: ...e AC free from absorptions so to carry out voltage checks please proceed as fol lows Remove the handlebar covers Detach the connections from the headlight and the 5 PIN con nector from the dashboard Remove the taillight bulb Remove the automatic choke connector from the system Access the voltage regulator start the engine and let it run at idle Insert the positive terminal from the tester setting ...

Page 50: ...Y DOES NOT RECHARGE The fault in the DC section of the voltage regulator may cause depending on the type of failure the following faults a Bursting of protection fuse due to exces sively high voltage regulator short circuited and resulting in the battery not recharging b Battery not recharging regulator circuit in terrupted Interventions a Bursting of protection fuse regulator short circuited Chec...

Page 51: ...al of the battery so to avoid damaging the instrument measuring the cur rent Check the voltage at idle is at least 13V charged battery and the recharge current is 1 5 2A with the lighting system and the choke device exclu ded as described in the chapter CHECKING THE VOLTAGE REGULATOR As the engine speed increases so do the recharge current and voltage and at speeds above 4 000 rpm a recharging cur...

Page 52: ...nd 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 the turn indicat...

Page 53: ...e battery Duration of the charge 5 h WARNING WHEN THE BATTERY IS REALLY FLAT WELL BELOW 12 6V IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF 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 batt...

Page 54: ...e power supply source must be implemented by connecting 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 the battery remove the plugs of each cell Keep the battery away from naked flames or sparks when charging Remove the battery from the vehicle rem...

Page 55: ...PEN END THAT YOU FIND FITTED TO THE VEHICLE TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger WARNING Battery electrolyte is toxic and it may cause serious burns It contains sulphuric acid Avoid contact with eyes skin and clothing In case of contact with eyes or skin flush abundantly with water for about 15 minut...

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

Page 57: ...move the muffler assembly Remove the rear wheel Remove the rear brake mechanical transmission Disconnect the electric terminals Remove the throttle grip transmission Disconnect the tubing petrol vacuum operated cock control Disconnect the swinging arm on the engine side Disconnect the rear shock absorber lower clamping WARNING Be very careful when handling fuel CAUTION When installing the battery ...

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

Page 59: ... THE APPROPRIATE 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 indicated 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 th...

Page 60: ...hing 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 bell housing with the specific tool Remove the nut the clutch bell housing and the w...

Page 61: ...the clutch 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 Spe...

Page 62: ...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 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 ET4 5...

Page 63: ...y means of the special tool N B PROPERLY SUPPORT THE HALF PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVING BELT Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide Inspecting the driven fixed half pulley Check that there are no signs of wear on the work surface of the belt If there are replace the half pulley Make sure the bearings do not show signs of un usual wear Measure th...

Page 64: ...er with a curved spout to lubricate the driven pulley unit with around 6 gr of grease This operation must be done through one of the holes inside the 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 Grease for the tone wheel revolving ring Soap based lithium grease containing NL...

Page 65: ...wise 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 ...

Page 66: ...locking clutch unit on pulley 55 60 Nm Refitting the driven pulley Refit the driven pulley assembly the clutch bell and the nut using the specific tool Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Driven pulley shaft nut 40 to 44 Nm Drive belt Make sure the driving belt is not damaged and does not have cracks in the toothed grooves Check the width of the belt Charact...

Page 67: ...ring 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 ...

Page 68: ... Refit the components of the assembly roller con tainer assembly with bushing limiting washer sta tionary 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 ...

Page 69: ...eeger and the Kick start lever Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN 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 ...

Page 70: ...d pull 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 Adaptor 37 mm Engine ET4 50 ENG 70 ...

Page 71: ... Extract 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 ET4 50 Engine ENG 71 ...

Page 72: ... Inspecting 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 ...

Page 73: ... the 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 Rec...

Page 74: ...onnect 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 ...

Page 75: ...ator fixing 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 ...

Page 76: ...ecover the 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 ET4 50 ENG 76 ...

Page 77: ...that may cause 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 ET4 50 Engine ENG 77 ...

Page 78: ...ecific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Flywheel nut 52 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 ...

