PIAGGIO MSS APE 50 Service Station Manual

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MANUALE STAZIONE DI SERVIZIO
677276 - 677281 (IT-EN-FR-DE-ES-EL)
MSS APE 50
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MANUALE
STAZIONE DI
SERVIZIO
MSS APE 50
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
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MANUALE STAZIONE DI
SERVIZIO
MSS APE 50
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.
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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
BRAKING SYSTEM BS
STEERING COLUMN SC
SUSPENSIONS SS
CHASSIS CH
PRE-DELIVERY PD
TIME-SHEET TEMP
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INDEX OF TOPICS
GENERAL GUIDELINES GEN
Page 8
Safety guidelines
- If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractor fans if necessary; never let the engine run in an enclosed area. Exhaust gasses 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. Petrol is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid open flames or sparks.
- Clean the blocks, the drums, and 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 blocks. Dust caused by shoe wear is toxic since it contains asbestos.
Maintenance guidelines
Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-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 removing these components, clean them using a non-flammable or high flash-point solvent. Lu­bricate all the work surfaces except the tapered couplings before refitting. After refitting, make sure that all the components have been installed correctly and work properly. For disassembly, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. 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 electrical connections have been made properly, particularly the ground connections.
General guidelines MSS APE 50
GEN - 8
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INDEX OF TOPICS
CHARACTERISTICS CH
Page 10
Identification
VEHICLE IDENTIFICATION
Vehicle Chassis prefix Engine prefix
APE 50 TL6T TL3T APE 50 EUROPA TL5T TL3T APE 50 mix ZAPC80000 C801M APE 50 EUROPE (EURO 2) ZAPC80000 C801M
Characteristics
SIZES
Sizes (mm) Deck Van
(1) Length 2670 2560 (2) Width 1250 (3) Height 1530 1560 (4) Wheelbase 1590 (5) Track 1100 (6) Turning spokes 2400 2400 (7) Rear cantilever 760 660
SIZES - LOAD COMPARTMENT
Sizes (mm)
Deck Van
(8) Length 1420 ­(9) Width 1200 -
WEIGHTS
(*) = besides the driver.
Characteristics MSS APE 50
CH - 10
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Kilograms (kg) Deck Van
Kerb vehicle weight 270 300 Useful load capacity (*) 200 170
SIZES - APE 50 EUROPA
Sizes (mm) Deck Short deck Van Cross
(1) Length 2660 2520 2560 2580 (2) Width 1250 1250 1250 1270 (3) Height 1530 1530 1560 1580 (4) Wheelbase 1590 1590 1590 1590 (5) Turning spokes 2400 2400 2400 2400
SIZES - LOAD COMPARTMENT - APE 50 EUROPA
Sizes (mm)
Deck Short deck Van Cross
(8) Length 1420 1270 1260 1270 (9) Width 1200 1200 1200 1200 (10) Height - - 960 ­Top box size - - - 900x460x300
WEIGHTS - APE 50 EUROPA
(*) = besides the driver.
Kilograms (kg)
Deck Short deck Van
Total dry weight 220 215 250 Useful load capacity (*) 200 205 170
SIZES - APE 50 EUROPE 2 - APE 50 MIX
Sizes (mm)
Long deck
base
Short deck
base
Van Cross Top long deck
(1) Length 2660 2490 2500 2700 2660 (2) Width 1260 1260 1260 1260 1260 (3) Height 1550 1550 1590 1610 1550 (4) Wheelbase 1590 1590 1590 1590 1590
MSS APE 50 Characteristics
CH - 11
Page 12
SIZES - LOAD COMPARTMENT - APE 50 EUROPE 2 - APE 50 MIX
Sizes (mm)
Long deck
base
Short deck
base
Van Cross Top long deck
(8) Length 1427 1257 1257 1427 1422 (9) Width 1211 1211 1211 1211 1262
WEIGHTS - APE 50 EUROPE 2 - APE 50 MIX
(*) = besides the driver.
Kilograms (kg)
Long Deck Short deck Van Cross Top
Total dry weight 230 230 260 245 230 Useful load capacity (*) 205 205 175 190 205
TECHNICAL DATA - CHASSIS
Specification
Desc./Quantity
Chassis stamped plate unitised body and a single central longitudinal
arm (integrated structure).
Seats in driving cab One.
TECHNICAL DATA - ENGINE
Specification
Desc./Quantity
Engine Single-cylinder, 2-stroke with rotating timing and with three
transfer ducts, with transmission and differential grouped on
the axis of the rear wheels.
Engine capacity 49.8 cm³
Bore x Stroke 38.4 mm x 43 mm
Compression ratio (10÷10.5):1
Ignition advance 15°±2° before TDC
Carburettor Dell'orto SHBC 18/16A.
Fuel 2% petrol-oil mixture (20 c.c. of oil per litre of regular petrol for
cars). Recommended oil: see "recommended products" table
Spark plug PIAGGIO P82M; BOSCHW5AC; CHAMPIONL82C;
LODGE2HN; AC430Z.
Characteristics MSS APE 50
CH - 12
Page 13
Specification Desc./Quantity
Consumption (CUNA) ~2.7 litres per 100 km.
Km range Around 370 Km.
GEAR RATIO
Specification Desc./Quantity
Gear ratio First 1/54.17
Gear ratio Second 1/29.75
Gear ratio Third 1/19.28
Gear ratio Fourth 1/13.35
Gear ratio Reverse 1/76.47
STEERING
Specification Desc./Quantity
Steering Steering tube pivoted on the arm with front wheel-holder oscil-
lating clamp.
SUSPENSION
Specification Desc./Quantity
Front - rear suspension Made using integrated helicoidal springs and hydraulic shock
absorber.
TYRES
Specification Desc./Quantity
Wheel rim 2.10" Front tyre pressure 1.5 bar. Rear tyre pressure 2.5 bar.
TYRES - APE 50 - APE 50 EUROPA - APE 50 EUROPE EURO 2 - APE 50 MIX
Specification
Desc./Quantity
Wheel rim 10-2.50"
Tyre 100/90x10"
Front tyre pressure 2 bar.
Rear tyres - inflation pressure 3 bar.
Tightening torques
ENGINE - DIFFERENTIAL UNIT
Name
Torque in Nm
Crankcase halves coupling nuts 13 to 15 Nm
Coil support fixing screw 3 to 5 Nm
Spark plug 14 to 18 Nm
Engine gear locking nut 50 to 55 Nm
Clutch assembly locking nut 40 ÷ 45 Nm
Fan flywheel locking nut 45 to 50 Nm
Filler joint fixing nuts 5 to 7 Nm
Nuts fixing the exhaust pipe to the cylinder 5 to 7 Nm
Clutch cover fixing bolts 6 to 8 Nm
Big end fixing bolts 13 to 18 Nm
Nuts fixing the cylinder to the crankcase 13 to 15 Nm
Nuts fixing the differential unit to the engine 32 to 35 Nm
Differential crankcase halves coupling nuts 8 to 10 Nm
Engine - chassis anchoring plate fixing nuts 20 to 24 Nm
Differential oil drain plug 20 ÷ 25 Nm
Gear control guide bushing 60 to 65 Nm
Nuts fixing the silencer to the engine support 23 to 25 Nm
Nuts fixing the elastic connection to the engine support 25 to 30 Nm
Engine front fixing bolt 25 to 30 Nm
MSS APE 50 Characteristics
CH - 13
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FRONT SUSPENSION UNIT
Name Torque in Nm
Wheel locking centre nut 75 to 90 Nm
Nuts fixing the wheel rim to the drum 20 to 28 Nm
Shock absorber lower anchoring nut 100 to 130 Nm
Shock absorber upper fixing nut 30 to 40 Nm
Steering upper seat 30 to 40 Nm
Steering upper bearing ring nut 50 to 60 Nm
REAR SUSPENSION UNIT
Name Torque in Nm
Nuts fixing the shoe support to the wheel hub 22 to 28 Nm
Nut fixing the wheel hub to the swinging arm 50 to 70 Nm
Nut for shock absorber lower and upper anchorage 30 to 40 Nm
Nut for anchoring the swinging arm to the chassis 40-50 Nm
Wheel locking centre nut 80 to 100 Nm
Nuts fixing the wheel rim to the drum 20 to 28 Nm
GENERAL PART
Name Torque in Nm
Brake pump to the chassis 12 to 20 Nm
Handlebar fixing bolt 35 to 60 Nm
Assembly clearances
FITTING CLEARANCES
Name
Description Dimensions Initials Quantity
Distance between the ends of seal rings within the upper and lower cyl-
inder-ring (mm)
0.2 to 0.3
Gearbox fitting clear-
ance (mm)
0.15 to 0.40
CAUTION
THE GEARBOX SHAFT FITTING CLEARANCE MUST BE VERIFIED WITH THE FEELER GAUGE.
Specific tooling
060824Y Probe
Cylinder-piston oversizes
CYLINDER - PISTON
Specification
Desc./Quantity
Normal cylinder nominal sizes Ø=38.40 +0.025 - 0.005
Normal piston nominal sizes Ø=38.265 ±0.015
CYLINDER COUPLING - PISTON
Name
Initials Cylinder Piston Play on fitting
Coupling 1st Oversize 38.600 to 38.620 38.455 to 38.475 0.145 Coupling 2nd Oversize 38.800 to 38.820 38.655 to 38.675 0.145 Coupling 3rd Oversize 39.000 to 39.020 38.855 to 38.875 0.145
Characteristics MSS APE 50
CH - 14
Page 15
Piston ring oversizes
SEALING RINGS
Specification Desc./Quantity
Upper seal ring (Nominal sizes) Diameter=38.40 mm Lower seal ring (Nominal sizes) Diameter=38.40 mm
CLEARANCE UPON FITTING
Name Description Dimensions Initials Quantity
Upper sealing ring 1st Oversize 38.60 0.20 to 0.60 Lower sealing ring 1st Oversize 38.60 0.20 to 0.60 Upper sealing ring 2nd Oversize 38.80 0.20 to 0.60 Lower sealing ring 2nd Oversize 38.80 0.20 to 0.60 Upper sealing ring 3rd Oversize 39.00 0.20 to 0.60 Lower sealing ring 3rd Oversize 39.00 0.20 to 0.60
Connecting rod - roller cage fitting
CONNECTING ROD - ROLLER CAGE
Connecting rod Roller cage
1.a category 4.a category
2.a category 3.a category
3.a category 2.a category
4.a category 1.a category
CAUTION
IN CASE OF NOISE, USE CAGE OF THE CATEGORY IMMEDIATELY BELOW.
