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km x 1,000

(months)

1

(4)

6

(12

)

10

(24

)

15

(36

)

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

Spark plug - Re-
placement

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

Carburettor -
Cleaning

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Carburetion -
Check

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Throttle grip/mixer
control - Adjust-
ment

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Condition and tyres
use - Check

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Tyre pressure - In-
spection

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Air filter - Cleaning

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Steering clearance
- Inspection

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Brake and clutch
lever - Grease

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Braking system flu-
id level

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Braking system flu-
id level - Replace-
ment

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

Gearbox oil - Re-
placement/Inspec-
tion

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

Differential oil - Re-
placement/Inspec-
tion

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

(I)

(R)

Battery fluid level -
Inspection

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Headlights - check/
adjust

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Suspension - In-
spection

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Flexible transmis-
sions - Lubrication

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Rear brake disc
piping - Replace-
ment

(R)

(R)

(R)

Vehicle and brake
test

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Drive shaft nut mix
- Inspection

(I)

(I)

(I)

(I)

(I)

(I)

SCHEDULED MAINTENANCE - APE 50 EUROPE

KEY: (*)= Every 2000 Km or 2 years.
(I) = Check and clean, adjust, lubricate or replace if necessary.
(R)=Replace

km x 1,000 (months)

1 (4)

5 (12)

10

(24)

15

(36)

20

25

30

35

40

45

50

Safety locks (wheels,brakes,steering,sus-
pensions) - Inspection

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Spark plug - Replacement

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

(R)

Carburettor - Cleaning

(I)

(I)

(I)

(I)

(I)

Carburetion - Check

(I)

(I)

(I)

(I)

(I)

(I)

Throttle grip/mixer control - Adjustment

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Condition and tyres use - Check

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Tyre pressure - Inspection

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Air filter - Cleaning

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Steering clearance - Inspection

(I)

(I)

(I)

(I)

(I)

Clutch brake lever - Grease

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Fluid level and braking system - Check

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Braking system fluid level - Replacement

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

(*)

Maintenance

MSS APE 50

MA - 30

Содержание 2012 MSS APE 50

Страница 1: ...MANUALE STAZIONE DI SERVIZIO 677276 677281 IT EN FR DE ES EL MSS APE 50...

Страница 2: ...0 Copyright 2010 PIAGGIO C S p A Pontedera All rights reserved No part of this publication may be reproduced This publication has been edited by After sales PIAGGIO C S p A V le Rinaldo Piaggio 23 560...

Страница 3: ...o 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 ob...

Страница 4: ......

Страница 5: ...ERISTICS CH SPECIAL TOOLS ST MAINTENANCE MA EMISSION CONTROLO SYSTEM CO EM TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ES ENGINE FROM VEHICLE EV ENGINE EN BRAKING SYSTEM BS STEERING COLUMN SC SUSPENSIONS...

Страница 6: ......

Страница 7: ...INDEX OF TOPICS GENERAL GUIDELINES GEN...

Страница 8: ...ced by the wear of the blocks Dust caused by shoe wear is toxic since it contains asbestos Maintenance guidelines Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non or...

Страница 9: ...INDEX OF TOPICS CHARACTERISTICS CH...

Страница 10: ...M APE 50 EUROPE EURO 2 ZAPC80000 C801M Characteristics SIZES Sizes mm Deck Van 1 Length 2670 2560 2 Width 1250 3 Height 1530 1560 4 Wheelbase 1590 5 Track 1100 6 Turning spokes 2400 2400 7 Rear cantil...

Страница 11: ...s mm Deck Short deck Van Cross 8 Length 1420 1270 1260 1270 9 Width 1200 1200 1200 1200 10 Height 960 Top box size 900x460x300 WEIGHTS APE 50 EUROPA besides the driver Kilograms kg Deck Short deck Van...

Страница 12: ...single central longitudinal arm integrated structure Seats in driving cab One TECHNICAL DATA ENGINE Specification Desc Quantity Engine Single cylinder 2 stroke with rotating timing and with three tran...