Page 79: ...et cover Remove the central screw and the belleville washer indicated in the figure and lock the cam shaft crown with the specific tool N B TO FACILITATE REMOVING THE HEAD COMPONENTS SET THE CRANKSHAFT TO THE TIMING POINT TDC OF THE COMPRESSION END Specific tooling 020565Y Flywheel lock calliper spanner Remove the camshaft control pulley and the washer below Remove the pinion of the crankshaft tim...

Page 80: ...ARATES FROM THE CAMSHAFT IT IS ESSENTIAL TO FIT A NEW BEAR Specific tooling 020450Y Camshaft fitting removal tool 004499Y Camshaft bearing extractor 004499Y001 Bearing extractor bell 004499Y002 Bearing extractor screw 004499Y006 Bearing extractor ring 004499Y027 Bearing extractor part Pull out the rocking lever bolt operating on the flywheel hole and remove the rocking levers at the same time N B ...

Page 81: ... NEEDED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS AND ROCKING LEVERS WITHOUT RE MOVING THE DRIVING PULLEY UNIT REMEMBER TO HOLD THE TIMING CHAIN WITH A PIECE OF METAL CA BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE FITTING Removing the valves Using the specific tool fitted with the element shown in the figure remove the cotters the plates and the spring between the valves Remove the oil seal...

Page 82: ...ings N B BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR ING REMOVAL Inspecting the small end Measure the internal diameter of the small end using an internal micrometer N B IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANK SHAFT CHAPTER Characteristic Max diameter admitted check...

Page 83: ...Carry out the measurement at 27 from the piston crown as shown in the figure Carefully clean the sealing rings housings with the aid of an old piston ring Measure the coupling clearance between the sealing rings and the piston grooves using a thickness gauge as shown in the figure If the clearances detected exceed the limits specified in the table the piston and the piston rings should be replaced...

Page 84: ...e roughness should be of R A 0 30 0 50 This is indispensable for a good seating of the sealing rings which in turn minimises oil consump tion and guarantees optimum performance The pistons are oversized due to cylinder rectifi cation and are subdivided into two categories 1st and 2nd with 0 2 0 4mm oversize They are also classified into 4 categories A A B B C C D D Inspecting the piston rings Alte...

Page 85: ... 30 mm oil scraper 0 20 0 70 mm 0 80 mm Removing the piston Install piston and wrist pin onto the connecting rod aligning the piston arrow the arrow facing to wards the exhaust Fit the pin stop ring onto the appropriate tool Specific tooling 020448Y Pin lock fitting tool With the opening in the position indicated on the tool set the lock ring into position in the tool with the punch Rest the tool ...

Page 86: ...tool on the cylinder and lock it with 2 nuts as shown in the figure Rotate the crankshaft until TDC the inverted point of the dial gauge rotation Measure piston protrusion compared with the head plane and determine the gasket thickness to be used according to the table below By correctly identifying the cylinder base gasket thickness an ade quate compression ratio is maintained Remove the specific...

Page 87: ... 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 VERSA Characteristic Shimming system to control the compression ratio CR 11 1 12 9 PISTON PROTRUSION CHECK Name Measure A Thickness shimming_1 0 05 0 25 0 35 shimming_2 0 25 0 40 0 25 ET4 50 Engine ENG 87 ...

Page 88: ...ified replace the piston rings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEARANCE BE TWEEN 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 COMBI NATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD SEALING RINGS Name Descripti on Dimensio ns Initials Quantity T...

Page 89: ...G PISTON RINGS 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 Refitting the cylinder Fit the base gasket of the chosen thickness pre viously determined Fit the cylinder as shown in the figure The piston can be kept out of the housing plane using the appropriate tool N B BE...

Page 90: ...der head cover surface the intake manifold and the exhaust manifold are not worn Characteristic Maximum admitted unevenness Head check 0 05 mm HEAD CHECK Specification Desc Quantity Standard diameter mm A Ø 32 015 32 025 mm Standard diameter mm B Ø 16 0 16 018 Standard diameter mm C Ø 11 0 11 018 Inspecting the timing system components Check that the guide shoe and the tensioner shoe are not worn ...