Crankshaft alignment check
With the proper equipment, check that the eccentricity of the surface of Ø "3"and "1" are contained within 0.003 mm. (the maximum reading limit on the dial gauge clock); Also check the eccentricity of Ø "2", which are allowed for 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, for much greater eccentricities replace the crankshaft.
Specific tooling
020074Y Crankshaft Alignment Check Tool
MSS APE 50 Characteristics
CH - 15
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Piston - Pin
PISTON - PIN ASSEMBLY CLEARANCE
Name
Description Dimensions Initials Quantity
Piston - pin assembly
clearance (mm)
0
Characteristics MSS APE 50
CH - 16
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INDEX OF TOPICS
SPECIAL TOOLS ST
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Tooling
SPECIAL TOOLS
Stores code Description
014499Y Bearing extractor
016029Y Lower Steering Bearing Fitting Tool on
the steering tube
017104Y Pliers for circlips
018119Y Axle Fitting Tool
020004Y Steering seats extraction punch
020042Y Steering tube bearing extractor
Special tools MSS APE 50
ST - 18
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Stores code Description
020043Y Rear Wheel Hub Roller Bearing Fitting
Punch
020044Y Front Wheel Hub Roller Bearing Fitting
Punch
020055Y Steering Ring Nut Key
020057Y Tool for Starter Motor Bushing Calking
020074Y Crankshaft Alignment Check Tool
020119Y Flywheel extractor
020120Y Punch for Clutch Side Secondary Shaft
Roller Bearing
MSS APE 50 Special tools
ST - 19
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Stores code Description
020121Y Punch for Flywheel Side Secondary
Shaft Roller Bearing
020123Y Valves Sealing Rings Punch
020125Y Punch to Fit Sealing Rings
020126Y Clutch Stop Key
020127Y Transmission Spider Calking Punch
020128Y Tool to Fit Sealing Rings
020129Y Engine Clearance Gear Check Tool
Special tools MSS APE 50
ST - 20
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Stores code Description
020130Y Punch to Fit Roller Casing of Main Shaft,
Flywheel Side Crankcase Half
020131Y Flywheel lock tool
020132Y Gearbox Shaft Shimming Gauge
020133Y Tappet plates replacement tool
020144Y Primary Sprocket Lock
020147Y Flywheel Cone Extractor
020150Y Support
MSS APE 50 Special tools
ST - 21
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Stores code Description
020151Y Heat gun
020156Y Clutch puller
020161Y Differential Box Extractor
020322Y Clutch Removal
020781Y Bearings Fitting Punch
020842Y Upper Steering Bearing Removal Punch
021071Y punch to fit bearings and sealing rings
Special tools MSS APE 50
ST - 22
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Stores code Description
021330Y Steering seats fitting tool
021467Y Bearing extractor
022465Y Pliers for circlips
023638Y Pliers for circlips
029551Y Clutch puller
029569Y Gear Engagement Fitting Tool
030250Y Clutch Stop Key
MSS APE 50 Special tools
ST - 23
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Stores code Description
032975Y Punches for Roller Casings
033970Y Punches for Roller Casings
038077Y Engine support
038137Y Rear Hub Extractor
038138Y Roller Casings Punch
048564Y Flywheel extractor
060824Y Probe
Special tools MSS APE 50
ST - 24
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Stores code Description
020095Y Flywheel Lock 020332Y Digital rev counter
494929 Exhaust fumes analyzer 021330Y003 Steering seats fitting 021330Y004 Steering seats fitting
020114Y Pane positioning band 018119Y007 Axle fitting 018119Y009 Axle fitting 018119Y014 Axle fitting 018119Y015 Axle fitting 021467Y009 extractor 021467Y013 extractor
MSS APE 50 Special tools
ST - 25
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INDEX OF TOPICS
MAINTENANCE MA
Page 27
WINDSCREEN WASHER FLUID TOP-UP - APE 50
Inside the passenger compartment in the front left part, there is a container for windscreen washer fluid. If the fluid does not escape when pressing the button, remove the pipe that goes from the container to the and blow inside with compressed air. Do the same for the pipe that goes from the pump to the external nozzle. Refit everything and try pressing the button several times to recharge the system. If despite the above operations, the fluid does not come out, clean the external nozzle with iron wire of a suitable diameter.
WINDSCREEN WASHER FLUID TOP-UP- APE 50 EUROPA
The windscreen washer fluid tank is located inside the passenger compartment, in the front right part. To fill the tank, unscrew the cover (1), restore the fluid level and recharge the system by using the pump on the left side of the passenger compart­ment several times, until the liquid comes out of the sprayer.
WINDSCREEN WASHER FLUID TOP-UP APE 50 MIX - APE 50 EUROPE
The windscreen washer fluid tank is located inside the cab on the front right panel. To fill the tank, unscrew cover(1), and top up. Use a specific detergent.
Scheduled maintenance chart
The following table must be regarded as a general guide for periodic inspections and lubrication inter­ventions. It is necessary to also consider the weather, terrain, geographic location and variety of special use. This interventions table must therefore be changed to reflect the particular needs of the owner. For example, if a vehicle is exposed to sea salt, all parts should be lubricated more frequently than shown in the table to prevent damage caused by corrosion to metal parts.
MSS APE 50 Maintenance
MA - 27
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MAINTENANCE OPERATIONS
In the event of prolonged vehicle inactivity, adhere to the following standards:
1) Clean the vehicle.
2) Remove the fuel from the vehicle.
3) Remove the air filter and with the engine is running at low rpm and input 30 cc. of specific oil through the diffuser of the carburettor.
4) Spread antirust grease on the unpainted metallic parts.
5) Lift the wheels off the ground. A) Operation to be carried out when the engine is warm. Amount of new oil: about 600 gr. for the engine unit (until touching the load hole) and about 300 gr. for the differential unit (maximum level on the check rod). B) For the oil level in the tank and to replace, use specific oil.
Unit Operations After the
first 1000
Km
Every
4000 Km
Every
8000 Km
In the
event of a
review
Notes
MOTOR
Carburettor locking See locking torque ta-
ble:
Piston - big end - cylin-
der lights descaling
See locking torque ta­ble:
Cleaning and descaling of the still usable engine
parts
See locking torque ta­ble:
TRANSMISSION AND DIFFERENTIAL
Oil replacement •(A) •(A)
Check and restore oil
level
air filter
Cleaning Clean with pure petrol
and dry with com-
pressed air
SPARK PLUG
Electrode gap and des-
caling check
Bosch W54C; Lodge 2HN; Champion L82C;
NGK B6HS;
Replacement Bosch W54C; Lodge
2HN; Champion L82C;
NGK B6HS;
BEARINGS
Grease • ARTICULATIONS AND CONTROL LEVERS (ENGINE SIDE)
Grease • HYDRAULIC BRAKE
Check and restore oil
level
•(B)
FLEXIBLE TRANSMIS­SIONS
Adjust
Lubricate • MAIN NUTS AND BOLTS OF THE VEHI­CLE
Locking check See locking torque ta-
ble:
SCHEDULED MAINTENANCE - APE 50 EUROPA
KEY: (*)= Every 2 years. (I) = Check and clean, adjust, lubricate or replace if necessary. (R)=Replace In the event of prolonged vehicle inactivity, adhere to the following standards:
1) Clean the vehicle.
2) Remove the fuel from the vehicle.
Maintenance MSS APE 50
MA - 28
Page 29
3) Remove the spark plug, enter from its hole 10/15 cc of oil recommended for the mixer, and then operate the starter lever 2-3 times and refit the spark plug.
4) Spread antirust grease on the unpainted metallic parts.
km x 1,000
(months)
1
(4)6(12
)
10
(24
)
15
(36
)
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
Locks - Inspection (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Spark plug - Re­placement
(R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R)
Carburettor ­Check
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Carburetion ­check
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Controls - Inspec­tion/Adjustment
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Condition and tyres use - Check
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Air filter - Cleaning (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Steering clearance
- Inspection
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Electrical system and battery - Check
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Cylinder fan sys­tem - Inspection
(I) (I) (I) (I)
Brake and clutch lever - Grease
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Battery level - In­spection
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Differential oil level
- Inspection
(I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R)
Brake fluid level ­Check
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Gearbox oil - re­placement
(R) (R) (R) (R) (R) (R) (R) (R) (R) (R)
Brake fluid - Re­placement
(*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*)
Tyre pressure - In­spection
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Headlights - check/ adjust
(I) (I) (I) (I) (I) (I) (I) (I) (I)
Vehicle and brake test - Inspection
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Suspension - In­spection
(I) (I) (I) (I) (I) (I) (I) (I) (I)
Flexible transmis­sions - Lubrication
(I) (I) (I) (I) (I) (I) (I) (I) (I)
Pressure flexible brakes pipes
(R) (R) (R)
SCHEDULED MAINTENANCE - APE 50 MIX
KEY: (*)= Every 2000 Km or 2 years. (I) = Check and clean, adjust, lubricate or replace if necessary. (R)=Replace In the event of prolonged vehicle inactivity, we recommend doing the following:
1) Clean the vehicle.
