PIAGGIO MSS APE 50 2012, 2012 MSS APE 50 Service Manual

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MANUALE STAZIONE DI SERVIZIO

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MSS APE 50 (2012)

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MANUALE

STAZIONE DI

SERVIZIO

MSS APE 50 (2012)

This publication has been edited by:

After sales - PIAGGIO & C. S.p.A.

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

ITALY

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MANUALE STAZIONE DI

SERVIZIO

MSS APE 50 (2012)

MANUALE STAZIONE DI SERVIZIO

Questo manuale per stazioni di servizio è stato realizzato da PIAGGIO & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici. Le descrizioni ed illustrazioni fornite nella presente pubblicazione s'intendono non impegnative; PIAGGIO perciò si riserva il diritto, ferme restando le caratteristiche essenziali del tipo qui descritto ed illustrato, di apportare in qualunque momento, senza impegnarsi ad aggiornare tempestivamente questa pubblicazione, le eventuali modifiche di organi, particolari o forniture di accessori, che essa ritenga conveniente per scopo di miglioramento o per qualsiasi esigenza di carattere costruttivo o commerciale. Non tutte le versioni riportate nella presente pubblicazione sono disponibili in ogni Paese. La disponibilità delle singole versioni deve essere verificata con la rete ufficiale di vendita Piaggio.

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.

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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

DIFFERENTIAL DI

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

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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.

MSS APE 50 (2012) General guidelines

GEN - 7

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INDEX OF TOPICS

CHARACTERISTICS CH

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Identification

The identification registration numbers are made up of a prefix that identifies the vehicle type and a progressive number punched on the chassis and engine. These numbers must always be quoted in the spare parts requests. It is advisable to check that the identification registration numbers on the vehicle and on the engine correspond with those indicated in the vehicle registration documents.

Check that the prefix and number punched on the chassis correspond to that shown on the vehicle documents. The chassis identification number is located on the right side of the cross member under the seat.

CAUTION

BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS MAY LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE. ETC.)

Check that the prefix and number punched on the engine correspond to that shown on the vehicle documents. The identification number is punched on the left side of the engine.

CAUTION

BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS MAY LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE. ETC.)

Located under the right side seat.

MANUFACTURER'S PLATE KEY:

1. Manufacturer of the vehicle.

2. Type-approval number.

3. Vehicle Identification Number V.I.N.

4. Noise level (dB) under prescribed engine (Rpm)

5. Type of engine.

6. Vehicle code.

MSS APE 50 (2012) Characteristics

CH - 9

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7. Country of production. COLOUR LABEL:

This colour label indicates:

1. Original paintwork manufacturer

2. Paintwork colour

3. Paintwork code

Characteristics

SIZES

N. millimetres (mm) TOP CROSS LONG Deck SHORT deck VAN

1 Length 2660 2700 2660 2490 2500 2 Width 1260 1260 1260 1260 1260 3 Height 1550 1610 1550 1550 1590 4 Wheelbase 1590 1590 1590 1590 1590 5 Deck length 1422 1427 1427 1257 1257 6 Deck width 1262 --- 1211 1211 1211

WEIGHTS

Kilograms (kg) TOP CROSS LONG Deck SHORT deck VAN

Kerb vehicle weight 230 245 230 230 260 Load capacity besides the driver 205 190 205 205 175

Characteristics MSS APE 50 (2012)

CH - 10

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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 (2012) Characteristics

CH - 11

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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

Specification Desc./Quantity

Fuel system Mixer petrol - oil through automatic carburettor/mixer (with

slave bearing to the engine speed and throttle valve opening)

and a gravity system.

Lubrication Carried out by the oil mixer for: piston, cylinder, crankshaft,

bearing of the flywheel side bench.

Water cooling, Arrangement for in cab heating system.

Heating Arrangement for in cab heating system.

Electronic ignition Consists of a capacitive discharge type device with H.V. coil

AT built-in. The system allows you to obtain a spark with a high voltage value, reached in very short time, and with a much reduced discharge duration, so it results in regular operation even with a dirty spark plug, easy cold starting, excellent combustion, limited wear of the electrodes and inalterability of the timing due

to the lack of components subject to wear.

Transmission From the crankshaft to the rear wheels through the clutch,

gearbox - differential - axle shaft.

Clutch Multiple discs in oil bath.

Transmission With four speeds with always driven gears.

Characteristics MSS APE 50 (2012)

CH - 12

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Specification Desc./Quantity

N.B.: THERE ARE 3 SPEEDS IN THE VERSION WITH

SPEED LIMITED TO 25 km/h.

Differential Connected to the gearbox shaft by cylinder gears, planetary

and satellite gears are bevel. The differential box is connected

to the two axle shafts that transmit the motion to the wheels.

The differential is equipped with a gear reversing device.

Exhaust silencer Combined, expansion and absorption type with double Cata-

lytic Converter and secondary air system (SAS box).

Steering and suspensions Steering tube pivoted on the oscillating arm with helicoidal

spring and coaxial hydraulic shock absorber; rear suspension

made with two independent oscillating arms with hydraulic

shock absorber and helicoidal springs.

Brakes With expansion on the three wheels:

•

Front: mechanical with control lever on the right

side handlebar.

•

Rear: hydraulically driven by a pedal with direct

control brake pump.

•

Safety: mechanical agent on the rear wheels with

control lever on the footrest central longitudinal

arm, right side internal cab.

Wheels Interchangeable, with printed sheet steel rims.

Wheels: rims from 10 - 2.50"; Michelin S83 tyres 100/90 x 10"

Toolkit Keys: a box-spanner (13/21 mm), a lever for box-spanner, a

screwdriver, a jack, a jack drive rod.