Page 91: ...e valves into the cylinder head Test the 2 valves alternatively The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers 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 hei...

Page 92: ...itting clearance Standard clearance Intake 0 015 0 042 mm Standard clearance drainage 0 025 0 052 mm Check that there are no signs of wear on the contact surface with the articulated register termi nal If the sealing surface on the valves is wider than the specified limit damaged in one or more points or curved replace the valve with a new one Characteristic Valve standard length Intake 70 1 mm Va...

Page 93: ...PE OF LAPPING COMPOUND BEING USED Inspecting the springs and half cones Check that the upper spring caps and the cotter halves show no signs of abnormal wear Refitting the valves Lubricate the valve guides with graphite grease Place the lower plates of the valve spring on the head Use the punch to fit the 2 sealing rings one at a time Specific tooling 020306Y Punch for assembling valve seal rings ...

Page 94: ...ew ones N B A BALL BEARING IS FITTED ON BEARING A CONSE QUENTLY BEARING B IS THE MOST IMPORTANT AS IT WORKS DIRECTLY ON THE HEAD ALUMINIUM Characteristic Standard 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 dia...

Page 95: ... nuts to the prescribed torque Specific tooling 020450Y Camshaft fitting removal tool Locking torques N m Head cylinder stud bolt nuts 6 7 135 90 Nm first fitting upon refitting tighten again at 6 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 CA...

Page 96: ...n Insert 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 tension...

Page 97: ...er spanner Locking torques N m Camshaft pulley screw 12 14 Head cover screw 8 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 ...

Page 98: ... Fit the 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 9 Nm Crankcase crankshaft First remove the following units Driving pulley Driven pulley Final reduction greasing Oil pump Flywheel with stator Cylinder piston head un...

Page 99: ...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 Connecting rod endfloat standard clearance 0 15 0 30 mm Connecting rod endfloat standard 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 ...

Page 100: ...earing extractor screw 004499Y006 Bearing extractor ring 004499Y034 Bearing extractor part Refitting the crankshaft bearings Heat a new main bearing in an oil bath at 120 Place the driving shaft on the support base and insert the bearing with the aid of an adequate piece of tube if necessary N B USE A NEW BEARING WHEN REFITTING WARNING THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT DO NO...

Page 101: ...o install the drive shaft on the support and to measure the misalignment 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 ...

Page 102: ...es carefully Insert the flywheel half casing Fit 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 10 Nm Fit a new O Ring on the mesh oil filter and on the filling cap lubricate the rings In...

Page 103: ...seal with a tube section of 30 mm in diameter Ø 32 mm Max Extract the flywheel oil seal from the crankcase being careful not to damage or score the crank case 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 SPECIFI...

Page 104: ...0358Y 37x40 mm adaptor Locking torques N m Timing chain oil pump compartment cover screws 4 5 Nm Oil pump Removal Remove the chain compartment cover undoing the 3 fixing screws indicated in the figure Take out the cover using the appropriate fusion couplings on the cover with a pair of pliers Undo the 2 clamping screws in the figure and re move the cover over the pump control crown gear Block the ...

Page 105: ...and the oil pump cover Remove the clip retaining the innermost rotor Remove and wash the rotors thoroughly with a degreasing solvent and compressed air Reassemble the rotors in the pump body keep ing the two reference marks visible Replace the clip Measure distance between rotors inner rotor outer rotor with a thickness gauge in the position shown in the picture Characteristic Admissible maximum c...

Page 106: ...ring replace the faulty parts or the assembly Fit the cover on the pump being careful to align the holes 2 on the cover and 2 on the pump body fixing the oil pump on the crankcase Fit the oil pump on the crankcase by tightening the two screws to the prescribed 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...

Page 107: ...NG THE LUBRICATION SYSTEM REFER TO THE CRANKCASE AND CRANKSHAFT CHAPTER RE GARDING LUBRICATION OF THE CRANKSHAFT AND CONNECTING ROD Locking torques N m Oil sump screws 8 10 Nm Fuel supply Disconnect the fuel supply and the suction taking pipe from the carburettor Check that there are no fuel leaks between the two tubes Close the fuel outlet pipe By means of the MITIVAC pump apply 0 1 bar of suctio...