2) With the engine off and the piston at bottom dead center, remove the spark plug, enter from the corresponding hole 10 to 15 cc of specific oil. Then press the engine start-up button 3-4 times, making the engine and the spark plug slowly turn.
3) Drain the fuel tank, cover the unpainted metal parts with rustproof grease;
4) For the battery, follow the instructions set out in the specifications section.
km x 1,000
(months)
1
(4)6(12
)
10
(24
)
15
(36
)
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
Safety locks (wheels,brakes,ste ering,suspensions)
- Inspection
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
MSS APE 50 Maintenance
MA - 29
Page 30
km x 1,000
(months)
1
(4)6(12
)
10
(24
)
15
(36
)
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
Spark plug - Re­placement
(R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) (R)
Carburettor ­Cleaning
(I) (I) (I) (I) (I) (I) (I) (I) (I) Carburetion -
Check
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Throttle grip/mixer control - Adjust­ment
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Condition and tyres use - Check
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Tyre pressure - In­spection
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Air filter - Cleaning (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Steering clearance
- Inspection
(I) (I) (I) (I) (I) (I) (I) (I) (I) Brake and clutch
lever - Grease
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Braking system flu­id level
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Braking system flu­id level - Replace­ment
(*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*)
Gearbox oil - Re­placement/Inspec­tion
(I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R)
Differential oil - Re­placement/Inspec­tion
(I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) (I) (R)
Battery fluid level ­Inspection
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Headlights - check/ adjust
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Suspension - In­spection
(I) (I) (I) (I) (I) (I) (I) (I) (I) Flexible transmis-
sions - Lubrication
(I) (I) (I) (I) (I) (I) (I) (I) (I) Rear brake disc
piping - Replace­ment
(R) (R) (R)
Vehicle and brake test
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Drive shaft nut mix
- Inspection
(I) (I) (I) (I) (I) (I)
SCHEDULED MAINTENANCE - APE 50 EUROPE
KEY: (*)= Every 2000 Km or 2 years. (I) = Check and clean, adjust, lubricate or replace if necessary. (R)=Replace
km x 1,000 (months)
1 (4) 5 (12) 10
(24)15(36)
20 25 30 35 40 45 50
Safety locks (wheels,brakes,steering,sus­pensions) - Inspection
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Spark plug - Replacement (R) (R) (R) (R) (R) (R) (R) (R) (R) (R) Carburettor - Cleaning (I) (I) (I) (I) (I) Carburetion - Check (I) (I) (I) (I) (I) (I) Throttle grip/mixer control - Adjustment (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Condition and tyres use - Check (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Tyre pressure - Inspection (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Air filter - Cleaning (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Steering clearance - Inspection (I) (I) (I) (I) (I) Clutch brake lever - Grease (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Fluid level and braking system - Check (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Braking system fluid level - Replacement (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*)
Maintenance MSS APE 50
MA - 30
Page 31
km x 1,000 (months) 1 (4) 5 (12) 10
(24)15(36)
20 25 30 35 40 45 50
Gearbox oil - Replacement/Inspection (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) Differential oil - Replacement/Inspection (I) (R) (I) (R) (I) (R) (I) (R) (I) (R) Battery fluid level - Inspection (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Headlights - check/adjust (I) (I) (I) (I) (I) (I) Suspension - Inspection (I) (I) (I) (I) (I) Flexible transmissions - Lubrication (I) (I) (I) (I) (I) Rear brake disc piping - Replacement (R) Vehicle and brake test (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) Air filter and SAS box (sponge) cleaning (R) (R) (R) (R) (R)
Suggested products chart
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGIP CITY TEC 2T Oil mixer for 2-stroke engines JASO FC, ISO-L-EGD Specifications
AGIP CITY HI TEC 4T Oil for lubricating the flexible transmission
lines (brakes, throttle grip, odometer,
etc.).
Specifications: SAE 5W-40, API SL,
ACEA A3, JASO MA
AGIP GEAR Differential Oil Specifications: SAE 80W-90; API GL-4 AGIP GEAR Gearbox oil SAE 80W-90; API GL-4
AGIP GREASE PV 2 Grease for brake control levers Specifications: NLGI 2 ; ISO-LXBIB2
AGIP GREASE MU3 Grease for odometer transmission gear
case
Specifications: NLGI 3; ISO-L-XBCHA3,
DIN K3K-20
AGIP BRAKE 4 Brake fluid FMVSS DOT 4
Carburettor
The carburettor is completely decomposed, check all calibrated parts (main jets, idle jets, emulsifiers tubes, etc.). The value of these calibrated parts must correspond to the adjustment data prescribed for the type of carburettor. For a thorough cleaning of all components of the carburettor, use a bath of suitable solvent and blow with compressed air. To clean the calibrated jets, avoid using metallic spikes or wires. All gaskets, seal rings and springs of the carburettor, should be replaced with each revision.
WARNING
THE CARBURETTOR IS VERY EXPLOSIVE; BE VERY CAREFUL NOT TO SPILL FUEL DURING THE REMOVAL OF THE CARBURETTOR
WARNING
USE EXTREME CAUTION WHEN WORKING ON COMPONENTS CONTAINING PETROL.
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
SPECIFICATIONS
Specification
Desc./Quantity
Dell'Orto type SHBC 18/16 A.
Diffuser mm. 16. Max. jet 60/100.
Minimum jet 42/100 long.
Minimum fixed air 110/100.
Maximum fixed air 150/100.
Starter jet 50/100.
MSS APE 50 Maintenance
MA - 31
Page 32
KEY:
1. Fuel adjustment screw at idle.
2. Minimum adjustment screw.
3. Minimum jet.
4. Starter valve.
5. Minimum air calibrator.
6. Maximum air calibrator.
7. Starter jet.
8. Float.
9. Max. jet
10. Throttle valve.
Air filter
CLEANING:
- Clean with a solvent with high flash point.
- Dry with compressed air.
CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.
Maintenance MSS APE 50
MA - 32
Page 33
Engine oil replacement
ENGINE OIL AND DIFFERENTIAL REPLACE­MENT
- The oil change must be performed with the en­gine warm.
- Remove the oil filler cap.
- Unscrew the oil drainage plug and drain out all the oil.
- Retighten the drainage plug and fill with oil (about
0.600 litres for the engine and about 0.300 litres for the differential).
- Start the engine and stop it after having run it for about 1 minute in idle.
- Restore, if necessary, the oil level and check for leaks.
- Use appropriate oils.
WARNING DO NOT REMOVE THE OIL COVER IMMEDIATELY AFTER
AN ACTIVITY WITH THE ENGINE AT FULL SPEED AND/OR WITH THE ENGINE RUNNING. THE HEATED OIL MAY LEAK, WITH THE RISK OF BURNING
Recommended products
AGIP GEAR Differential Oil
Specifications: SAE 80W-90; API GL-4
AGIP CITY TEC 2T Oil mixer for 2-stroke en­gines
JASO FC, ISO-L-EGD Specifications
Spark plug
- Disconnect the spark plug pipe and remove it.
- Examine it carefully and if the insulators are chip­ped or damaged replace them.
- Measure the distance between the electrodes using a feeler gauge and adjust if necessary by carefully bending the outer electrode.
- Make sure that the seal washer is in good con­dition.
MSS APE 50 Maintenance
MA - 33
Page 34
Fit the spark plug, screw by hand and then tighten with a key for the spark plug to the prescribed tor­que.
Characteristic
Electrode gap
0.6 to 0.7 mm
Recommended spark plugs
PIAGGIO P82M; Champion L82C; Bosch W54C; Lodge 2HN; Ac 430Z.
Locking torques (N*m)
Spark plug 14 to 18 Nm
Mixer timing
To adjust the timing, operate on the transmission adjuster screw so that the reference stamped on the mobile control coincides with that made on the mixer body.
N.B. CHECK FOR THE PROPER TIMING OF THE MIXER, IT IS
NECESSARY TO FIRST REMOVE THE METAL COVER FIXED WITH THREE SCREWS ON THE CLUTCH COVER. DUE TO THE PASSAGE OF AN EXHAUST PIPE ON ONE OF THE SCREWS, THE LATTER'S HOUSING HOLE HAS BEEN MADE OPEN TO REMOVE THE LID BY LOOSENING ONLY ONE OF THE SCREWS IN QUESTION.
N.B. WHENEVER REMOVING THE MIXER FROM THE CLUTCH
COVER, THE SEALING O-RING LOCATED ON THE COL­LAR OF THE MIXER MUST BE REPLACED.
CAUTION IN THE EVENT OF REMOVAL OR EXHAUSTION OF THE
OIL IN THE TANK, PROCEED TO BLEED THE MIXER AS FOLLOWS: WITH THE MIXER FITTED ON THE VEHICLE WITH THE ENGINE TURNED OFF, PULL OFF THE MIXER TUBE FROM THE CARBURETTOR AND LOOSEN THE BLEED SCREW UNTIL OIL STARTS TO FLOW. TIGHTEN THE SCREW, START THE ENGINE AND WAIT UNTIL OIL COMES OUT OF THE DELIVERY LINE TO THE CARBU­RETTOR (PREVIOUSLY DISCONNECTED). RECONNECT THE PIPE TO THE CARBURETTOR FIXING IT WITH A BAND.
In carrying out this operation, the engine must be fed with a mixture of 2% of appropriate oil (at least
0.5 litres if the tank is empty).
