MANUALE STAZIONE DI SERVIZIO
667270 - 667275 (IT-EN-FR-DE-ES-EL)
APE TM Benzina
MANUALE
STAZIONE DI
SERVIZIO
APE TM Benzina
© Copyright 2012 - PIAGGIO & C. S.p.A. Pontedera.
All rights reserved. No part of this publication may be reproduced.
This publication has been edited by:
After sales - PIAGGIO & C. S.p.A.
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
ITALY
www.piaggio.com
MANUALE STAZIONE DI
SERVIZIO
APE TM Benzina
WORKSHOP MANUAL
This workshop manual has been drawn up by PIAGGIO & C. Spa to be used by the workshops of Piaggio
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.
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 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.
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. Refers to
specific procedures to carry out for preventing damages to the vehicle. Refers to specific procedures to
carry out for preventing damages to the vehicle. 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.
INDEX OF TOPICS
GENERAL GUIDELINES GEN
CHARACTERISTICS CH
SPECIAL TOOLS ST
MAINTENANCE MA
EMISSION CONTROLO SYSTEM CO EM
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ES
ENGINE FROM VEHICLE EV
ENGINE EN
GEAR-BOX GE
DIFFERENTIAL DI
BRAKING SYSTEM BS
STEERING COLUMN SC
SUSPENSIONS SS
TIPPER VERSION VR
CHASSIS CH
PRE-DELIVERY PD
INDEX OF TOPICS
GENERAL GUIDELINES GEN
APE TM Benzina General guidelines
Maintenance guidelines
RULES TO BE FOLLOWED IN THE EVENT OF INTERVENTION ON THE ELECTRIC SYSTEM - APE
TM
A) ESSENTIAL WARNINGS
The check or in any case the intervention on the circuits of the devices for the electronic ignition can
be done with relative ease by the electronic repairers of Service Station Workshops; it is essential,
however, that they take observe the notices below, since, in case of failure to observe, they could
irreparably damage the devices.
All inspection operations of the system involving disconnection of cables (verification of the connections
and devices that are part of the ignition circuit, therefore including the main key switch) must be made
with the engine off: otherwise the control unit could be irreparably damaged.
The ignition circuit works on AC, and obviously,
must be definitely separated from that of DC
In fact the latter, powered by the battery and dynamotor, serves only for the service user groups
(city lights, stop, horn, lights, headlight, etc.).
KEY:
1 = Red (direct current)
2 = White (direct current)
3 = Grey - Red (direct current)
4 = Purple (alternating current engine stop)
5 = Black (ground)
6 = White - Red (direct current)
* = Connection connected to the red cable of the condenser charging coil.
** = Connections with electronic ignition.
If there is a connection of two circuits, i.e., if the
ignition one was routed by the DC, there would
be instantaneous deterioration of the control
unit. It is therefore necessary and important
that, in case of removal or disconnection of cables,
particularly of those which depend on the main key
switch and the control unit, during reassembly pay
attention to correctly reconnect each cable to the
GEN - 7
General guidelines APE TM Benzina
corresponding terminal; for this purpose it is al-
ways advisable to consult the electrical circuit
diagrams.
KEY:
1 = Red (direct current)
2 = White (direct current)
3 = Grey - Red (direct current)
4 = Purple (alternating current engine stop)
5 = Black (ground)
6 = White - Red (direct current)
7 = Grey (direct current)
8 = Black
* = Connection connected to the red cable of the condenser charging coil.
** = Connections with electronic ignition.
For obvious reasons it is essential that, in case of
replacement of one or more devices in the system
(main switch, stator unit of the flywheel, control
unit) during reassembly, a device is used that is
similar to the existing one: if in fact similar devices
were used, but not specific to the same ignition
system, they would not work, risking irreparable
damage to the control unit.
KEY:
1 = White
2 = Red
3 = Green
B) INSPECTIONS TO BE PERFORMED IN THE EVENT OF IGNITION IRREGULARITIES
In the event of failure and abnormal operation of the ignition, whose causes are not detectable by a
visual inspection, it is necessary first to replace the control unit with a corresponding, safely functional
one. Remember that the disconnections and connections to replace the control unit must be performed
when the engine is off.