Page 108: ...ove the petrol delivery tube and the suction tube Loosen the clip and remove the tap Clean the tank and the filter of the tap with a spe cific solvent Refit the tap making sure that there is an O Ring Turn the tap to the direction it had before it was removed and block the clip N B THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING Removing the carburettor To detach the carburettor f...

Page 109: ...ROL IN THE TANK DOES NOT EMULSIFY Remove the 2 fixing screws indicated in the fig ure the vacuum chamber cover and the spring Remove the vacuum valve together with the di aphragm the pin the spring and its plastic guide WARNING DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Remove the 3 fixing screws and the tank with the gasket Remove the tank components ...

Page 110: ...ection and the diaphragm together with the pipe O Ring Remove the accelerating pump 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 Engine ET4 50 ENG 110 ...

Page 111: ...EMOVE IT AS THIS WILL ONLY DAM AGE IT Remove the idle flow screw with the O ring and the spring CAUTION 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 ET4 50 Engine ...

Page 112: ...zzle support hides other inaccessible inter nal calibrations Blow the intake nozzle properly The acceleration nozzle outlet is extremely 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 tank and the diaphragm are not dented Check that the depression valve housing pipe is not scratched Che...

Page 113: ...of the shock ab sorber pin and the return clamp Replace the rod if worn out Check that the float is not worn on the pin housing or on the contact plate with the rod and that there are no fuel infiltrations Replace it in case of anomalies 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 ba...

Page 114: ...ctly positioned Fit the rubber bellows protecting the pin in the upper part of the accelerating pump Level check Tilt the carburettor so that the needle valve at the fuel supply is closed and the float weight does not affect it Check that the diaphragm closing line and the float central line are parallel as shown in the figure Blow air in to the tank and then assembly it and its gasket on the carb...

Page 115: ...ecial attention to the spring Inspecting the automatic choke device Check that the automatic starter piston is not de formed or rusty Check that the piston slides freely in its seating Check that the piston sealing O Ring is not de formed The starter must be more or less functional de pending on the ambient temperature Measure the protrusion of the piston as shown in the figure and check its corre...

Page 116: ...5 Use battery to power the automatic starter and check that piston protrudes as much as possible The correct warm up time depends on the ambi ent temperature If protrusion resistance or timing 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 ...

Page 117: ...carburettor make sure to respect requirements on lubrication valve clearance 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 p...

Page 118: ...s the CO 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 carburetion is considered correct Further information can be drawn from the analyser carbon dioxide pe...

Page 119: ...gnition 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 ET4 50 Engine ENG 119 ...

Page 120: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 121: ...able drift Drive out the ball bearing from the needle bearing side Fit the needle bearing by means of the specially designed drift Fit the ball bearing Position the seal ring and the circlip CAUTION BEFORE REFITTING SMEAR THE PARTS WITH JOTA 3 FS GREASE IN THE AREAS MARKED WITH AN ASTERISK Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease wit...

Page 122: ...PLIT PINS FOR REFITTING Slacken the brake calliper screw and the plate screw as shown in the figure Remove the rubber seal and the speedo gear Fit the new gear by following the steps in reverse order Refitting the front wheel When refitting tighten the 5 screws to the speci fied torque Locking torques N m Nut tightening torque 20 to 25 N m Suspensions ET4 50 SUSP 122 ...

Page 123: ...S BEING REMOVED TO REMOVE THE STEERING TILT THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS Refitting Carry out the operations in the reverse order to the removal observing the prescribed tightening tor que Locking torques N m Handlebar lock nut 45 50 Front fork Removal After removing the upper seat lean the vehicle on one side and extract the steering tube completely from the fork Sp...

Page 124: ...of a pointed end For the second washer repeat the operation us ing the punch on the side opposite to the one shown in the figure A Ø12 Punch B Sharp edged end Overhaul CAUTION USE NEW ROLLER CASINGS PIN SEALING RINGS AND DUST GUARDS FOR REFITTING Refitting Lubricate the sealing rings with mineral oil and half fill the roller casings with grease Insert the seal ring on the pin and the roller bush i...