Recommended products
AGIP CITY TEC 2T Oil mixer for 2-stroke engines
JASO FC, ISO-L-EGD Specifications
Maintenance MSS APE 50
MA - 34
Page 35
Secondary air system
FILTER CLEANING AND INTEGRITY CHECK
To clean the sponge filters of the secondary air system, proceed as follows:
1) Unscrew the fixing screws «1» from the alumi­nium lid of the secondary air box to access the polyurethane sponge contained inside the same box.
2) Clean the polyurethane sponge by washing with soap and water, then dry everything with com­pressed air and reposition everything back in the corresponding seats, after checking at the same time that the blade is not warped, cracked and/or does not guarantee its seal on its contact surface; replace if necessary.
N.B. WHEN REASSEMBLING, TAKE CARE TO PROPERLY RE-
POSITION THE BLADE IN ITS SEAT ON THE TWO PLASTIC AND ALUMINIUM COVERS.
CAUTION DURING THE OPERATION 1) ALWAYS CHECK THE IN-
TEGRITY AND THE SEAL OF THE RUBBER SLEEVE LO­CATED ON THE END OF THE SECONDARY AIR TUBE; IF NECESSARY, REPLACE THE FIXING CLAMPS.
Headlight alignment check
APE 50 - APE 50 EUROPA
Position the unloaded vehicle on a flat surface and at 10 m away from a white screen located in the dark. Make sure that the vehicle axis is perpendicular to the screen. Draw a horizontal line on the screen with a height corresponding to 58-60 cm.; Check that the tyres are inflated to the pressure required, start the engine and lock the throttle twist grip at approximately 1/3 of its travel, turn on the headlight, insert the low beam and aim it so that the horizontal demarcation line between the dark and the lighted area does not fall above the horizontal line marked on the screen.
WARNING
THE HEADLIGHT IS FITTED WITH TWO ADJUSTMENT SCREWS, LOCATED AT THE TOP TO ALLOW CORRECTION OF ANY ALTERATION OF THE LIGHT BEAMS. TO ACCESS THESE SCREWS AND, IT IS NECESSARY TO REMOVE THE PROTECTIVE FRONT COWL OF THE HEAD­LIGHT UNIT BY TURNING THE TWO SCREWS THAT FIX THE SHIELD OF THE FRAME.
MSS APE 50 Maintenance
MA - 35
Page 36
HEADLIGHTS AIMING INSPECTION
N.B.
BEFORE CARRYING OUT THE OPERATION FOR HEADLIGHTS AIMING, CHECK THAT THE TYRES ARE INFLATED TO THE PRESSURES INDICATED IN THE SPECIFIC SECTION.
Proceed as follows:
1. Place the vehicle in conditions of use, without load, with the tyres inflated to the prescribed pres­sure on flat grounds at 10 m from a white screen placed in the shade. Make sure the vehicle axis is perpendicular to the screen;
2.Draw two vertical lines «a-a» at a distance «1» corresponding to the distance between headlight axes. Draw a horizontal line «b-b» at height «2» from ground corresponding to the headlight centre height from ground multiplied by 0.9;
3.Start the engine and lock the throttle twist grip at approximately 1/3 of its travel. Switch the dipped beam headlight on. Direct the beam so that the horizontal line between the light and the shade falls above the horizontal line «b-b» drawn on the screen;
Maintenance MSS APE 50
MA - 36
Page 37
4.If this is not so, adjust the headlight by means of the two screws (1) to correct any beam alterations.
Cables adjustment
SPLITTER_ADJUSTMENT CONTROL CABLE
Splitter control cable «1»: adjust so that clearance is felt on the throttle grip. Mixer cable «2»: see section "Mixer timing". Throttle grip cable «3»: adjust so that the sheath does not have clearance.
TRANSMISSIONS ADJUSTMENTS
Adjust the control cables: Cable mix: see "mixer timing" specification section. Gas cable: adjust so that the sheath does not have clearance. Splitter control cable: adjust so that clearance is felt on the throttle grip. All transmissions must be adjusted so that the sheaves have no clearances.
MSS APE 50 Maintenance
MA - 37
Page 38
INDEX OF TOPICS
EMISSION CONTROLO SYSTEM CO EM
Page 39
CO check
The test must be done after a thorough cleaning of all parts of the carburettor, with the air filter clean and spark plug in good condition.
1) Heat the vehicle for the time necessary to acti­vate the catalytic converter.
2) Turn off the vehicle for the time necessary to perform the operations of 3) and 4).
3) Insert an extension pipe of ~ 50 cm at the ex­haust fumes socket on the silencer.
4) With the utmost care, check the seal between silencer and tube. Insert the probe of the exhaust fumes analyser into the tube.
5) Start the engine.
6) Wait for a minute for the minimum to stabilise.
7) Without ever operating the accelerator and us­ing the appropriate screw (1), bring the engine speed to 1350 ± 100g/min.
8) Record the flow screw (2) in order to have a value of «CO» at a minimum of 2.0 ± 1.0.
9) Operate the throttle grip by slowly speeding up the engine to a speed of 4000 rpm. and return to the closed position; check that the idle speed re­mains at the previously established value, other­wise repeat the procedure starting from point 3).
Specific tooling
020332Y Digital rev counter 494929 Exhaust fumes analyzer
MSS APE 50 Emission Controlo System
CO EM - 39
Page 40
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Page 41
Probable cause and troubleshooting
DETONATIONS TO THE EXHAUST
Possible Cause Operation
Detonations in the silencer to the gas release Check the ducts and the membrane of the choke device on the
carburettor.
NOISE - KNOCKS
Possible Cause Operation
Worn or leaking shock absorbers Replace.
Flexible buffers of the swinging arms Replace.
Insufficient lubrication of the hubs Remove the hubs and fill the appropriate chamber with special
grease.
RUBBER JOINT FAILURE OF THE SECONDARY PIPE ON THE AIR SILENCER
Possible Cause Operation
Secondary air reed locking Replace.
Secondary air filter clogging Clean the filter and the box.
Clogging of the secondary air joint on the silencer Descale the joint taking care to not let the residues fall into the
silencer.
THE VEHICLE PULLS TO ONE SIDE
Possible Cause
Operation
The pressure of one of the tyres is not right Check and set to the prescribed pressure
Rear swinging arms Straighten out if possible, or replace.
Worn rubber buffers Replace.
Engine
ENGINE STOP
Possible Cause
Operation
Idle speed too low Work on the appropriate adjuster screw del of the carburettor.
Dirt or water in the mixture of the ducts Clean thoroughly.
Inefficient spark plug Clean and adjust the gap between the electrodes or replace.
Cock obstruction Clean.
H.V. cable or spark plug hood damaged Check or replace.
Fuel tank cap breather obstruction (defective fuel system) Clean properly.
CRANKSHAFT KNOCKS
Possible Cause
Operation
Excessive clearance of the main bearings Replace.
Big end failure Replace the crankshaft.
Crankshaft unbalanced Check the alignment
Piston pin worn Replace.
RINGING OF THE PISTON
Possible Cause
Operation
Excessive clearance between the piston and cylinder Replace the piston and correct the cylinder.
Excessive clearance of the roller pin-connecting rod small end
or piston pin
Review (for any replacement of the rollers of the connecting rod
small end, see the section "Specifications").
MSS APE 50 Troubleshooting
TROUBL - 41
Page 42
Poor performance
LOW POWER
Possible Cause Operation
Timing incorrect Perform the foreseen checks.
Cylinder head or spark plug not fitted correctly Correct the locking and the fitting.
Leakage of current of the ignition system Locate the dispersion and act accordingly.
Excessive incrustation on the lights of the cylinder Descale.
Silencer blocked Descale with iron wire bent into a hook or with compressed air
introduced into the cylinder nozzle fixed to the cylinder after the
external exhaust pipe.
Starting difficulties
PROBLEMS WITH STARTING
Possible Cause
Operation
Battery terminals oxidised or not properly locked Clean, tighten and protect with neutral petroleum jelly
Discharged battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. Fre­quently check that the fluid level fully covers the plates; if not, restore the level adding distilled water (never use natural water, even if it is drinking water) and check fluid density at the same
time.
If the vehicle is not used for some time (1 month or longer) the
battery needs to be recharged periodically. The battery runs down completely in the course of three months. When the bat­tery is being placed on the vehicle, make sure that the connec­tions are not misplaced, keeping in mind that the black ground cable with the terminal attached to the frame is to be connected to the negative terminal whereas, the other cable, must be con-
nected to the terminal marked +.
Carburettor body nozzles Remove and clean in petrol; dry with a compressed air jet.
Inefficient spark plug Replace.
Troubleshooting MSS APE 50
TROUBL - 42
Page 43
Clutch slipping
CLUTCH SLIPPAGE
Possible Cause Operation
Insufficient idle stroke Adjust the stroke.
Weak return spring Replace.
Worn or burned driven disc gasket Replace the disc.
Insufficient oil in the differential transmission or unsuitable oil Restore the oil level or replace.
Gearbox
OIL LOSS FROM THE TRANSMISSION - DIFFERENTIAL UNIT
Possible Cause Operation
Excessive filling Bring back to level.
Loosening of the crankcase halves locking nuts and the differ-
ential cover
Check the locks, replace the gaskets if necessary.
Axle shaft oil seal hood worn or broken Replace.
Cracked crankcase Replace.
Loose oil drain plug Lock and replace if damaged
Gears disengage abruptly or are difficult to engage
SPONTANEOUS GEARS DISENGAGEMENT
Possible Cause
Operation
Gearbox housing worn or damaged Verify and replace if necessary
Badly adjusted control cable Adjust.
Trasmission gears or spiders not properly assembled or worn Review.
Noisy gears
NOISY TRANSMISSION
Possible Cause
Operation
Excessive clearance between the gears of the transmission Review and replace the worn components.
Insufficient oil in the differential transmission Restore the oil level or replace.
Bearings of the gear shaft are noisy Replace.
Locked brakes
BRAKES LOCKED EVEN WHEN YOU CEASE TO PRESS THE PEDAL
Possible Cause
Operation
Return springs stretched Replace.
Compensation hole on the pump clogged Clean and bleed the air out of the system.
Rubber gasket swollen or sized Check the system, replace all the rubber parts and the fluid,
bleed air from the system: use the recommended oil
Noisy suspension
NOISY FRONT SUSPENSION
Possible Cause
Operation
Hub bearings worn or with excessive clearance Replace.
The wheel hub chamber needs to be greased Disassemble and apply grease.
MSS APE 50 Troubleshooting
TROUBL - 43
Page 44
Possible Cause Operation
Hydraulic absorber inefficient or discharged Replace.
Roller casings of swinging arm worn Replace.
Difficult riding
GUIDE IRREGULARITIES
Possible Cause Operation
The vehicle "pulls" to one side due to deformation of the steer-
ing tube
Check the steering unit and replace if necessary.
Steering is hard or knocks Check the steering fifth wheels: if they are loose they must be
properly tightened; if marked with pricks, they must be re-
placed.
Troubleshooting MSS APE 50
TROUBL - 44
Page 45
INDEX OF TOPICS
ELECTRICAL SYSTEM ES
Page 46
Dispositivi e accessori
ELECTRICAL SYSTEM DEVICES - APE 50
1. FRONT HEADLIGHTS, 12V-15W AND FROM 12V-5W BULBS
2. HORN
3. FRONT TURN INDICATORS, 12V-10W BULBS
4. WINDSCREEN WIPER
5. INDICATOR UNIT, 12V-1.2 W BULBS
6. WINDSCREEN WIPER SWITCH
7. START-UP BUTTON
8. LIGHT SWITCH
9. TURN INDICATOR SWITCH
10.HORN BUTTON
11. IGNITION SWITCH
12. STOP BUTTON
13.TURN INDICATOR CONTROL DEVICE
14. LOW FUEL WARNING LIGHT INDICATOR
15. START-UP MOTOR
16. 7.5A FUSE
17. START-UP REMOTE CONTROL SWITCH
18. REGULATOR
19.12V-32Ah BATTERY
20. ELECTRONIC CONTROL UNIT
21. SPARK PLUG
22.MAGNETO FLYWHEEL
23.REAR DAYLIGHT RUNNING LIGHTS, 12V- 4W BULBS
24. STOPLIGHTS, 12V-10W BULBS
25. REAR TURN INDICATORS, 12-10W BULBS
Electrical system MSS APE 50
ES - 46
Page 47
ELECTRICAL CABLES COLOUR CODING - APE 50 B = White Bl = Blue G = Yellow M = Brown N = Black BV = White-Green GN = Yellow-Black RN = Red-Black Gr = Grey Rs = Pink R = Red Vi = Purple V = Green A = Orange VN = Green-Black BN = White-Black BBI = White-Blue BR = White-Red
CAUTION
MSS APE 50 Electrical system
ES - 47
Page 48
WHEN INTERVENING ON THE ELECTRICAL SYSTEM, MAKE ESPECIALLY SURE THAT THE WIRES LEADING TO THE ELECTRONIC CONTROL UNIT ARE CORRECTLY CONNECTED AND RESPECT THE COLOUR CODING GIVEN ON THE CONTROL UNIT.
IGNITION SECTION KEY:
1.Alternator
2. Electronic control unit
3. Spark plug
4. Engine stop
STARTER AND RECHARGE SECTION KEY:
1.Alternator
2.Voltage regulator
3.Starter motor
4.Starter button
5. Key switch
6. 7.5A Fuse
7.Remote control
8. 12V-32Ah battery
Electrical system MSS APE 50
ES - 48
Page 49
TURN INDICATORS - STOP - WINDSCREEN WIPER KEY:
1. Windscreen wiper switch
2. Windscreen wiper
3. 12V-1.2W turn indicator warning light
4. No. 4 12V-10W turn indicator bulbs
5. Turn indicator command
6. Turn indicator switch
7. No.2 12V-10W stop bulbs
8. Stop switch
9. From B+ of the regulator
MSS APE 50 Electrical system
ES - 49
Page 50
HORN SECTION - LEVEL TRANSMITTER KEY:
1. Turn indicators
2.Horn button
3. Horn
4. 12V-1.2W Low fuel warning light
5.Fuel warning light transmitter
6. From B+ of the regulator
Electrical system MSS APE 50
ES - 50
Page 51
LIGHTS SECTION KEY:
1.Alternator
2. 12V-15W Headlight light
3. 12V-5W City lights
4. 12V-4W Rear daylight running light
5. 12V-1.2W headlight warning light
6. Light switch
7. Voltage regulator
MSS APE 50 Electrical system
ES - 51
Page 52
ELECTRICAL SYSTEM DEVICES - APE 50 EUROPA
1. FRONT HEADLIGHTS, 12V-3W, 12V- 15W AND 12V-10W BULBS
2. HORN
3. REAR HEADLIGHTS, 12V-4W, 12V-10W AND 12V-10W BULBS
4. WINDSCREEN WIPER
5. INSTRUMENT PANEL, 12V- 1.2W BULBS
6. WINDSCREEN WIPER SWITCH
7. STARTER BUTTON
8. LIGHT SWITCH
9. TURN INDICATOR SWITCH
10. HORN BUTTON
11. IGNITION SWITCH
12. STOP BUTTON
13. TURN INDICATOR CONTROL DEVICE
14. LOW FUEL WARNING LIGHT CONTROL
15. START-UP MOTOR
16. 8A FUSE
17. START-UP REMOTE CONTROL SWITCH
18. VOLTAGE REGULATOR
19. 12V-9Ah BATTERY
20. ELECTRONIC CONTROL UNIT
Electrical system MSS APE 50
ES - 52
Page 53
21. SPARK PLUG
22.MAGNETO FLYWHEEL
23. INTERNAL LIGHT FITTING, 12V-5W BULB
24. ALTERNATOR LIGHT, 12V-1.2W BULB
25. STOP SWITCH
ELECTRICAL CABLES COLOUR CODING - APE 50 EUROPA B = White Bl = Blue G = Yellow M = Brown N = Black BV = White-Green GN = Yellow-Black RN = Red-Black Gr = Grey Rs = Red Vi = Purple V = Green VN = Green-Black BN = White-Black BBI = White-Blue
MSS APE 50 Electrical system
ES - 53
Page 54
BR = White-Red A = Blue Ar = Orange
CAUTION
WHEN INTERVENING ON THE ELECTRICAL SYSTEM, MAKE ESPECIALLY SURE THAT THE WIRES LEADING TO THE ELECTRONIC CONTROL UNIT ARE CORRECTLY CONNECTED AND RESPECT THE COLOUR CODING GIVEN ON THE CONTROL UNIT.
LIGHTS SECTION - APE 50 EUROPA KEY:
1.Alternator
2. 12V-15W Headlights
3. 12V-5W City lights
4. 12V-4W Rear daylight running light
5. Headlight warning light
6. Light switch
7. Voltage regulator
ELECTRICAL SYSTEM DEVICES (TOP AND BASE) - APE 50 mix
1. FRONT HEADLIGHTS AND TURN INDICATORS, 12V-3W, 12V- 15W AND 12V-10W BULBS
2. HORN
3. REAR LIGHTS, 12V-4W, 12V-10W AND 12V-10W BULBS
Electrical system MSS APE 50
ES - 54
Page 55
4. WINDSCREEN WIPER
5. INSTRUMENT PANEL, 12V- 1.2W BULBS
6. WINDSCREEN WIPER SWITCH
7. STARTER BUTTON
8. LIGHT SWITCH
9. TURN INDICATOR SWITCH
10. HORN BUTTON
11. IGNITION SWITCH
12. STOP BUTTON ON THE REAR BRAKE
13. CIGARETTE LIGHTER
14. LOW FUEL WARNING LIGHT CONTROL
15. OIL RESERVE WARNING LIGHT CONTROL
16. START-UP MOTOR
17. CIGARETTE LIGHTER LIGHTING, 12V-1.2W BULB
18. STOP BUTTON ON THE FRONT BRAKE
19. STARTER RELAY
20. Voltage regulator
21. 12V-9AH BATTERY
22.ELECTRONIC CONTROL UNIT
23.SPARK PLUG
24. MAGNETO FLYWHEEL
25. INTERNAL LIGHT FITTING, 12V-5W BULB
26. 7.5A (GENERAL) FUSE
27. (CIGARETTE LIGHTER AND LIGHT FITTING) 10A FUSE
28. DIGITAL CLOCK LIGHTING, 12V-1.2W BULBS (TOP VERSION ONLY)
29. DIGITAL CLOCK (TOP VERSION ONLY)
MSS APE 50 Electrical system
ES - 55
Page 56
ELECTRICAL CABLES COLOUR CODING - APE 50 mix Ar = Orange B = White BBI = White-Blue BIN = Blue-Black BIR = Blue-Red BN = White-Black BVi = White-Purple GN = Yellow-Black Gr = Grey GrR = Grey-Red GV = Yellow-Green M = Brown N = Black Rs = Pink V = Green R = Red Vi = Purple VN = Green-Black
CAUTION
Electrical system MSS APE 50
ES - 56
Page 57
WHEN INTERVENING ON THE ELECTRICAL SYSTEM, MAKE ESPECIALLY SURE THAT THE WIRES LEADING TO THE ELECTRONIC CONTROL UNIT ARE CORRECTLY CONNECTED AND RESPECT THE COLOUR CODING GIVEN ON THE CONTROL UNIT.