GEN - 8
APE TM Benzina General guidelines
If replacing restores the ignition operation, the fault
lies in the control unit, which obviously needs to be
replaced. In the event that the failure persists, it is
necessary to carry out checks on the alternator
and on the stator components as follows:
After a visual inspection of the connections, stator
and couplings, measurements are carried out on
the charging coil and the ignition coil using an Ohm
meter, capable of detecting resistance from 1 to
1000 ohm, as follows:
- Connect the instrument between the WHITE cable and the RED cable; there must be continuity
and ohmic value (430 to 480 ohm);
KEY:
1) White
2) Red
3) Green
- Connect the + terminal of the instrument with the
WHITE cable and the - terminal of the instrument
with the RED cable there must be continuity and
ohmic value (7 to 9 ohm).
KEY:
1) White
2) Red
3) Green
If failures are detected in the inspections of the charging coil and ignition coil, proceed to replace the
damaged parts.
If there is no tool available to check the stator, when it is established that the ignition problem is not
related to the power control unit nor to other visible causes (bad connections, damaged cables, damaged spark plug), proceed to replace the complete stator. In relation to what described in the preceding
paragraphs we recommend, therefore, to include in the control tools an Ohm meter with the characteristics outlined above.
C) IGNITION TIMING CHECK
GEN - 9
General guidelines APE TM Benzina
The timing check may be useful for example if the motor is not operating properly (start-up difficulties;
decreased performance and power; difficult or irregular recovery speed etc.); if the failure does not
depend on the carburetion, it may be caused by irregularities of the ignition timing.
This possibility is, however, considered quite rare since, due to the characteristics of the ignition system,
the timing adjustment remains unchanged over time; since the problem arises in most cases from irregular operation of the control unit, to be sure please follow the steps outlined on the side for verification
of the aforementioned device.
If however, after checking the carburetion and the
control unit, the desired improvements are not obtained and there is doubt whether the anomalies
are due to the ignition timing, proceed to check the
latter, operating as follows:.
1) Insert, into the hole (1) a rod of Ø 5 mm.; run the
engine manually until when the end of the rod,
coming into correspondence with the other hole on
the rotor, does not fit.
In this condition the engine is in ignition advance position.
2) Make a mark with white paint on the fan cover, in correspondence with the flap of the flywheel bearing
the reference for the timing.
3) Connect a stroboscopic lamp (type TECNOTEST 130/P or other similar) at ignition; the connection
will be made directly on the spark plug or on the H.V. cable, etc. depending on the type of stroboscopic
lamp available and the specific operating instructions. Then start the engine and bring it to about
4000-5000 rpm.
4) The engine will be properly timed to the lamp when the two marks are aligned, or at most, moved to
within a tolerance range of 4° (i.e., within 2° to the right and 2° to the left of alignment position).
5) If the mark of the flywheel rotor is shifted compared to the crankcase more than the allowed tolerance
(or other major irregularities appear during the check), replace the stator or the control unit.
N.B.
FOR VEHICLES OF NEXT PRODUCTION, THE FAN COVER WILL BE FITTED WITH A REFERENCE FOR TIMING, SO THE OPERATIONS DESCRIBED IN POINTS 1 AND 2 WILL NOT BE
NECESSARY.
RULES TO BE FOLLOWED IN THE EVENT OF INTERVENTION ON THE ELECTRIC SYSTEM - APE
TM P703 FL2
A) ESSENTIAL WARNINGS
The check or in any case the intervention on the circuits of the devices for the electronic ignition can
be done with relative ease by the electronic repairers of Service Station Workshops; it is essential,
however, that they take observe the notices below, since, in case of failure to observe, they could
irreparably damage the devices.
GEN - 10
APE TM Benzina General guidelines
All inspection operations of the system involving disconnection of cables (verification of the connections
and devices that are part of the ignition circuit, therefore including the main key switch) must be made
with the engine off: otherwise the control unit could be irreparably damaged.
The ignition circuit works on AC, and obviously,
must be definitely separated from that of DC
In fact the latter, powered by the battery and dynamotor, serves only for the service user groups
(city lights, stop, horn, lights, headlight, etc.).
KEY:
1 = Red (direct current)
2 = White (direct current)
3 = Red (direct current)
4 = Purple (alternating current engine stop)
5 = Black (ground)
* = Connection connected to the fuses.
** = Connection connected to the starter relays.
*** = Connection connected to the white-red cable of the light switch.
**** = Connections with electronic ignition.
***** = Connection connected to the voltage regulator.
If there is a connection of two circuits, i.e., if the
ignition one was routed by the DC, there would
be instantaneous deterioration of the control
unit. It is therefore necessary and important
that, in case of removal or disconnection of cables,
particularly of those which depend on the main key
switch and the control unit, during reassembly pay
attention to correctly reconnect each cable to the
corresponding terminal; for this purpose it is al-
ways advisable to consult the electrical circuit
diagrams.
For obvious reasons it is essential that, in case of replacement of one or more devices in the system
(main switch, stator unit of the flywheel, control unit) during reassembly, a device is used that is simi-
lar to the existing one: if in fact similar devices were used, but not specific to the same ignition system,
they would not work, risking irreparable damage to the control unit.
B) INSPECTIONS TO BE PERFORMED IN THE EVENT OF IGNITION IRREGULARITIES
GEN - 11
General guidelines APE TM Benzina
In the event of failure and abnormal operation of the ignition, whose causes are not detectable by a
visual inspection, it is necessary first to replace the control unit with a corresponding, safely functional
one. Remember that the disconnections and connections to replace the control unit must be performed
when the engine is off.
If replacing restores the ignition operation, the fault
lies in the control unit, which obviously needs to be
replaced. In the event that the failure persists, it is
necessary to carry out checks on the alternator
and on the stator components as follows:
After a visual inspection of the connections, stator
and couplings, measurements are carried out on
the charging coil and the ignition coil using an Ohm
meter, capable of detecting resistance from 1 to
1000 ohm, as follows:
- Connect the instrument between the WHITE cable and the RED cable, there must be continuity
and ohmic value (430 to 480 ohm);
KEY:
1 = White
2 = Red
3 = Green
- Connect the + terminal of the instrument with the
WHITE cable and the - terminal of the instrument
with the GREEN cable there must be continuity
and ohmic value (7 to 9 ohm).
KEY:
1 = White
2 = Red
3 = Green
If failures are detected in the inspections of the charging coil and ignition coil, proceed to replace the
damaged parts.
If there is no tool available to check the stator, when it is established that the ignition problem is not
related to the power control unit nor to other visible causes (bad connections, damaged cables, damaged spark plug), proceed to replace the complete stator. In relation to what described in the preceding
GEN - 12
APE TM Benzina General guidelines
paragraphs we recommend, therefore, to include in the control tools an Ohm meter with the characteristics outlined above.
C) IGNITION TIMING CHECK
The timing check may be useful for example if the motor is not operating properly (start-up difficulties;
decreased performance and power; difficult or irregular recovery speed etc.); if the failure does not
depend on the carburetion, it may be caused by irregularities of the ignition timing.
This possibility is, however, considered quite rare since, due to the characteristics of the ignition system,
the timing adjustment remains unchanged over time; since the problem arises in most cases from irregular operation of the control unit, to be sure please follow the steps outlined on the side for verification
of the aforementioned device.
If however, after checking the carburetion and the
control unit, the desired improvements are not obtained and there is doubt whether the anomalies
are due to the ignition timing, proceed to check the
latter, operating as follows:.
1) Insert, into the hole (1) a rod of Ø 5 mm.; run the
engine manually until when the end of the rod,
coming into correspondence with the other hole on
the rotor, does not fit.
In this condition the engine is in ignition advance position.
2) Make a mark with white paint on the fan cover, in correspondence with the flap of the flywheel bearing
the reference for the timing.
3) Connect a stroboscopic lamp (type TECNOTEST 130/P or other similar) at ignition; the connection
will be made directly on the spark plug or on the H.V. cable, etc. depending on the type of stroboscopic
lamp available and the specific operating instructions. Then start the engine and bring it to about 4000
- 5000 rpm.
4) The engine will be properly timed to the lamp when the two marks are aligned, or at most, moved to
within a tolerance range of 4° (i.e., within 2° to the right and 2° to the left of alignment position).
5) If the mark of the flywheel rotor is shifted compared to the crankcase more than the allowed tolerance
(or other major irregularities appear during the check), replace the stator or the control unit.
N.B.
FOR VEHICLES OF NEXT PRODUCTION, THE FAN COVER WILL BE FITTED WITH A REFERENCE FOR TIMING, SO THE OPERATIONS DESCRIBED IN POINTS 1 AND 2 WILL NOT BE
NECESSARY.
GEN - 13
INDEX OF TOPICS
CHARACTERISTICS CH
APE TM Benzina Characteristics
Characteristics
SIZES
millimetres Deck Long
Deck
(1) Length 3175 3375 3175 3230
(2) Width 1480 - - 1510
(3) Height 1630 - 1750 1630
(4) Wheelbase 2170 2170 2170 2170
(5) Track 1300 1300 1300 1300
(6) Turning spokes 3300 3300 3300 3300
WEIGHTS
(*) = without the driver
(*) = including the driver
Van Tipper
Kilograms (kg) Deck Long
Deck
Dry weight (*) 445 450 465 465
Vehicle weight in running order (with refuelling, tools and accessories) 1160 1160 1160 1160
Load capacity (**) 715 710 695 695
Van Tipper
TECHNICAL DATA - CHASSIS
Specification
Chassis Sheet steel body and a single central longitudinal arm (inte-
grated structure). Removable deck integrated into the struc-
Driver's cab Welded to the chassis.
Seats in driving cab Two.
Desc./Quantity
ture.
TECHNICAL DATA - ENGINE
Specification
Matriculation data The identification codes consist of a prefix (ATM2T on the
chassis, ATM2M on the engine) and a number.
Engine Single-cylinder, 2-stroke engine, with "rotating" timing and with
three transfer ducts, with transmission and differential grouped
Engine capacity 217.9 cm³
Bore X Stroke 68 x 60
Compression ratio 8.6 : 1
Ignition advance 14° ± 1°30' before T.D.C.:
Carburettor Dell'Orto SHB 22/22.
Fuel Pure petrol with separate engine lubrication, "LS" device.
Spark plug Marelli CW7N, or Bosch W4AC; Lodge 3HN; Champion L82;
Maximum speed (CUNA STANDARDS) 60÷65 km/h.
Air filter At the intake of the type with paper cartridge filter.
Cartridge AC AIRAC FLAT PACK.
Consumption (CUNA) ~4.3 litres per 100 km.
Km range Around 330 Km.
Desc./Quantity
on the axis of the rear wheels.
AC430Z; NGK B7HS.
TRANSMISSION
Specification
Gear ratio First 1/48.47
Gear ratio Second 1/26.54
Gear ratio Third 1/15.56
Gear ratio Fourth 1/9.16
Gear ratio Reverse 1/80.78
Desc./Quantity
CH - 15
Characteristics APE TM Benzina
STEERING
Specification Desc./Quantity
Steering Built with tube pivoted on the arm with front wheel-holder os-
cillating hub.
SUSPENSION
Specification Desc./Quantity
Front suspension Built using helical spring.
Rear suspension Built with flexible rubber components in progressive rate. Sus-
pensions consist of hydraulic shock absorbers.
TYRES
Specification Desc./Quantity
Wheel rim From 3.50".
Front wheel and spare wheel "Normal" type 4.00-12 C- PR6.
Rear wheels "Radial" type 4.00-12 C- PR6. (for example Michelin C-XZX
Front tyre pressure 2.8 bar
Rear tyres - inflation pressure 4.5 bar
N.B.:
When installing the spare wheel in place of one of the rear wheels (for example due to a puncture) it is recommended to replace
it as soon as possible by reinstalling the "radial" tyre which is more suitable for use.
It is not advisable to install the radial tyre on the front wheel as there would be excessive sensitivity, especially when driving on
twisting or bumpy roads.
PR.6. for deck, van, tipper, Urban Cleansing van and cabriolet
versions).
"Radial" type 4.00-R12 C- PR8. (for example Michelin C-XZX
PR.8. for versions with external fixed elaborations and those
with hydraulic tipping).
REFILLING
(*)= specific for versions with tipper deck.
Litres (l)
Fuel tank (reserve) 15 (3.5) 15 (3.5) 15 (3.5) 15 (3.5)
Engine oil (reserve) 3.0 (0.75) 3.0 (0.75) 3.0 (0.75) 3.0 (0.75)
Hydraulic oil (*) 3.0 3.0 3.0 3.0
Deck Long
Deck
Van Tipper
DIMENSIONS - APE TM KAT - APE TM P703 FL2
millimetres
(1) Length 3175 3390 3210 3225 3150
(2) Width 1480 - - 1500
(3) Height 1630 1630 1780 1630
(4) Wheelbase 2170 2170 2170 2170
(5) Track 1300 1300 1300 1300
(6) Turning spokes 3300 3300 3300 3300
Deck Long
Deck
Van Tipper Motor
chassis
WEIGHTS - APE TM KAT - APE TM P703 FL2
(*) = without the driver
(*) = including the driver
Kilograms (kg)
Dry weight (*) 465 465 505 505
Vehicle weight in running order (with refuelling, tools and accessories) 1270 1270 1270 1270
Load capacity (**) 805 805 765 765
Deck Long
Deck
Van Tipper
CH - 16
APE TM Benzina Characteristics
TECHNICAL DATA - CHASSIS - APE TM KAT - APE TM P703 FL2
Specification Desc./Quantity
Chassis Sheet steel body and a single central longitudinal arm (inte-
Versions Sheet metal deck, integrated into the structure.
Aluminium alloy deck, hydraulic tipper for engine inspection.
Driver's cab Welded to the chassis.
Seats in driving cab Two.
TECHNICAL DATA - ENGINE - APE TM KAT
Specification Desc./Quantity
Matriculation data The identification codes consist of a prefix (ATM2T on the
chassis, ATM2M on the engine) and a number.
Engine Single-cylinder, 2-stroke engine, with "rotating" timing and with
three transfer ducts, with transmission and differential grouped
Engine capacity 217.9 cm³
Bore X Stroke 68 x 60
Compression ratio 8.6 : 1
Ignition advance 14° ± 1°30' before T.D.C.:
Carburettor Dell'Orto SHB 22/22.
Fuel Pure petrol with separate engine lubrication, "LS" device.
Spark plug Champion RL78C; NGK BR8HS.
Maximum speed (CUNA STANDARDS) 60÷65 km/h.
Air filter At the intake of the type with paper cartridge filter.
Consumption (CUNA) ~4.1 litres per 100 km.
Km range Around 330 Km.
grated structure).
Long deck.
on the axis of the rear wheels.
TECHNICAL DATA - ENGINE - APE TM P703 FL2
Specification
Matriculation data The identification codes consist of a prefix (ATM2T on the
chassis, ATM2M on the engine) and a number.
Engine Single-cylinder, 2-stroke engine, with "rotating" timing and with
three transfer ducts, with transmission and differential grouped
Engine capacity 217.9 cm³
Bore X Stroke 68 x 60
Compression ratio 8.6 : 1
Ignition advance 14° ± 1°30' before T.D.C.:
Carburettor Dell'Orto SHB 22/22.
Fuel Pure petrol with separate engine lubrication, "LS" device.
Spark plug Bosch W4AC; Lodge 3HN; Champion L78C AC430Z.
Maximum speed (CUNA STANDARDS) 60÷65 km/h.
Air filter At the intake of the type with paper cartridge filter.
Consumption (CUNA) ~4.1 litres per 100 km.
Km range Around 330 Km.
Desc./Quantity
on the axis of the rear wheels.
TRANSMISSION - APE TM KAT - APE TM P703 FL2
Specification
Gear ratio First 1/48.47
Gear ratio Second 1/26.54
Gear ratio Third 1/15.56
Gear ratio Fourth 1/9.16
Gear ratio Reverse 1/80.78
Desc./Quantity
STEERING - APE TM KAT - APE TM P703 FL2
Specification
Steering Built with tube pivoted on the arm with front wheel-holder os-
Desc./Quantity
cillating hub.
CH - 17
Characteristics APE TM Benzina
SUSPENSION - APE TM KAT - APE TM P703 FL2
Specification Desc./Quantity
Front suspension Built using helical spring.
Rear suspension Built with flexible rubber components in progressive rate. Sus-
pensions consist of hydraulic shock absorbers.
TYRES - APE TM KAT - APE TM P703 FL2
Specification Desc./Quantity
Wheel rim From 3.50".
Front tyre (handlebar version) 4.00-12CNTL
Rear tyre (handlebar version) 125R12C XZX TL
Front tyre (steering wheel version) 125R12C XZX TL
Rear tyre (steering wheel version) 125R12C XZX TL
Front tyre pressure 2.5 bar
Rear tyres - inflation pressure 4.5 bar
REFILLING - APE TM KAT - APE TM P703 FL2
(*)= specific for versions with tipper deck.
Litres (l) Deck Long
Deck
Fuel tank (reserve) 15 (3.5) 15 (3.5) 15 (3.5) 15 (3.5)
Engine oil (reserve) 3.2 (0.75) 3.2 (0.75) 3.2 (0.75) 3.2 (0.75)
Hydraulic oil (reserve) (*) 15 (3.2) 15 (3.2) 15 (3.2) 15 (3.2)
Van Tipper
Tightening torques
ENGINE UNIT
Name
Transmission cross control stem 35 to 40 Nm (a)
3rd and 4th speed cross control stem 19 to 21 Nm (b)
1st and 2nd speed cross control stem 25 to 30 Nm (b)
Spark plug 18 to 24 Nm
Bolts locking dynamotor to differential crankcase 30 to 35 Nm
Bolts locking dynamotor to engine crankcase 20 to 25 Nm
Clutch assembly locking nut 180 to 220 Nm
Multi-gear pin nut 35 to 40 Nm
Fan flywheel locking nut 60 to 65 Nm
Silencer manifold fixing nut 19 to 21 Nm
Silencer to crankcase fixing bolts 18 to 22 Nm
Clutch cover fixing bolt 13 to 17 Nm
Cylinder head fixing bolt 20 to 23 Nm
Engine to deck fixing bolt 20 - 25 Nm
Spring line to frame fixing bolt 20 - 25 Nm
Spring line to frame anchor bolt 20 to 25 Nm
Oil drain plug 22 to 25 Nm
Bolt connecting the crankcase halves 13 to 15 Nm
Dynamotor pulley lock nut 35 to 40 Nm
Crankcase admission joint lock bolts 14 to 18 Nm
Change control support lock bolts 14 to 18 Nm
(a)= Specific for version with handlebar
(b)= Specific for version with steering wheel
Torque in Nm
CH - 18
DIFFERENTIAL UNIT
Name
Differential box toothed sprocket lock bolts 54 to 64 Nm
Differential cover fixing bolt 30 to 40 Nm
Torque in Nm
APE TM Benzina Characteristics
FRONT SUSPENSION UNIT
Name Torque in Nm
Shock absorber upper anchoring nut 30-40
Shock absorber lower anchoring nut 100-120
Steering upper bearing lock gear 50 to 70
Wheel rim to drum locking 60-70
Wheel locking centre nut 100-120
Shoes self-centring plate lock nuts 20 - 25
REAR SUSPENSION UNIT
Name Torque in Nm
Wheel to drum lock nut 60-70
Drum centre lock nut 200 to 240
Shock absorber lower lock nut 100 to 140 Nm
Shock absorber upper lock nut 30-40
Swinging arm lock nut 40-50 Nm
Flexible coupling lock nut 40 - 50
Hub to axle shaft lock nut 50-70
Hub to wheel axle lock nut 140-180
Hub to swinging arm lock nut 40 - 50
Shoes self-centring plate lock nut 18 to 20 Nm
Name Torque in Nm
Handle bar to steering tube lock bolts 42 to 52 (a)
Steering control lever to steering tube lock bolts 30 to 35
Steering housing lock nuts 20 to 25 (b)
Steering wheel lock nut 30 to 35 (b)