Page 125: ...C and 120 C NLGI 2 ISO L XBCIB2 Fit both dust guard rings C on the swinging hub as shown in the detail drawing A Connect the swinging hub to the steering tube with the guide pin part 5 Use the specific tool fitted with part 3 on its stem and with part 4 at the bottom of the tool Insert the previously greased pin on the swinging hub and with the tool handgrip move part 3 until it stops on the steer...

Page 126: ...move the spacers part 17 fill with grease the area between the steering tube and the swinging hub and place the dust guard rings in that place Supplied with the tool N B ASSEMBLE THE LOWER HOUSING ON HE STEERING TUBE WITH A TUBE SECTION OF AN ADEQUATE DIAME TER Specific tooling 020021Y Front suspension service tool 001330Y Tool for fitting steering seats Recommended products AGIP GREASE PV2 Grease...

Page 127: ...LEEVE Specific tooling 020004Y Punch for removing fifth wheels from headstock Overhaul The front suspension service operation is useful to replace the connecting parts between the steering tube and the swinging hub of the front wheel holder provided that the steering tube and the wheel holder hub are in excellent conditions Shock absorber calliper bracket Removal Using a suitable drift drive out t...

Page 128: ... protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Steering bearing Removal Lubricate the races and balls with grease Tighten to the specified torque and then turn the tool 120 anti clockwise Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous calcium based grease ...

Page 129: ...ar wheel Straighten the split pin and remove the cap Remove the wheel acting on the central fixing point Refitting the rear wheel Fit the wheel tighten the nut to the prescribed torque Refit the cap and the split pin folding it correctly as shown in the figure Locking torques N m Locking torque 137 152 Nm ET4 50 Suspensions SUSP 129 ...

Page 130: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 131: ...acken the two fixings between the support and the shock absorber Remove the circlip from the wheel spindle Remove the speedometer cable Withdraw the calliper support Overhaul Remove the calliper assembling bolts and take out the internal bodies and components If necessary in order to make it easier to take out the plungers inject shorts blasts of compressed air through the brake fluid pipe ET4 50 ...

Page 132: ... support by tightening the bolts Lock the pipe joint to the calliper at the prescribed torque Upon fitting the parts must be perfectly clean and free of traces of oil diesel fuel grease etc They should be washed thoroughly in denatured alcohol before proceeding The sealing rings must be immersed in the operating liquid the use of the PRF1 protection is tolerated CAUTION RUBBER PARTS SHOULD NEVER B...

Page 133: ...b apply recommended product on the fixing bolts Tighten to the specified torque N B THE SURFACE OF THE DISC WITH THE STAMPED AR ROW INDICATING THE DIRECTION OF ROTATION MUST FACE THE SHOCK ABSORBER Recommended products Loctite 242 product description Apply LOCTITE medium type 242 threadlock Locking torques N m tightening torque 5 6 5 Nm Disc Inspection Specific tooling 020335Y Magnetic support for...

Page 134: ... 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 THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES THE BRAKING EFFICIENCY IN THIS CASE REPLACE THE PADS AND CLEAN THE DISC WITH A...

Page 135: ...rrect 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 Spring Rear drum brake Once the muffler and the wheel have been re moved follow these steps 1 Remove the shoe spring using the specific span ner 2 Remove the shoe with the aid of a lever 3 Refit the new shoes giving a few taps with the mall...

Page 136: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 137: ... up the saddle Remove the helmet compartment Remove the plastic fairing under the saddle after unscrewing the three screws shown in the figure Remove the plastic cover on the luggage carrier Unscrew the three screws and remove the lug gage carrier ET4 50 Chassis CHAS 137 ...

Page 138: ... the handlebar rear section Instrument panel Loosen the two screws and disconnect the termi nal block Remove the rubber hood and then the retaining clip as shown in the figure Operate the 4 screws shown in the figure to re place the instrument panel Chassis ET4 50 CHAS 138 ...