ELECTRICAL SYSTEM DEVICES - APE 50 mix (CROSS VERSION)
1. FRONT HEADLIGHTS AND TURN INDICATORS, 12V-3W, 12V- 15W AND 12V-10W BULBS
2. HORN
3. REAR LIGHTS, 12V-4W, 12V-10W AND 12V-10W BULBS
4. WINDSCREEN WIPER
5. INSTRUMENT PANEL, 12V- 1.2W BULBS
6. WINDSCREEN WIPER SWITCH
7. STARTER BUTTON
8. LIGHT SWITCH
9. TURN INDICATOR SWITCH
10. HORN BUTTON
11. IGNITION SWITCH
12. STOP BUTTON ON THE REAR BRAKE
13. CIGARETTE LIGHTER
14. LOW FUEL WARNING LIGHT CONTROL
15. OIL RESERVE WARNING LIGHT CONTROL
16. START-UP MOTOR
17. CIGARETTE LIGHTER LIGHTING, 12V-1.2W BULB
18. STOP BUTTON ON THE FRONT BRAKE
19. STARTER RELAY
20. Voltage regulator
21. 12V-9AH BATTERY
22.ELECTRONIC CONTROL UNIT
23.SPARK PLUG
24. MAGNETO FLYWHEEL
25. INTERNAL LIGHT FITTING, 12V-5W BULB
26. 20A (GENERAL) FUSE
27.(CIGARETTE LIGHTER AND LIGHT FITTING) 10A FUSE
28. 7.5A (SERVICE) FUSE
29. 4A FUSE (DAYLIGHT RUNNING LIGHT)
30. 4A FUSE (LOW-BEAM LIGHTS)
31. DIGITAL CLOCK LIGHTING, 12V-1.2W BULBS
32. DIGITAL CLOCK
33. TURN INDICATOR CONTROL DEVICE
MSS APE 50 Electrical system
ES - 57
Page 58
ELECTRICAL CABLES COLOUR CODING - APE 50 mix (CROSS VERSION) Ar = Orange B = White BBI = White-Blue BIN = Blue-Black BIR = Blue-Red BN = White-Black BVi = White-Purple G = Yellow GN = Yellow-Black Gr = Grey GrN = Grey-Black GV = Yellow-Green M = Brown N = Black R = Red RB = Red-White Rs = Pink V = Green Vi = Purple ViN = Purple-Black
Electrical system MSS APE 50
ES - 58
Page 59
VN = Green-Black
CAUTION
WHEN INTERVENING ON THE ELECTRICAL SYSTEM, MAKE ESPECIALLY SURE THAT THE WIRES LEADING TO THE ELECTRONIC CONTROL UNIT ARE CORRECTLY CONNECTED AND RESPECT THE COLOUR CODING GIVEN ON THE CONTROL UNIT.
ELECTRICAL SYSTEM DEVICES - APE 50 EUROPE
1. HORN
2. NO.2 BULBS FOR FRONT TURN INDICATORS
3. CABLE ASSEMBLY
4. COMPLETE WINDSCREEN WIPER
5. CIGARETTE LIGHTER
6. COMPLETE FRONT COWL
7. COMPLETE BULB HOLDER
8. CLOCK
9. No.2 BULBS FOR HEADLIGHTS
10. No.2 BULBS FOR DAYLIGHT RUNNING LIGHT
11. No.2 BULBS FOR FRONT TURN INDICATORS
12. CABLE ASSEMBLY OF THE CHASSIS
13. STOP BUTTON ON THE FRONT BRAKE
14. LIGHT SWITCH
15. WINDSCREEN WASHER SWITCH
16. START-UP BUTTON
17. IGNITION SWITCH
18. INSTRUMENT PANEL BULB
19. INSTRUMENT PANEL WITH No.6 BULBS
20. MIX OIL WARNING LIGHT
21. TURN INDICATOR WARNING LIGHT
22. CARB. RESERVE WARNING LIGHT
23. HEADLIGHT WARNING LIGHT
24. CABLE HARNESS
25. LIGHT FITTING
26. HORN BUTTON
27. TURN INDICATOR SWITCH
28. VOLTAGE REGULATOR
29. FUSE HOLDER WITH FUSE
30. FUSE HOLDER WITH FUSE
31. Battery
MSS APE 50 Electrical system
ES - 59
Page 60
32. NEGATIVE BATTERY CABLE
33. STARTER RELAY
34. LOW FUEL WARNING LIGHT CONTROL
35. No.2 BULBS FOR STOP LIGHT
36. No.2 BULBS FOR REAR TURN INDICATORS
37. No.2 BULBS FOR DAYLIGHT RUNNING LIGHT
38. No.2 REAR LIGHTS
39. LIGHT FOR LICENCE PLATE WITH BULB
40. MIX OIL WARNING LIGHT CONTROL
41. CHASSIS-ENGINE GROUND CABLE
42. STARTER MOTOR
43. ELECTRONIC IGNITION DEVICE
44. MAGNETO FLYWHEEL
45. GROUND ON THE CHASSIS
46. Electric screen washer pump
47. STOP BUTTON ON THE REAR BRAKE
ELECTRICAL CABLES COLOUR CODING - APE 50 EUROPE B = White Bl = Blue G = Yellow M = Brown
Electrical system MSS APE 50
ES - 60
Page 61
N = Black BV = White-Green GN = Yellow-Black RN = Red-Black Gr = Grey Rs = Pink R = Red Vi = Purple V = Green A = Orange VN = Green-Black BN = White-Black BBI = White-Blue BR = White-Red RGr = Red-Grey BIN = Blue-Black BVi = White-Purple RBI = Red-Blue
CAUTION
WHEN INTERVENING ON THE ELECTRICAL SYSTEM, MAKE ESPECIALLY SURE THAT THE WIRES LEADING TO THE ELECTRONIC CONTROL UNIT ARE CORRECTLY CONNECTED AND RESPECT THE COLOUR CODING GIVEN ON THE CONTROL UNIT.
Key-switch
LOCK Position: contacts 7-8, ground ignition, ex-
tractable key, locked steering. OFF: contacts 7-8, ground ignition. Key may be removed. ON Position: contacts 1 -3 (c.c. to the services) and 5-6 (Provision to the ignition of the daylight running light in c.a.). Key may not be removed. Position 1: contacts 7-8 (ground ignition) and 3-5 (c.c. to the daylight running light). Parking extract­able key.
MSS APE 50 Electrical system
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Page 62
Turn signal switch
Position 0: no contact. Position 1: contact between the Blue and White ­Blue cables. Position 2: contact between the Blue and Brown cables.
Horn button
Button in working position, contact between the White and Grey Black cables.
Headlight switch
Position O: no contact. Position 1: contact between the Pink and Grey ca­bles. Position 2: contact between the Pink and Grey and Purple cables.
Electrical system MSS APE 50
ES - 62
Page 63
Wiper switch
In working position, contact between the White and White Black cables.
POSITIONS OF THE WINDSCREEN WIPER SWITCH - APE 50 MIX - APE 50 EUROPE 0 = Windscreen wiper turned off 1 = Windscreen wiper turned on 2 = Windscreen washer enabling
Pulsante avviamento
In working position, contact between the White and Green Black cables.
MSS APE 50 Electrical system
ES - 63
Page 64
Interventions
The failure of the alternate current section of the voltage regulator can cause, depending on the type of fault, the following problems:
1) Burning of the bulbs (regulator stopped).
2) Operation failure of the lighting (short circuit in the regulator).
FAILURE 1
Replace the regulator because it is securely inefficient.
FAILURE 2
a) Check the correct current output of the alterna­tor: disconnect the grey regulator cable, place a voltmeter between the cable and ground to detect the alternate current voltages and to check that the output voltage at 3000 rpm is greater than or equal to 20V. b) If the checks carried out disclose no failures, replace the regulator. c) If replacing the regulator does not restore proper operation, proceed to the checks of the electrical system connections.
interventions
The failure of the direct current section of the voltage regulator can cause, depending on the type of fault, the following problems:
3) Burning of the protective fuse (short circuit in the regulator) and subsequent battery recharge failure.
4) Battery recharge failure(regulator stopped).
FAILURE 3
Replace the regulator, because it is securely inefficient and replace the protective fuse.
FAILURE 4
a) Insert an ammeter between the regulator and the battery and verify that the current ouput at 3000 rpm is greater than 1 amp, with the battery maintained at 13V. If the values are lower than required, replace the regulator.
Electrical system MSS APE 50
ES - 64
Page 65
b) If replacing the regulator does not restore proper operation, check the voltage output from the alter­nator, as in point 2a. Checking the output voltage at 3000 rpm on the c.c. section is greater than or equal to 25V.
Characteristics
STARTER MOTOR
Specification Desc./Quantity
Rated voltage 12V.
rated power 0.25 Kw.
Rotation Left.
Bench tests
TESTS TO BE PERFORMED AT THE BENCH WHEN THE STARTER MOTOR HAS TO BE OVER­HAULED.
1) No-load test: the starter motor, under no-load, must draw a maximum of 30 Amp. with a supply voltage of 11.5 to 12V and must rotate at rpm 11,000.
2) Load test: braking the starter motor so that it draws 60 Amp, and with a supply voltage of 10 to 10.5 V a torque 0.06 kgm must be obtained, for no lower than 4,600 rpm.
3) Pickup test: with rotor locked and a supply voltage 8 to 8.5V the current drawn must not be higher than 160 Amp and the torque must be no lower than 0.3 kgm.
N.B.
THE VALUES SHOWN ABOVE MUST BE TAKEN WITH A CHARGED BATTERY AND AFTER THE STARTER MOTOR HAS BEEN ROTATING FOR 30" UNDER CONDITIONS OF POINT 1.
MSS APE 50 Electrical system
ES - 65
Page 66
KEY: 1 = Starter button 2 = Remote control
Starter motor removal
Safety cap removal
Coupling pin removal
Remove the retainer ring and remove the pinion.