Rack pressure roller lid lock nuts 8 to 12 (b)
Pressure roller adjustment screw lock nut 40 to 60 (b)
Lever holder locking screw 7 to 8.5
Brake oil pump piston end stroke screw 6 to 10 Nm
Pedal assembly bolt lock nut 15 to 25
Stop switch 1.5 to 3
Cab doors lock bolt 23 to 30
Windshield wiper motor lock 8 to 9
Brake pump body lock bolts 12 to 20 (a)
Brake pump body lock bolts 8 to 12
Floor to cab panel lock bolts 20 - 25
Floor to centre cross member lock nuts 20 - 25
(a) Specific for versions with handlebar
(a) Specific for versions with steering wheel
Vehicle overhaul data
Assembly clearances
FRAME ASSEMBLY
SHOULDER RINGS
Specification
Shoulder ring (Nominal sizes) B= 1 +0 -0.06 (mm)
Desc./Quantity
CH - 19
Characteristics APE TM Benzina
SHOULDER RING - CLEARANCE "A" UPON FITTING
Name Description Dimensions Initials Quantity
Shoulder ring 1st Oversize 1.1 +0 -0.06 0.15 to 0.50
Shoulder ring 2nd Oversize 1.2 +0 -0.06 0.15 to 0.50
Shoulder ring 3rd Oversize 1.3 +0 -0.06 0.15 to 0.50
Shoulder ring 4th Oversize 1.5 +0 -0.06 0.15 to 0.50
For the clearance check, use the specific equipment.
N.B.
IF YOU DO NOT GET THE CLEARANCE "A" WITH SHOULDER RING "B", REPLACE THE LATTER
WITH A RING LARGE ENOUGH TO GET THE REQUIRED CLEARANCE.
Specific tooling
T.0060824 Control probe axle clearance gear change
Cylinder-piston oversizes
FITTING CLEARANCES
Pistons and cylinders supplied as spare parts by the Manufacturer are marked with the letters of the
alphabet. When both pistons and cylinders are replaced, the pieces with the same letter must be
matched.
NORMAL CYLINDER- PISTON NOMINAL SIZES
Specification
Normal cylinder nominal sizes E=68 +0.025 - -0.005
Normal piston nominal sizes C=67.76 +0.025 -0.005
CYLINDER COUPLING - PISTON
Name
Coupling: 1st Oversize 68.20 to 68.22 67.96 to 67.98 0.24
Coupling: 2nd Oversize 68.40 to 68.42 68.16 to 68.18 0.24
Coupling: 3rd Oversize 68.60 to 68.62 68.36 to 68.38 0.24
Initials Cylinder Piston Play on fitting
Desc./Quantity
CH - 20
APE TM Benzina Characteristics
If, however, the cylinder should be increased, the size "E" (see figure) must exceed the size "C" of the
piston to be installed (marked on the piston itself) of the indicated value, "Cylinder clearance - pis-
ton".
Fitting clearance
Cylinder - piston clearance 0.24
CAUTION
AT REPLACEMENT OF PISTON IN THE CYLINDER, MAKE SURE THAT THE ARROW STAMPED
ON THE PISTON SPROCKET IS FACING THE EXHAUST PORT OF THE CYLINDER.
Piston ring oversizes
SEALING RINGS
Specification Desc./Quantity
Seal ring (Nominal sizes) Diameter = 68 (mm)
CLEARANCE "A" UPON FITTING
Name
Sealing ring 1st Oversize 68.20 0.25 to 0.40
Sealing ring 2nd Oversize 68.40 0.25 to 0.40
Sealing ring 3rd Oversize 68.60 0.25 to 0.40
Description Dimensions Initials Quantity
Crankshaft alignment check
With the proper equipment (1), check that the eccentricity of the surface of Ø "E" and "F" are contained within 0.03 mm. (the maximum reading limit
on the dial gauge clock); also check the eccentricity of the diameter "D", for which there shall be a
maximum reading of 0.02 mm.