Page 139: ... To remove the handlebars use 2 spanners 17 13 mm as shown in the figure after detaching the LH and RH controls Locking torques N m Handlebar lock nut 45 50 Headlight assy To replace the headlight unscrew the 2 screws Remove the bulbs as shown in the figure ET4 50 Chassis CHAS 139 ...

Page 140: ... turn to extract and replace them Legshield To replace the grille first remove the Piaggio emblem and then the screw located underneath Footrest Operate on the 3 screws shown in the figure once the glove box and fairing have been removed Chassis ET4 50 CHAS 140 ...

Page 141: ...s by disengaging the interlocking elements License plate holder Unscrew the 2 side screws and the 2 nuts at the back of the splash guard Unclip the number plate light Rear central cover Unscrew the screw as shown in the figure then remove the spark plug access door ET4 50 Chassis CHAS 141 ...

Page 142: ...stic fairing Top case Front Press the spring clip with a screwdriver and with draw the switch lock To remove the part of the lock that is left inside the steering tube you must first disassemble the steering tube Loosen the 2 screws and detach the door Chassis ET4 50 CHAS 142 ...

Page 143: ...w the 2 screws shown in the figure placed under the front grille Remove the 3 screws shown in the figure placed inside the glove box they can be reached after opening the glove box door ET4 50 Chassis CHAS 143 ...

Page 144: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 145: ...according to directions Check the following devices Keyswitch Headlight full dipped beam panel indicator lights side lights Headlight adjustment Taillight Brake light front and rear brake Turn signals and relative indicators Speedometer and instrument panel lighting Horn Start button CAUTION TO ENSURE BEST PERFORMANCE BATTERY MUST BE CHARGED BEFORE USE ONLY IF VOLTAGE IS BELOW 12 7V FAILURE TO REC...

Page 146: ...R ABOUT 15 MINUTES AND SEEK MEDICAL ASSISTANCE IM MEDIATELY IN THE CASE OF INGESTION OF ELECTROLYTE DRINK PLENTY OF WATER OR VEGETABLE OIL AND CALL A DOCTOR IMMEDIATELY Levels check Brake fluid Hub oil Engine oil level Road test Cold start Speedometer check Throttle check Riding stability Front and rear brake efficiency Front and rear shock absorbers Unusual noises Hot engine restart Leakages afte...

Page 147: ...CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST WARNING BE VERY CAREFUL WHEN HANDLING FUEL ET4 50 Pre delivery PRE DE 147 ...

Page 148: ...INDEX OF TOPICS TIME TIME ...

Page 149: ...Engine ENGINE Code Action Duration 1 001001 Engine from frame Removal and re fit 2 001127 Engine Complete service 3 003064 Engine oil Change 4 003057 Engine retainer Tighten nuts ET4 50 Time TIME 149 ...

Page 150: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase replace Crankshaft Time ET4 50 TIME 150 ...

Page 151: ...placement 2 001099 Oil seal flywheel side Replacement 3 001100 Oil seal clutch side Replacement 4 001118 Main bearings Replacement Cylinder assy CYLINDER ASSY Code Action Duration 1 001002 Cylinder piston Replacement Cylinder head assy ET4 50 Time TIME 151 ...

Page 152: ...001079 Head parts Disassembly assembly 4 001126 Head Replacement 5 001049 Valves Adjustments Rocker arms support assy CAMSHAFT SUPPORT Code Action Duration 1 003056 Head Cylinder Nut tightening 2 001148 Rocking lever valve Replacement 3 001044 Camshaft Replacement Time ET4 50 TIME 152 ...

Page 153: ...Cylinder head cover HEAD COVER Code Action Duration 1 001093 Spark plug Replacement 2 001088 Head cover gasket change 3 001097 Cooling hood Replacement 4 001089 Head cover change ET4 50 Time TIME 153 ...

Page 154: ...Driven pulley Replacement 2 001012 Driven pulley Overhaul 3 003065 Gear casing oil Replacement 4 001022 Clutch Replacement 5 003072 Clutch assembly Wear check 6 001156 Reduction gearing cover Replace ment 7 001155 Clutch bell housing Replacement Time ET4 50 TIME 154 ...