CAUTION ALWAYS REPLACE THE INDICATED GASKET GIVEN TO-
GETHER WITH THE SPECIFIC RECOMMENDED PROD­UCT.
Electrical system MSS APE 50
ES - 66
Page 67
Safety cap calkin
- Position the hood.
- Chamfer, as shown, the hood with the appropri­ate tool.
CAUTION REPLACING THE BRUSHES, AND REMOVE THE REAR LID
AND REPLACE.
Specific tooling
020057Y Tool for Starter Motor Bushing Calk­ing
Controllo impianto di accensione
All system check operations involving disconnec­tion of the cables (inspections of connections and devices that are part of the ignition circuit) must be made with the engine turned off: otherwise the control unit could be irreparably damaged. It is therefore important and necessary that in case of removal of the cables, when refitting attention is paid to correctly reconnecting each cable to the corresponding coupling respecting the distinct col­our codings.
KEY: 1 = Red 2 = White 3 = Green
INSPECTIONS TO BE PERFORMED IN THE EVENT OF IGNITION IRREGULARITIES
In the event of failure and abnormal operation of the ignition, whose causes are not detectable by a visual inspection, it is necessary first to replace the control unit with a corresponding, safely functional replacement. Remember that the disconnections and connections to replace the control unit must be performed when the engine stopped. If replacing it 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 parts as follows: After a visual inspection of the electrical connections, measurements are carried out on the loading coil and on the pick-up using an Ohm meter, capable of detecting the resistance from 1 to 1000 ohms.
MSS APE 50 Electrical system
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Page 68
Connect the instrument between the green cable and the white one, there must be continuity and an ohmic value of 500± 20 ohm.
KEY: 1 = Red 2 = White 3 = Green 4 = Black 5 = Blue
Connect the instrument between the red and white cables, there must be continuity and an ohmic val­ue of 110± ±5 ohm.
KEY: 1 = Red 2 = White 3 = Green 4 = Black 5 = Blue
If there are failures on the checks on the loading coil and on the pick-up, proceed to the replacement.
Electrical system MSS APE 50
ES - 68
Page 69
INDEX OF TOPICS
ENGINE FROM VEHICLE EV
Page 70
Remove the oil from the engine. Disconnect the negative cable from the battery and the starter motor cables. Remove the fuel delivery line. Remove the throttle grips, starter, etc. Remove the axle shaft complete with hubs. Remove the three fixing bolts (due at the front, and one at the rear) and remove the differential engine unit of the chassis.
WARNING
WE RECOMMEND THE USE OF EYE PROTECTION WHEN USING CONTACT TOOLS.
WARNING
DO NOT REMOVE THE OIL COVER IMMEDIATELY AFTER AN ACTIVITY WITH THE ENGINE AT FULL SPEED AND/OR WITH THE ENGINE RUNNING. THE HEATED OIL MAY LEAK, WITH THE RISK OF BURNING
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG­ATIVE LEAD.
Engine from vehicle MSS APE 50
EV - 70
Page 71
INDEX OF TOPICS
ENGINE EN
Page 72
Engine type 1
Flywheel
Remove the scroll cover.
Using the special tool to block the flywheel.
Specific tooling
020095Y Flywheel Lock
Using the appropriate tool, unscrew the lock-nut of the flywheel.
Specific tooling
048564Y Flywheel extractor
Engine MSS APE 50
EN - 72
Page 73
Stator
For refit operations, operate in the opposite direc­tion to the removal, bearing in mind the following: position the stator as shown, correctly position the key, and lock the flywheel nut to the prescribed torque.
Locking torques (N*m)
Fan flywheel locking nut 45 to 50 Nm
Crankcase splitting
Fitting:
Clean the mating surfaces thoroughly. Position a new gasket on the flywheel side crank­case halves. Join the two crankcase halves.
Insert the flywheel side seal ring.
MSS APE 50 Engine
EN - 73
Page 74
Half-crankcase splitting
Removal:
Undo the screws and disassemble the crankcase halves.
Crankcase bearings
Removal:
Remove the circlips and with punches of a suitable diameter to eject the bearings.
Specific tooling
022465Y Pliers for circlips
Fitting:
Heat the crankcase to around 80° C. Position the bearings. Fit the retainer ring. Fit the bench seal ring.
Specific tooling
020150Y Support 020151Y Heat gun 022465Y Pliers for circlips
Engine MSS APE 50
EN - 74
Page 75
Fly-wheel side half-crankcase
Removal:
Remove the bench bearing, operate with a punch of an adequate diameter.
Specific tooling
021467Y Bearing extractor 021467Y013 extractor 021467Y009 extractor
After warming the crankcase, remove it with light taps of the hammer. Remove the bearing from the shaft, by leveraging it with 2 screwdrivers.
Fitting:
Heat the crankcase to around 80° C. Fit the bench ball bearing. Fit main shaft of the transmission complete with bearing.
Specific tooling
020150Y Support 020151Y Heat gun Fitting:
Let the crankcase cool and fit the roller bearing.
Specific tooling
032975Y Punches for Roller Casings
MSS APE 50 Engine
EN - 75
Page 76
Gear-box coupling replacement
Removal:
Using the special tool remove the gear retaining seeger.
Specific tooling
023638Y Pliers for circlips
Removal.
Fitting.
Fitting:
Reposition the transmission secondary shaft in its seat.
Engine MSS APE 50
EN - 76
Page 77
Overhaul
Using the appropriate tool, disassemble the gear engagement. Inspect the components and replace those that are damaged.
Specific tooling
023638Y Pliers for circlips
Coupling refitting
Using the appropriate tool, reassemble the gear engagement.
Specific tooling
029569Y Gear Engagement Fitting Tool
Clutch drum
Removal:
After removing the circlips (for the piston pin), us­ing a hard plastic mallet, remove the clutch hous­ing
Specific tooling
023638Y Pliers for circlips
MSS APE 50 Engine
EN - 77
Page 78
Fitting:
Position the clutch housing with light taps with the hard plastic mallet. Fit the locking circlip.
Specific tooling
023638Y Pliers for circlips
Differential assembly
WARNING
REFIT THE PARTS IN REVERSE ORDER OF THE REMOVAL, TAKING CARE TO CORRECTLY INSERT THE REVERSE GEAR CONTROL FORK INTO THE SLIDING GEAR.
WARNING
AFTER INSTALLING THE AXLE SHAFT IN THE CROWN WHEEL, CHECK THE PROPER SWING OF THE AXLE SHAFT IN RELATION TO THE CROWN WHEEL.
Engine MSS APE 50
EN - 78
Page 79
Cover removal
Undo the indicated screws.
Differential box and transmission gears
Remove the gears
Differential case
Undo the indicated screws.
MSS APE 50 Engine
EN - 79
Page 80
Remove the bearing using a section of tube. Refit the bearing as shown in figure.
Specific tooling
038138Y Roller Casings Punch
Differential box overhaul
Inspect all components and replace damaged parts
Clutch cover and thrust plate
Removal:
Undo the indicated screws.
Fitting:
In order to correctly position the thrust plate ac­tuating pad, follow these steps: hold the clutch lever full stroke, insert the actuating pad into its housing and holding the actuating pad, slowly re­lease the clutch lever, check that the references on the clutch lever and on the cover are the same as shown in the figure.
Engine MSS APE 50
EN - 80
Page 81
Clutch and engine gear
Using the special tool to block the clutch assembly.
Specific tooling
030250Y Clutch Stop Key
Using the special tool, undo the fixing nut of the clutch assembly
Specific tooling
029551Y Clutch puller
Fitting:
Reposition the clutch assembly and the engine gear in their seat. Tighten to the specified torque.
CAUTION
REFIT ALL PARTS, COMPONENTS, THE UNIT IN RE­VERSE ORDER TO THE REMOVAL, PAYING ATTENTION TO REPOSITION THE CLUTCH KEY AND ENGINE GEAR MOTOR.
Specific tooling
030250Y Clutch Stop Key
Locking torques (N*m)
Engine gear locking nut 50 to 55 Nm Clutch as­sembly locking nut 40 ÷ 45 Nm
MSS APE 50 Engine
EN - 81
Page 82
Clutch overhaul
Using the special tool to disassemble the clutch assembly.
Specific tooling
020322Y Clutch Removal
Inspect the components and replace damaged parts.
Cylinder head
Undo the fixing screws and remove the cylinder hood
Undo the fixing screws of the cylinder head.
Engine MSS APE 50
EN - 82
Page 83
Piston
Remove the seal ring of the pin. Remove the seal ring by removing the pin.
CAUTION
REFIT THE PARTS IN REVERSE ORDER TO THE DISAS­SEMBLY, TAKING CARE TO POSITION THE PISTON WITH THE ARROW STAMPED ON THE SKY IN THE SAME DI­RECTION AS THE EXHAUST.
Crankshaft
Removal:
To remove the crankshaft, separate the crankcase halves and using gentle taps with a rubber mallet to remove it.
CAUTION
SUPPORT THE CRANKSHAFT TO PREVENT DAMAGE BY FALLING.
Fitting:
Using the appropriate tools necessary, position the crankshaft in its seat.
Specific tooling
018119Y Axle Fitting Tool 018119Y009 Axle fitting 018119Y007 Axle fitting
MSS APE 50 Engine
EN - 83
Page 84
Engine timing
Coil support operation check.
ENGINER TIMING CHECK
Check to be carried with the Tecno- test 130/P strobe gun (or a similar one that is able to function properly up to at least 11,000 times per minute).
CAUTION BEFORE PERFORMING THE TESTS ABOVE, CHECK THE
CORRECT JOINING OF THE FLYWHEEL ON THE CRANK­SHAFT.