Страница 13: ...r tyres inflation pressure 3 bar Tightening torques ENGINE DIFFERENTIAL UNIT Name Torque in Nm Crankcase halves coupling nuts 13 to 15 Nm Coil support fixing screw 3 to 5 Nm Spark plug 14 to 18 Nm Eng...

Страница 14: ...e Torque in Nm Brake pump to the chassis 12 to 20 Nm Handlebar fixing bolt 35 to 60 Nm Assembly clearances FITTING CLEARANCES Name Description Dimensions Initials Quantity Distance between the ends of...

Страница 15: ...ller cage 1 a category 4 a category 2 a category 3 a category 3 a category 2 a category 4 a category 1 a category CAUTION IN CASE OF NOISE USE CAGE OF THE CATEGORY IMMEDIATELY BELOW Crankshaft alignme...

Страница 16: ...Piston Pin PISTON PIN ASSEMBLY CLEARANCE Name Description Dimensions Initials Quantity Piston pin assembly clearance mm 0 Characteristics MSS APE 50 CH 16...

Страница 17: ...INDEX OF TOPICS SPECIAL TOOLS ST...

Страница 18: ...9Y Bearing extractor 016029Y Lower Steering Bearing Fitting Tool on the steering tube 017104Y Pliers for circlips 018119Y Axle Fitting Tool 020004Y Steering seats extraction punch 020042Y Steering tub...

Страница 19: ...Y Front Wheel Hub Roller Bearing Fitting Punch 020055Y Steering Ring Nut Key 020057Y Tool for Starter Motor Bushing Calking 020074Y Crankshaft Alignment Check Tool 020119Y Flywheel extractor 020120Y P...

Страница 20: ...y Shaft Roller Bearing 020123Y Valves Sealing Rings Punch 020125Y Punch to Fit Sealing Rings 020126Y Clutch Stop Key 020127Y Transmission Spider Calking Punch 020128Y Tool to Fit Sealing Rings 020129Y...

Страница 21: ...g of Main Shaft Flywheel Side Crankcase Half 020131Y Flywheel lock tool 020132Y Gearbox Shaft Shimming Gauge 020133Y Tappet plates replacement tool 020144Y Primary Sprocket Lock 020147Y Flywheel Cone...

Страница 22: ...un 020156Y Clutch puller 020161Y Differential Box Extractor 020322Y Clutch Removal 020781Y Bearings Fitting Punch 020842Y Upper Steering Bearing Removal Punch 021071Y punch to fit bearings and sealing...

Страница 23: ...30Y Steering seats fitting tool 021467Y Bearing extractor 022465Y Pliers for circlips 023638Y Pliers for circlips 029551Y Clutch puller 029569Y Gear Engagement Fitting Tool 030250Y Clutch Stop Key MSS...

Страница 24: ...n 032975Y Punches for Roller Casings 033970Y Punches for Roller Casings 038077Y Engine support 038137Y Rear Hub Extractor 038138Y Roller Casings Punch 048564Y Flywheel extractor 060824Y Probe Special...

Страница 25: ...ust fumes analyzer 021330Y003 Steering seats fitting 021330Y004 Steering seats fitting 020114Y Pane positioning band 018119Y007 Axle fitting 018119Y009 Axle fitting 018119Y014 Axle fitting 018119Y015...

Страница 26: ...INDEX OF TOPICS MAINTENANCE MA...

Страница 27: ...rew the cover 1 restore the fluid level and recharge the system by using the pump on the left side of the passenger compart ment several times until the liquid comes out of the sprayer WINDSCREEN WASH...

Страница 28: ...locking torque ta ble Piston big end cylin der lights descaling See locking torque ta ble Cleaning and descaling of the still usable engine parts See locking torque ta ble TRANSMISSION AND DIFFERENTI...

Страница 29: ...I I I I I I I I I I I I I Gearbox oil re placement R R R R R R R R R R Brake fluid Re placement Tyre pressure In spection I I I I I I I I I I I I I I I I I I I Headlights check adjust I I I I I I I I...