Page 155: ...hain change 2 001112 Oil pump change 3 001042 Oil pump overhaul 4 001121 Chain cover oil seal Replacement 5 001122 Oil pump chain change 6 001125 Chain guide pads change 7 001130 Oil sump change 8 001129 Chain tightener overhaul and re place ET4 50 Time TIME 155 ...

Page 156: ...Final gear assy REDUCTION GEAR Code Action Duration 1 001010 Gear reduction unit Inspection 2 004125 Rear wheel axle Replacement Time ET4 50 TIME 156 ...

Page 157: ...ley DRIVING PULLEY Code Action Duration 1 001006 Driving pulley Overhaul 2 001086 Driving half pulley replace 3 001066 Driving pulley Removal and refitting 4 001011 rear view belt Replacement ET4 50 Time TIME 157 ...

Page 158: ...ER Code Action Duration 1 001096 Transmission crankcase cover re place 2 001132 Transmission air intake pipe Re placement 3 001131 Transmission air intake Replace ment 4 001135 Transmission cover bearing Re placement Time ET4 50 TIME 158 ...

Page 159: ...Duration 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 ET4 50 Time TIME 159 ...

Page 160: ...EL FAN 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 ET4 50 TIME 160 ...

Page 161: ... TANK Code Action Duration 1 004005 Fuel tank Replacement 2 004110 Fuel tank hose Replacement 3 005010 Tank float Replacement 4 004007 Fuel valve Replacement 5 004109 Fuel tank breather Replacement ET4 50 Time TIME 161 ...

Page 162: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement Time ET4 50 TIME 162 ...

Page 163: ...Air cleaner AIR FILTER Code Action Duration 1 001014 Air filter Replacement Cleaning 2 001015 Air filter box Replacement ET4 50 Time TIME 163 ...

Page 164: ...Duration 1 004001 Frame replace 2 004023 Shield rim Replacement 3 004012 Rear fairings Removal and refitting 4 004059 Spark plug inspection flap Replace ment 5 006001 Frame Painting 6 006032 Door Painting Time ET4 50 TIME 164 ...

Page 165: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 001053 Stand bolt Replacement 3 001072 Swinging arm Engine chassis con nection Replacement ET4 50 Time TIME 165 ...

Page 166: ...Rear cover GLOVE COMPARTMENT Code Action Duration 1 004081 Glove box door Replacement 2 004083 Glove box Replacement Plate holder Time ET4 50 TIME 166 ...

Page 167: ...nce plate light glass Replace ment 2 005031 Licence plate light bulb Replace ment 3 005048 Licence plate holder Replacement Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement ET4 50 Time TIME 167 ...

Page 168: ... absorber FRONT SHOCK ABSORBER COVER Code Action Duration 1 003011 Front shock absorber Removal and Refitting 2 003044 Shock absorber cover Replace ment 3 006038 Shock absorber cover Painting Time ET4 50 TIME 168 ...

Page 169: ...REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and Refitting Steering column bearings ET4 50 Time TIME 169 ...

Page 170: ...bar covers ODOMETER HANDLEBAR COVERS Code Action Duration 1 004018 Handlebar 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 006014 Handlebar rear part Painting Time ET4 50 TIME 170 ...

Page 171: ... Code Action Duration 1 002037 Brake or clutch lever Replacement 2 002071 Left hand grip Replacement 3 003001 Handlebar Removal and refitting 4 004066 Driving mirror Replacement 5 003075 Handlebar left control Replacement ET4 50 Time TIME 171 ...

Page 172: ... right control Replace ment 5 002047 Front brake fluid and air bleeding system Replacement 6 002024 Front brake pump Removal and Re fitting 7 002063 Throttle control transmission Re placement 8 005017 Stop switch Replacement Seat SADDLE Code Action Duration 1 004008 Luggage rack Replacement 2 004003 Saddle Replacement 3 004054 Seat lock hook Replacement Time ET4 50 TIME 172 ...

Page 173: ...68 Rear turn indicator bulb Replace ment 4 005005 Taillight Replacement 5 005022 Rear turn indicators Replacement Front wheel FRONT WHEEL Code Action Duration 1 003047 Front tyre re place 2 003037 Front wheel rim Removal and Refitting 3 004123 Front wheel Re placement 4 003063 Tyre pressure Check 5 006018 Wheel rim Paintwork ET4 50 Time TIME 173 ...

Page 174: ...t in the event of noise of the indicated components The grease recommen ded is TUTELA MRM 2 soap based lithium grease with Molybde num disulphide In the following points we indicate with an ar row the area to be greased 1 Drive 2 Tone wheel Rear wheel REAR WHEEL Code Action Duration 1 001016 Rear wheel Replacement 2 004126 Rear wheel tyre Replacement 3 001071 Rear wheel rim Replacement Time ET4 50...

Page 175: ...ADLIGHT Code Action Duration 1 005008 Front headlamp bulbs Replacement 2 005002 Front headlamp Replacement 3 005012 Front turn indicator Replacement 4 005067 Front turn indicator bulb Replace ment 5 005044 Front lights cable unit Replacement 6 004020 Headlight frame Replacement ET4 50 Time TIME 175 ...

Page 176: ... 2 001094 Spark plug cap Replacement 3 005009 Voltage regulator Replacement 4 005001 Electrical system Removal and re fitting 5 005035 Headlight remote control Replace ment 6 001023 Control unit Replacement 7 005074 Choke control device Replacement Time ET4 50 TIME 176 ...

Page 177: ...r turn indicators Re placement 3 005039 Headlight switch Replacement 4 005040 Horn button Replacement 5 005041 Starter button Replacement 6 004010 Antitheft lock replace 7 004096 Lock series Replacement 8 005069 Left switch Replacement 9 005016 Key switch Replacement ET4 50 Time TIME 177 ...

Page 178: ...n Duration 1 005007 Battery Replacement 2 005011 Start up remote control switch Re placement 3 005019 Fuse terminal block Replacement 4 005024 Battery fuse Replacement 5 005025 Battery fuse holder Replacement Time ET4 50 TIME 178 ...

Page 179: ...eter transmission assembly Replacement 2 002049 Odometer cable Replacement 3 002053 Rear brake transmission complete Replacement 4 002043 Rear brake cable Replacement 5 003060 Rear brake cable Adjustment 6 002021 Front brake piping Replacement ET4 50 Time TIME 179 ...

Page 180: ...calliper Removal and Refitting 3 002011 Odometer movement sensor Re placement 4 003036 Shock abs and brake caliper support bearings Replacement 5 003070 Front brake pads Shoes Check wear 6 002007 Front brake shoes pads Remov and Refitt 7 003002 Steering fifth wheel Replacement 8 003073 Steering clearance Adjustment Time ET4 50 TIME 180 ...

Page 181: ...Footrests MATS Code Action Duration 1 004015 Footrest Removal and Refitting 2 004078 Front rear footboard rubber cover Replacement 3 004075 Front mat Replacement ET4 50 Time TIME 181 ...

Page 182: ...ation 1 003045 Steering tube Replacement 2 003010 Front suspension Service 3 002041 Brake disc Replacement 4 003040 Front wheel bearings Replacement 5 001064 Odometer reel Replacement 6 003033 Front wheel hub Replacement Time ET4 50 TIME 182 ...

Page 183: ...Code Action Duration 1 004016 Helmet compartment Removal and Refitting 2 004071 Battery compartment Replacement 3 005046 Battery cover Replacement 4 001027 Body air cleaner union Replace ment Braking system ET4 50 Time TIME 183 ...

Page 184: ...BRAKE LEVER Code Action Duration 1 002002 Shoes Rear brake pads Replace ment Time ET4 50 TIME 184 ...

Page 185: ...1 133 135 180 C Carburettor 10 28 108 112 161 E Engine oil 31 F Fuel 36 107 H Headlight 139 Hub oil 30 I Identification 8 Instrument panel 138 M Maintenance 7 25 O Odometer S Saddle Spark plug 29 Stand T Tank Transmission 9 37 59 69 158 Tyres 10 ...

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