Engine MSS APE 50
EN - 84
Page 85
INDEX OF TOPICS
B
RAKING SYSTEM BS
Page 86
Brake pump
Key pump section:
1) Lug
Braking system MSS APE 50
BS - 86
Page 87
2) Gasket
3) Seeger ring
4) Washer
5) Gasket
6) Buffer
7) Plug
8) Pump body
9) Piston
10) Ring
11) Toric gasket
12) Spring
13) Cup
14) Spring
Brake pump overhaul specifications
After washing all the parts with a specific solvent, never use oil, petrol or solvents that have a corrosive effect on the rubber, check that: The pump body does not show signs of internal damage or corrosion as this may result in sealing ring or piston failure; the latter must also be replaced if worn or scratched. The rubber parts in the piston and the valve are not dilated or damaged as this most likely leads to poor braking. The piston return spring is in good condition. The passages connecting the pump tank to the pump body are not clogged or dirty.
Removing brake fluid reservoir and pump from chassis
Removal:
After removing the brake fluid, remove the tank.
CAUTION
BRAKE FLUID IS HARMFUL TO THE EYES. IF IT COMES INTO CONTACT WITH THE EYES WASH THE AFFECTED PART CAREFULLY AND CONSULT A DOCTOR.
FOR CORRECT OPERATION OF THE BRAKES, USE ONLY THE RECOMMENDED BRAKE FLUID.
FOLLOW THE INSTRUCTIONS PROVIDED BY THE BRAKE FLUID MANUFACTURER.
NEVER MIX LIQUIDS WITH DIFFERENT TECHNICAL SPECIFICATIONS.
USE ONLY BRAKE FLUID KEPT IN SEALED CONTAINERS. IF THE LIQUID IS EXPOSED TO THE AIR FOR TOO LONG IT ABSORBS HUMIDITY AND LOSES ITS EFFICIENCY.
KEEP THE BRAKE FLUID FREE OF LITTER, SAND OR DUST.
MSS APE 50 Braking system
BS - 87
Page 88
IF THE BRAKE FLUID LEVEL FALLS CONSID­ERABLY, HAVE THE BRAKING SYSTEM CHECKED BY AN AUTHORISED PIAGGIO SERVICE CENTRE.
Refitting brake fluid reservoir and pump from chassis
Fitting:
Reposition the brake fluid tank appropriately. Restore the correct level and bleed the system.
Air bleed of brake hydraulic circuit
Push down the pedal to the end of its travel and slowly let it return to its starting position, repeating the operation until the pedal feels a back pressure.
As this operation is carried out add fluid to the tank to prevent the pump from discharging.
Lower the pedal, keeping it pressed, undo the bleed screw on a rear wheel, let the air out, after this bleed point has been connected through a small rubber pipe to a tray full of brake fluid. Screw the bleed screw.
Repeat the above operations until the escape of air bubbles from the that tube does not stop. Repeat the above operations for the other wheel.
CAUTION
THE AIR COMING OUT OF THE TUBE MAY ENTER DURING THE CONTINUOUS BLEEDING OP­ERATION; IN SUCH A CASE INSPECT ALL FITTINGS AND THE CORRECT TIGHTENING OF THE GASKETS OF THE PUMP AND OF THE CYLINDERS OF THE WHEEL.
In performing the circuit filling operation shown above, ensure that the liquid level in the tank never falls below the minimum, and top up continuously with the recommended product.
Braking system MSS APE 50
BS - 88
Page 89
CAUTION
BRAKE FLUID IS HYGROSCOPIC; IT TENDS TO ABSORB MOISTURE FROM THE SURROUND­ING AIR. IF THE HUMIDITY IN THE BRAKE FLUID IS ABOVE A GIVEN VALUE, BRAKING IS POOR. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THE FLUID EVERY TWO YEARS. IF THE BRAKES UNDERGO SEVERE OPERATING CONDITIONS THE LIQUID SHOULD BE RE­PLACED MORE FREQUENTLY.
CAUTION
WHEN REFILLING TO LEVEL USE ONLY THE TYPE OF LIQUID THAT HAD BEEN USED PREVI­OUSLY.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4
Drum removal
In the filling operations, a maximum oversize of 0.4 mm on the regular drum diameter is allowed.
Shoe and drum clearance adjustment
Before performing the adjustment between the shoe and the drums, it is necessary to set the brakes in motion, in a way that ensures the cen­tring of said shoe. Then act as follows for each wheel: Lift the wheel off the ground, lower of the brake pedal to the bottom until it brings the shoe against the drum. Holding down the pedal, rotate the nuts of the ad­justment eccentricities outwards until they stop, then rotate them in the opposite direction by about 45°.
MSS APE 50 Braking system
BS - 89
Page 90
Then release the pedal and check that the wheel turns freely.
Parking brake adjustment
In order to adjust the travel of the control hand lev­er, proceed as follows: Bring the lever to its rest position and move it up­ward by two teeth on the sector. Act on the tensioner so as to prevent the rotation by hand of the wheels. Lock the tensioner in position with its lock nut.
CAUTION REMEMBER THAT A NORMAL ADJUSTMENT OF THE
TENSION OF THE CABLE AFFECTS THE OPERATION OF THE BRAKE ON THE REAR WHEELS.
Front drum brake
For the mechanical adjustment of the front brake, act on the adjuster screw «1», so that, with the lever in its rest position, the wheel turns freely.
CAUTION
FOR ADJUSTMENTS RELATING TO THE BRAKING SYS­TEM, WE RECOMMEND CONTACTING AN AUTHORISED PIAGGIO SERVICE CENTRE.
Braking system MSS APE 50
BS - 90
Page 91
INDEX OF TOPICS
STEERING COLUMN SC
Page 92
Handlebar
INSTALLING
Locking torques (N*m)
Locking bolts 35 to 60 Nm
Steering wheel from chassis
Specific tooling
020055Y Steering Ring Nut Key
STEERING ON THE CHASSIS - LOCKING
Specific tooling
020055Y Steering Ring Nut Key
Locking torques (N*m)
Upper seat 30 to 40 Nm Steering ring nut 50 to 60
Nm
Steering column MSS APE 50
SC - 92
Page 93
Steering bearing housing from chassis
UPPER SEAT
Specific tooling
020842Y Upper Steering Bearing Removal Punch
LOWER SEAT
Specific tooling
020004Y Steering seats extraction punch
Lower housing from steering column
Specific tooling
020042Y Steering tube bearing extractor
MSS APE 50 Steering column
SC - 93
Page 94
Dust ring
DUST GUARD AND LOWER SEAT ON THE STEERING TUBE
Specific tooling
016029Y Lower Steering Bearing Fitting Tool on the steering tube
Steering bearing housing on chassis
Specific tooling
021330Y003 Steering seats fitting 021330Y004 Steering seats fitting
Steering column MSS APE 50
SC - 94
Page 95
INDEX OF TOPICS
SUSPENSIONS SS
Page 96
Brake drum
FRONT WHEEL DRUM LOCKING
CAUTION ALWAYS USE NEW NUTS, CHAMFERING THEM IN THE
APPROPRIATE WAY.
Locking torques (N*m)
Brake drum locking 75 to 90 Nm
Drum bearings
DRUM BEARINGS
Use a Ø 17 section of tube for the ball bearing and a Ø 23 section of tube for the roller bearing.
Suspensions MSS APE 50
SS - 96
Page 97
Roller cage and split ring on brake drum
Specific tooling
033970Y Punches for Roller Casings
Ball bearing and split ring on brake drum
Heat the bearing housing area with the appropriate tools and fit the ball bearing and the circlip.
CAUTION BEFORE REFITTING THE DRUM, FILL THE INTERNAL
CHAMBER WITH THE SPECIFIC GREASE.
Specific tooling
020151Y Heat gun
Drum and rear wheel
MSS APE 50 Suspensions
SS - 97
Page 98
REAR WHEEL BRAKE DRUM LOCKING
When refitting the drum brake on the wheel axle, do not reuse the previously removed chamfered nut, but replace it with a new one; the locking must be carried out, chamfering carefully with a (steel) punch, the collar in the existing groove on the wheel-holder shaft, then fit the cover after filling it with specific grease.
Recommended products
AGIP GREASE PV 2 Grease for brake control levers
Specifications: NLGI 2 ; ISO-LXBIB2
Locking torques (N*m)
Rear wheel brake drum locking 80 to 100 Nm
KEY: *= chamfer.
Parking brake control and brake shoes
Brake cylinder and shoe disc
Suspensions MSS APE 50
SS - 98
Page 99
Wheel hub
Unscrew the indicated clamps and using the tool remove the hub.
Specific tooling
038137Y Rear Hub Extractor
Planetary and half-pins
In order to optimise the joint of the axle shaft, be careful:
- when refitting the two half-pins;
- that the most open part is facing the axle
shaft.
Ball bearing and split ring on hub
Heat the housing area with the appropriate tools and fit the ball bearing and the remaining parts.
Specific tooling
020151Y Heat gun
MSS APE 50 Suspensions
SS - 99
Page 100
BALL BEARING AND ROLLER BEARING FROM THE HUB
Use a Ø 24 section of tube for the ball bearing and a Ø 24 section of tube for the roller bearing.
Spacer, roller cage and split ring
SPACER - ROLLER BEARING - SEAL RING
CAUTION BEFORE FITTING THE SPACE AND THE ROLLER BEAR-
ING, FILL THE INTERNAL CHAMBER OF THE HUB WITH SPECIFIC GREASE.
Wheel hub on half-shaft
Prepare the dust gaiter cap (1), the seal ring (2) and the spacer (3) on the axle shaft, then fit the hub as described below:
1) - Use the appropriate tool complete with part. 15 and push the hub until it enters the axle shaft in the ball bearing.
Suspensions MSS APE 50
SS - 100
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