Страница 30: ...I I I I I I I I I I I I Headlights check adjust I I I I I I I I I I Suspension In spection I I I I I I I I I Flexible transmis sions Lubrication I I I I I I I I I Rear brake disc piping Replace ment...

Страница 31: ...2 ISO LXBIB2 AGIP GREASE MU3 Grease for odometer transmission gear case Specifications NLGI 3 ISO L XBCHA3 DIN K3K 20 AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Carburettor The carburettor is completely de...

Страница 32: ...ator 6 Maximum air calibrator 7 Starter jet 8 Float 9 Max jet 10 Throttle valve Air filter CLEANING Clean with a solvent with high flash point Dry with compressed air CAUTION NEVER RUN THE ENGINE WITH...

Страница 33: ...G DO NOT REMOVE THE OIL COVER IMMEDIATELY AFTER AN ACTIVITY WITH THE ENGINE AT FULL SPEED AND OR WITH THE ENGINE RUNNING THE HEATED OIL MAY LEAK WITH THE RISK OF BURNING Recommended products AGIP GEAR...

Страница 34: ...LID BY LOOSENING ONLY ONE OF THE SCREWS IN QUESTION N B WHENEVER REMOVING THE MIXER FROM THE CLUTCH COVER THE SEALING O RING LOCATED ON THE COL LAR OF THE MIXER MUST BE REPLACED CAUTION IN THE EVENT O...

Страница 35: ...F THE SECONDARY AIR TUBE IF NECESSARY REPLACE THE FIXING CLAMPS Headlight alignment check APE 50 APE 50 EUROPA Position the unloaded vehicle on a flat surface and at 10 m away from a white screen loca...

Страница 36: ...ke sure the vehicle axis is perpendicular to the screen 2 Draw two vertical lines a a at a distance 1 corresponding to the distance between headlight axes Draw a horizontal line b b at height 2 from g...

Страница 37: ...le 2 see section Mixer timing Throttle grip cable 3 adjust so that the sheath does not have clearance TRANSMISSIONS ADJUSTMENTS Adjust the control cables Cable mix see mixer timing specification secti...

Страница 38: ...INDEX OF TOPICS EMISSION CONTROLO SYSTEM CO EM...

Страница 39: ...of the exhaust fumes analyser into the tube 5 Start the engine 6 Wait for a minute for the minimum to stabilise 7 Without ever operating the accelerator and us ing the appropriate screw 1 bring the en...

Страница 40: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Страница 41: ...ribed pressure Rear swinging arms Straighten out if possible or replace Worn rubber buffers Replace Engine ENGINE STOP Possible Cause Operation Idle speed too low Work on the appropriate adjuster scre...

Страница 42: ...trical device in the system that requires the most frequent inspections and thorough maintenance Fre quently check that the fluid level fully covers the plates if not restore the level adding distille...

Страница 43: ...erify and replace if necessary Badly adjusted control cable Adjust Trasmission gears or spiders not properly assembled or worn Review Noisy gears NOISY TRANSMISSION Possible Cause Operation Excessive...

Страница 44: ...EGULARITIES Possible Cause Operation The vehicle pulls to one side due to deformation of the steer ing tube Check the steering unit and replace if necessary Steering is hard or knocks Check the steeri...

Страница 45: ...INDEX OF TOPICS ELECTRICAL SYSTEM ES...

Страница 46: ...SWITCH 9 TURN INDICATOR SWITCH 10 HORN BUTTON 11 IGNITION SWITCH 12 STOP BUTTON 13 TURN INDICATOR CONTROL DEVICE 14 LOW FUEL WARNING LIGHT INDICATOR 15 START UP MOTOR 16 7 5A FUSE 17 START UP REMOTE...

Страница 47: ...0 B White Bl Blue G Yellow M Brown N Black BV White Green GN Yellow Black RN Red Black Gr Grey Rs Pink R Red Vi Purple V Green A Orange VN Green Black BN White Black BBI White Blue BR White Red CAUTIO...

