Gilera DNA 50 Workshop Manual

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WORKSHOP MANUAL
633507
DNA 50
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WORKSHOP
MANUAL
DNA 50
The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of single
versions should be checked at the official Piaggio sales network.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
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WORKSHOP MANUAL
DNA 50
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio­Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
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INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME
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INDEX OF TOPICS
CHARACTERISTICS CHAR
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This section describes the general specifications of the vehicle.
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well­ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. 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, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.
DNA 50 Characteristics
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Vehicle identification
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Frame prefix ZAPC2700000001001
Engine prefix C271M
Dimensions and mass
DIMENSIONS AND MASS
Specification
Desc./Quantity
Maximum width 780 mm
Maximum length 1970 mm
Wheel base 1350 mm
Saddle height 810 mm
Dry weight 99 kg.
Characteristics DNA 50
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Engine
ENGINE
Specification
Desc./Quantity
Motor Fluid-cooled, two-cycle, single-cylinder.
Engine capacity 49 cm³
Bore x stroke 40 X 39.3 mm
Compression ratio 11.3 ÷ 12.8 : 1
Supply. With high-octane, 95 N.O.R. lead-free petrol mix - oil via car-
burettor, automatic mixer (with variable capacity depending on
the engine speed and opening of throttle valve) petrol pump.
Intake By means of a compression valve on the casing
Dellorto Carburettor PHVA 17.5
Lubrication Engine lubrication (piston, cylinder, crankshaft, main bearings)
with mixer oil.
Transmission
TRANSMISSION
Specification
Desc./Quantity
Transmission With automatic expandable pulley variator, torque server, V
belt, automatic clutch, gear reduction unit.
DNA 50 Characteristics
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Capacities
CAPACITIES
Specification Desc./Quantity
Fuel tank Plastic, capacity ~ 9 lt. (including reserved ~ 1.2 lt.).
Oil mixer tank In plastic, of capacity ~ 1.3 lt. (including reserve ~ 0.500 lt.)
Rear hub oil ~ 85 cc
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Electronic ignition A capacitor discharge microprocessor device, with built-in HV
coil.
Spark advance (Before T.D.C.) 20°±1 at 4000 rpm
Spark plug CHAMPION RN1C
Battery 12V-4Ah Main fuse 7.5 A Generator In alternate current with three output sections
Frame and suspensions
FRAME AND SUSPENSIONS
Specification
Desc./Quantity
Chassis Double steel diagonal beam
Front suspension Hydraulic telescopic fork
Steer torque 123 mm
Front suspension stroke 80 mm
Rear suspension With coaxial spring and hydraulic shock absorber. Chassis to
engine support with swinging arm.
Max. rear wheel travel 83 mm.
Brakes
BRAKES
Specification
Desc./Quantity
Front brake 240 mm dia. disc brake with hydraulic control activated from
handlebar with right lever
Rear brake 200 mm dia. disc brake with hydraulic control activated from
handlebar with left lever
Wheels and tyres
WHEELS AND TYRES
Specification
Desc./Quantity
Wheel rim
Front: 3.00 x 15' light-alloy
Rear: 3.50 x 14' light-alloy
Front tyre 120/70 - 15''
Rear tyre 140/70 - 14''
Front wheel pressure: 1.8 bar
Rear tyre pressure: 2 bar
Characteristics DNA 50
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Secondary air
To clean the sponge filters of the secondary air system, proceed as follows: Unscrew the two studs ( 2) of the aluminium lid of the secondary air box to access the polyurethane sponge contained inside the box; after cleaning with water and neutral soap, dry the sponge with a clean cloth and reassemble the system, check­ing that the steel blade is not warped and/or does not guarantee the seal on its strike surface; re­place if necessary.
N.B. UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE
TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMI­NIUM COVERS.
CAUTION DURING THE OPERATION, CHECK THE INTEGRITY AND
SEAL OF THE TWO SLEEVES (3) IN RUBBER LOCATED AT THE ENDS OF THE SECONDARY AIR HOSE; IF NEC­ESSARY, REPLACE THEM USING NEW CLAMPS TO FAS­TEN.
Carburettor
50cc Version
Dell'Orto
DELL'ORTO CARBURETTOR
Specification
Desc./Quantity
Type PHVA 17.5 ID
Diffuser diameter Ø 17.5
Reference number of adjustment 8439
Maximum nozzle: 53
Maximum air nozzle (on the body): Ø 1.5
Tapered pin stamped code: A22
Pin position (notches from above): 1
Diffuser: 209 HA
Minimum nozzle: 32
Minimum air nozzle (on the body): Free
Secondary minimum air hole Ø 2.5
Initial minimum mix screw opening: 1 1/2
Starter jet 50
Starter air nozzle (on the body): Ø 1.5
Stroke of starter pin: 11 mm
Fuel inlet hole Ø 1.0
DNA 50 Characteristics
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Tightening Torques
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut (safety locks) 35 to 40 Nm Lower steering ring nut (safety locks) 8 to 10 Nm
Handlebar fixing pin (safety locks) 45 to 50 Nm
FRAME ASSEMBLY
Name Torque in Nm
Swinging arm-engine pin (safety locks) 33 to 41 Nm
Swinging arm-frame pin (safety locks) 64 to 72 Nm Shock absorber - frame nut (safety locks) 20 to 25 Nm Shock absorber-engine pin (safety locks) 33 to 41 Nm
Rear wheel axis (safety locks) 104 to 126 Nm
Bolt holding stand to the engine 18 to 19 Nm
Side stand fixing screw 12 ÷ 20
Side stand bracket fixing screw 15 ÷ 20
Rear rim fixing screw 20÷25
FRONT SUSPENSION
Name Torque in Nm
Front wheel axle 45 ÷ 50
Wheel axle clamp screw 6 ÷ 7 Nm
Lower leg screw 15 to 20 Nm
Hydraulic cartridge stem nut 15 to 18 Nm
FRONT BRAKE
Name
Torque in Nm
Viti fissaggio coperchio pompa freno 1,5 ÷ 2 Nm
Brake pump support fixing screw 7 to 10 Nm
Brake fluid pump - hose fitting 13 to 18 Nm
Brake fluid tube - calliper fitting 20 to 25 Nm
Calliper tightening screw 20 to 25 Nm
Disc tightening screw (safety locks - lock with LOCTITE
THREADLOCK MEDIUM TYPE 243)
6 ÷ 7 Nm
Oil bleed screw 7 to 10 Nm
Calliper coupling screw 20 to 25 Nm
REAR BRAKE
Name
Torque in Nm
Fastening screws calliper to the crankcase 20 - 25
Brake reservoir cover fixing screw 2÷4 N·m (Grimeca) - 0,8÷1,5 N·m (Brembo) - 1,5÷2 N·m (Heng-
tong)
Brake pump support fixing screw 7 to 10 Nm
Brake fluid pump - hose fitting 13 to 18 Nm
Brake fluid tube - calliper fitting 20 to 25 Nm
Oil bleed screw 7 to 10 Nm
ENGINE ASSEMBLY
Name
Torque in Nm
Clutch bell nut 40 to 44 Nm
Clutch lock ring nut 55 ÷ 60
nut locking driving pulley on the crankshaft 40 to 44 Nm
Start-up lever screw 12 ÷ 13
Flywheel nut 40 to 44 Nm
Flywheel fan screws 3 ÷ 4
Half-crank case joint bolts 12 ÷ 13
Bolts holding exhaust pipe to the crankcase 22 ÷ 24
Screws holding the filter box to the crank case 4 ÷ 5
Head nuts 10 ÷ 11
Starter screws 12 ÷ 13
Characteristics DNA 50
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Name Torque in Nm
Ignition spark plug 25 ÷ 30 Hub oil drainage cap 3 ÷ 5 Oil hub level dipstick Manual
Rear hub cap screws 12 ÷ 13
Transmission cover screws 12 ÷ 13
Inlet manifold screws 8 ÷ 9
Flywheel hood fixing screws 1 ÷ 2
Cylinder hood fixing screws 3.5 ÷ 5
Stator clamping screws 3 ÷ 4
Pick-Up clamping screw 4 ÷ 5
Mixer clamping screws 3 ÷ 4
Screw fixing brake lever to the journal on the engine 12 ÷ 13
Overhaul data
Assembly clearances
Cylinder - piston assy.
CYLINDER-PISTON FITTING
Name
Initials Cylinder Piston Play on fitting
Standard fitting M 39.997-40.004 39.943-39.95 0.047-0.061 Standard fitting N 40.004-40.011 39.95-39.957 0.047-0.061 Standard fitting O 40.011-40.018 39.957-39.964 0.047-0.061
Standard fitting P 40.018-40.025 39.964-39.971 0.047-0.061 1st oversize fitting M1 40.197-40.204 40.143-40.15 0.047-0.061 1st oversize fitting N1 40.204-40.211 40.15-40.157 0.047-0.061 1st oversize fitting O1 40.211-40.218 40.157-40.164 0.047-0.061 1st oversize fitting P1 40.218-40.225 40.164-40.171 0.047-0.061
2nd oversize fitting M2 40.397-40.404 40.343-40.35 0.047-0.061 2nd oversize fitting N2 40.404-40.411 40.35-40.357 0.047-0.061 2nd oversize fitting O2 40.411-40.418 40.357-40.364 0.047-0.061 2nd oversize fitting P2 40.418-40.425 40.364-40.371 0.047-0.061
Piston rings
SEALING RINGS
Name
Description Dimensions Initials Quantity
Compression ring 40 A 0.10 to 0.25
Compression ring 1st
oversize
40.2 A 0.10 to 0.25
Compression ring 2nd
Oversize
40.4 A 0.10 to 0.25
DNA 50 Characteristics
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Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD
Name Description 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+0.040 C clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
Flywheel-side half-shaft 13.75+0.040 D clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
Lining between the
shoulders
40.64 H clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
Cage 11.800-0.35 B clearance F = 0.20 to
0.75
Slot packing system
- Fit the cylinder without installing the basic gasket.
- Apply a centimetre dial gauge on the special tool and zero it on the ground plane
- Fit the tool to the top of the cylinder fixing it with two nuts to the studbolts and take the piston to the T.D.C.
- The thickness of the gasket to fit will change depending on the value detected. For this purpose, there are three with different thicknesses
Specific tooling
Characteristics DNA 50
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020272Y Piston position check tool
SLOT PACKING SYSTEM
Name Measure A Thickness
Shimming 2.80 ÷ 3.04 0,4 Shimming 3.04 ÷ 3.24 0,6
Spacing 3,24÷3,48 0,8
Products
TABLE OF RECOMMENDED PRODUCTS
Product
Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions
(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-
creased adhesiveness
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing
NLGI 2 Molybdenum disulphide; ISO-L-
XBCHB2, DIN KF2K-20
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
MONTBLANC MOLYBDENUM
GREASE
Grease for driven pulley shaft adjusting ring and movable driven pulley housing
Grease with molybdenum disulphide
AGIP GREASE PV2 Grease for the steering bearings, pin
seats and swinging arm
White anhydrous-calcium based grease
to protect roller bearings; temperature
range between -20 C and +120 C; NLGI
2; ISO-L-XBCIB2.
AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
DNA 50 Characteristics
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INDEX OF TOPICS
TOOLING TOOL
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TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54 mm bearing
001467Y009 Driver for OD 42-mm bearings
001467Y013 Pliers to extract ø 15-mm bearings
001467Y014 Pliers to extract ø 15-mm bearings
DNA 50 Tooling
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Stores code Description
001467Y017 Bell for bearings, OD 39 mm
001467Y021 Extraction pliers for ø 11 mm bearings
002465Y Pliers for circlips
006029Y Punch for fitting fifth wheel seat on steer-
ing tube
020004Y Punch for removing fifth wheels from
headstock
020209Y Spring hook
Tooling DNA 50
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Stores code Description
020055Y Wrench for steering tube ring nut
020074Y Support base for checking crankshaft
alignment
020150Y Air heater support
020151Y Air heater
020162Y Flywheel extractor
020163Y Crankcase splitting plate
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Stores code Description
020164Y Driven pulley assembly sheath
020165Y Start-up crown lock
020166Y Pin lock fitting tool
020167Y Arrest key for impeller pump
020168Y Water seal punch mount on half-crank-
case
020169Y Water pump crankshaft fitting and remov-
al spanner
Tooling DNA 50
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Stores code Description
020170Y Water pump/mixer command gear ex-
tractor
020261Y Starter spring fitting
020262Y Crankcase splitting strip
020265Y Bearing fitting base
020325Y Brake-shoe spring calliper
020329Y MityVac vacuum-operated pump
DNA 50 Tooling
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Stores code Description
020330Y Stroboscopic light to check timing
020331Y Digital multimeter
020332Y Digital rev counter
020334Y Multiple battery charger
Tooling DNA 50
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Stores code Description
020335Y Magnetic support for dial gauge
020350Y Electrical system check instrument
020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor
020376Y Adaptor handle
020412Y 15 mm guide
DNA 50 Tooling
TOOL - 23
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Stores code Description
020456Y Ø 24 mm adaptor
020483Y 30 mm guide
020565Y Flywheel lock calliper spanner
Tooling DNA 50
TOOL - 24
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INDEX OF TOPICS
MAINTENANCE MAIN
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Maintenance chart
EVERY 2 YEARS
Action
Brake fluid - change Coolant - change
AT 1000 KM OR 4 MONTHS
50'
Action
Hub oil - change Oil mixer/throttle linkage - adjustment Steering - adjustment Brake control levers - greasing Coolant level - check Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test
AT 5000 KM OR 12 MONTHS, 25000 KM, 35000 KM AND 55000 KM
40'
Action
Hub oil level - check Spark plug/electrode gap - replacement Air filter - clean Oil mixer/throttle linkage - adjustment Coolant level - check Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test
AT 10000 KM OR 24 MONTHS AND 50000 KM
95'
Action
Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idle speed (*) - adjustment Oil mixer/throttle linkage - adjustment Variable speed rollers - replacement Driving belt - checking Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test
(*) see the section "Idle adjustment"
Maintenance DNA 50
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AT 15000 KM AND 45000 KM
65'
Action
Hub oil level - check Spark plug/electrode gap - replacement Air filter - cleaning Oil mixer/throttle linkage - adjustment Driving belt - replacement Coolant level - check Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check SAS box (sponge) (**) - cleaning Vehicle and brake test - road test
(**) See the regulations of the "Secondary air system" section
AT 20000 KM AND 40000 KM
120'
Action
Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idling speed (*) - adjustment Cylinder cooling system - check/cleaning Oil mixer/throttle linkage - adjustment Driving belt - checking Variable speed rollers - replacement Mixer belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test
(*) See the section "Idle adjustment"
AT 30000 KM
130'
Action
Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idling speed (*) - adjustment Oil mixer/throttle linkage - adjustment Driving belt - replacement Variable speed rollers - replacement Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Flexible brake tubes - replacement Brake fluid level - check Transmission elements - lubrication
DNA 50 Maintenance
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Action
Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check SAS box (sponge) (**) - cleaning Vehicle and brake test - road test
(**) See the regulations of the "Secondary air system" section
AT 60000 KM
160'
Action
Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idling speed (*) - adjustment Oil mixer/throttle linkage - adjustment Driving belt - replacement Variable speed rollers - replacement Mixer belt - replacement Coolant level - check Radiator - external cleaning/ check Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Flexible brake tubes - replacement Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check SAS box (sponge) (**) - cleaning Vehicle and brake test - road test
(**) See the regulations of the "Secondary air system" section
Checking the spark advance
- Check to be effected at 4000 rpm with strobo­scopic gun. The measured lead must be 17° be­fore dead centre point.
- The rubber cap shown in the figure needs to be removed before this check; this makes it possible to see a reference mark in the magneto cover
N.B. IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS
PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER. CAUTION BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK
THE CORRECT KEYING OF THE FLYWHEEL ON THE CRANKSHAFT.
Specific tooling
020330Y Stroboscopic light to check timing
Maintenance DNA 50
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Page 29
Spark plug
-Put the vehicle on its centre stand;
-Disconnect the cap of the spark plug HV lead;
-Unscrew the spark plug using a pipe spanner;
-Examine the conditions of the spark plug, make sure its isolation is not damaged, measure the distance between the electrodes using the specific feeler gauge.
-Adjust the distance if necessary carefully bending the side electrode. If the spark plug is defective replace it with the prescribed type;
- Insert the spark plug with the correct inclination, screw it down by hand, then lock with a spanner to the prescribed torque;
-Put the cap tightly back on the spark plug;
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5000 KM. USE OF STARTERS NOT CONFORMING OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Electrode gap
0.6 ÷ 0.7 mm
Spark plug
CHAMPION RN1C
Locking torques (N*m)
Spark plug 25 - 30 Nm
Hub oil
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Page 30
Check
To check the hub oil level, proceed as follows:
1. Place the scooter on its stand on a level sur­face;
2. Unscrew the dipstick «A», dry it with a clean rag and then reinsert it, screwing it tightly into place;
3. Unscrew the dipstick again and check that the oil level barely reaches the 2nd notch from the bottom;
4. Screw the dipstick back into place complete­ly.
The screw «B» is the hub oil drainage tap.
CAUTION
USING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH THE WRONG LUBRICANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY CAUSE SERIOUS DAMAGE.
CAUTION
USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOR OIL REPLACEMENT, CONTACT AN AUTHORISED SERVICE CENTRE, WHICH IS EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY.
N.B. THE NOTCHES ON THE HUB OIL LEVEL DIPSTICK, EX-
CEPT THOSE INDICATING THE MAXIMUM AND MINIMUM LEVELS, REFER TO OTHER MODELS BY THE MANUFAC­TURER, AND HAVE NO SPECIFIC FUNCTION FOR THIS MODEL.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Characteristic
Rear hub oil
Quantity: approx. 85 cc
Maintenance DNA 50
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Page 31
Replacement
- Remove oil filler cap «A».
- Loosen oil draining cap «B» and allow for the system to drain completely.
- Refit the draining cap and refill the hub with the prescribed oil.
Characteristic
Rear hub oil
~ 85 cc
Air filter
-Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter. Cleaning:
-Wash with water and neutral soap.
- Dry with a clean cloth and short blasts of com­pressed air.
-Saturate with a 50% mixture of gasoline and oil.
-Drip dry the filter and then squeeze it between the hands without wringing.
-Let it dry and refit it again.
CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.
Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased ad­hesiveness
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transmissions
During this phase the engine must be fuelled with a 2% mixture (at least 0.5 litres if the tank is emp­ty). Remove the carburettor guard. Start the vehicle and adjust the idle using the adjusting screw A on the carburettor. Adjust the control wires: Handle control: remove the rubber cap and adjust the lead adjusting screw so that there is no play in the gas handle. Carburettor control: remove the rubber cap and adjust the lead adjusting screw so that there is no play in the shielding. Mixer control: remove the cap on the crankcase and adjust the adjusting screw so that when the gas handle is released the reference mark on the rotating plate is aligned with the reference mark on the mixer body as shown in the figure. Move the gas handle to the end of its stroke a few times and make sure the adjustments have been made correctly, then lock all the adjusting screws.
CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN
THE RESERVOIR BLEED THE MIXER AS FOLLOWS: RE­FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE MIXER PIPE FROM THE CARBURETTOR AND LOOSEN THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE) UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH THE RELEVANT METAL CLIP.
Recommended products
AGIP CITY TEC 2T Mixer oil
synthetic oil for 2-stroke engines: JASO FC, ISO­L-EGD
Maintenance DNA 50
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Page 33
Braking system
Level check
Proceed as follows:
- Rest the vehicle on its centre stand with the han­dlebars perfectly horizontal;
- Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the pads.
Top-up
Proceed as follows:
- Remove the tank cap by loosening the two screws, remove the gasket and top up using only the liquid specified without exceeding the maxi­mum level.
CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL 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, IT ABSORBS MOISTURE FROM
DNA 50 Maintenance
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THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEF­FICIENT. NEVER USE BRAKE LIQUID IN OPEN OR PAR­TIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS.
N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO
THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Headlight adjustment
Proceed as follows:
1. Place the vehicle in running order and with the
tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;
2. Turn on the headlight and check that the bor-
derline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and high­er than 7/10;
3. If otherwise, adjust the right headlight with screw
«A».
N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI­MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU­TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.
Maintenance DNA 50
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INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Page 36
This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given.
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Defective fuel pump or damaged depression line Replace the pump or control lines
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Fuel filter on the tank outlet fitting dirty or clogged Clean the fitting filter
Excess of encrustations in the combustion chamber Remove the encrustations
Lack of compression wear of the piston rings or cylinder Check the worn parts and replace them
Exhaust pipe clogged due to excessive encrustations Replace the exhaust pipe and check the carburation and mixer
timer
Air filter blocked or dirty Clean according to the procedure
Starter inefficient (stays on) Check the mechanical sliding, continuity of the circuit, the pres-
ence of power and electrical wiring
Clutch slipping Check the centrifugal brake shoe assembly and /or clutch bell
and replace if necessary
Defective mobile pulley sliding Check the parts, change the faulty parts and lubricate the driv-
en pulley using only Montblanc-Molibdenum Grease (dis.
498345) grease
Transmission belt worn Replace
Roller wear; Presence of oil; Dirt Clean the speed variator, replace the rollers if worn out
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 and replace it if it is damaged
Starting difficulties
DIFFICULTY STARTING
Possible Cause
Operation
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Defective fuel pump or damaged depression line Replace the pump or control lines
Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Battery flat Check the state of the battery. If it shows signs of sulphation
replace it and bring the new battery into service charging it for
eight hours at a current of 1/10 of the capacity of the battery
itself
- Engine flooded. Start up keeping the throttle fully open alternating approximate­ly five seconds of turning it with five seconds still. If however it does not start, remove the spark plug, the engine over with the
throttle open being careful to keep the cap in contact with the
spark plug and the spark plug grounded but away from its hole.
Refit a dry spark plug and start the vehicle.
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Defective spark plug or with incorrect electrode gap Remove the encrustation, restore the plug gap or replace being
sure to use the types of spark plug recommended at all times.
Troubleshooting DNA 50
TROUBL - 36
Page 37
Possible Cause Operation
Bear in mind that many problems engines have, derive from
the use of the wrong spark plug
Intake joint cracked or with a bad seal Replace the intake joint and check its tightness on the crank-
case and on the carburettor
Purifier-carburettor fitting damaged Replace
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST
Possible Cause Operation
Excess of encrustations in the combustion chamber Remove the encrustations
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE
Possible Cause Operation
Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air
Dirty carburettor Wash the carburettor with solvent and dry with compressed air
Water 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
valve
Tank breather hole obstructed Restore the proper tank aeration
Engine tends to cut-off at idle
ENGINE STOP IDLING
Possible Cause
Operation
Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air
Starter that stays open Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Reed valve does not close Check / replace the reed pack
Wrong idling adjustment Correctly adjust the engine idling and check the level of the
C.O.
Spark plug defective or faulty Replace the spark plug with one with the specified degree and
check the plug gap
Excessive exhaust noise
INCREASED NOISINESS
Possible Cause
Operation
Secondary metal air pipe deteriorated Check the seal of the piping on the crankcase and on the hous-
ing, check the piping between the housing and the muffler.
Good condition of the missing secondary air circuit components Check the individual components and the piping, check the
precision of the fitting. Replace the damaged components
High fuel consumption
HIGH FUEL CONSUMPTION
Possible Cause
Operation
Air filter blocked or dirty. Clean according to the procedure
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Page 38
Possible Cause Operation
Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Engine overheating
ENGINE OVERHEATING
Possible Cause Operation
Lack of liquid in the cooling circuit. Restore the level and check the absence of losses from the
circuit
Incorrect air bleeding Repeat the operation
Thermostat remains closed Replace
Liquid leak from the radiator Replace radiator
Liquid leak from the system Overhaul of the system
Bearings shaft support impeller blocked Replace the bearings and the shaft with impeller
Breakage of mixer belt Replace the belt and check that the thermal unit has not been
damaged
SAS malfunctions
SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-
FLER
Possible Cause
Operation
Secondary air reed blocking Replace Secondary air filter clogging Clean the filter and the housing
Blockage of the secondary air fitting on the muffler Remove the encrustations from the joint being careful not to let
the debris fall into the muffler
Transmission and brakes
Clutch grabbing or performing inadequately
CLUTCH
Possible Cause
Operation
Tear or irregular functioning
Check that the masses open and return normally
Check that there is no grease on the masses Check that the clutch masses' contact surface with the clutch bell is mainly in the middle with charac-
teristics equivalent on the three masses
Check that the clutch bell is not scored or worn
abnormally
Never operate the engine without the clutch bell
Insufficient braking
INSUFFICIENT BRAKING
Possible Cause
Operation
Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Troubleshooting DNA 50
TROUBL - 38
Page 39
Possible Cause Operation
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Brakes overheating
OVERHEATING BRAKES
Possible Cause Operation
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Defective piston sliding Check calliper and replace any damaged part.
Electrical system
Battery
BATTERY
Possible Cause Operation
Battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery
needs to be recharged periodically. The battery runs down completely in the course of 5 ÷ 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keep-
ing in mind that the black ground wire is connected to the negative terminal while the red wire 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
POOR ROAD HOLDING
Possible Cause
Operation
Faulty suspension Check that the rear shock absorber and/or the front fork is/are
in good working order. Replace or overhaul the front fork and/
or replace the rear shock absorbers in case of malfunction
Tyres deflated or damaged Check the correct pressure of the tyres and the condition of the
tread. Inflate to the correct pressure or replace.
Loosen the anchorage points of the front and/or rear suspen-
sion unit.
Check the tightness between the frame, swinging arm and en-
gine and the fixing of the wheels to the hub and/or the axle.
Check the correct tightening of the steering ring nut.
Heavy steering
STEERING HARDENING
Possible Cause
Operation
Torque not conforming
Check the tightening of the top and bottom ring
nuts.
If irregularities continue in turning the steering
even after making the above adjustments, check
DNA 50 Troubleshooting
TROUBL - 39
Page 40
Possible Cause Operation
the seats in which the ball bearings rotate: replace
if they are recessed.
Excessive steering play
EXCESSIVE STEERING CLEARANCE
Possible Cause Operation
EXCESSIVE STEERING CLEARANCE
Check the tightening of the top and bottom ring
nuts.
If irregularities continue in turning the steering
even after making the above adjustments, check
the seats in which the ball bearings rotate: replace
if they are recessed.
Noisy suspension
NOISY SUSPENSION
Possible Cause Operation
Components of the front suspension damaged. Check the quiet operation in the compression or release pha-
ses of the fork and if necessary overhaul it. Check that there is no noise or seizing during the wheel rotation; if there is, change
the wheel bearing.
Components of the rear suspension damaged. Check the absence of noise in the compression or release of
the suspension, if necessary check the proper tightness to the swinging arm unit and the absence of rust or replace the entire shock absorber. Check that there is no noise or seizing during the wheel rotation; if there is noise or seizing overhaul the final
reduction assembly.
Suspension oil leakage
SUSPENSION LEAKS OIL
Possible Cause
Operation
Rear shock absorption malfunctioning Replace the complete shock absorption unit
Hydraulic cartridge in the fork damaged. Replace the hydraulic cartridge
Troubleshooting DNA 50
TROUBL - 40
Page 41
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS
Page 42
1. Electronic ignition device
2. Spark plug
3. Flywheel magneto
4. Voltage regulator
5. Main 7.5 A fuse
6. Key-switch
7. Battery
8. Starter motor
9. Starter relay
10. Starter button
11. Stoplight switch on rear brake
12. Stoplight switch on front brake
13. Turn signal switch
14. Low-oil warning light sender
15. Automatic choke
16. Thermal switch
17. Antitheft LED pre-wiring
18. Antitheft box pre-wiring
19. Phonic wheel encoder
20. Fuel level sender
Electrical system DNA 50
ELE SYS - 42
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21. Blinker switch
22. Headlight switch
23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight
24. Headlight A. Turn signal light bulb B. Low-beam light bulb C. High-beam light bulb
25. Horn button
26. Horn
27. Dashboard assy. A. Low-oil warning light B. Dashboard light bulbs
Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black, Ro = Pink, Rs = Red, Ve = Green, Vi = Purple
Conceptual diagrams
DNA 50 Electrical system
ELE SYS - 43
Page 44
Ignition
1. Electronic ignition device
2. Sparkplug
3. Magneto
6. Key switch
Electrical system DNA 50
ELE SYS - 44
Page 45
Headlights and automatic starter section
3. Flywheel magneto
4. Voltage regulator
5. Main 7.5 A fuse
6. Key-switch
7. Battery
15. Automatic choke
21. Blinker switch
22. Headlight switch
23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight
24. Headlight A. Turn signal light bulb B. Low-beam light bulb C. High-beam light bulb
27. Dashboard assy. A. Low-oil warning light
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ELE SYS - 45
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B. Dashboard light bulbs
Battery recharge and starting
3. Flywheel magneto
4. Voltage regulator
5. Main 7.5 A fuse
6. Key-switch
7. Battery
8. Starter motor
9. Starter relay
10. Starter button
11. Stoplight switch on rear brake
12. Stoplight switch on front brake
14. Low-oil warning light sender
23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight
27. Dashboard assy. A. Low-oil warning light
Electrical system DNA 50
ELE SYS - 46
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B. Dashboard light bulbs
Level indicators and enable signals section
3. Flywheel magneto
4. Voltage regulator
5. Main 7.5 A fuse
6. Key-switch
7. Battery
14. Low-oil warning light sender
16. Thermal switch
19. Phonic wheel encoder
20. Fuel level sender
27. Dashboard assy. A. Low-oil warning light B. Dashboard light bulbs
DNA 50 Electrical system
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Turn signal lights
3. Flywheel magneto
4. Voltage regulator
5. Main 7.5 A fuse
6. Key-switch
7. Battery
13. Turn signal switch
23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight
24. Headlight A. Turn signal light bulb B. Low-beam light bulb C. High-beam light bulb
25. Horn button
26. Horn
27. Dashboard assy. A. Low-oil warning light
Electrical system DNA 50
ELE SYS - 48
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B. Dashboard light bulbs
Digital instrument panel
INSTRUMENT UNIT CONNECTOR
1. Rpm signal
2. Fuel signal
3. Water temperature signal
4. Spare
5. Earth
6. Phonic wheel signal
7. Oil level
8. Parking lights
9. Oil check
10. Phonic wheel supply
11. Under key positive
12. Battery positive
13. Phonic wheel earth
14. Left turn indicator
15. Right turn indicator
16. High beam lamp
INSTRUMENT PANEL
DNA 50 Electrical system
ELE SYS - 49
Page 50
1. Rpm counter
2. Fuel warning lamp
3. Oil mix warning lamp
4. Parking light lamp
5. High beam lamp
6. Turn indicator lamp
7. Temperature indicator
8. Fuel level indicator
9. Speedometer
10. Odometer
11. Digital display buttons
Checks and inspections
Checks to be made in the case of ignition irregularities and/or no spark on the spark plug
1. Check the condition of the spark plug (clean it with a metal brush, remove the encrustations, blast it with compressed air and, if necessary, replace it).
2. Without removing the stator, carry out the following checks:
CHECK ON THE PICK UP
Specification
Desc./Quantity
1 Red and white cable 90±140 ohm
After visually checking the electrical wiring, perform measurements on the loading reel, the pickup (see chart) and the continuity using the appropriate tester. If checks on the loading reel, pickup and continuity show abnormalities, replace the stator; otherwise replace the central unit. Remember that disconnections due to replacement of the central unit must be done with the engine off.
Specific tooling
020331Y Digital multimeter
Electrical system DNA 50
ELE SYS - 50
Page 51
CHECKING THE RECHARGE COIL
Specification Desc./Quantity
1 Yellow/Red cable 800±1100 ohm
CHECK CONTINUITY
Specification Desc./Quantity
1 White cable-frame continuity 2 White cable-engine continuity
Ignition circuit
All the control operations of the system that require the disconnection of cables (checks of the con­nections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irreparably dam­aged.
Stator check
- Using a tester, check the resistance between the red-ground and green-ground terminal.
N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERA­TURE LEADS TO VALUES HIGHER THAN THOSE STATED.
Electric characteristic
Stator : green - ground
~ 1 (Stator)
Pick-Up: red - ground
approx. 170 (Pick-Up)
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Voltage regulator check
The malfunctioning of the voltage regulator might cause the following problems depending on the type of fault:
1. The lighting system bulbs burn out.
2. The lighting system bulbs stop working.
3. The battery overcharges (the main fuse blows).
4. Non-recharging of the battery.
5. Non functioning of the turn indicators.
Operations FAULT 1
Replace the regulator because it is definitely faul­ty.
FAULT 2
Make sure the bulbs work properly. With the vehicle running check for battery voltage on the yellow-black wire of the high beam/low beam switch. If there is no voltage make sure volt­age is coming correctly from the stator: without disconnecting the regulator connector and with the vehicle running, use a tester to measure the alter­nate voltages between the connection of the grey­blue wire and black wire make sure it is within the indicated values, if not replace the stator. If no irregularities occur during these checks re­place the regulator. If replacement of the regulator does not restore correct operation, carry out the checks of the elec­trical system.
Specific tooling
020331Y Digital multimeter
Characteristic
Voltage distributed at 3000 rpms
25 to 30V
FAULT 3
After checking that there are no short circuits in the system towards the earth, replace the regulator because it is certainly inefficient and replace it with a protective fuse. Following the replacement, measure the current and the recharging voltage on the battery end.
Electrical system DNA 50
ELE SYS - 52
Page 53
FAULT 4
Start the vehicle and make sure that when the tester is placed between the connection of the red wire and yellow one on the stator, the voltage de­livered by the generator is within the indicated value. In the event of a fault check the continuity of the stator or continue with the checks. Insert an ammeter between the stator (red wire) and the battery and use a tester to make sure that the current delivered at 3000 rpm and the battery maintained between 12 and 13 V is as indicated. If the measured values are lower than those pre­scribed, replace the regulator otherwise replace the battery.
N.B. BEFORE CARRYING OUT THE CHECKS ON THE REGU-
LATOR AND RELATIVE SYSTEM, IT IS ALWAYS GOOD PRACTICE TO CHECK THAT THERE IS CONTINUITY BE­TWEEN THE BLACK CABLE AND THE GROUND.
N.B. TO KEEP THE BATTERY BETWEEN 12 AND 13V, CAUSING
CURRENT ABSORPTION BY THE SYSTEM, A 12V - 35W BULB CONNECTED BETWEEN THE + BATTERY AND GROUND CAN BE USED.
Specific tooling
020331Y Digital multimeter
Characteristic
Distributed current
1.5 to 2A
Voltage distributed at 3000 rpms
25 to 30V
FAULT 5
If the turn indicators do not work, do the following:
Without removing the connector from the voltage regulator, move the key­controlled switch to ON and verify the presence of intermittent voltage be­tween contact 7 and the ground. If there is voltage, the failure must be at­tributed to the flashing indicator switch
DNA 50 Electrical system
ELE SYS - 53
Page 54
or the wiring, otherwise carry on with tests.
With the engine off, remove the regu­lator connector, and insert the ends of the tester between contact 5 and the ground.
Move the key controlled switch to ON and check there is battery voltage. If no voltage is detected, check the wiring and the contacts on the key switch and on the battery.
Repeat the same procedure with the ends of the tester inserted between contact 5 (+) and 6 (-) and check the presence of the battery voltage with the key switch at on. If this does not hap­pen, check the regulator's ground ca­ble.
If these last two tests have a positive result replace the regulator because it is certainly not functioning properly.
Specific tooling
020331Y Digital multimeter
Fuses
The electrics are protected by a fuse located on the right side next to the battery well. To replace it, remove the transparent protection mounted on the fuse holder. The ignition system, front headlight and rear taillight are not protected by fuses.
CAUTION
BEFORE REPLACING THE BLOWN FUSE, SEARCH AND ELIMINATE THE BREAKDOWN THAT HAS LED TO THE BLOW OUT. NEVER TRY TO REPLACE A FUSE USING DIF­FERENT MATERIAL (FOR EXAMPLE A PIECE OF ELECTRIC WIRE) OR A FUSE FOR A HIGH­ER AMPERAGE THAN THE INDICATED ONE.
Electric characteristic
Electrical system DNA 50
ELE SYS - 54
Page 55
Fuse
7.5 A
Sealed battery
Putting the watertight battery into operation
INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a normal tester.
- If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge 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 battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the 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 RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Dry-charge battery
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON­TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP­PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF REACH OF CHILDREN
Use of dry-cell batteries :
1. Having removed the short, closed tube and removed the caps, put into the elements sulphuric acid of the type for specific weight 1.26 accumulators corresponding to 30° Bé at a temperature of no less than 15°, until you reach the upper level.
DNA 50 Electrical system
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2. Leave to stand for at least 2 hours; afterwards top-up to the level with sulphuric acid.
3. Within twenty four hours, recharge with the special (single or multiple) battery charger that re­charges at an intensity the same as approximately 1/10 the rated capacity of the said battery. At the end of the charge, make sure that the density of the acid is around 1.27, corresponding to 31° Bé and that these values are stabilised.
4. Once the charge is over, level 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 that it is wired up properly..
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE
THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE­SPONDING LONG TUBE (WITH OPEN 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
1 Hold the vertical tube 2 Look at the level 3 The float must be freed
Battery maintenance
The battery is an electrical device which requires careful monitoring and diligent maintenance. The maintenance rules are:
1) Check the level of the electrolyte
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear.
2)Load status check
After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery.
Electrical system DNA 50
ELE SYS - 56
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The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the -negative clamp while the other two red wires marked (+) must be con­nected to the clamp marked with the +positive sign.
3) Recharging the battery
Remove the battery from the vehicle removing the negative clamp first. The normal bench charging must be carried out with the specific (single or multiple) battery charger, placing the battery charger selector on the type of battery to be recharged. The connections to the power supply must be made by connecting to the corresponding poles (+ with+ and -with -).
4) Battery cleaning
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 SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Specific tooling
020334Y Multiple battery charger 020333Y Single battery charger
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INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE
Page 59
Removal of the engine from the vehicle
1. Disassemble the complete muffler.
2. Disassemble the rear wheel.
3. Disassemble the carburettor casing using the
four screws.
4. Disassemble the air filter using the two set screws as shown in the figure.
5. Remove the three brake hose supports and dis­assemble the calliper using the 5 screws as shown in the photo.
6. Drain the cooling system by collecting the cool­ant in a container and disconnecting the related hose to the engine
7. Disconnect the electrical system connection from the magneto, choke, thermistor and starter.
8. Disconnect the accelerator and mixer control drives.
9. Disconnect the mixer oil, carburettor and vac­uum pump hoses on the carburettor.
10. Disconnect the HV lead from the spark plug.
11. Remove the rear shock absorber set bolt from
the engine.
12. Unscrew the nut on the right side, then remove the set pin for the engine-rocker arm from the left side.
Locking torques (N*m)
Engine-swinging arm bolt 33 ÷ 41 Shock absorb­er-engine pin 33 to 41 Nm Rear wheel axle nut 104
÷ 126
DNA 50 Engine from vehicle
ENG VE - 59
Page 60
Engine from vehicle DNA 50
ENG VE - 60
Page 61
INDEX OF TOPICS
ENGINE ENG
Page 62
questa sezione è in lavorazione
Automatic transmission
Transmission cover
- Unscrew the 14 screws and remove the trans­mission cover using a mallet.
N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT
FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.
Kickstart
- Upon refitting, apply the recommended grease to the bushing, to the spring and along the toothed sector.
- Use the special tool for the charging of the spring, as shown in the figure.
- Refit the seeger ring after checking that it is in good condition.
Specific tooling
020261Y Starter spring fitting
Recommended products
AGIP GREASE MU3 Grease for odometer transmission gear case
Soap-based lithium grease with NLGI 3; ISO-L­XBCHA3, DIN K3K-20
Engine DNA 50
ENG - 62
Page 63
- Remove the screws shown in the figure and re­move the engine starting lever.
- For the assembly, 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.
- Dismantle the dog gear from its seat, slackening the tension that the toothed sector applies to it by means of the spring; to do this, it is necessary to rotate the toothed sector slightly (see the figure).
CAUTION WHILE REMOVING THE TOOTHED SECTOR, BE VERY
CAREFUL OF THE SPRING TENSION: IT COULD CONSTI­TUTE A HAZARD FOR THE OPERATOR.
Removing the driven 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 CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-
AMETER EXTRACTOR CAN BE USED.
Refitting the driven pulley shaft bearing
-Refit the bearing with the aid of a bushing 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 PAINTED SURFACE.
DNA 50 Engine
ENG - 63
Page 64
Removing the driven pulley
- Lock the clutch bell housing with the specific tool.
- Remove the nut, the clutch bell housing and the whole of the driven pulley assembly.
N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE
PULLEY MOUNTED.
Specific tooling
020565Y Flywheel lock calliper spanner
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.
- Measure the inner diameter of the clutch bell.
Characteristic
Clutch bell diameter/standard value
Ø 107+0.2 +0 mm
Clutch bell diameter/max. value allowed after use
Ø 107.5 mm
Eccentricity measured /max.
0.20 mm
Removing the clutch
- Equip the tool with long pins screwed into position «A» from the outside, insert the entire driven pulley in the tool and put the central screw under stress.
CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW
IS TIGHTENED UP TOO FAR.
Engine DNA 50
ENG - 64
Page 65
- Using a 34 mm socket wrench remove the clutch locking nut.
- Loosen the central screw thereby undoing the driven pulley unit
- Separate the components.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch
Inspecting the clutch
- Check the thickness of the clutch mass friction material.
- 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 CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE AN­OTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.
CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
DNA 50 Engine
ENG - 65
Page 66
- Remove the three guide pins and the mobile half pulley.
Removing the driven half-pulley bearing
- Remove the roller bearing with the special ex­tractor inserted from the bottom of the fixed half­pulley.
CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI-
ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
Specific tooling
001467Y029 Bell for bearings, O.D. 38 mm
- Remove the 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 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 half­pulley..
- Make sure the bearings do not show signs of un­usual wear.
- Measure the external diameter of the pulley bush­ing.
Characteristic
Engine DNA 50
ENG - 66
Page 67
Stationary driven half-pulley/Standard diame­ter
Ø 33.965 to 33.985 mm
Stationary driven half-pulley / Minimum diam­eter admitted after use
Ø 33.96 mm
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two O­rings.
- Measure the inside diameter of the mobile half­pulley bushing.
Characteristic
Mobile driven half-pulley/ Maximum diameter allowed
Ø 34.08 mm
- Check the belt contact surfaces.
- Insert the new oil seal and O-rings on the mobile half-pulley.
- Fitting the half-pulley on the bushing.
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel revolving ring
Soap-based lithium grease containing NLGI 2 Mo­lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Use a greaser 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 NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
DNA 50 Engine
ENG - 67
Page 68
Refitting the driven half-pulley bearing
- Fit a new ball bearing with the specific tool.
- Fit the ball bearing retention snap ring.
- Fit the new roller bearing with the wording visible from the outside.
CAUTION PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT
DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED.
Specific tooling
020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 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 spring
Characteristic
Standard length
118 mm
Minimum length allowed after use
XXXX
Refitting the clutch
- Preassemble the driven pulley group with spring, sheath and clutch.
- Position the spring with the sheath
- Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded bar.
Engine DNA 50
ENG - 68
Page 69
- Reassemble the nut securing the clutch and tight­en to the prescribed torque.
CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK-
ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE
NUT IN CONTACT WITH THE CLUTCH
Locking torques (N*m)
Nut 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.
Characteristic
Transmission belt/Minimum width
17.5 mm
DNA 50 Engine
ENG - 69
Page 70
Removing the driving pulley
- Lock the driving pulley using the appropriate tool.
- Remove the central nut with the related washer, then remove the drive and the plastic fan.
- Remove the stationary half-pulley.
- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the
rollers and contrast plate fitted loosely on it do not come off.
Specific tooling
020451Y Starting ring gear lock
Mixer gears and belt
- Remove gear and belt.
CAUTION PAY PARTICULAR ATTENTION TO NOT TOUCHING OR
BENDING THE BELT BECAUSE THIS COULD BREAK SUD­DENLY 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 THE BELT EVERY 20000 KM.
Inspecting the rollers case
1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring 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.
Engine DNA 50
ENG - 70
Page 71
4) Check the integrity of the sliding blocks of the contact plate.
- Check that the internal bushing shown in the fig­ure is not abnormally worn and measure inside diameter «A».
- Measure outside diameter «B» of the pulley slid­ing bushing shown in the figure.
CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING.
Characteristic
Driving pulley / Maximum diameter:
20.12 mm
Driving pulley/ Standard diameter:
20.021 mm
Driving pulley bushing/ Diameter maximum:
XXX mm
Driving pulley bushing/ Standard diameter:
20 -0.020/-0.041mm
Refitting the driving pulley
- Manually move the movable 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 WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE.
- Refit the components of the assembly (roller con­tainer assembly with bushing, limiting washer, sta­tionary half-pulley, cooling fan belt with drive, washer and nut).
- With the specific tool, tighten the lock nut to 20 Nm and then perform a final 90° locking in order to prevent the rotation of the driving pulley.
N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT­MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN
DNA 50 Engine
ENG - 71
Page 72
ORDER TO AVOID WRONG TIGHTENING AND CONSE­QUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling
020451Y Starting ring gear lock
Locking torques (N*m)
Crankshaft pulley nut 18 to 20 + 90° Nm
End gear
Removing the hub cover
• Remove the transmission cover
• Remove the clutch assembly
• Discharge the rear hub oil.
• Remove the 5 screws indicated in the figure.
• Remove the hub cover with driven pulley shaft.
See also
Refitting the clutch
Removing the wheel axle
- Remove the intermediate gear and the complete gear wheel axle.
- When removing the intermediate gear pay atten­tion to the various shim adjustments.
Engine DNA 50
ENG - 72
Page 73
Removing the wheel axle bearings
- Remove the oil seal and the seeger ring.
- Remove the bearing by pushing from the outside towards the inside of the gear compartment, using the appropriate punch.
Specific tooling
020363Y 20 mm guide 020376Y Adaptor handle 020358Y 37x40-mm adaptor
Removing the driven pulley shaft bearing
- Remove the seeger ring inside the cover.
- Remove the oil seal from the outside.
- Remove the centring dowels and position the cover on a plane.
- Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press.
Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft
- Position the special tube on the internal raceway of the bearing and from the shaft toothed side as indicated in the figure. Expel the driven pulley shaft with the aid of a press.
Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft
DNA 50 Engine
ENG - 73
Page 74
Inspecting the hub shaft
- Check that the three shafts exhibit no wear or deformation on the toothed surfaces, at the bear­ing housings and at the oil guards.
- In case of anomalies, replace the damaged com­ponents.
- Check that the fitting surface is not dented or dis­torted.
- If faults are found, replace the hub cover.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.
- If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing
- Support the inner track of the bearing from the outside of the hub cover with the specific tool posi­tioned 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
• Heat the hub cover and insert the bearing with the specific punch.
• Fit the snap ring with the concave or radial part on the bearing side.
N.B. FIT THE BALL BEARING WITH THE SHIELD FACING THE
OIL SEAL.
Specific tooling
020151Y Air heater 020376Y Adaptor handle 020439Y 17 mm guide 020358Y 37x40-mm adaptor
Engine DNA 50
ENG - 74
Page 75
Refitting the wheel axle bearing
- Heat the half crankcase on the transmission side using a thermal gun.
- After lubricating its outer strip, insert the bearing with the special adapter with the aid of a hammer.
- Refit the seeger ring and the oil seal using the 42 x 47 mm adapter and the handle.
Specific tooling
020151Y Air heater 020376Y Adaptor handle 020363Y 20 mm guide 020359Y 42x47-mm adaptor
Refitting the ub cover
- Refit the whole wheel axle.
- Refit the intermediate gear paying attention to the two shim thicknesses.
- Apply LOCTITE 510 for surfaces to the hub cov­ers and refit the same with driven pulley shaft.
- Refit 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 PREVI­OUS GASKETS BEFORE APPLYING A NEW ONE.
Locking torques (N*m)
Locking torque: 11 to 13 Nm
Flywheel cover
DNA 50 Engine
ENG - 75
Page 76
Removing the stator
- Remove the three stator fixings shown in the photo
- Remove the two pick-up fixings shown in the photo
- Remove the stator with the wiring
Refitting the stator
- Refit the stator and flywheel proceeding in the inverse direction, tightening the studs to the pre­scribed torque.
THREAD THE CABLE OF THE STATOR INTO THE SPECIF­IC HOUSING OF THE CRANKCASE AND MAKE SURE THAT IT IS LOCKED BY THE TAB OF THE RETURN LINE OF THE COOLING SYSTEM.
Locking torques (N*m)
Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4
Refitting the flywheel cover
Fit the rubber seal on the flywheel con­nector and around the inlet coolant hose.
Engine DNA 50
ENG - 76
Page 77
Keeping the flywheel connector rubber clamp on the coolant inlet hose, refit the flywheel cover paying attention in inserting the strap in the groove.
Tighten the 4 studs, noting that the two longer golden screws are inserted in the 2 top holes and are also responsi­ble for restraining the secondary air­box.
Flywheel and starting
Removing the starter motor
• Remove the central stand by unscrewing the 3 set screws of the engine support
• Remove the set screws indicated in the figure
DNA 50 Engine
ENG - 77
Page 78
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
Inspecting the flywheel components
- Check the condition of the flywheel and any dis­tortions that might cause rubbing on the stator and on the Pick-Up.
Engine DNA 50
ENG - 78
Page 79
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key properly.
- Lock the flywheel nut at the prescribed torque
- Check the Pick-Up air gap.
- The air gap may not be modified in the fitting of the Pick-Up.
- Other values derive from deformations visible on the Pick-Up support.
N.B. A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO
A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING, KNOCKING ETC.
Locking torques (N*m)
Flywheel nut 40 to 44 N.m
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.
- Fit the starter on the crankcase, locking the two 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)
Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
Removing the intake manifold
Use an anti-tampering TORX spanner to remove the two clamping screws of the intake manifold
DNA 50 Engine
ENG - 79
Page 80
Removing the cylinder head
Remove the 4 screws shown in the figure
Removing the cylinder - piston assy.
Remove the cylinder very carefully
Remove the snap rings and remove the pin
CAUTION AFTER EACH REMOVAL OPERATION REPLACE THE PIN
RETENTION SNAP RINGS
Engine DNA 50
ENG - 80
Page 81
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 CRANK­SHAFT" CHAPTER".
Characteristic
Rod small end: standard diameter
17 +0.011-0.001
Rod small end: maximum allowable diameter
17,060 mm
Inspecting the wrist pin
- Check the wrist pin external diameter using a mi­crometer
Characteristic
Wrist pin: standard diameter
12 +0.005 +0.001 mm
Inspecting the piston
- Measure the bearings on the piston using a bore meter
- Calculate 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
DNA 50 Engine
ENG - 81
Page 82
- Measure the outer diameter of the piston, per­pendicular to the pin axis.
- Take the measurement in the position shown in the figure To classify the cylinder-piston fitting, check the ap­propriate table
See also
Cylinder - piston assy.
Inspecting the cylinder
- Check that the cylinder does not show seizures. Otherwise, replace it or adjust it respecting the al­lowable increases
- Measure the internal diameter of the cylinder with a bore meter, according to the directions given in the figure
- Check that the fitting surface with the head is not dented or distorted. To classify the cylinder-piston fitting, check the ap­propriate table
See also
Cylinder - piston assy.
Inspecting the piston rings
- Alternatively insert the two sealing rings in the cylinder Using the piston, insert the seals 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 prescri­bed in the chart, substitute the rings
Engine DNA 50
ENG - 82
Page 83
Removing the piston
- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.
-Push detail 2 into detail 1 until the stop and extract detail 2.
- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3 all the way in.
N.B.
REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM THE REMOVAL OPERATIONS
Specific tooling
020166Y Pin lock fitting tool
Locking torques (N*m)
Locking head nuts: 10 to 11 N·m
- Use new wrist pin snap rings.
- Use new cylinder base gasket.
- Before refitting carefully clean all the surfaces.
- Use oil to 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 PISTON WITH THE SPECIFIC TOOL
Recommended products
AGIP CITY TEC 2T Oil
Recommended oil
DNA 50 Engine
ENG - 83
Page 84
Inspecting the timing system components
CAUTION CHECK THE CORRECT REED UNIT SEAL; NO LIGHT
MUST PASS BETWEEN THE SUPPORT AND LAMELLA.
Crankcase - crankshaft
Splitting the crankcase halves
Remove the eight crankcase union fasteners.
Engine DNA 50
ENG - 84
Page 85
Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side
Specific tooling
020163Y Crankcase splitting plate
Removing the crankshaft
- Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length.
- Remove the crankshaft from the transmission side half crankcase
Specific tooling
020163Y Crankcase splitting plate
Removing the crankshaft bearings
The bearings can stay on either the half crankcase 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 mal­let blows.
Specific tooling
004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring 004499Y002 Bearing extractor screw 004499Y007 Half rings
DNA 50 Engine
ENG - 85
Page 86
- Using the specific tool remove any bearings left on the half crankcase
Specific tooling
001467Y007 Driver for OD 54 mm bearing 001467Y006 Pliers to extract 20 mm bearings
Refitting the crankshaft bearings
Heat the bearings in an oil bath at around 150°C and fit them on the crankshaft, if necessary using a section of tube that acts on the bearing's inner track
Specific tooling
020265Y Bearing fitting base
Inspecting the crankshaft alignment
With the specific tool shown check that the eccen­tricity of the surfaces of diam. «A»-«B»-« C» are within 0.03 mm. (reading limit on the dial 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 acting on the counterweights with a shim or tighten them
Engine DNA 50
ENG - 86
Page 87
in a clamp (with an aluminium bushing) as re­quired..
Specific tooling
020335Y Magnetic support for dial gauge 020074Y Support base for checking crankshaft
alignment
Refitting the crankshaft
- Position the transmission side half crankcase on two wooden supports
- Using a thermal gun, heat the bearing seat to about 120°
- Firmly insert the crankshaft until the bearing rea­ches the end-of-stroke stop
- Let the temperature of the half crankcase settle at the temperature of the crankshaft.
- Again install the special crankcase separation plate NOT installing the crankshaft protection
- During the assembly phase keep the central thrust screw loose.
- Take the four clamping screws to the end of the
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 tooling
DNA 50 Engine
ENG - 87
Page 88
020163Y Crankcase splitting plate
Refitting the crankcase halves
- Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the sur­face using a suitable solvent (e.g. trichloroethy­lene)
- Heat the flywheel-side half crankcase with a ther­mal gun.
Recommended products
Loctite 510 Liquid sealant
Gasket
- Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement
- Insert at least three clamping screws and tighten up rapidly
- Insert the other 5 screws and tighten them to the specified torque.
Locking torques (N*m)
crankcase coupling screws 11 - 13
- Move the crankcase separation plate in a position 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 maximum limit allowed, re­peat the crankcase coupling procedure
Specific tooling
Engine DNA 50
ENG - 88
Page 89
020335Y Magnetic support for dial gauge
Characteristic
Axial clearance with warm crankcase
0.10 ÷ 0.12 mm
Axial clearance with cold crankcase
0.06 to 0.08 mm
Limit value with cold crankcase
0.02 ÷ 0.03 mm
Lubrication
Crankshaft oil seals
Refitting
- Install a new flywheel-side oil seal only with the special tool's punch The flywheel-side oil seal is recognised by its smaller diameter
N.B.
THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE WITH THE 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 seal is recognised by the larger diameter
Specific tooling
020340Y Flywheel and transmission oil seals fitting punch
Oil pump
DNA 50 Engine
ENG - 89
Page 90
Removal
- Remove the 2 screws shown in the figure
Remove the tube passage seal from the crank­case shown in the figure
Refitting
To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure
Engine DNA 50
ENG - 90
Page 91
Fuel supply
The vehicle comes with a membrane pump con­trolled by the depression that is generated in the intake manifold. Therefore, the tank has an intake in the lowest point that sends the fuel to the pump and from here to the carburettor. To determine the correct functioning of the pump, the following measurements can be made on the amounts distributed:
1) Start up the engine, bring it to normal operating temperature and then shut it off.
2) Disconnect the fuel adduction line on the car­burettor and insert it into a graduated tube.
3) Start up the engine without the accelerator and keep it idle.
4) After the engine is started, count to 10 and then turn it off.
5) Check that the quantity of fuel is not less than the prescribed value.
Characteristic
Fuel distributed
~100cc X 10"
DNA 50 Engine
ENG - 91
Page 92
INDEX OF TOPICS
SUSPENSIONS SUSP
Page 93
Sospensioni anteriore
This section is devoted to operations that can be carried out on the suspension.
Front
Removing the front wheel
- Loosen the wheel axle set screws A
- Unscrew and extract the wheel axle B
Refitting the front wheel
- When reassembling be careful of the correct po­sitioning of the odometer movement socket.
Locking torques (N*m)
Front wheel axle 45 ÷ 50 Wheel axle clamp screw 6 ÷ 7 Nm
Handlebar
DNA 50 Suspensions
SUSP - 93
Page 94
Removal
- Remove the drives and disconnect the electrical terminals.
- Remove the bracket using the four screws.
Front fork
Removal
Pump unit disassembly
- Disassemble the front brake calliper using the two screws.
- Remove the front wheel.
- Remove the front bumper
- Loosen the four set screws of the fork leg to the plates and front cover indicated in the photo in or­der to be able to remove the pump unit from below. During disassembly be careful to support the cover only with the brackets anchored to the fork leg.
Suspensions DNA 50
SUSP - 94
Page 95
Disassembling the complete fork
- Remove the front wheel.
- Remove the front brake calliper. Take out the brake hose and the speedometer lead from the support bracket anchored on the lower plate.
- Remove the handlebar support bracket and bring the handlebar forward without disconnecting the drives.
- Loosen the four front cover support screws on the fork legs.
- Loosen the two pump unit set screws on the up­per plate, remove ring nut A and pull out the upper plate.
- Remove ring nut B, extract the rubber protection and the washer.
- Remove the complete fork from the bottom being careful to support the cover only with the brackets anchored to the fork legs.
- Use the extractor to remove the bearing from the seat in the chassis.
- Remove the roller bearing and sealing ring of the lower plate
See also
Front
brake calliper
Handlebar
DNA 50 Suspensions
SUSP - 95
Page 96
Refitting
For the assembly proceed in the opposite order of the disassembly making sure to lubricate the seats and bearing with recommended grease.
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 to protect roller bearings; temperature range between -20 °C and +120 °C; NLGI 2; ISO-L-XBCIB2
Locking torques (N*m)
Locking torque: 50 to 60 Nm
Removing the rear wheel
- Use a screwdriver as a lever between the drum and the cover.
-Straighten the split pin and remove the cap.
-Remove the wheel acting on the central fixing point.
WARNING
-ALWAYS USE NEW SPLIT PINS FOR REFITTING.
Shock absorbers
Removal
To replace the shock absorber you just need to remove the battery access flap to get and remove the shock absorber/ frame anchorage nut. Then remove the shock absorber/engine anchorage nut.
Suspensions DNA 50
SUSP - 96
Page 97
Refitting
When refitting, tighten the shock absorber/frame anchorage nut and the shock absorber/engine pin at the prescribed torque.
Locking torques (N*m)
Shock absorber/frame nut torque 20 to 25 Nm Shock absorber/engine pin torque 33 to 41 N·m
Centre-stand
Extracting the pin securing the stand to the bracket
- Remove the stand support bracket from the en­gine.
- Drill a 5 mm hole in the bracket so that the pin «P» can come out.
Assembly and caulking stand pin to the bracket
- Caulk 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 ATTACHMENTS AND THE PIN.
Replacing the complete stand
DNA 50 Suspensions
SUSP - 97
Page 98
- Work on the screws shown in the figure.
- When refitting, secure to the prescribed torque.
Locking torques (N*m)
Stand screw torque 18.5 to 19 Nm
Suspensions DNA 50
SUSP - 98
Page 99
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS
Page 100
questa sezione è in lavorazione
Front brake calliper
Removal
Check that the brake piping, gasket and fitting are in good condition. If you see any oil on the brake calliper and/on the components of the system, it is necessary to replace them.
- Disconnect the oil line from the cal­liper, collecting the oil in a container.
- Remove the two clamps highlighted in the diagram.
Overhaul
Proceed as follows:
1) remove the two male hexagonal screws (1) and take out the two pads (10);
2) remove the two male hexagonal screws (2) and remove the reaction plate (3);
3) take out the fixed plate (4) from the guide;
4) remove the internal elements from the floating body (5) with the help of short blows of com­pressed air through the brake fluid pipe in order to facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in good condition;
- that the cylinder and the floating body of the cal­liper do not show signs of scratches or erosion, otherwise replace the entire calliper;
- that the guides of the fixed plate are not scratched or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.
Reassembly
Braking system DNA 50
BRAK SYS - 100
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