In the case of eccentricities not much greater than
that prescribed, perform the straightening of the
shaft by means of counterweights with a wedge,
or tightening it in a vice (equipped with aluminium
bushings) as needed.
CH - 21
Characteristics APE TM Benzina
Specific tooling
19.1.20074 Crankshaft checking tool
Rod small end bushing - Pin
CONNECTING ROD SMALL END - PIN - ROLLER CAGE
The connecting rods and cages are divided into 4
categories (marked with incisions at the foot of the
same connecting rod and on the cage frames).
CONNECTING ROD - ROLLER CAGE
Connecting rod Roller cage
1st category 4th category
2nd category 3rd category
3rd category 2nd category
4th category 1st category
CAUTION
IN CASE OF NOISE, USE CAGE OF LOWER CATEGORY.
Oil pump
Name
Cylinder B=22.225 -0 +0.033 0.040 to 0.106
Piston C=22.225 -0.040 -0.073 0.040 to 0.106
Name
Cylinder B=25.40 -0 +0.033 0.150 to 0.125
Piston C=25.40 -0.040 -0.092 0.150 to 0.125
FRONT BRAKE CYLINDER - CLEARANCE "A" FOR FITTING
Description Dimensions Initials Quantity
REAR BRAKE CYLINDERS - CLEARANCE "A" FOR FITTING
Description Dimensions Initials Quantity
CH - 22
APE TM Benzina Characteristics
FRONT AND REAR BRAKE CYLINDERS - CLEARANCE "A" FOR FITTING - APE TM P703
FL2
Name Description Dimensions Initials Quantity
Cylinder B=25.40 -0 +0.033 0.040 to 0.125
Piston C=25.40 -0.040 -0.092 0.040 to 0.125
CLEARANCE "A" UPON FITTING
Name Description Dimensions Initials Quantity
Cylinder B=19 +0.033 -0 0.040 to 0.106
Piston C=19 +0.040 -0.073 0.040 to 0.106
CH - 23
INDEX OF TOPICS
SPECIAL TOOLS ST
APE TM Benzina Special tools
Tooling
SPECIAL TOOLS
Stores code Description
T.0014499 Bearing extractor
T.0021467 Bearing extractor
T.0017104 Pliers for circlips
T.0022465 Pliers for circlips
0023638 Pliers for circlips
T.0018119 Tool for fitting shafts
ST - 25
Special tools APE TM Benzina
Stores code Description
19.1.20000 Tool for front suspension overhaul
19.1.20004 Tool for disassembling steering bearing
19.1.20024 Crankshaft removal tool
19.1.20041 Steering upper bearing ring nut gear
19.1.20042 Extract the bottom seat of the steering
from the frame
wrench
bottom bearing
ST - 26
19.1.20043 Rear wheel hub roller bearing fitting
punch
19.1.20044 Front wheel hub roller bearing fitting
punch
APE TM Benzina Special tools
Stores code Description
19.1.20045 Tool for fitting steering lower bearing low-
19.1.20046 Clutch puller
19.1.20047 Pliers for chamfering nuts
er seat
19.1.20049 Window positioning tool
19.1.20050 Lower retainer clamp for strip
19.1.20051 Upper retainer clamp for strip
19.1.20074 Crankshaft checking tool
ST - 27
Special tools APE TM Benzina
Stores code Description
0019978 Oven
T.0020322 Clutch removal and refitting tool
T.0020781 Bearings Fitting Punch
T.0021071 Punch to fit bearings and seal rings
T.0021330 Steering seats fitting tool
T.0023589 Punch for bearings and sealing rings
T.0025095 Engine support plane
ST - 28
APE TM Benzina Special tools
Stores code Description
T.0025127 Wedge
T.0027338 Punch to fit sealing rings
T.0030632 Wrench for helical gear nut
T.0031729 Clutch stop key
T.0033970 Punch for fitting roller bearings
T.0035731 Flywheel extractor and differential hous-
T.0039152 Punch for roller bearing
ing
ST - 29
Special tools APE TM Benzina
Stores code Description
T.0039153 Punch for roller bearing
T.0043062 Stop key of flywheel and dynamotor pul-
T.0060824 Control probe axle clearance gear
ley
change
ST - 30
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