Страница 48: ...D AND RESPECT THE COLOUR CODING GIVEN ON THE CONTROL UNIT IGNITION SECTION KEY 1 Alternator 2 Electronic control unit 3 Spark plug 4 Engine stop STARTER AND RECHARGE SECTION KEY 1 Alternator 2 Voltage...

Страница 49: ...iper switch 2 Windscreen wiper 3 12V 1 2W turn indicator warning light 4 No 4 12V 10W turn indicator bulbs 5 Turn indicator command 6 Turn indicator switch 7 No 2 12V 10W stop bulbs 8 Stop switch 9 Fr...

Страница 50: ...ORN SECTION LEVEL TRANSMITTER KEY 1 Turn indicators 2 Horn button 3 Horn 4 12V 1 2W Low fuel warning light 5 Fuel warning light transmitter 6 From B of the regulator Electrical system MSS APE 50 ES 50...

Страница 51: ...TION KEY 1 Alternator 2 12V 15W Headlight light 3 12V 5W City lights 4 12V 4W Rear daylight running light 5 12V 1 2W headlight warning light 6 Light switch 7 Voltage regulator MSS APE 50 Electrical sy...

Страница 52: ...ANEL 12V 1 2W BULBS 6 WINDSCREEN WIPER SWITCH 7 STARTER BUTTON 8 LIGHT SWITCH 9 TURN INDICATOR SWITCH 10 HORN BUTTON 11 IGNITION SWITCH 12 STOP BUTTON 13 TURN INDICATOR CONTROL DEVICE 14 LOW FUEL WARN...

Страница 53: ...TOR LIGHT 12V 1 2W BULB 25 STOP SWITCH ELECTRICAL CABLES COLOUR CODING APE 50 EUROPA B White Bl Blue G Yellow M Brown N Black BV White Green GN Yellow Black RN Red Black Gr Grey Rs Red Vi Purple V Gre...

Страница 54: ...N THE CONTROL UNIT LIGHTS SECTION APE 50 EUROPA KEY 1 Alternator 2 12V 15W Headlights 3 12V 5W City lights 4 12V 4W Rear daylight running light 5 Headlight warning light 6 Light switch 7 Voltage regul...

Страница 55: ...WARNING LIGHT CONTROL 16 START UP MOTOR 17 CIGARETTE LIGHTER LIGHTING 12V 1 2W BULB 18 STOP BUTTON ON THE FRONT BRAKE 19 STARTER RELAY 20 Voltage regulator 21 12V 9AH BATTERY 22 ELECTRONIC CONTROL UN...

Страница 56: ...range B White BBI White Blue BIN Blue Black BIR Blue Red BN White Black BVi White Purple GN Yellow Black Gr Grey GrR Grey Red GV Yellow Green M Brown N Black Rs Pink V Green R Red Vi Purple VN Green B...

Страница 57: ...TOR SWITCH 10 HORN BUTTON 11 IGNITION SWITCH 12 STOP BUTTON ON THE REAR BRAKE 13 CIGARETTE LIGHTER 14 LOW FUEL WARNING LIGHT CONTROL 15 OIL RESERVE WARNING LIGHT CONTROL 16 START UP MOTOR 17 CIGARETTE...

Страница 58: ...nge B White BBI White Blue BIN Blue Black BIR Blue Red BN White Black BVi White Purple G Yellow GN Yellow Black Gr Grey GrN Grey Black GV Yellow Green M Brown N Black R Red RB Red White Rs Pink V Gree...

Страница 59: ...9 No 2 BULBS FOR HEADLIGHTS 10 No 2 BULBS FOR DAYLIGHT RUNNING LIGHT 11 No 2 BULBS FOR FRONT TURN INDICATORS 12 CABLE ASSEMBLY OF THE CHASSIS 13 STOP BUTTON ON THE FRONT BRAKE 14 LIGHT SWITCH 15 WINDS...

Страница 60: ...No 2 REAR LIGHTS 39 LIGHT FOR LICENCE PLATE WITH BULB 40 MIX OIL WARNING LIGHT CONTROL 41 CHASSIS ENGINE GROUND CABLE 42 STARTER MOTOR 43 ELECTRONIC IGNITION DEVICE 44 MAGNETO FLYWHEEL 45 GROUND ON T...

Страница 61: ...CTRONIC CONTROL UNIT ARE CORRECTLY CONNECTED AND RESPECT THE COLOUR CODING GIVEN ON THE CONTROL UNIT Key switch LOCK Position contacts 7 8 ground ignition ex tractable key locked steering OFF contacts...

Страница 62: ...act between the Blue and Brown cables Horn button Button in working position contact between the White and Grey Black cables Headlight switch Position O no contact Position 1 contact between the Pink...

Страница 63: ...s POSITIONS OF THE WINDSCREEN WIPER SWITCH APE 50 MIX APE 50 EUROPE 0 Windscreen wiper turned off 1 Windscreen wiper turned on 2 Windscreen washer enabling Pulsante avviamento In working position cont...

Страница 64: ...sclose no failures replace the regulator c If replacing the regulator does not restore proper operation proceed to the checks of the electrical system connections interventions The failure of the dire...

Страница 65: ...he starter motor under no load must draw a maximum of 30 Amp with a supply voltage of 11 5 to 12V and must rotate at rpm 11 000 2 Load test braking the starter motor so that it draws 60 Amp and with a...

Страница 66: ...arter motor removal Safety cap removal Coupling pin removal Remove the retainer ring and remove the pinion CAUTION ALWAYS REPLACE THE INDICATED GASKET GIVEN TO GETHER WITH THE SPECIFIC RECOMMENDED PRO...

Страница 67: ...EY 1 Red 2 White 3 Green INSPECTIONS TO BE PERFORMED IN THE EVENT OF IGNITION IRREGULARITIES In the event of failure and abnormal operation of the ignition whose causes are not detectable by a visual...

Страница 68: ...Red 2 White 3 Green 4 Black 5 Blue Connect the instrument between the red and white cables there must be continuity and an ohmic val ue of 110 5 ohm KEY 1 Red 2 White 3 Green 4 Black 5 Blue If there...

Страница 69: ...INDEX OF TOPICS ENGINE FROM VEHICLE EV...

Страница 70: ...ont and one at the rear and remove the differential engine unit of the chassis WARNING WE RECOMMEND THE USE OF EYE PROTECTION WHEN USING CONTACT TOOLS WARNING DO NOT REMOVE THE OIL COVER IMMEDIATELY A...

Страница 71: ...INDEX OF TOPICS ENGINE EN...

Страница 72: ...he scroll cover Using the special tool to block the flywheel Specific tooling 020095Y Flywheel Lock Using the appropriate tool unscrew the lock nut of the flywheel Specific tooling 048564Y Flywheel ex...

Страница 73: ...tly position the key and lock the flywheel nut to the prescribed torque Locking torques N m Fan flywheel locking nut 45 to 50 Nm Crankcase splitting Fitting Clean the mating surfaces thoroughly Positi...

Страница 74: ...rclips and with punches of a suitable diameter to eject the bearings Specific tooling 022465Y Pliers for circlips Fitting Heat the crankcase to around 80 C Position the bearings Fit the retainer ring...

Страница 75: ...remove it with light taps of the hammer Remove the bearing from the shaft by leveraging it with 2 screwdrivers Fitting Heat the crankcase to around 80 C Fit the bench ball bearing Fit main shaft of th...

Страница 76: ...lacement Removal Using the special tool remove the gear retaining seeger Specific tooling 023638Y Pliers for circlips Removal Fitting Fitting Reposition the transmission secondary shaft in its seat En...

Страница 77: ...38Y Pliers for circlips Coupling refitting Using the appropriate tool reassemble the gear engagement Specific tooling 029569Y Gear Engagement Fitting Tool Clutch drum Removal After removing the circli...

Страница 78: ...ers for circlips Differential assembly WARNING REFIT THE PARTS IN REVERSE ORDER OF THE REMOVAL TAKING CARE TO CORRECTLY INSERT THE REVERSE GEAR CONTROL FORK INTO THE SLIDING GEAR WARNING AFTER INSTALL...

Страница 79: ...Cover removal Undo the indicated screws Differential box and transmission gears Remove the gears Differential case Undo the indicated screws MSS APE 50 Engine EN 79...

Страница 80: ...cover and thrust plate Removal Undo the indicated screws Fitting In order to correctly position the thrust plate ac tuating pad follow these steps hold the clutch lever full stroke insert the actuatin...

Страница 81: ...uller Fitting Reposition the clutch assembly and the engine gear in their seat Tighten to the specified torque CAUTION REFIT ALL PARTS COMPONENTS THE UNIT IN RE VERSE ORDER TO THE REMOVAL PAYING ATTEN...

Страница 82: ...emble the clutch assembly Specific tooling 020322Y Clutch Removal Inspect the components and replace damaged parts Cylinder head Undo the fixing screws and remove the cylinder hood Undo the fixing scr...

Страница 83: ...SAME DI RECTION AS THE EXHAUST Crankshaft Removal To remove the crankshaft separate the crankcase halves and using gentle taps with a rubber mallet to remove it CAUTION SUPPORT THE CRANKSHAFT TO PREVE...

Страница 84: ...to be carried with the Tecno test 130 P strobe gun or a similar one that is able to function properly up to at least 11 000 times per minute CAUTION BEFORE PERFORMING THE TESTS ABOVE CHECK THE CORREC...

Страница 85: ...INDEX OF TOPICS BRAKING SYSTEM BS...

Страница 86: ...Brake pump Key pump section 1 Lug Braking system MSS APE 50 BS 86...

Страница 87: ...The piston return spring is in good condition The passages connecting the pump tank to the pump body are not clogged or dirty Removing brake fluid reservoir and pump from chassis Removal After removi...

Страница 88: ...pedal keeping it pressed undo the bleed screw on a rear wheel let the air out after this bleed point has been connected through a small rubber pipe to a tray full of brake fluid Screw the bleed screw...

Страница 89: ...P BRAKE 4 Brake fluid FMVSS DOT 4 Drum removal In the filling operations a maximum oversize of 0 4 mm on the regular drum diameter is allowed Shoe and drum clearance adjustment Before performing the a...

Страница 90: ...and of the wheels Lock the tensioner in position with its lock nut CAUTION REMEMBER THAT A NORMAL ADJUSTMENT OF THE TENSION OF THE CABLE AFFECTS THE OPERATION OF THE BRAKE ON THE REAR WHEELS Front dru...

Страница 91: ...INDEX OF TOPICS STEERING COLUMN SC...

Страница 92: ...Nm Steering wheel from chassis Specific tooling 020055Y Steering Ring Nut Key STEERING ON THE CHASSIS LOCKING Specific tooling 020055Y Steering Ring Nut Key Locking torques N m Upper seat 30 to 40 Nm...

Страница 93: ...cific tooling 020842Y Upper Steering Bearing Removal Punch LOWER SEAT Specific tooling 020004Y Steering seats extraction punch Lower housing from steering column Specific tooling 020042Y Steering tube...

Страница 94: ...ERING TUBE Specific tooling 016029Y Lower Steering Bearing Fitting Tool on the steering tube Steering bearing housing on chassis Specific tooling 021330Y003 Steering seats fitting 021330Y004 Steering...

Страница 95: ...INDEX OF TOPICS SUSPENSIONS SS...

Страница 96: ...SE NEW NUTS CHAMFERING THEM IN THE APPROPRIATE WAY Locking torques N m Brake drum locking 75 to 90 Nm Drum bearings DRUM BEARINGS Use a 17 section of tube for the ball bearing and a 23 section of tube...

Страница 97: ...aring and split ring on brake drum Heat the bearing housing area with the appropriate tools and fit the ball bearing and the circlip CAUTION BEFORE REFITTING THE DRUM FILL THE INTERNAL CHAMBER WITH TH...

Страница 98: ...with a steel punch the collar in the existing groove on the wheel holder shaft then fit the cover after filling it with specific grease Recommended products AGIP GREASE PV 2 Grease for brake control...

Страница 99: ...s In order to optimise the joint of the axle shaft be careful when refitting the two half pins that the most open part is facing the axle shaft Ball bearing and split ring on hub Heat the housing area...

Страница 100: ...CAUTION BEFORE FITTING THE SPACE AND THE ROLLER BEAR ING FILL THE INTERNAL CHAMBER OF THE HUB WITH SPECIFIC GREASE Wheel hub on half shaft Prepare the dust gaiter cap 1 the seal ring 2 and the spacer...

Страница 101: ...acer ring touches the ball bearing 3 3 Position the seal ring 2 the dust gaiter 1 and the external seal ring CAUTION FITTING OF THE REMAINING COMPONENT PARTS OF THE UNIT PROCEED IN REVERSE ORDER TO TH...

Страница 102: ...INDEX OF TOPICS CHASSIS CH...

Страница 103: ...cal tool blades abrasive elements etc Check that the frame profile is not deformed straighten if required If necessary touch up the area that houses the pane using original varnish so as to ensure the...

Страница 104: ...FOR THE FUTURE EXCEEDING OF THE STORAGE LIMITS PRE SCRIBED BELOW BY THE BOSTON COMPANY CAUTION THE EXPIRATION DATE OF THE RECOMMENDED PROD UCTS IS 12 MONTHS FROM THE DATE OF PRODUCTION Specific toolin...

Страница 105: ...he frame edge CAUTION FIT THE THREE STRIPS WITH THE TOP EDGE FACING THE PANE THEN APPLY THE BAND ON THE LOWER TRIM AND THE TAPE FROM THE BODYWORK ON THE SIDE STRIPS TO ENSURE A PERFECT ADHERENCE IN TH...

Страница 106: ...INDEX OF TOPICS PRE DELIVERY PD...

Страница 107: ...IN AND CLOTHING In case of contact with eyes or skin rinse with abundant water for about 15 minutes and seek medical attention at once If it is swallowed immediately drink large quantities of water or...

Страница 108: ...INDEX OF TOPICS...

Страница 109: ...TIME SHEET TEMP...

Страница 110: ...FRAME RE PLACEMENT 2 001032 ENGINE SUPPORT REPLACE MENT 3 003016 ENGINE SUPPORT FRONT BUF FERS REPLACEMENT 4 003017 ENGINE SUPPORT REAR BUFFER REPLACEMENT 5 003052 IGNITION TIMING 6 003057 ENGINE ANCH...

Страница 111: ...Crankcase CRANKCASE Code Action Duration 1 001118 Main bearings Replacement 2 001120 ENGINE CRANKCASE BEARINGS REPLACEMENT MSS APE 50 Time sheet TEMP 111...

Страница 112: ...Crankshaft CRANKSHAFT Code Action Duration 1 001101 CRANKSHAFT OVERHAUL 2 001117 CRANKSHAFT REPLACEMENT Time sheet MSS APE 50 TEMP 112...

Страница 113: ...Cylinder pistston wrist pin unit CYLINDER PISTON PIN Code Action Duration 1 001002 CYLINDER PISTON REPLACE MENT 2 001107 CYLINDER PISTON INSPEC TION CLEANING MSS APE 50 Time sheet TEMP 113...

Страница 114: ...ead cover HEAD COVER Code Action Duration 1 001093 Spark plug Replacement 2 001094 Spark plug hood Replacement 3 001097 COOLING HOOD REPLACEMENT 4 003056 HEAD CYLINDER TIGHTENING Time sheet MSS APE 50...

Страница 115: ...Oil pump OIL PUMP Titolo Durata Valore Testo Breve 4000 car Indirizzo Immagine OIL PUMP MSS APE 50 Time sheet TEMP 115...

Страница 116: ...Control 98 D Differential 78 80 E Engine 33 41 70 72 81 84 110 F Filter 32 Fluid 87 88 H Horn 62 I Identification 10 M Maintenance 8 27 O Oil 33 115 P Products 31 S Safety 8 66 67 Specifications 87 Sw...

Страница 117: ...W Weights Wheel 92 97 99 100...

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