PIAGGIO Liberty 50 Catalyzed Скачать руководство пользователя страница 8

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Vehicle identification

FRAME/ENGINE PREFIX

Specification

Desc./Quantity

Frame prefix

ZAPC42100÷1001

Engine prefix

C421M÷1001

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification

Desc./Quantity

Kerb weight

88 Kg

Width

735 mm

Length

1.960 mm

Wheel base

1.330 mm

Saddle height

775 mm

Engine

ENGINE

Specification

Desc./Quantity

Engine type

Two-stroke, single cylinder Piaggio Hi-PER2

Bore x stroke

40 X 39.3 mm

Cubic capacity

49.40 cc

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 petrol).

Starting system

electric starter/kick starter

Lubrication

With blend and variable oil variable according to the engine

revolutions and the throttle valve opening by means of a pump

controlled by the driving shaft with toothed belt.

Fuel system

Gravity feed, with unleaded petrol (with a minimum octane rat-

ing of 95) with carburettor.

Cooling system

forced coolant circulation system

Characteristics

Liberty 50 Catalyzed

CHAR - 8

Содержание Liberty 50 Catalyzed

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

Страница 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...

Страница 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...

Страница 4: ......

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 122: ...INDEX OF TOPICS TIME TIME...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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