ENGINE

Specification Desc./Quantity

Engine 2-stroke single-cylinder with rotating timing system

Bore 38.4 mm

Stroke 43 mm

Engine capacity 49.8 cm3

Compression ratio 10 ÷ 10.5:1

Ignition advance (before TDC) 15°± 2°

Carburettor Dell'Orto SHBC 18/16P

Engine-wheel transmission ratio 1st spe. 1/54.17

2nd spe. 1/29.75

3a spe. 1/19.28

4a spe. 1/13.35 RM. 1/76.47

N.B.: THERE ARE 3 SPEEDS IN THE VERSION WITH

SPEED LIMITED TO 25 km/h.

Maximum speed Following the applicable regulations

TYRE PRESSURE

Specification Desc./Quantity

Rear tyre pressure 2.2 bar

Front tyre pressure 1.8 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

MSS APE 50 (2012) Characteristics

CH - 13

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Name Torque in 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 to 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

GRUPPO SOSPENSIONE ANTERIORE

Name Torque in Nm

Front shock absorber (upper part) - Steering tube 34.3 ± 4.9 Nm Front shock absorber (lower part) - Steering tube 112.7 ± 14.7 Nm

Brake drum - Steering tube 53.9 ± 5 Nm

Front wheel - Brake drum 23.6 ± 4 Nm

GRUPPO SOSPENSIONE POSTERIORE

Name Torque in Nm

Brake drum - Semi axle 85.8 ± 7.4 Nm

Rear wheel - Brake drum 23.6 ± 4 Nm

Shoe holder disc - Wheel hub 23.6 ± 4 Nm

Wheel hub - Rear suspension arm 58.8 ± 9.8 Nm

Rear shock absorber (upper part) - Chassis 34.3 ± 4.9 Nm

Rear shock absorber (lower part) - Wheel hub 34.3 ± 4.9 Nm

Rear suspension arm - Frame 44.1 ± 4.9 Nm

PARTE GENERALE

Name Torque in Nm

Windshield wiper - Chassis (external) 8 ± 0.5 Nm

Rear wheel- Drum 24 ± 4 Nm

Silencer - Engine head 5.9 ± 1 Nm

Silencer - Engine support 23.6 ± 1 Nm

Engine support bracket - Chassis 22 ± 2 Nm

Brake pump - Chassis 15.7 ± 4 Nm

Engine - Chassis 27.5 ± 2.5 Nm

Vehicle overhaul data

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

Characteristics MSS APE 50 (2012)

CH - 14

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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

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.

MSS APE 50 (2012) Characteristics

CH - 15

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Specific tooling

020074Y Crankshaft Alignment Check Tool

Piston - Pin

PISTON - PIN ASSEMBLY CLEARANCE

Name Description Dimensions Initials Quantity

Piston - pin assembly

clearance (mm)

Characteristics MSS APE 50 (2012)

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 (2012)

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 (2012) 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 (2012)

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 (2012) Special tools

ST - 21

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Stores code Description

020151Y Heat gun

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

021330Y Steering seats fitting tool

Special tools MSS APE 50 (2012)

ST - 22

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Stores code Description

021467Y Bearing extractor

022465Y Pliers for circlips

023638Y Pliers for circlips

009551Y Clutch puller

029569Y Gear Engagement Fitting Tool

030250Y Clutch Stop Key

032975Y Punches for Roller Casings

MSS APE 50 (2012) Special tools

ST - 23

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Stores code Description

033970Y Punches for Roller Casings

038077Y Engine support

038137Y Rear Hub Extractor

038138Y Roller Casings Punch

048564Y Flywheel extractor

060824Y Probe

020095Y Flywheel Lock 020332Y Digital rev counter

494929 Exhaust fumes analyser 021330Y003 Steering seats fitting 021330Y004 Steering seats fitting

020114Y Pane positioning band 018119Y007 Axle fitting 018119Y009 Axle fitting 018119Y014 Axle fitting

Special tools MSS APE 50 (2012)

ST - 24

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Stores code Description

018119Y015 Axle fitting 021467Y009 extractor 021467Y013 extractor

MSS APE 50 (2012) Special tools

ST - 25

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INDEX OF TOPICS

MAINTENANCE MA

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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.

MSS APE 50 (2012) Maintenance

MA - 27

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Manutenzione Batterie

CHARGE CHECK

Connect the terminals of the specific equipment to the respective poles of the battery.

Check the charge of the battery. If necessary replace the battery.

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.

SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Replace every 2 years

km x 1,000 1 5 10 15 20 25 30 35 40 45 50

Brake fluid level * I I I I R I I I R I I Spark plug R R R R R R R R R R Air filter C C C C C C C C C C Gearbox oil I R I R I R I R I R Differential Oil I R I R I R I R I R Carburettor I C C C C C SAS box C C C C C Clutch and brake lever L L L L L L L L L L Flexible brake hoses I I I I I Rear brake pipe R Flexible transmissions L L L L L Acceleration/mixer control

A A A A A A A A A A A

Steering clearance I I I I I Suspension I I I I I

Maintenance MSS APE 50 (2012)

MA - 28

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km x 1,000 1 5 10 15 20 25 30 35 40 45 50

Electrical system and battery

I I I I I I I I I I I

Hinges - Door locking Transmissions

L L L L L

Tyre pressure and wear I I I I I I I I I I I Headlights I A A A A A Safety clamps I I I I I I I I I I I Test drive I I I I I I I I I I I OPERATION TIME 60 60 120 60 120 60 150 60 120 60 120

N.B.

THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE THE TIME DEVOTED TO MANAGEMENT ACTIVITIES.

PIAGGIO MSS APE 50 2012, 2012 MSS APE 50 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual