Piaggio Typhoon 50 4t 4v (EN)

SERVICE STATION MANUAL677691 EN

Typhoon 50 4t 4v

SERVICE STATIONMANUAL

Typhoon 50 4t 4v

The descriptions and images in this publication are given for illustrative purposes only and are not binding.While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,to make any changes to components, parts or accessories, which it considers necessary to improve the

product or which are required for manufacturing or construction reasons.Not all versions/models shown in this publication are available in all countries. The availability of each

model should be checked at the official PIAGGIO sales network.© Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or

in part is prohibited.Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy

www.piaggio.com

http://www.piaggio.com/

SERVICE STATION MANUALTyphoon 50 4t 4v

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops ofPiaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicleshas a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significantchanges to vehicle characteristics or to specific repair operations will be communicated by updates tothis manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and toolsare unavailable. It is therefore advisable to read the sections of this manual concerning special tools,along with the special tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personalinjury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water

and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working

area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that

you do not breathe in the dust produced by the wear of the friction material. Even though the latter

contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all

the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,

nuts and screws are not interchangeable with coupling members using English measurements. Using

unsuitable coupling members and tools may damage the vehicle.

- 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 and battery connec-

tions.

Characteristics Typhoon 50 4t 4v

CHAR - 6

Vehicle identification

VEHICLE IDENTIFICATIONSpecification Desc./QuantityChassis prefix ZAPC50Engine prefix C37CM

Dimensions and mass

WEIGHTS AND DIMENSIONSSpecification Desc./Quantity

Maximum length 76.38 in (1940 mm)Overall width 28.35 in (720 mm)

Max. height to the windshield 44.69 in (1135 mm)Wheelbase 53.15 in (1350 mm)Kerb weight 242 lbs (110 Kg)

Engine

DATI TECNICI MOTORESpecification Desc./Quantity

Motore Monocilindrico 4 tempi, 4 valvole raffreddato ad ariaDistribuzione monoalbero a camme in testa a 4 valvole

Cilindrata 3,03 in³ (49,0 cc)Alesaggio per corsa 1,54 x 1,63 in (39 x 41,35 mm)

Gioco Valvole aspirazione: 0,006 in (0,15 mm)scarico: 0,006 in (0,15 mm)

Transmission Automatic continuous variatorClutch Automatic centrifugal dry clutch

Typhoon 50 4t 4v Characteristics

CHAR - 7

Specification Desc./QuantityLubrication Wet crankcase

Cooling forced air circulationElectric Starter and kick starter

Carburatore KEIHIN NCV Ø 20Fuel Unleaded petrol 90 (M+R) /2 minimum octane

Spark plug NGK ER9EH-6N

Transmission

TRANSMISSIONSpecification Desc./QuantityTransmission With automatic expandable pulley variator, torque server, V-

belt, automatic clutch, gear reduction unit.

Capacities

CAPACITYSpecification Desc./Quantity

Fuel tank capacity ~1.5 gal (including 0.4 gal reserve) ~ 7 litres (including 1.5 lreserve)

Hub oil ~ 0.0225 gal (~ 85 cc)Engine oil ~0.225 gal (~850 cc)

Electrical system

ELECTRICAL COMPONENTSSpecification Desc./Quantity

1 Ignition advance reference in table2 Spark plug NGK ER9EH-N3 Battery 12V - 9Ah4 Fuses 1 15A - 1 10A - 1 7.5A5 Generator single-phase alternating current

STATOR - PICKUP

- Power: 120 W.

- Resistance between BLUE cable and GROUND

CONNECTION: 1 ohm.

- Resistance between green cable and ground

connection: approximately 170 Ohm.


CHAR - 8

- Primary resistance: 0.5 to 0.6 Ohm

- Resistance between primary and ground con-

nection: infinite

- Resistance between primary and HV output: 3 to

3.6 kOhm

- Shielded cap: 5000 Ohm

Frame and suspensions

FRAME AND SUSPENSIONSpecification Desc./Quantity

Frame Tubular steel frame with sheet metal reinforcementsFront suspension Hydraulic telescopic fork; Ø 1,36 in (Ø 32) - 2.99 (76 mm)rear suspension Hydraulic single shock absorber and spring adjustable to 4 po-

sitions at preloading; travel: 3.40 in (86.5 mm).

Brakes

BRAKESSpecification Desc./QuantityFront brake Disc brake Ø 8.6 in (220 mm) with hydraulic control (lever on

the far right of the handlebar) and floating calliper.Rear brake Drum Ø 5.51 in (Ø 140 mm)

Wheels and tyres

WHEELS AND TYRESSpecification Desc./Quantity

Wheel rims Die-cast aluminium alloyFront wheel rim 3.00 x 14"Rear wheel rim 3.50 x 14

Tyre type Without inner tube (Tubeless)Front tyre 120/70 - 14" 55 PRear tyre 120/70 - 14" 55 P

Standard front tyre pressure [with passenger] 23 psi (1.6 bar) [29 psi (2.0 bar)]Standard rear tyre pressure [with passenger] 29 psi (2.0 bar) [32 psi (2.2 bar)]

Tightening Torques

ENGINE ASSEMBLYName Torque in Nm

Ignition spark plug 7.4 - 11 lb ft (10 - 15 Nm)Floating head cover screws 4.4 - 5.2 lb ft (6 - 7 Nm)Head-cylinder stud bolt nuts 4.4 - 5.2 lb ft + 90° + 90° (6 - 7 Nm + 90° + 90°)

Head nut tightening (only for stud bolt replacement) 4.4 - 5.2 lb ft + 135° + 90° (6-7 Nm + 135° + 90°)Screws fixing head and cylinder to crankcase 5.9 - 7.4 lb ft (8 - 10 Nm)

Chain tensioner pad screw 3.7 - 5.2 lb ft (5 - 7 Nm)Timing chain tensioner central screw 3.7 - 4.4 lb ft (5 - 6 Nm)


CHAR - 9

Name Torque in NmCamshaft pulley screw 8.8 - 10.3 lb ft (12 - 14 Nm)

Rocking lever axle and camshaft bearing screw 2.2 - 2.9 lb ft (3 - 4 Nm)Rocker adjusting nuts 5.2 - 6.6 lb ft (7 - 9 Nm)

Engine oil pre-filter cover 18.4 - 20.6 lb ft (25 - 28 Nm)Engine oil drainage cap 29.5 - 32.4 lb ft (40 - 44 Nm)

Flywheel nut 2.2 - 2.9 lb ft (3 - 4 Nm)Stator screws 2.2 - 2.9 lb ft (3 - 4 Nm)

Pick-up screws 2.2 - 2.9 lb ft (3 - 4 Nm)Oil pump bulkhead screw 2.9 - 3.7 lb ft (4 - 5 Nm)

Timing chain/oil pump compartment cover screws 2.9 - 3.7 lb ft (4 - 5 Nm)Oil decantation labyrinth sheet screws 5.2 - 5.9 lb ft (7 - 8 Nm)

Oil pump sprocket gear screw 5.9 - 7.4 lb ft (8 - 10 Nm)Screws fixing oil pump to the crankcase 3.7 - 4.4 lb ft (5 - 6 Nm)

Oil sump screws 5.9 - 7.4 lb ft (8 - 10 Nm)Inlet manifold screw 5.2 - 6.6 lb ft (7 - 9 Nm)

Carburettor/manifold clamp screw 0.9 - 1.1 lb ft (1.2 - 1.5 Nm)Screws fixing cables to starter motor 0.9 - 1.1 lb ft (1.2 - 1.5 Nm)

Starter motor screws 8.1 - 9.6 lb ft (11 - 13 Nm)Transmission cover screws 8.1 - 9.6 lb ft (11 - 13 Nm)

Start-up lever screw 8.1 - 9.6 lb ft (11 - 13 Nm)Crankcase cooling cover screw 1.5 - 1.8 lb ft (2 - 2.5 Nm)

Clutch assembly nut 40.5 - 44.2 lb ft (55 - 60 Nm)Crankshaft pulley nut 13.3 - 14.8 lb ft + 90° (18 - 20 Nm + 90°)Driven pulley shaft nut 29.5 - 32.4 lb ft (40 - 44 Nm)Hub oil drainage screw 2.2 - 3.7 lb ft (3 - 5 Nm)Rear hub cap screws 8.1 - 9.6 lb ft (11 - 13 Nm)

Crankcase half union screw 5.9 - 7.4 lb ft (8 - 10 Nm)

STEERING ASSEMBLYName Torque in Nm

Steering upper ring nut 27.7 lb ft (37.5 Nm)Steering lower ring nut 9.6 lb ft (13 Nm)Headstock handlebar 38.7 lb ft (52.5 Nm)

CHASSIS ASSEMBLYName Torque in Nm

Engine side swinging arm 31.3 lb ft (42.5 Nm)Chassis side swinging arm 31.3 lb ft (42.5 Nm)

Passenger handle 15.1 lb ft (20.5 Nm)Centre stand pin 31.3 lb ft (42.5 Nm)

Saddle plate fixing nut 7.4 lb ft (10 Nm)Mirror fixing spacer 18.4 lb ft (25 Nm)

Chassis fuel tank retainer screws 7.4 lb ft (10 Nm)Handlebar brake pump 5.9 lb ft (8 Nm)

FRONT SUSPENSIONName Torque in Nm

Plate fork stanchions 29.5 lb ft (40 Nm)Sleeve fork stanchions 22.1 lb ft (30 Nm)Front wheel axle hub 7.3 lb ft (10 Nm)

Fork wheel axle 34.3 lb ft (46.5 Nm)

REAR SUSPENSIONName Torque in Nm

Shock absorber upper part 27.3 lb ft (37 Nm)Shock absorber lower part 27.3 lb ft (37 Nm)

Rear wheel hub 87.8 lb ft (115 Nm)

FRONT AND REAR BRAKEName Torque in Nm

Brake disc 6.6* lb ft (9* Nm)Front brake calliper to fork 18.8 lb ft (25.5 Nm)Brake pad fastening screw 11-14.7 lb ft (15-20 Nm)


CHAR - 10

Name Torque in NmRear brake adjustment nut 3.69 lb ft (5 Nm)

Brake fluid hose-pump fitting 14.75 - 18.44 lb ft (20-25 Nm)Oil bleed screw 5.9 - 8.8 lb ft (8-12 Nm)

*with Loctite 243

Overhaul data

Assembly clearances

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDERName Initials Cylinder Piston Play on fitting

Cylinder A 1.535157 - 1.535433 in(38.993 - 39.000 mm)

1.533622 - 1.533898 in(38.954 - 38.961 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Cylinder B 1.535433 - 1.535709 in(39.000 - 39.007 mm)

1.533898 - 1.534173 in(38.961 - 38.968 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Piston C 1.535709 - 1.535984 in(39.007 - 39.014 mm)

1.534173 - 1.534449 in(38.968 - 38.975 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Piston D 1.535984 - 1.536260 in(39.014 - 39.021 mm)

1.534449 - 1.534724 in(38.975 - 38.982 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Cylinder 1st oversize A1 1.543031 - 1.543307 in(39.193 - 39.200 mm)

1.541496 - 1.541772 in(39.154 - 39.161 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Cylinder 1st oversize B1 1.543307 - 1.543583 in(39.200 - 39.207 mm)

1.541772 - 1.542047 in(39.161 - 39.168 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Piston 1st oversize C1 1.543583 - 1.543858 in(39.207 - 39.214 mm)

1.542047 - 1.542323 in(39.168 - 39.175 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Piston 1st oversize D1 1.543858 - 1.544134 in(39.214 - 39.221 mm)

1.542323 - 1.542598 in(39.175 - 39.182 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Cylinder 2nd oversize A2 1.550906 - 1.551181 in(39.393 - 39.400 mm)

1.549370 - 1.549646 in(39.354 - 39.361 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Cylinder 2nd oversize B2 1.551181 - 1.551457 in(39.400 - 39.407 mm)

1.549646 - 1.549921 in(39.361 - 39.368 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)


CHAR - 11

Name Initials Cylinder Piston Play on fittingPiston 2nd oversize C2 1.551457 - 1.551732 in

(39.407 - 39.414 mm)1.549921 - 1.550197 in(39.368 - 39.375 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Piston 2nd oversize D2 1.551732 - 1.552008 in(39.414 - 39.421 mm)

1.5590197 - 1.550472in (39.375 - 39.382 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Cylinder 3rd oversize A3 1.558780 - 1.559055 in(39.593 - 39.600 mm)

1.557244 - 1.557520 in(39.554 - 39.561 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Cylinder 3rd oversize B3 1.559055 - 1.559331 in(39.600 - 39.607 mm)

1.557520 - 1.557795 in(39.561 - 39.568 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Piston 3rd oversize C3 1.559331 - 1.559006 in(39.607 - 39.614 mm)

1.557795 - 1.558071 in(39.568 - 39.575 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

Piston 3rd oversize D3 1.559006 - 1.559882 in(39.614 - 39.621 mm)

1.558071 - 1558346 in(39.575 - 39.582 mm)

0.00126 - 0.001811 in(0.032 - 0.046 mm)

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARKFACING UPWARDS.

- Measure the outer diameter of the gudgeon pin.

CharacteristicPin outside diameter0.511811 +0 -0.000157 in (13 +0 -0.004 mm)

Minimum admissible diameter gudgeon pin0.511417 in (12.990 mm)

- Measure the diameter of the bearings on the pis-

ton.

CharacteristicPin seat diameter0.511811 +0.000197 +0.000394 in (13 +0.005

+0.010 mm)

- Calculate the piston pin coupling clearance.N.B.

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENTMUST BE MADE ACCORDING TO THE PISTON AXIS

CharacteristicStandard clearance

0.000197 - 0.000551 in (0.005 - 0.014 mm)

- Carefully clean the seal housings.

- Measure the coupling clearance between the sealing rings and the piston grooves using suitable

sensors, as shown in the diagram.

- If the clearance is greater than that indicated in the table, replace the piston.N.B.


CHAR - 12

MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THESECOND SEAL RING SIDE.

ASSEMBLY CLEARANCESName Description Dimensions Initials Quantity

Top piston ring standard coupling clear-ance

0.001181 - 0.002559 in(0.03 - 0.065 mm)

Top piston ring maximum admissibleclearance after use

0.002756 in (0.07 mm)

Middle piston ring standard coupling clear-ance

0.000787 - 0.002165 in(0.02 - 0.055 mm)

Middle piston ring maximum admissibleclearance after use

0.002362 in (0.06 mm)

scraper ring standard coupling clear-ance

0.001575 - 0.006299 in(0.04 - 0.16 mm)

scraper ring maximum admissibleclearance after use

0.006693 in (0.17 mm)

- Using a bore meter, measure the inner cylinder

diameter at three different points according to the

directions shown in the figure.

- Check that the coupling surface with the head is

not worn or misshapen.

- Pistons and cylinders are classified into catego-

ries based on their diameter. The coupling is car-

ried out in pairs (A-A, B-B, C-C, D-D).

CharacteristicMaximum allowable run-out0.001 in (0.05 mm)


CHAR - 13

Piston rings

- Alternately insert the three sealing rings into the

cylinder, in the area where it retains its original di-

ameter. Using the piston, insert the rings perpen-

dicularly to the cylinder axis.

- Measure the opening, see figure, of the sealing

rings using a thickness gauge.

- If any measurements are greater than specified,

replace the piston rings.N.B.BEFORE REPLACING ONLY THE PISTON RINGS, ENSURETHAT THE CLEARANCE BETWEEN THE PISTON RINGSAND THE PISTON RING GROOVES, AND BETWEEN THEPISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANYCASE, NEW PISTON RINGS USED IN COMBINATION WITHA USED CYLINDER MAY HAVE DIFFERENT BEDDINGCONDITIONS THAN THE STANDARD.

SEALING RINGSName Description Dimensions Initials Quantity

1st Compression ring 1.535433 x 0.03937 in(39 x 1 mm)

A 0.003150 - 0.007874 in(0.08 - 0.20 mm)

2nd Compression ring 1.535433 x 0.03937 in(39 x 1 mm)

A 0.001969 - 0.007874 in(0.05 - 0.20 mm)

Oil scraper ring 1.535433 x 0.07874 in(39 x 2 mm)

A 0.007874 - 0.027559 in(0.20 - 0.70 mm)

1st Compression ring1st Oversize

1.543307 x 0.03937 in(39.2 x 1 mm)

A 0.003150 - 0.007874 in(0.08 - 0.20 mm)

2nd Compression ring1st Oversize

1.543307 x 0.03937 in(39.2 x 1 mm)

A 0.001969 - 0.007874 in(0.05 - 0.20 mm)

Oil scraper ring 1stOversize

1.543307 x 0.07874 in(39.2 x 2 mm)

A 0.007874 - 0.027559 in(0.20 - 0.70 mm)

1st Compression ring2nd Oversize

1.551181 x 0.03937 in(39.4 x 1 mm)

A 0.003150 - 0.007874 in(0.08 - 0.20 mm)

2nd Compression ring2nd Oversize

1.551181 x 0.03937 in(39.4 x 1 mm)

A 0.001969 - 0.007874 in(0.05 - 0.20 mm)

Oil scraper ring 2ndOversize

1.551181 x 0.07874 in(39.4 x 2 mm)

A 0.007874 - 0.027559 in(0.20 - 0.70 mm)


CHAR - 14

Name Description Dimensions Initials Quantity1st Compression ring

3rd Oversize1.559055 x 0.03937 in

(39.6 x 1 mm)A 0.003150 - 0.007874 in

(0.08 - 0.20 mm)2nd Compression ring

3rd Oversize1.559055 x 0.03937 in

(39.6 x 1 mm)A 0.001969 - 0.007874 in

(0.05 - 0.20 mm)Oil scraper ring 3rd

Oversize1.559055 x 0.07874 in

(39.6 x 2 mm)A 0.007874 - 0.027559 in

(0.20 - 0.70 mm)

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASEName Description Dimensions Initials Quantity

Half-shaft, transmissionside

0.551181 +0 -0.000197in (14 +0 -0.005 mm)

A

Flywheel-side half shaft 0.629921 +0 -0.000197in (16 +0 -0.005 mm)

B

Connecting rod 0.582677 + 0.001969 in(14.8 +0,05 mm)

C

Spacer tool 1.771654 in / Fittingclearance D = 0.005906

- 0.011811 in (45.00mm / Fitting clearance

E

CharacteristicClearance between crankshaft and connecting rod

A = 0.005906 - 0.011811 in (A = 0.15 - 0.30 mm)


CHAR - 15

Measure the bearings along X and Y axes

CharacteristicCrankshaft bearing, transmission side0.787402 -0.000472 -0.000984 in (20 -0.012

-0.025 mm)

Crankshaft bearing, flywheel side0.669291 +0 +0.000276 in (17 +0 +0.007 mm)

- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded

tangs are in good working order.

- In case of failures, replace the crankshaft.

Specific tooling020074Y Support base for checking crankshaft alignment


CHAR - 16

To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated

in figure.N.B.IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC-TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-SERTING A WOODEN WEDGE BETWEEN THE HALFSHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-DED. IF EVEN AFTER THIS OPERATION THE VALUES ARENOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.

CharacteristicOff-line maximum admitted - A0.005906 in (0.15 mm)

Off-line maximum admitted - B0.000787 in (0.02 mm)

Off-line maximum admitted - C0.000787 in (0.02 mm)

Off-line maximum admitted - D0.003937 in (0.10 mm)

- Using a bore gauge, measure the connecting rod

small end diameter.N.B.IF THE CONNECTING ROD SMALL END DIAMETER EX-CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OROVERHEATING, PROCEED TO REPLACE THE CRANK-SHAFT AS DESCRIBED IN THE CRANKCASE ANDCRANKSHAFT CHAPTER.

CharacteristicRod small end diameter0.511811 +0.000591 +0.000984 in (13 +0.015 +

0.025 mm)

Max. diameter admitted: Connecting rod smallend check-up0.512992 in (13.030 mm)

Calculate the coupling clearance between pin and rod small end

CharacteristicPin - connecting rod clearance

0.000591 - 0.001142 in (0.015 - 0.029 mm)


CHAR - 17

Slot packing system

CharacteristicCompression ratio11.5 to 12 : 1

PISTON PROTRUSION CHECKName Measure A Thickness

Shimming 1 0.066929 - 0.076772 in (1.7 - 1.95 mm) 0.009843 in (0.25 mm)Shimming 2 0.076772 - 0.086614 in (1.95 - 2.2 mm) 0.013780 in (0.35 mm)

Products

RECOMMENDED PRODUCTS TABLEProduct Description Specifications

eni i-Ride PG 5W-40 Synthetic based lubricant for high-per-formance four-stroke engines.

JASO MA, MA2 - API SL - ACEA A3

AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis-sions.

API GL-4

AGIP FORK 7.5 W Oil for fork. -AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116

- DOT 3/4 - ISO 4925 - CUNA NC 956DOT 4

AGIP FILTER OIL Special product for the treatment of foamfilters.

-

NEUTRAL GREASE OR PETROLEUMJELLY

Battery poles Neutral grease or petroleum jelly

Loctite 510 Liquid sealant GasketLoctite 243 Medium-strength threadlock Medium Loctite 243 threadlock

AGIP GREASE SM 2 Gray black smooth-textured lithiumgrease, containing molybdenum disul-

phide.

-

AGIP GREASE MU3 Yellow-brown, lithium-base, medium-fi-bre multipurpose grease.

ISO L-X-BCHA 3 - DIN 51 825 K3K -20

UNIT OF MEASURE - CONVERSION - ENGLISH SYSTEM TO INTERNATIONAL SYSTEM (IS).Specification Desc./Quantity

1 Inch (in) 25.4 Millimetres (mm)1 Foot (ft) 0.305 Meter (m)1 Mile (mi) 1.609 Kilometre (km)

1 US Gallon (USgal) 3.785 Litre (l)1 Pound (lb) 0.454 Kilogram (kg)

1 Cubic inch (in³) 16.4 Cubic centimetres (cm³)1 Foot pound (lb ft) 1,356 Newton meter (Nm)

1 Miles per hour (mi/h) 1.602 Kilometres per hour (km/h)1 Pound per square inch (PSI) 0.069 (bar)

1 Fahrenheit (°F) 32+(9/5) Celsius (°C)


CHAR - 18

INDEX OF TOPICS

TOOLING TOOL

SPECIFIC TOOLSStores code Description

001330Y Tool for fitting steering seats

001467Y009 Bell for OD 42-mm bearings

001467Y013 Pliers to extract ø 15-mm bearings

001467Y029 Bell for bearings, O.D. 38 mm

008119Y009 Tube to assemble shafts and axles

002465Y Pliers for circlips

Tooling Typhoon 50 4t 4v

TOOL - 20

Stores code Description004499Y Bearing extractor. Fitted with: 1 Bell, 2

Sleeve, 3 Screw, 6 Ring, 7 Half rings, 27Half rings, 34 Half rings

005095Y Engine support

006029Y Punch for fitting fifth steering bearing onsteering tube

020004Y Punch for removing fifth wheels fromheadstock

020055Y Wrench for steering tube ring nut

020150Y Air heater support

020151Y Air heater

Typhoon 50 4t 4v Tooling

TOOL - 21

Stores code Description020162Y Flywheel extractor

020171Y Punch for Ø 17 mm roller bearing

020193Y Oil pressure check gauge

020201Y Spacer bushing driving tube020265Y Bearing fitting base

020271Y Tool for removing-fitting silent bloc

020288Y Fork to assemble piston on cylinder


TOOL - 22

Stores code Description020291Y Valve fitting/ removal tool

020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter


TOOL - 23

Stores code Description020332Y Digital rpm indicator

020334Y Multiple battery charger

020335Y Magnetic support for dial gauge

020363Y 20-mm guide

020364Y 25-mm guide


TOOL - 24

Stores code Description020376Y Adaptor handle

020412Y 15-mm guide

020428Y Piston position check mounting

020431Y Valve oil seal extractor

020439Y 17-mm guide

020444Y Tool for fitting/ removing the driven pulleyclutch


TOOL - 25

Stores code Description020448Y Pin lock fitting tool

020450Y Camshaft fitting/removal tool

020451Y Starting ring gear lock

020452Y Tube for removing and refitting the drivenpulley shaft

020565Y Flywheel lock calliper spanner


TOOL - 26

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

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

mi x 1.000 0.62

1.9 3.7 5.6 7.5 9.3 11.2

13 14.9

16.8

18.6

20.5

22.4

24.2

26.1

28 29.8

31.7

33.6

35.4

37.3

km x 1,000 1 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60Safety fasteners I I I I I ISpark plug R R R R R R R R R RDrive belt I R I R I R I R I RThrottle control A A A A A ATyre condition andwear

I I I I I

Air filter C C C C COil filter (mesh) C C C C C C C C C CSolenoid filter C C C C C C C C C CValve clearance I I I I I IElectrical systemand battery

I I I I I I I I I I I

Cylinder ventila-tion system

I I

Brake levers L L L L L LBrake oil level (*) I I I I I I I I I I IHub oil level R I R I R I R I R I REngine oil R I R I R I R I R I R I R I R I R I R I RBrake Pads/Shoes I I I I I I I I I I ITyre pressure I I I I I I I I I I IHeadlight A A A A AVehicle road test I I I I I I I I I I IIdle speed A A A A A AOdometer gear L L L L LCVT rollers I R I R I R I R I RSuspension I I I I ISteering A A A A A ATransmission L L L L LOperation time 90' 10' 60' 10' 13

0'10' 60' 10' 18

0'10' 60' 10' 16

5'10' 60' 10' 18

0'10' 60' 10' 13

0'N.B.

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

Carburettor

The carburettor features a solenoid valve "A" that,

via an ECU, manages an extra flow of air.

It is connected to the carburettor via flexible pipes

as shown in the figure.

The valve is positioned under the helmet compart-

ment.

The piping is joined to a filter positioned inside the

body. The solenoid filter should be cleaned ac-

Maintenance Typhoon 50 4t 4v

MAIN - 28

cording to the kilometres travelled as instructed in

the scheduled maintenance chart.

- Disassemble the carburettor in its parts, wash all

of them with solvent, dry all body grooves with

compressed air to ensure adequate cleaning.

- Check carefully that the parts are in good condi-

tion.

-The throttle valve should move freely in the

chamber. Replace valve in case of wear due to

excessive clearance.

- If there are wear marks in the chamber causing

inadequate tightness or a free valve slide (even if

it is new), replace the carburettor.

- It is advisable to replace the gaskets at every refit.WARNINGPETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THEGASKETS TO AVOID PETROL LEAKS

1. Needle valve - 2. Idle adjustment screw - 3. Max jet - 4. Accelerating pump - 5. Tapered pin - 6. Jet

holder - 7. Float - 8. Reservoir - 9. Starter device - 10. Depression valve - 11. Cover - 12. Minimum jet.

Spark plug

Remove the rear central cover.

Typhoon 50 4t 4v Maintenance

MAIN - 29

Undo the central cover fixing screws and remove

it.

Disconnect the spark plug HV wire cap;

Remove the wire cap.

Unscrew the spark plug.

- Check the conditions of the spark plug, make

sure the insulation is intact, that the electrodes are

not excessively worn or sooty, the conditions of the

washer, and measure the distance between the

electrodes using the appropriate feeler gauge.

-Adjust the distance, if necessary, by bending the

side electrode very carefully. In case of anomaly

(as described before), replace the spark plug with

another of the recommended type.

- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the

special spanner to tighten it.


MAIN - 30

- Refit the cover.

- Place the cap fully over the spark plug, and tie down the cable to the bracket.

- Carry out refit operations.CAUTION

THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD.THE SPARK PLUG MUSTBE REPLACED EVERY 20,000 KM. THE USE OF NON CONFORMING ELECTRONIC IGNITIONCONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLYDAMAGE THE ENGINE.

CharacteristicElectrode gap

0.028 - 0.031 in (0.7 - 0.8 mm)

Spark plug

NGK ER9EH-6N

See alsoChassis

Hub oil

Check

- Park the vehicle on flat ground and rest it on the

centre stand.

- Unscrew the oil dipstick/cover, dry it with a cloth

and reinsert it screwing it in thoroughly.

- Remove the dipstick/cover and check that the oil level is between MIN and MAX.

- If the level is below the MIN value, restore the proper amount of oil in the hub.

- Screw the oil dipstick back and check it is locked.


MAIN - 31

Replacement

- Remove the oil dipstick/cover.

- Remove the rear wheel.

- Prepare an adequately sized container.

- Unscrew the oil drainage plug and drain out all

the oil.

Screw the drainage cap back on and fill the hub with the prescribed oil.

Recommended productsAGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions.

API GL-4

CharacteristicHub oil

~ 0.0225 gal (~ 85 cc)

Air filter

Remove the cap of the air cleaner, unscrewing the

screws and the fixing knob. Take out the filtering

element.


MAIN - 32

Cleaning:

Wash with water and neutral soap. Dry with a

clean cloth and short blasts of compressed air.

Saturate with a 50% mixture of petrol and oil.

Drip dry the filtering element and then squeeze it

with your hands without wringing.

Let it dry and refit it.CAUTIONNEVER RUN THE ENGINE WITHOUT THE AIR FILTER,THIS WILL RESULT IN AN EXCESSIVE CYLINDER ANDPISTON WEAR AND ALSO IN CARBURETTOR DAMAGE.

Recommended productsAGIP FILTER OIL Special product for the treat-ment of foam filters.-

FILTER BOX REMOVAL

Undo the screws indicated.

- Loosen the indicated clamps and slide off the fil-

ter box.

Engine oil


MAIN - 33

Replacement

Change oil and replace filter as indicated in the

scheduled maintenance table. The engine must be

emptied by draining off the oil through the drainage

plug of the mesh pre-filter, flywheel side; further-

more, to facilitate oil drainage, loosen or remove

the cap/dipstick. Once all the oil has drained

through the drainage hole, unscrew the oil car-

tridge filter and remove it. To carry out this opera-

tion the complete exhaust must be removed.

Make sure the pre-filter and drainage plug O-rings

are in good conditions.

Lubricate them and refit the mesh filter and the oil

drainage plug, screwing them up to the specified

torque. Refit the new cartridge filter being careful

to lubricate the O-ring before fitting it.

Change the engine oil. Since a certain quantity of

oil still remains in the circuit, oil must be filled from

oil dipstick/cover.

Then start up the vehicle, leave it running for a few

minutes and switch it off: After about five minutes,

check the level and, if necessary, top-up but never

exceeding the MAX level reference mark.

The cartridge filter must be replaced every time the

oil is changed. Use new oil of the recommended

type for topping up and changing purposes.N.B.THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended productseni i-Ride PG 5W-40 Synthetic based lubricantfor high-performance four-stroke engines.JASO MA, MA2 - API SL - ACEA A3

CharacteristicEngine oil~0.225 gal (~850 cc)

See alsoEngineoil filter


MAIN - 34

Check

This operation must be carried out with the engine

cold and following the procedure below:

- Place the vehicle on its centre stand and on flat

ground.

- Undo cap/dipstick, dry it off with a clean cloth and

reinsert it, screwing down completely.

- Remove the cap/dipstick again and check that

the level is between the MIN and MAX reference

marks; top up if necessary.

The MAX level mark indicates a quantity of around

0.225 gal (850 cc) of engine oil. If the check is car-

ried out after the vehicle has been used, and there-

fore with a hot engine, the level will be lower; in

order to carry out a correct check, wait at least 10

minutes after the engine has been stopped so as

to get the correct level.

Engine oil top-up

The oil should be topped up after having checked

the level and in any case by adding oil without

ever exceeding the MAX. level.

Restoration of the level from MIN to MAX requires

approximately 0.053 gal (200 cc).

Engine oil filter

Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the rec-

ommended type for topping up and changing purposes.

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the

mesh filter and the oil drainage plug, screwing them up to the specified torque. Refit the new cartridge

filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended productseni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines.

JASO MA, MA2 - API SL - ACEA A3


MAIN - 35

transmissions

Proceed as follows:

Rest the vehicle on its centre stand and lift the

saddle (as described in the «Saddle opening» sec-

tion).

Undo screw «A» in order to remove the helmet

compartment cover.

To adjust the idle speed, start the engine, then

loose or tighten the screw «B» until you reach the

recommended idle speed taking care the engine

does not make the rear wheel move.WARNING

ADJUST IDLE SPEED WHEN THE ENGINE IS FAIRLY HOTAND HAS BEEN RUNNING FOR AT LEAST FIVE MINUTES.BEFORE THIS OPERATION, MAKE SURE THAT THETHROTTLE GRIP HAS THE RECOMMENDED BACKLASH.IF BACKLASH IN THE THROTTLE CONTROL TRANSMIS-SION NEEDS ADJUSTING TAKE YOUR SCOOTER TO ANAUTHORISED DEALER OR SERVICE CENTRE.

CharacteristicEngine idle speed1700 - 1900

Checking the ignition timing

-Remove the flywheel fan.

-Rotate the flywheel until the reference (arrow)

matches the crankcase operation end as shown in

the figure (TDC). Make sure that the 2V reference

point on the camshaft control pulley is aligned with

the reference point on the head as shown in the

second figure. If the reference mark is opposite the

indicator on the head, make the crankshaft turn

once more.

-The TDC reference mark is repeated also be-

tween the flywheel cooling fan and the flywheel

cover.


MAIN - 36

To use this reference mark, remove the spark plug

and turn the engine in the opposite direction to the

normal direction of rotation using a compass span-

ner applied to the camshaft drive sprocket hous-

ing.N.B.TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.

Checking the valve clearance

-To check valve clearance, centre the reference marks of the timing system.

- Use a feeler gauge to check that the clearance between the valve and the register corresponds with

the indicated values. When the valve clearance values, intake and exhaust respectively, are different

from the ones indicated below, adjust them by loosening the lock nut and operate on the set screw with

a screwdriver.

Intake: 0.006 in (0.15 mm) (when cold)

Exhaust: 0.006 in (0.15 mm) (when cold)

Braking system

Level check

Proceed as follows:

- Rest the vehicle on its centre stand with the han-

dlebars perfectly horizontal;

- Check the fluid level through the corresponding

sight glass.

A certain lowering of the level is caused by wear

on the brake pads.

Top-up

Proceed as follows:

- Remove the front handlebar cover.

- Remove the reservoir cap by loosening the two screws, remove the gasket and top-up using only the

fluid specified without exceeding the maximum level.


MAIN - 37

CAUTION

ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASEOF ACCIDENTAL CONTACT, WASH WITH WATER.CAUTION

BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITHPAINTED PARTS.CAUTION

BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-ING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE,BRAKING WILL BE INEFFICIENT.NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS.UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLUID AS INDICATED IN THE SCHED-ULED MAINTENANCE TABLE.N.B.

SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUIDAND THE BLEEDING OF AIR FROM THE CIRCUITS.

Recommended productsAGIP BRAKE 4 Brake fluid.

Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4

Headlight adjustment

Proceed as follows:

1. Place the vehicle in running order and with the

tyres inflated to the prescribed pressure, on a flat

surface 10 m away from a white screen situated in

a shaded area, making sure that the longitudinal

axis of the vehicle is perpendicular to the screen;

2. Turn on the headlight and check that the bor-

derline of the projected light beam on the screen

is no higher than 9/10 or lower than 7/10 of the

distance from the ground to the centre of the ve-

hicle's headlamp;

3. Otherwise, adjust the headlight by turning the

knobs of the body inside the wheel housing.

- Tighten the screw (clockwise) to raise the light

beam;

- undo the screw (anticlockwise) to lower the light

beam.N.B.


MAIN - 38

THE ABOVE PROCEDURE COMPLIES WITH THE EURO-PEAN STANDARDS REGARDING MAXIMUM AND MINI-MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-TORY REGULATIONS IN FORCE IN EVERY COUNTRYWHERE THE VEHICLE IS USED.


MAIN - 39

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Engine

Poor performance

POOR PERFORMANCEPossible Cause Operation

Air filter blocked or dirty Remove the sponge, wash with water and car shampoo, thensoak it in a mixture of 50% petrol and 50% specific oil. Presswith your hand without squeezing, allow it to drip dry and refit.

Excessive drive belt wear Check it and replace, if necessaryLack of compression: parts, cylinder and valves worn Replace the worn parts

Oil level exceeds maximum Check for causes and fill to reach the correct levelExcess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves

Incorrect timing or worn timing system elements Time the system again or replace the worn partsMuffler obstructed Replace

Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-aged parts and lubricate the movable guide of the driven pulley

with grease.Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace the valvesValve seat distorted Replace the head unit

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings

Starting difficulties

DIFFICULTY STARTING UPPossible Cause Operation

Flat battery Check the state of the battery. If it shows signs of sulphation,replace it and bring the new battery into service by charging itfor not more than ten hours at a current of 1/10 of the capacity

of the battery itself.Faulty spark plug Replace the spark plug

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearanceStarter motor and start-up system fault Check starter motor.

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refillAir filter obstructed or dirty. Remove the sponge, wash with water and car shampoo, then

soak it in a mixture of 50% petrol and 50% specific oil. Presswith your hand without squeezing, allow it to drip dry and refit.

Fuel pump fault Check the pump.

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTIONPossible Cause Operation

Wrong valve adjustment Adjust the valve clearance properlyOverheated valves Remove the head and the valves, grind or replace the valves

Misshapen/worn valve seats Replace the head unitWorn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings

Worn or broken piston rings or piston rings that have not beenfitted properly

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling sealWorn valve oil guard Replace the valve oil sealWorn valve guides Check and replace the head unit if required

Typhoon 50 4t 4v Troubleshooting

TROUBL - 41

Insufficient lubrication pressure

POOR LUBRICATION PRESSUREPossible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean theBy-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump componentsOil filter too dirty Replace the cartridge filterOil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible Cause Operation

Slippage or irregular functioning Check that there is no grease on the masses.Check that the faying surface between the clutch masses andthe clutch housing is mainly in the middle and with equivalent

specifications on the three masses.Check that the clutch housing is not scored or worn abnormally

Insufficient braking

INEFFICIENT OR NOISY BRAKINGPossible Cause Operation

Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk ordrum wear conditions.

Front brake disk loose or deformed Check the brake disc screws are locked; use a dial gauge anda wheel mounted on the vehicle to measure the axial shift of

the disc.Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be

no flexible movement of the brake lever).Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Excessive clearance in the rear brake control cable Adjust the clearance with the appropriate adjuster located onthe back part of the crankcase.

Brakes overheating

BRAKES OVERHEATINGPossible Cause Operation

Rubber gaskets swollen or stuck Replace gaskets.Compensation holes on the pump clogged Clean carefully and blast with compressed air

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge anda wheel mounted on the vehicle to measure the axial shift of

the disc.Defective piston sliding Check calliper and replace any damaged part.

Electrical system

Troubleshooting Typhoon 50 4t 4v

TROUBL - 42

Battery

BATTERYPossible Cause Operation

Battery The battery is the electrical device in the system that requiresthe most frequent inspections and thorough maintenance. If thevehicle is not used for some time (1 month or more) the battery

needs to be recharged periodically. The battery runs downcompletely in the course of 5 to 6 months. If the battery is fittedon a motorcycle, be careful not to invert the connections, keep-

ing in mind that the black ground wire is connected to thenegative terminal while the red wire is connected to the terminalmarked+. Follow the instructions in the ELECTRICAL SYSTEM

chapter for the recharging of the batteries.

Steering and suspensions

Heavy steering

STEERING HARDENINGPossible Cause Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-larities continue in turning the steering even after making theabove adjustments, check the seats in which the ball bearingsrotate: if they are recessed or if the balls are squashed, replace

them.

Excessive steering play

EXCESSIVE STEERING CLEARANCEPossible Cause Operation

Excessive steering clearance Check the tightening of the top ring nut. If irregularities continuein turning the steering even after making the above adjust-ments, check the seats in which the ball bearings rotate: re-

place if they are recessed.

Noisy suspension

NOISY SUSPENSIONPossible Cause Operation

NOISY SUSPENSION If the front suspension is noisy, check: That the shock absorberworks properly inside the stanchions and that the steering ballbearings are in good condition. Finally, check the locking torqueof the wheel axle nut, the brake calliper and the disc. Check

that the swinging arm connecting the engine to the chassis andthe rear shock absorber work properly.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSIONPossible Cause Operation

Faulty or broken seals Replace the shock absorber Check the condition of wear of thesteering covers and the adjustments.

Typhoon 50 4t 4v Troubleshooting

TROUBL - 43

Troubleshooting Typhoon 50 4t 4v

TROUBL - 44

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system list of components:

1 12V-9Ah Battery

2 Ground point on chassis

3 Starter relay

4 Starter motor

5 15A Fuse

6 7.5A Fuse

7 10A Fuse

8 Starter button

9 Ignition switch

10 Voltage regulator

11 Magneto flywheel

12 Low fuel warning light

Electrical system Typhoon 50 4t 4v

ELE SYS - 46

13 Fuel gauge instrument

14 Fuel level transmitter

15 S.I.S. solenoid valve

16 Horn button

17 Horn

18 Stop light

19 Front stop switch

20 Rear stop switch

21 Engine stop

22 PTC heater

23 Left rear turn indicator

24 Left front turn indicator

25. Turn indicator signal warning light

26 Right front turn indicator

27 Right rear turn indicator

28. Turn indicator switch

29 Spark plug

30 HV coil

31 NTC temperature sensor

32 External lighting on relay

33 Diagnostics socket

34 Electronic ignition device

35 Light switch

36 Automatic starter

37 Headlight

38 Instrument panel

39. License plate light

40 >. Tail light

Cable colour:

Az = Sky blue

Bi = White

Ar = Orange

Gi = Yellow

BL = Blue

Ma = Brown

Ne = Black

Rs = Red

Ro = Pink

Typhoon 50 4t 4v Electrical system

ELE SYS - 47

Ve = Green

Vi = Violet

Gr = Grey

Components arrangement


ELE SYS - 48

1. FRONT STOP SWITCH - 2. REAR STOP

SWITCH - 3. LIGHTING RELAY - 4. IGNITION

SWITCH - 5. ELECTRONIC IGNITION DEVICE

Remove the legshield and the front handlebar cov-

er to reach them.

6. STARTER BUTTON - 7. ENGINE STOP

SWITCH

Remove the front and rear handlebar covers to

reach it.

8. HORN BUTTON - 9. TURN INDICATOR

SWITCH - 10. LIGHT SWITCH

Remove the front and rear handlebar covers to

reach it.

11. 10 A - 12 FUSE. 7.5 A FUSE

Open the glove compartment door in the leg shield

back plate to reach them.


ELE SYS - 49

13. HORN

Remove the footrests to reach it.

14. VOLTAGE REGULATOR - 15. SPARK PLUG

- 16. SIS VALVE

Remove the rear central cover to reach it.

17. PTC HEATER - 18. AUTOMATIC STARTER

- 19. STARTER MOTOR - 20. ENGINE TEMPER-

ATURE SENSOR

Remove the helmet compartment to reach it.

21. GROUND POINT ON CHASSIS - 22. START-

ER RELAY - 23. HV COIL - 24. MAGNETO FLY-

WHEEL AND PICK-UP

Remove the right fairing to reach it.


ELE SYS - 50

25. BATTERY - 26. 15 A - 27 FUSE. DIAGNOS-

TICS SOCKET - 28. FUEL LEVEL TRANSMIT-

TER

Lift the saddle and remove the cover to access it.

Ground points

There is a ground point on the vehicle under the

right fairing.

There is a ground point on the vehicle on the volt-

age regulator.

Electrical system installation


ELE SYS - 51

Front side

1. Starter button connector

2. Front right turn indicator connector

3. Right hand stop switch

4. Engine stop switch connector

5. Low fuel warning light connector

6. Instrumentation connector

7. Horn connector

8. Front left turn indicator connector

9. Turn indicator switch connector

10. Light switch connector

11. Left hand stop switch

12. Ignition switch

13. Lighting relay

14. High beam connectors

15. Electronic ignition device

16. Low beam connector

17. Auxiliary fuses

18. Cable harness section toward handlebar

19. Main cable harness

20. Horn

Back side

21. Main cable harness

22. Automatic starter connector

23. PTC connector

24. S.I.S. Valve

25. Voltage regulator

26. Engine temperature sensor

27. HV coil

28. Starter relay

29. Starter motor cabling

30. Battery connectors

31. Main fuse

32. Diagnostic connector

33. Fuel gauge connector


ELE SYS - 52

Conceptual diagrams

Ignition

List of components

1 12V-9Ah Battery


5 15A Fuse

7 10A Fuse

9 Ignition switch


11 Magneto flywheel

14 Pickup

21 Engine stop

29 Spark plug

30 HV coil



ELE SYS - 53

Battery recharge and starting

List of components

1 12V-9Ah Battery


3 Starter relay

4 Starter motor

5 15A Fuse

6 7.5A Fuse

7 10A Fuse

8 Starter button

9 Ignition switch


11 Magneto flywheel


20 Rear stop switch

21 Engine stop

22 PTC heater

29 Spark plug

30 HV coil




ELE SYS - 54

36 Automatic starter

Level indicators and enable signals section

List of components

1 12V-9Ah Battery


5 15A Fuse

6 7.5A Fuse

9 Ignition switch


11 Magneto flywheel

12 Low fuel warning light

13 Fuel gauge instrument

14 Fuel level transmitter

15 S.I.S. solenoid valve

31 NTC temperature sensor



ELE SYS - 55

Instruments and warning lights control board

Key

A - Low fuel warning light;

B - Fuel level indication;

C - Turn indicator warning light;

D - Speedometer;

E - High-beam warning light;

F - Low beam warning light

G - Odometer.

BULBSSpecification Desc./Quantity

1 High beam/low beam bulb Type: Halogen H8Power: 12V - 35W

Quantity: 22 Front turn indicator light bulb Type: Amber spherical

Power: 12V - 10WQuantity: 1 RHS + 1 LHS

3 Rear turn indicator light bulb Type: Amber sphericalPower: 12V - 10W

Quantity: 1 RHS + 1 LHS4 Stop/position light bulb Type: Twin-filament

Power: 12V - 21/5WQuantity: 1

5 12V - 1.2W warning light bulb Type: ALL GLASSApplication: 1 Turn indicator warning light - 1 High

beam warning light - 1 Low beam warning light - 2 In-strument illumination warning lights - 1 Low fuel warning

light


ELE SYS - 56

Specification Desc./QuantityQuantity: 6

6 License plate light 12V - 5W

Devices and accessories

List of components

1 12V-9Ah Battery


5 15A Fuse

6 7.5A Fuse

7 10A Fuse

9 Ignition switch

16 Horn button

17 Horn

33 Diagnostics socket



ELE SYS - 57

Lights and turn indicators

List of components

1 12V-9Ah Battery


5 15A Fuse

6 7.5A Fuse

7 10A Fuse

9 Ignition switch


18 Stop light


20 Rear stop switch

23 Left rear turn indicator

24 Left front turn indicator

25. Turn indicator signal warning light

26 Right front turn indicator

27 Right rear turn indicator

28. Turn indicator switch



35 Light switch


ELE SYS - 58

37 Headlight

38 Instrument panel

39. License plate light

40 >. Tail light

Checks and inspections

Ignition circuit

All the control operations of the system that entail disconnecting cables (to check connections and the

devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls

might be irretrievably damaged.

The battery provides the basic power supply. The system is adjusted so that the start-up system im-

mediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition

system.

The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected

to the Pick-Up by the chassis and the engine ground lead.

To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis

ground connection bonding is efficient.

No spark plug

Once the lack of power to the spark plug has been

detected you can proceed as follows:

- Check the Pick-Up.

The check includes the Pick-Up and its power line.

Disconnect the control unit connector and meas-

ure the resistance between terminal No. 10 (Blue/

Yellow) and terminal No. 12 (Blue).

If the value measured is incorrect, repeat the

check directly on the component. Disconnect the

pick-up connector on the engine and measure the

resistance between the pin corresponding to the

Blue-Yellow cable of the wiring and the ground

connection on the engine.

If correct values are detected, check that the cable

is not interrupted.

Electric characteristicPick-up resistance value


ELE SYS - 59

~ 170 Ohm

- HV primary coil check

Disconnect the control unit connector and check

that the cable between terminal No. 4 (White/Vio-

let) and terminal No. 12 (Blue) is not interrupted

(see figure).

If non-conforming values are measured, check

again the HV coil primary directly on the positive

and negative terminals.

If the values are correct, repair the cable harness

or reset the connections; otherwise, replace the

HV coil

Electric characteristicHigh voltage coil primary resistance valueHigh voltage coil primary resistance value: ~ 0.5

Ohm

- HV coil secondary check

Disconnect the spark plug cap from the HV cable

and measure the resistance between the HV cable

terminal and the HV coil negative terminal (see

figure).

If non-conforming values are measured, replace

the HV coil. To carry out a more complete diagno-

sis, check the peak voltage with the multimeter

adaptor.

Electric characteristicHigh voltage coil secondary resistance valueHigh voltage coil secondary resistance value: ~

3000 ± 300 Ohm

- HV coil

With the control unit and HV coil connected to the

circuit, measure the voltage of the coil primary dur-

ing the start-up test with the voltage peak adaptor

and connect the positive terminal to the ground

one and the negative to the coil positive connector.

If non-conforming values are measured, replace

the control unit.


ELE SYS - 60

WARNINGTHE POSITIVE TERMINAL OF THE HV COIL PRIMARY ISBLACK.

Electric characteristicHigh voltage coil voltage valueHigh voltage coil voltage value: > 100 Volt

Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel.

The generator is directly connected to the voltage regulator.

This, in its turn, is connected directly to the ground and the battery positive terminal passing through

the 20A main protection fuse.

This system therefore requires no connection to the ignition switch.

The three-phase alternator provides good recharge power and at low revs a good compromise is ach-

ieved between generated power and idle stability.

For this reason, it is very important that the idle speed is adjusted as prescribed.

Specific tooling020334Y Multiple battery charger

Switches check

To check buttons and switches, check that, according to their position, the continuity of contacts is

correct as indicated in the following charts.

KEY

Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

STARTER BUTTON


ELE SYS - 61

LIGHT SWITCH

TURN INDICATOR SWITCH

HORN BUTTON

Stator check

Disconnect the connector from the voltage regu-

lator and check there is continuity between any

yellow cable and the other two cables.

Electric characteristicOhm value:1 ± 1 Ohm


ELE SYS - 62

Also check that all yellow cables are insulated from

the ground connection.

If non-conforming values are detected, repeat the

checks directly to the stator. In case of further rep-

etitions of incorrect values replace the stator or

repair the wiring.

Voltage regulator check

With a perfectly charged battery and lights off,

measure voltage at the battery poles with a high

running engine.

The voltage should not exceed 14.5 Volt.

In case higher voltages are detected, replace the

regulator.

In case of voltage values lower than 14 Volt, check

the stator and the corresponding cable harness.

Recharge system voltage check

Connect the ammeter induction clamp to the volt-

age regulator positive terminal (Red/Orange),

measure the battery voltage and turning on the

vehicle lights with the engine off, wait for the volt-

age to settle at about 12 Volt. Start the engine and

measure the current generated by the system with

the lights on and a high running engine.


ELE SYS - 63

In case the generated current value is lower than

8A, repeat the test using a new regulator and/sta-

tor alternatively.

CharacteristicDistributed current13A at 6000 rpm

Starter motorWARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.

If it does not work:

- Check the continuity of the Green/Red cable between the 7.5A fuse (B) and stop buttons.

- Check the continuity between the starter button Green/Red cable and the stop button Green/Yellow

cables.

- Check continuity between the Yellow/Red cable between the starter button and the start-up solenoid.

- Check that the Red cable between the battery and the start-up solenoid, and the latter and the starter

motor are not interrupted.

- Check the start-up solenoid.

- Check the contacts of the ignition switch, the starter button and the stop buttons.

- Check the efficiency of the fuses.

- Check that the starter motor is grounded.

- If all the tests are positive, replace the starter motor.


ELE SYS - 64

Horn control

KEY

1. Battery

2. Main fuse (A) 20A

3. Ignition switch contacts

4. Secondary fuse (C) 15A

5. Horn button

6. HornWARNING


If the horn does not work:

- Check the efficiency of the fuses.

- Check the ignition switch and the horn button contacts.

- If the components are not damaged, check wiring for continuity.

- Check the continuity of the Green cable which connects the horn button to 15A fuse (C).

- Check the continuity of the Grey cable which connects the switch to the horn.

- If all the tests are positive, replace the horn.


ELE SYS - 65

Choke Inspection

Refer to the engine section to check the resistance

and operating conditions of the component. As re-

gards voltage supply, keep the connector connec-

ted to the system and check that the two terminals

receive battery voltage when the engine is on

(see figure).

If no voltage is detected, connect the multimeter

negative probe to the ground lead and the positive

probe to the automatic starter Yellow cable; with

the ignition switch set to "ON" check whether there

is battery voltage; if there is no voltage, check the

wiring connections to the ignition switch.

If there is voltage, check again the ignition control unit connector.

After disconnecting the starter, start up the engine and keep it at idle speed and check there is voltage

when the multimeter positive terminal is connected to terminal No. 9 (Green/Red) and the negative one

to terminal No. 11 (Green/Black).

Replace the control unit if there is no voltage; otherwise, check the wiring connections between the

starter and the control unit.

Turn signals system checkWARNING


Check that bulb operates properly.

Check continuity of the Blue-Black cable between the CDI control unit and the turn indicators switch.

Check that the turn indicator switch works properly.

Check continuity of the Red and Blue cables which connect the switch to the bulbs.

level indicatorsWARNING



ELE SYS - 66

If faults are detected:

- With a multimeter, check resistance values be-

tween the Grey-Green cable and the Blue cable of

the fuel level transmitter by moving the arm with

the float.

- If the transmitter operates correctly but the indi-

cation on the instrument panel is not exact, check

that the cable harnesses between them are not in-

terrupted.

- Check continuity of the Green cable which con-

nects the instrument panel to the 15A secondary

fuse (C).

- Check continuity of the Grey/Green cable which

connects the instrument panel to the probe check-

ing fuel level.

Electric characteristicResistance value when the tank is full~ 7.4 Ω

Resistance value when the tank is empty~ 101 Ω

Fuses

The electrical system is protected by a main fuse

(A) connected on the left-hand side of the helmet

compartment next to the battery.

The battery cover must be removed to reach it.


ELE SYS - 67

Starter circuit, light circuit, horn and instrument

panel are protected by two secondary fuses (B)

and (C) located inside the glove-box.CAUTIONBEFORE REPLACING THE BLOWN FUSE, SEARCH ANDSOLVE THE PROBLEM THAT CAUSED IT TO BLOW.NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSEOF A DIFFERENT RATING THAN THAT SPECIFIED OR US-ING OTHER MATERIAL (FOR EXAMPLE, A PIECE OFELECTRICAL WIRE).

FUSESSpecification Desc./Quantity

1 Fuse No. 1 Capacity: 15 AProtected circuits: general, recharge battery, starter

relay2 Fuse no. 2 Capacity: 10 A

Protected circuits: live: electronic ignition device3 Fuse No. 3 Capacity: 7.5 A

Protected circuits: live: minimum circuit heater (PTC),low fuel warning light, horn, fuel level indicator, front andrear stop buttons, voltage regulator, engine stop switch

Dry-charge battery

Where providedWARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CON-TACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTESAND SEEK IMMEDIATE MEDICAL ATTENTION.IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGEQUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.SEEK IMMEDIATE MEDICAL ATTENTION.BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS ORCIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES.KEEP OUT OF THE REACH OF CHILDREN


ELE SYS - 68

Use of dry-cell batteries:

1) - Remove the short closed tube and the caps,

then pour sulphuric acid into the cells, using the

type specified for batteries with a specific gravity

of 0.0455 lb/in3 (1.26 Kg/l), corresponding to 30°

Bé, at a minimum temperature of 59°F (15°C). until

the upper level is reached.

2) - Leave to rest for at least 2 hours; then, restore

the level with sulphuric acid.

3) - Within the following 24 hours, recharge using

the specific battery charger (single) or (multiple) at

a density of about 1/10 of the battery nominal ca-

pacity until fully charged; check that the acid den-

sity is about 0.0459 lb/in3 (1.27 Kg/l), correspond-

ing to 31° Bé, and that these values are stabilised.

4) - Once the charge is over, level the acid (by

adding distilled water). Close and clean carefully.

5) Once the above operations have been per-

formed, install the battery on the vehicle ensuring

that it is wired up properly.

1 Hold the vertical tube

2 Look at the level

3 The float must be freedWARNING- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VE-HICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE(WITH CLOSED END) NEAR THE + POSITIVE TERMINALWITH THE CORRESPONDING LONG TUBE (WITH OPENEND), THAT YOU FIND FITTED TO THE VEHICLE, TO EN-SURE THAT THE GASES THAT FORM CAN ESCAPEPROPERLY.


Battery maintenance

The battery is an electrical device which requires careful monitoring and careful maintenance. The

maintenance rules are:

1) Check the level of the electrolyte

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled

water, to restore this level. If water topping is required too often, check the vehicle electrical system:

the battery works overcharged and is subject to quick wear.

2)Load status check


ELE SYS - 69

After topping-up the electrolyte level, check its density using an appropriate densitometer (see figure).

With the battery charged, a density of 30-32 Bé, corresponding to a specific weight of 0.0455 - 0.0462

lb/in3 (1.26 - 1.28 Kg/l) must be at a minimum temperature of 59º F (15° C).

A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore

be recharged.

If the vehicle is not used for a given time (1 month or more) it will be necessary to periodically recharge

the battery.

The battery runs down completely in the course of three months. If it is necessary to refit the battery in

the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked

(-) must be connected to the -negative clamp while the other two red wires marked (+) must be con-

nected to the clamp marked with the +positive sign.

3) Recharging the battery

Remove the battery from the vehicle disconnecting the negative terminal first.

Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),

setting the battery charger selector to the type of battery to be recharged. Connections to the power

supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).

4) Cleaning the battery

The battery should always be kept clean, especially on its top side, and the terminals should be coated

with Vaseline.CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. THEUSE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THEWHOLE VEHICLE OR EVEN CAUSE A FIRE.CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FORTHE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.CAUTION

TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.LACK OF PROPER CHARGING OF THE BATTERY BEFORE FIRST USE AT LOW ELECTROLYTELEVEL, CAN LEAD TO PREMATURE BATTERY LIFE.


Connectors

LOW BEAM CONNECTOR

1. Ma - Light switch control.

2. Ne - Ground.


ELE SYS - 70

HIGH BEAM CONNECTOR

1. Vi - Light switch control.

2. Ne - Ground.

BATTERY POSITIVE TERMINAL

1. Rs - Positive starter relay/Positive 15A fuse

BATTERY NEGATIVE TERMINAL

1. Ne - Chassis ground

HV COIL CONNECTOR

1. Vi - Command from electronic ignition device.

2. Ne - Negative from electronic ignition device.

HORN CONNECTOR

1. Ne - Ground.

2. GrNe - Command from horn button.

IGNITION SWITCH CONNECTOR

1. Ar - Positive with key on for secondary fuses and

voltage regulator.

2. RsBL - Positive from 15A fuse.

3. Ne - Ground.

4. BL - Ground with key on for electronic ignition

device and stop engine switch.

TURN INDICATOR SWITCH CONNECTOR

1. BLNe - Power supply from voltage regulator.

2. BiBL - Command for right side turn indicators

and for emergency flashers on warning light.

3. Ro - Command for left side turn indicators and

for emergency flashers on warning light.


ELE SYS - 71

"A" ELECTRONIC IGNITION DEVICE CONNEC-

TOR

1. Ne - Negative for high voltage regulator.

2. BL - Ground after ignition key switch.

3. Vi - High coil and lights relay.

"B" ELECTRONIC IGNITION DEVICE CONNEC-

TOR

1. ArNe - 7.5A fused power supply with key on.

2. BiNe - PTC heater control.

3. Ve - Lights relay control.

4. Ne - Ground.

5. Ma - S.I.S. solenoid valve control

6. GiRo - NTC temperature sensor signal.

7. Az - Lights relay control. 8. RsNe - Diagnostics.

8. RsNe - Diagnostics.

LIGHT SWITCH CONNECTOR

1. Vi - High beam control and high beams on.

2. GiNe - Lights relay power supply.

3. Ma - Low beam control and low beams on.

4. GiNe - Jumper with pin 2.

SIS SOLENOID VALVE CONNECTOR

1. Ma - Command from electronic ignition device.

2. Bi - 10A fused positive with key on.

TAILLIGHT CONNECTOR

1. BiNe - Stop light control.

2. GiNe - Rear tail light control.

3. Ne - Ground.

15 A FUSE CONNECTOR

1. Rs - Positive from battery.

2. RsBL - Positive to ignition key switch.

SECONDARY FUSES CONNECTOR

1. Ar - Live positive lead

2. ArNe - Electronic ignition device power supply

(10A).


ELE SYS - 72


4. Bi - Services power supply (7.5A).

INSTRUMENT PANEL CONNECTOR

1. Vi - High beams on warning light control.

2. Ma - Low beams on warning light control.

3. Not connected.

4. GiNe - Instrument lighting control.

5. BiBL - Right side flashers warning light control.

6. Ne - Ground.

7. Ro - Left side flashers warning light control.

8. Bi - Positive lead for fuel level indicator gauge.

9. BiVe - Signal from fuel level transmitter.

LICENCE PLATE LIGHTING CONNECTOR

1. Ne - Ground.

2. GiNe - Lights relay power supply control.

Engine stop switch connector

1. Ne - Ground.

2. BL - Ground from ignition key switch.

3. GiRs - Starter relay control.

FRONT RIGHT TURN INDICATOR CONNEC-

TOR

1. BiBL - Command from flashers control switch.

2. Ne - Ground.

FRONT LEFT TURN INDICATOR CONNECTOR

1. Ro - Command from flashers control switch.

2. Ne - Ground.

REAR RIGHT TURN INDICATOR CONNECTOR

1. BiBL - Command from flashers control switch.

2. Ne - Ground.


ELE SYS - 73

REAR LEFT TURN INDICATOR CONNECTOR

1. Ro - Command from flashers control switch.

2. Ne - Ground.

VOLTAGE REGULATOR GROUND- Ne

CHASSIS GROUND - Ne

DIAGNOSTICS SOCKET CONNECTOR

1. Not connected.

2. Ne - Ground.

3. RsNe - Connection to electronic ignition device.

STARTER BUTTON CONNECTOR

1. BiNe - Positive after stop button.

2. VeNe - Starter relay control.

HORN BUTTON CONNECTOR

1. Bi - Power from 7.5A fuse.

2. GrNe - Horn control.

FRONT BRAKE STOP BUTTON CONNECTOR

1. BiNe - Brake pressed signal for stop light and

starter consent.


STOP BUTTON ON REAR BRAKE CONNEC-

TOR

1. BiNe - Brake pressed signal for stop light and

starter consent.



ELE SYS - 74

VOLTAGE REGULATOR CONNECTOR

1. Gi - Positive lead for lights relay.

2. Ne - Ground.


4. BL - Positive lead for turn indicators.

5. BLNe - Signal from magneto flywheel.

MAGNETO FLYWHEEL CONNECTOR

1. Ve - Engine speed sensor for electronic ignition

device.

2. Not connected.

3. Bl - Signal for voltage regulator.

4. Not connected.

5. Not connected.

6. Not connected.

PTC heater connector


2. BiNe - Negative from electronic ignition device.

NTC TEMPERATURE SENSOR CONNECTOR

GiRo - Signal to electronic ignition device.

LOW FUEL WARNING LIGHT CONNECTOR

1. Bi - Positive from 7.5A fuse.

2. GrVe - Low fuel signal from fuel level transmit-

ter.

AUTOMATIC STARTER CONNECTOR

1. Ne - Ground.

2. GiNe - Lights relay power supply control.

LIGHTS RELAY CONNECTOR

85. Vi - Command from electronic ignition device.

86. Az - Command from electronic ignition device.

87. GiNe - Positive lead for external lighting.

30. Gi - Positive lead from voltage regulator.


ELE SYS - 75

FUEL LEVEL TRANSMITTER CONNECTOR

1. BiVe - Signal for fuel level indicator gauge.

2. Ne - Ground.

3. GrVe - Signal for low fuel warning light.


ELE SYS - 76

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

Remove the fixing nuts from the manifold to the

head.

Remove the exhaust fixing screws to the crank-

case, then remove the exhaust.

Removal of the engine from the vehicleCAUTION

SUITABLY SUPPORT THE VEHICLE AND THE ENGINE TO AVOID ACCIDENTAL FALL.

- Disconnect the battery.

- Remove the helmet compartment.

- Remove the lower cover.

- Slide the HV wire cap off the spark plug.

- Disconnect the engine temperature sensor.

Engine from vehicle Typhoon 50 4t 4v

ENG VE - 78

Remove the rear brake transmission bracket fixing

screws indicated in the photograph.

Disconnect the rear brake transmission by un-

screwing the adjuster screw.

Disconnect the magneto flywheel cable harness

connector.

Disconnect the starter motor connector from the

relay and the ground.

Typhoon 50 4t 4v Engine from vehicle

ENG VE - 79

Remove the accelerator cable.

Remove the accelerator cable supporting clamp.

Remove the S.I.S. valve piping. Disconnect the

fuel piping and the depression piping.

Disconnect the throttle body sensor (PTC) and the

automatic starter pins, moving the protective

sheaths and removing the clamps.

Engine from vehicle Typhoon 50 4t 4v

ENG VE - 80

Remove the nut connecting the crankcase to the

rear shock absorber.

Remove the pin connecting the engine to the chas-

sis.

Typhoon 50 4t 4v Engine from vehicle

ENG VE - 81

INDEX OF TOPICS

ENGINE ENG

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- Remove the 12 fixing screws.

- Remove the oil filling cap and then slide out the

cover.

If this operation is carried out directly on the vehi-

cle, it is necessary to remove the transmission

cooling coupling and the air filter housing retain-

ers.N.B.USE A MALLET ON THE APPROPRIATE COUPLINGS TOREMOVE THE COVER.

Kickstart

-To remove the start up pinion push the starter

lever to facilitate extracting the pinion.

-Remove the kick-start screw and lever.

-Remove the Seeger ring and the washer indica-

ted in the figure.

-Pull out the toothed sector.WARNINGTHE SECTOR KEEPS THE SPRING SET, BE CAREFUL SOAS NOT TO CAUSE ANY ACCIDENTS

Air duct

- To remove the intake throat on the transmission

cover, just remove the three fixing screws indica-

ted in the figure.

Typhoon 50 4t 4v Engine

ENG - 83

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side

to avoid damaging the coated surface and use the

driven pulley shaft or a pin of the same diameter

to remove the bearing.N.B.IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-AMETER EXTRACTOR CAN BE USED.

Refitting the driven pulley shaft bearing

Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing

after slightly heating the crankcase from the inside.N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE COVERPAINTED SURFACE.

Removing the driven pulley

- Lock the clutch housing with the specific tool.

- Remove the nut, the clutch housing and the

whole of the driven pulley assembly.N.B.THE UNIT CAN ALSO BE REMOVED WITH THE DRIVINGPULLEY MOUNTED.

Specific tooling020565Y Flywheel lock calliper spanner

Engine Typhoon 50 4t 4v

ENG - 84

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

Characteristicclutch housing diameter/standard valueØ 4.212598 + 0.007874 + 0 in (Ø 107+0.2 +0 mm)

Clutch housing diameter/maximum admissiblevalueØ 4.232283 in (Ø 107.5 mm)

Eccentricity measured /max.0.007874 in (0.20 mm)

Removing the clutch

- Equip the tool with long pins screwed into position

«A» from the outside, insert the entire driven pulley

in the tool and have the central screw make con-

tact.CAUTIONTHE TOOL WILL BE DEFORMED IF THE CENTRAL SCREWIS TIGHTENED UP TOO FAR.

- Using a 34 mm socket wrench remove the clutch

locking nut.

- Loosen the central screw by undoing spring of

the driven pulley unit

- Separate the components.

Specific tooling020444Y Tool for fitting/ removing the drivenpulley clutch


ENG - 85

Inspecting the clutch

- Check the thickness of the clutch mass friction

material.

- The masses must not show traces of lubricants;

otherwise, check the driven pulley unit seals.N.B.UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-TRAL FAYING SURFACE AND MUST NOT BE DIFFERENTFROM ONE ANOTHER.VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TOTEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLS TO PREVENTA VARIATION IN THE RETURN SPRING LOAD.

CharacteristicCheck minimum thickness0.03937 in (1 mm)

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

- Remove the three guide pins and the mobile half

pulley.


ENG - 86

Removing the driven half-pulley bearing

- Remove the roller bearing with the special ex-

tractor inserted from the bottom of the fixed half-

pulley.CAUTIONPOSITION THE HOLDING EDGE OF THE EXTRACTION PLI-ERS BETWEEN THE END OF THE BEARING AND THEBUILT IN SEAL RING.

Specific tooling001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch

housing by means of the special tool.N.B.PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TODEFORM THE SLIDING SURFACE OF THE DRIVE BELT

Specific tooling020376Y Adaptor handle

020363Y 20-mm guide

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work

surface of the belt. If there are, replace the half-

pulley..

- Make sure the bearings do not show signs of un-

usual wear.

- Measure the outside diameter of the pulley bush-

ing.

CharacteristicStationary driven half-pulley/Standard diame-terØ 1.337205 - 1.337992 in (Ø 33.965 - 33.985 mm)

Stationary driven half-pulley / Minimum diam-eter admitted after useØ 1.337008 in (Ø 33.96 mm)


ENG - 87

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two O-

rings.

- Measure the inside diameter of the mobile half-

pulley bushing.

CharacteristicMobile driven half-pulley/ Maximum diameteradmissibleØ 1.341732 in (Ø 34.08 mm)

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile

half-pulley.

- Fitting the half-pulley on the bushing.

Recommended productsAGIP GREASE SM 2 Gray black smooth-tex-tured lithium grease, containing molybdenumdisulphide.-

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Using a curved-spout grease gun, lubricate the driven pulley unit with approximately 0.013 lb (6 grams)

of grease. Apply grease through one of the holes in the bushing until it comes out through the hole on

the opposite side. This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended productsAGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum di-sulphide.

-

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible

from the outside.CAUTIONPROPERLY SUPPORT THE HALF-PULLEY TO PREVENTDAMAGE TO THE THREADED END WHILE THE BEARINGSARE BEING FITTED.



ENG - 88

020456Y Ø 24-mm adaptor

020362Y 12 mm guide

020171Y Punch for Ø 17 mm roller bearing

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley

does not show signs of deformation

- Measure the free length of the spring

CharacteristicStandard length4.645669 in (118 mm)

- Check the thickness of the clutch mass friction

material.

-The masses must not show traces of lubricants;

otherwise, check the driven pulley unit.N.B.UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-ENT FROM ONE ANOTHER. VARIOUS CONDITIONS CANCAUSE THE CLUTCH TO TEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLS SO AS TOPREVENT A VARIATION IN THE RETURN SPRING LOAD.

CharacteristicMinimum thickness permitted:0.03937 in (1 mm)

Refitting the clutch

- Preassemble the driven pulley group with spring,

sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the

spring being careful not to damage the plastic

sheath and the end of the threaded shank.


ENG - 89

- Reassemble the nut securing the clutch and tight-

en to the prescribed torque.CAUTIONSO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK-ET WRENCH WITH SMALL CHAMFER.CAUTIONPOSITION THE NON-CHAMFERED SURFACES OF THENUT IN CONTACT WITH THE CLUTCH

Locking torques (N*m)Clutch assembly nut 40.5 - 44.2 lb ft (55 - 60 Nm)

Refitting the driven pulley

-Refit the driven pulley assembly, the clutch bell

and the nut, using the specific tool.


Locking torques (N*m)Driven pulley shaft nut 29.5 - 32.4 lb ft (40 - 44 Nm)

Drive-belt

- Make sure the drive belt is not damaged and does

not have cracks in the toothed grooves.

- Check the width of the belt.

CharacteristicDrive belt/Minimum width0.688976 in (17.5 mm)


ENG - 90

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer,

then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the

rollers and contrast plate fitted loosely on it do not come off.

Specific tooling020451Y Starting ring gear lock

Inspecting the rollers case

1) Check that the bushing and the sliding rings of

the mobile pulley do not show signs of scoring or

deformation.

2) Check the roller running tracks on the contact

pulley; there must not be signs of wear and check

the condition of the contact surface of the belt on

the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of

marked facetting on the sliding surface and that

the metallic insert does not come out of the plastic

shell borders.

4) Check the integrity of the sliding shoes of the

contact plate.

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inside

diameter «A».

- Measure outside diameter «B» of the pulley slid-

ing bushing shown in the figure.CAUTIONDO NOT LUBRICATE OR CLEAN THE BUSHING.

CharacteristicDriving pulley / Maximum diameter:


ENG - 91

0.792126 in (20.12 mm)

Driving pulley/ Standard diameter:0.788228 in (20.021 mm)

Driving pulley bushing/ Standard diameter:0.787402 -0.000787 -0.001614 in (20 -0.020

-0.041mm)

Refitting the driving pulley

- Manually move the movable driven half-pulley

away by pulling it towards the clutch unit and insert

the belt observing the direction of rotation of the

first fitting.N.B.IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SOTHAT THE WORDS CAN BE READ IN CASE IT DOES NOTSHOW A FITTING SIDE.

- Refit the components of the assembly (roller

housing assembly with bushing, limiting washer,

stationary half-pulley, cooling fan belt with drive,

washer and nut).

- With the specific tool, tighten the lock nut to 14.75

lb·ft (20 N·m) and then perform a final 90° locking

in order to prevent the rotation of the driving pulley.N.B.REPLACE THE NUT WITH A NEW ONE AT EVERY REFITCAUTIONUPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-MOST IMPORTANCE THAT THE BELT IS FREE INSIDE INORDER TO AVOID WRONG TIGHTENING AND CONSE-QUENTLY DAMAGING THE CRANKSHAFT KNURLING.

Specific tooling020451Y Starting ring gear lock

Locking torques (N*m)Crankshaft pulley nut 13.3 - 14.8 lb ft + 90° (18 - 20 Nm+ 90°)


ENG - 92

Refitting the transmission cover

- Check the following for wear: toothed section,

toothed section shaft, cover seat bushing, pinion

shaft and its seating in the crankcase and the re-

turn spring.

- Remove the damaged components.

- Grease the spring.

- Remove the toothed sector and load the spring

with an appropriate tool.

- Refit the washer, the Seeger and the Kick-start

lever.

Recommended productsAGIP GREASE MU3 Yellow-brown, lithium-base, medium-fibre multipurpose grease.ISO L-X-BCHA 3 - DIN 51 825 K3K -20

- Insert the pinion in its seating by pushing the starter lever.

- Fit the intake throat and tighten the 3 screws.

-Make sure the oil sump presents centring dowels

and sealing gaskets.

- Replace the cover tightening the 12 screws to the

prescribed torque.

-Refit the oil filling cap.

Locking torques (N*m)Transmission cover screws 8.1 - 9.6 lb ft (11 - 13Nm)

End gear


ENG - 93

Removing the hub cover

• Remove the transmission cover

• Remove the clutch assembly

• Discharge the rear hub oil.

• Remove the 5 screws indicated in the figure.

• Remove the hub cover with driven pulley shaft.

See alsoRefitting the clutch

Removing the wheel axle

- Remove the intermediate gear and the complete

gear wheel axle.

- When removing the intermediate gear pay atten-

tion to the various shim adjustments.

Removing the wheel axle bearings

- Remove the oil seal and the Seeger ring.

- Remove the bearing by pushing from the outside

towards the inside of the gear compartment, using

the appropriate punch.

Specific tooling020363Y 20-mm guide

020376Y Adaptor handle

020358Y 37x40-mm Adaptor


ENG - 94

Removing the driven pulley shaft bearing

- Remove the Seeger ring inside the cover.

- Remove the oil seal from the outside.

- Remove the centring dowels and position the

cover on a plane.

- Position the special tool on the internal track of

the bearing and remove said bearing with the aid

of a press.

Specific tooling020452Y Tube for removing and refitting thedriven pulley shaft

- Position the special tube on the internal raceway

of the bearing and from the shaft toothed side as

indicated in the figure. Expel the driven pulley shaft

with the aid of a press.


Inspecting the hub shaft

- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and

the oil seal housings.

- If faults are found, replace the damaged compo-

nents.

- Check capacity (A) of the transmission gear

(wear, deformations, etc.)

- Check the pulley shaft seating: Superficial wear

(B) may indicate irregularities in the crankcase

seats or in the pulley shaft capacities

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.


ENG - 95

Refitting the driven pulley shaft bearing

- Support the inner track of the bearing from the

outside of the hub cover with the specific tool posi-

tioned under the press and insert the driven pulley

axle.

- Refit the oil seal flush with the cover.


• Heat the hub cover and insert the bearing with

the specific punch.

• Fit the snap ring with the concave or radial part

on the bearing side.N.B.FIT THE BALL BEARING WITH THE SHIELD FACING THEOIL SEAL.

Specific tooling020151Y Air heater


020439Y 17-mm guide


Refitting the wheel axle bearing

- Heat the half crankcase on the transmission side

using a thermal gun.

- After lubricating its outer strip, insert the bearing

with the special adapter with the aid of a hammer.

- Refit the Seeger ring and the oil seal using the 42

x 47 mm adapter and the handle.



020363Y 20-mm guide



ENG - 96

Refitting the ub cover

- Refit the whole wheel axle.

- Refit the intermediate gear paying attention to the

two shim washers.

- Apply LOCTITE 510 for surfaces to the hub cov-

ers and refit the same with driven pulley shaft.

- Refit the 5 screws and tighten them to the speci-

fied torque.N.B.CLEAN THE CONTACT SURFACES OF THE HUB COVERAND THE HALF CRANKCASE OF RESIDUE FROM PREVI-OUS GASKETS BEFORE APPLYING A NEW ONE.

Locking torques (N*m)Rear hub cap screws 8.1 - 9.6 lb ft (11 - 13 Nm)

Flywheel cover

Cooling hood

- Remove the manifold and the carburettor undo-

ing the 2 fixing screws on the head

- Remove the fastening clamp of the secondary air

pipe and disconnect it

- Remove the 4 front coupling screws (1 of them is

a knob) and the side fixing screw at the crankcase

base.

- Remove the 4 side screws

- Extract the 3 covers - Remove the cover sealing

gaskets on the head

- For refitting, repeat the removal steps but in re-

verse orderCAUTIONTAKE CARE TO CORRECTLY POSITION THE FLYWHEELCONNECTOR.N.B.WHEN REFITTING THE COVER, TAKE CARE NOT TO DAM-AGE THE STATOR WIRING.


ENG - 97

Cooling fan

- Remove the cooling fan by undoing the 3 screws

fixing it to the rotor

- When refitting the fan, pay attention that the

screw holes in the fan and the rotor coincide, then

tighten screws at the specified torque.

Removing the stator

- Remove the 2 Pick-Up screws and the 2 stator

fixing screws indicated in the figure.

- Remove the stator and its wiring.


ENG - 98

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-

ers to the specified torque.N.B.THE PICK-UP CABLE MUST BE POSITIONED ADHERINGTO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCHA WAY AS TO AVOID BEING CRUSHED BY THE FAN COV-ER ASSEMBLY.

Locking torques (N*m)Pick-up screws 2.2 - 2.9 lb ft (3 - 4 Nm) Statorscrews 2.2 - 2.9 lb ft (3 - 4 Nm)

Flywheel and starting

Removing the starter motor

- Undo the screw on the power positive contact

and disconnect the cable

- Undo the 2 screws fixing the starter motor to the

crankcase and recover the power wiring.


ENG - 99

Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper

spanner.

- Remove the nut.CAUTIONTHE USE OF A CALLIPER SPANNER OTHER THAN THEONE SUPPLIED COULD DAMAGE THE STATOR COILS

- Extract the flywheel with the extractor.


020162Y Flywheel extractor

Inspecting the flywheel components

- Check that the flywheel internal magnets are in

good conditions.

- Check that the flywheel splines exhibit no loos-

ening.

- Check there are no deformations that may cause

rubbing on the stator and the Pick-Up.

- Check that the stator winding, its ferromagnetic

support and the pick-up are in good conditions.


ENG - 100

Starter gear rim

- Check the toothing is level and in good conditions

Intermediate gear

- Check that the keying toothing on the crown and

the starter motor are in good conditions.

- Check that the Bendix opens and returns ade-

quately.

Refitting the flywheel magneto

- Refit the stator and the pick-up being careful to

pass the wiring through the appropriate crankcase

couplings.

- Refit the flywheel to the crankshaft being careful

to respect the keying, then lock rotation with the

specific tool and tighten the nut to the prescribed

torque.N.B.A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TOA VARIATION IN THE IGNITION ADVANCE SUCH AS TOCAUSE PINGING, KNOCKING ETC.


Locking torques (N*m)Flywheel nut 2.2 - 2.9 lb ft (3 - 4 Nm)


ENG - 101

Refitting the starter motor

- Install the starter motor in its seating in the crank-

case.

- Tighten the screw on the head side but do not

lock it, screw the second screw inserting the earth

cable (black), then tighten the 2 screws at the pre-

scribed torque.

- Tighten the locking screw of the positive cable

(red) on the side contact.N.B.REFIT THE REMAINING PARTS AS DESCRIBED IN THECYLINDER HEAD, TIMING, LUBRICATION, FLYWHEELAND TRANSMISSION CHAPTERS.

Locking torques (N*m)Starter motor screws 8.1 - 9.6 lb ft (11 - 13 Nm)

Cylinder assy. and timing system

Removing the rocker-arms cover

- Remove the cooling covers

- Remove the 4 retainers of the tappet cover

- Remove the cover and the O-ring

- Remove the 3 screws and then remove the Blow-

by cover

- Clean the nozzle labyrinth and the membrane

(replace it, if necessary), then remove the cover

unit.


ENG - 102

Removing the timing system drive

- Temporarily loosen the tensioner central screw

and remove it together with the spring.

- Unscrew the 2 retainers indicated in the figure

and remove the chain tightener support being

careful to recover the sealing gasket.N.B.SHOULD THE GASKET NOT BE IN GOOD CONDITIONS,REPLACE IT AFTER CAREFULLY CLEANING THE FAYINGSURFACE IN ORDER TO AVOID ENGINE OIL LEAKS

- Remove the driving pulley

- Remove the oil pump chain

- Remove the tappet cover

- Remove the central screw and the belleville

washer indicated in the figure and lock the cam-

shaft crown with the specific tool.N.B.TO FACILITATE REMOVING THE HEAD COMPONENTS,SET THE CRANKSHAFT TO THE TIMING POINT (TDC OFTHE COMPRESSION END).


- Remove the camshaft control pulley and the washer below.

- Remove the pinion of the crankshaft timing control

- To remove the chain lower guiding pad, remove the head by pulling it upwardsN.B.

IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE DIRECTION OF RO-TATION IS MAINTAINED.

See alsoRemoving the rocker-arms coverRemovalRemoving the driving pulley


ENG - 103

Removing the cam shaft

- Remove the limit screw of the rocking lever pins

shown in the figure.

- Remove the Seeger ring retaining the camshaft

bearing.

- Remove pins and rocking levers.

- Remove the calibrated padsN.B.MARK THE ASSEMBLY POSITION OF THE ROCKING LEV-ERS IN ORDER TO AVOID MISPLACING THE INTAKE ANDDISCHARGE ENDS.

- Remove the entire camshaft with bearing using

the specific tool shown in the figure.

- Take out the camshaft bearing with the aid of the

specific tool, being careful to mount a screw on the

camshaft in order to protect its thread.N.B.IF A BEARING SEPARATES FROM THE CAMSHAFT, IT ISESSENTIAL TO FIT A NEW BEAR.

Specific tooling020450Y Camshaft fitting/removal tool

004499Y Camshaft bearing extractor

004499Y001 Bearing extractor bell

004499Y002 Bearing extractor screw

004499Y006 Bearing extractor ring

004499Y027 Bearing extractor part


ENG - 104

Removing the cylinder head

- Remove the cooling covers, the timing control,

the camshaft and the rocking levers.

- Remove the spark plug.

- Remove the 2 side fixings shown in the figure.

- Loosen the 4 head-cylinder fastening nuts in two

or three stages and in criss-cross fashion.

- Remove the head, the two alignment dowels and

the gasket.N.B.IF NEEDED, THE HEAD MAY BE REMOVED WITH THECAMSHAFT, PINS AND ROCKING LEVERS WITHOUT RE-MOVING THE DRIVING PULLEY UNIT. REMEMBER TOHOLD THE TIMING CHAIN WITH A PIECE OF METAL CA-BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE-FITTING.

Removing the valves

- Using the specific tool fitted with the part shown

in the figure, remove cotters, caps and valve

springs.

- Remove the oil seals with the appropriate tool.

Specific tooling020431Y Valve oil seal extractor

020382Y Valve cotters equipped with part 012removal tool


ENG - 105

Removing the cylinder - piston assy.

- Remove the cylinder paying attention to the 2

cylinder centring dowels in the housing.

- Remove the cylinder base gasket.

To avoid damaging the piston, keep it fixed while

removing the cylinder.

- Remove the two stop rings, the wrist pin and the

piston.

- Remove the 3 piston rings from the piston.N.B.BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR-ING REMOVAL.

Inspecting the small end

- Measure the internal diameter of the connecting rod small end using an internal micrometer.N.B.

IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAME-TER ADMISSIBLE, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFTAS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER".

For the dimensions see the SPECIFICATIONS

chapter

Inspecting the wrist pin

- Measure the outer diameter of the gudgeon pin.


ENG - 106


chapter

Inspecting the piston

- Measure the diameter of the bearings on the piston.


chapter

- Carefully clean the seal housings.

- Measure the coupling clearance between the sealing rings and the piston grooves using suitable

sensors, as shown in the diagram.

- If the clearance is greater than that indicated in the table, replace the piston.N.B.

MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THESECOND SEAL RING SIDE.


chapter


ENG - 107

Inspecting the cylinder

- Using a bore meter, measure the inner cylinder diameter at three different points according to the

directions shown in the figure.

- Check that the coupling surface with the head is not worn or misshapen.

- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried

out in pairs (A-A, B-B, C-C, D-D).

CharacteristicMaximum allowable run-out

0.001 in (0.05 mm)

Inspecting the piston rings

- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di-

ameter. Using the piston, insert the rings perpendicularly to the cylinder axis.

- Measure the opening, see figure, of the sealing rings using a thickness gauge.

- If any measurements are greater than specified, replace the piston rings.N.B.

BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEENTHE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THECYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITHA USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.


ENG - 108

SEALING RINGSName Description Dimensions Initials Quantity

1st Compression ring 1.535433 x 0.03937 in(39 x 1 mm)

A 0.003150 - 0.007874 in(0.08 - 0.20 mm)

2nd Compression ring 1.535433 x 0.03937 in(39 x 1 mm)

A 0.001969 - 0.007874 in(0.05 - 0.20 mm)

Oil scraper ring 1.535433 x 0.07874 in(39 x 2 mm)

A 0.007874 - 0.027559 in(0.20 - 0.70 mm)

1st Compression ring1st Oversize

1.543307 x 0.03937 in(39.2 x 1 mm)

A 0.003150 - 0.007874 in(0.08 - 0.20 mm)

2nd Compression ring1st Oversize

1.543307 x 0.03937 in(39.2 x 1 mm)

A 0.001969 - 0.007874 in(0.05 - 0.20 mm)

Oil scraper ring 1stOversize

1.543307 x 0.07874 in(39.2 x 2 mm)

A 0.007874 - 0.027559 in(0.20 - 0.70 mm)

1st Compression ring2nd Oversize

1.551181 x 0.03937 in(39.4 x 1 mm)

A 0.003150 - 0.007874 in(0.08 - 0.20 mm)

2nd Compression ring2nd Oversize

1.551181 x 0.03937 in(39.4 x 1 mm)

A 0.001969 - 0.007874 in(0.05 - 0.20 mm)

Oil scraper ring 2ndOversize

1.551181 x 0.07874 in(39.4 x 2 mm)

A 0.007874 - 0.027559 in(0.20 - 0.70 mm)

1st Compression ring3rd Oversize

1.559055 x 0.03937 in(39.6 x 1 mm)

A 0.003150 - 0.007874 in(0.08 - 0.20 mm)

2nd Compression ring3rd Oversize

1.559055 x 0.03937 in(39.6 x 1 mm)

A 0.001969 - 0.007874 in(0.05 - 0.20 mm)

Oil scraper ring 3rdOversize

1.559055 x 0.07874 in(39.6 x 2 mm)

A 0.007874 - 0.027559 in(0.20 - 0.70 mm)


ENG - 109

Removing the piston

- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-

wards the exhaust.

- Fit the pin retainer ring onto the appropriate tool.

Specific tooling020448Y Pin lock fitting tool

- With the opening in the position indicated on the

tool, set the lock ring into position in the tool with

the punch.

- Rest the tool on the piston paying attention that

the 90°chamfered side faces upwards as indicated

in the figure.

- Fit the gudgeon pin stop using the plug.CAUTIONUSING A HAMMER TO POSITION THE RINGS CAN DAM-AGE THE LOCKING HOUSING.

Refitting the piston rings

- Fit the oil scraper ring starting from the spring,

taking care that the spring ends do not superim-

pose. Fit the two piston rings so that their gaps and

that of the oil scraper ring are never aligned.

- Fit the 2nd sealing ring with the identifying letter

«T» facing towards the piston crown.

- Fit the 1st sealing ring with the reference letter

«T» facing towards the piston crown.

- Misalign the lining openings at 120° as shown in

the figure.

- Lubricate the components with engine oil.N.B.IN ORDER TO OBTAIN A GOOD BEDDING, THE 2 SEALINGPISTON RINGS ARE MADE OF CONE SHAPED CONTACTSECTION TO THE CYLINDER. AS A RESULT IT IS IMPOR-TANT TO RESPECT THE FITTING INSTRUCTION TO AS-SEMBLY THE RINGS WITH THE "T" MARK FACINGUPWARDS.


ENG - 110

Refitting the cylinder

- Insert the cylinder base gasket.

- Fit the cylinder as shown in the figure.

- The piston can be kept out of the housing plane

using the appropriate tool.N.B.BEFORE FITTING THE CYLINDER, CAREFULLY BLOWOUT THE LUBRICATION DUCT AND OIL THE CYLINDERLINER.

Specific tooling020288Y Fork to assemble piston on cylinder

If the four cylinder stud bolts should be replaced in this kind of engine, it is necessary to tighten the

head nuts strictly following the procedure below.

Locking torques (N*m)Head nut tightening (only for stud bolt replacement) 4.4 - 5.2 lb ft + 135° + 90° (6-7 Nm + 135° +90°)

Inspecting the cylinder head

- Using a trued bar check that the cylinder head

surface is not worn or distorted.

- Check that the camshaft and rocking lever pin

bearings show no signs of wear.

- Check that the cylinder head cover surface, the

intake manifold and the exhaust manifold are not

worn.

- It is advisable to replace the head if any failure is

found.

CharacteristicMaximum allowable run-out:0.003937 in (0.1 mm)


ENG - 111

Measure the camshaft bearing seats and rocking

lever support pins with a bore meter

HEAD CHECKSpecification Desc./Quantity

Standard diameter in (mm) A Ø 1.260433 - 1.260827 (Ø 32.015 - 32.025)Standard diameter in (mm) B Ø 0.629921 - 0.63063 (Ø 16.0 - 16.018)Standard diameter in (mm) C Ø 0.433071 - 0.43378 (Ø 11.0 - 11.018)

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.

- Ensure that the camshaft drive pulley, the chain

assembly and the sprocket wheel are not worn.

- If sings of wear are found, replace the parts. if the

chain, pinion or pulley are worn, replace the whole

assembly.

- Remove the central screw and the tensioner

spring. Check that the one-way mechanism is not

worn.

- Check the condition of the tensioner spring.

- If examples of wear are found, replace the whole

unit.


ENG - 112

Inspecting the valve sealings

- Remove any carbon deposits from the valve

seats.

- Check the width of the mark on the valve seat

«V» with Prussian blue.

CharacteristicStandard value:0.03937 - 0.051181 in (1 - 1.3 mm)

Admissible limit:0.062992 in (1.6 mm)

- If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45°

milling cutter and then grind.

- In case of excessive wear or damage, replace the head.

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust

valves.

- The test is carried out by filling the manifold with

petrol and checking that the head does not ooze

through the valves when these are just pressed

with the fingers.

Inspecting the valves

VALVE STANDARD LENGTHSpecification Desc./Quantity

Inlet: standard length 2.948919 in (74.9 mm)Outlet: standard length 2.927165 in (74.35 mm)


ENG - 113

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

STANDARD DIAMETERSpecification Desc./Quantity

Intake 0.156299 - 0.156890 in (3.970 - 3.985 mm)Exhaust 0.155906 - 0.156496 in (3.960 - 3.975 mm)

MINIMUM ADMISSIBLE DIAMETERSpecification Desc./Quantity

Intake 0.155827 in (3.958 mm)Exhaust 0.155315 in (3.945 mm)

- Calculate the clearance between valve and valve guide.

- Check the concentricity of the valve head by

placing a dial gauge at right angles to the valve

head and rotating it on the «V» shaped support.

CharacteristicAdmissible limit:0.001181 in (0.03 mm)

- Check the deviation of the valve stem by resting

it on a «V» shaped support and measuring the ex-

tent of the deformation using a dial gauge.

CharacteristicLimit values admitted:0.003937 in (0.1 mm)


ENG - 114

Inspecting the valve stem guide clearance

Measure the valve guides

VALVE GUIDE DIAMETERSpecification Desc./Quantity

Standard valve guide diameter 0.15748 + 0.000472 in (4 + 0.012 mm)Valve guide Maximum admissible diameter 0.15748 + 0.000866 in (4 + 0.022 mm)

- After measuring the valve guide diameter and the

valve stem diameter, check clearance between

guide and stem.

INTAKESpecification Desc./Quantity

Standard clearance 0.000590 - 0.001654 in (0.015 - 0.042 mm)Admissible limit 0.002362 in (0.06 mm)

EXHAUSTSpecification Desc./Quantity

Standard clearance 0.000984 - 0.002047 in (0.025 - 0.052 mm)Admissible limit 0.002756 in (0.07 mm)


ENG - 115

Refitting the valves

- Lubricate the valve guides with graphite grease.

- Place the lower caps of the valve spring on the

head.

- Use the punch to fit the 4 sealing rings one at a

time.

- Fit the valves, the springs and the upper caps.

- Using the appropriate tool, compress the springs

and insert the cotters in their seats.

Inspecting the cam shaft

- Inspect the camshaft for signs of abnormal wear

on the cams.

CharacteristicStandard diameter - Bearing A:Ø 0.472441 +0.000079 +0.000394 in (Ø 12 +0.002

+0.010 mm)

Standard diameter - Bearing B:Ø 0.629921 -0.000591 -0.000906 in (Ø 16 -0.015

-0.023 mm)

Minimum diameter admissible - Bearing A:Ø 0.471654 in (Ø 11.98 mm)

Minimum diameter admissible - Bearing B:Ø 0.628346 in (Ø 15.96 mm)

- Using a gauge, measure the height of the cams.

Check the axial clearance of the camshaft


ENG - 116

- If any of the above dimensions are outside the

specified limits, or there are signs of excessive

wear, replace the defective components with new

ones.N.B.A BALL BEARING IS FITTED ON BEARING «A»; CONSE-QUENTLY, BEARING «B» IS THE MOST IMPORTANT AS ITWORKS DIRECTLY ON THE HEAD ALUMINIUM

CharacteristicStandard height - Inlet0.960512 in (24.397 mm)

Standard height - Outlet0.944724 in (23.996 mm)

Fitting clearanceMaximum admissible axial clearance: 0.019685(0.5 mm)

- Measure the outside diameter of the rocking lever pins

- Check the rocking lever pins do not show signs of wear or scoring.

- Measure the internal diameter of each rocker.

- Check that the pad in contact with the cam is not worn.

DIAMETER OF PINS AND ROCKING LEVERSSpecification Desc./Quantity

Rocking levers - Inside diameter 0.433661 - 0.434449 in (11.015 - 11.035 mm)Rocking levers - Pins diameter 0.432165 - 0.43248 in (10.977 - 10.985 mm)

Refitting the head and timing system components

- Fix the head on a workbench.

- Screw the tool to fit the camshaft fully down on the bearing's inner track.

- Fit the camshaft fully into its seating together with the bearing with the aid of a mallet.

- Remove the tool.

- Fit the head gasket after cleaning the faying surface carefully.


ENG - 117

- Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque.

Specific tooling020450Y Camshaft fitting/removal tool

- Fit pins, inlet rocking lever and discharge rocking

lever.

- Lubricate the 2 rocking levers through the holes.N.B.IF A BEARING SEPARATES FROM THE CAMSHAFT, IT ISESSENTIAL TO FIT A NEW BEARING.

- Screw up the limit screw of the rocking lever pins

and tighten it to the prescribed torque.

- Reposition the Seeger ring retaining the cam-

shaft

Locking torques (N*m)Rocking lever axle and camshaft bearingscrew 2.2 - 2.9 lb ft (3 - 4 Nm)

- Finish the head tightening following the proce-

dure below: screw the four head nuts to an initial

torque at two crossed passes. Afterwards tighten

the nuts with 2 turns of 90° each to be done at two

crossed passes.

-Finish the tightening of the head to the crankcase

with the 2 side screws.N.B.SHOULD THE CRANKCASE OR THE CYLINDER STUDBOLTS BE REPLACED, IT IS NECESSARY TO CARRY OUTAN INITIAL TIGHTENING PLUS OTHER 3 TURNS OF 90°EACH AT 3 CROSSED PASSES

Locking torques (N*m)Head-cylinder stud bolt nuts 4.4 - 5.2 lb ft + 90° +90° (6 - 7 Nm + 90° + 90°) Floating head coverscrews 4.4 - 5.2 lb ft (6 - 7 Nm)


ENG - 118

Refitting the timing chain

- Insert the timing chain pads in their correspond-

ing seatings, the screw and the spacer as indica-

ted in the figure.

- Tighten to the prescribed torque and check the

tensioner pad moves adequately.

- Insert the timing pinion in driving shaft with the

chamfered side facing the insertion (towards the

main bearing).

- Loop the timing chain around the sprocket on the

crankshaft.

Locking torques (N*m)Chain tensioner pad screw 3.7 - 5.2 lb ft (5 - 7 Nm)

- Refit the spacer on the camshaft.

- Rotate the engine so that the piston is at top dead

centre, using the reference marks on the flywheel

and the crankcase.

- With this operation, insert the chain on the cam-

shaft control pulley and make the reference notch

coincide with the point on the head.

- Fit the pulley onto the camshaft.

- Fit the belleville washer so that the outer rim

touches the pulley.

- Bring the screw closer but without reaching its

final locking point.

- Push the tensioner pad lightly so as to check the

correct timing.

- Use the specific tool to lock the camshaft crown

gear and tighten the screw.

- Adjust valve clearance.

- Replace the O-ring on the tappet cover.

- Fit the tappet cover and lock it with the 4 fixing

screws indicated in the figure.


Locking torques (N*m)


ENG - 119

Camshaft pulley screw 8.8 - 10.3 lb ft (12 - 14 Nm)Floating head cover screws 4.4 - 5.2 lb ft (6 - 7 Nm)

- Set the tensioner cursor in the rest position.

- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the specified

torque.

- Insert the spring with the central screw and tighten it to the prescribed torque.

- Fit the spark plug.

CharacteristicElectrode distance

0.023622 in (0.6 mm)

Electric characteristicSpark plug

NGK ER9EH-6N

Locking torques (N*m)Timing chain tensioner central screw 3.7 - 4.4 lb ft (5 - 6 Nm) Ignition spark plug 7.4 - 11 lb ft (10- 15 Nm)

Refitting the rocker-arms cover

- Carry out the removal procedure but in reverse

order and tighten the four fixing screws to the

specified torque.N.B.FIT A NEW O-RING ON THE TAPPET COVER.

Refitting the intake manifold

-Fit the cover sealing gaskets on the head.

-Fit the 2 covers.

- Fit the inlet manifold and do up the 2 screws to

the specified torque.

-Fit the carburettor on the inlet manifold and lock

the clamp.

-Fit the secondary air pipe and fix it with the ap-

propriate clamp.N.B.


ENG - 120

FIT THE CARBURETTOR THROUGH THE SUPPLEMENTON THE MANIFOLD.

Locking torques (N*m)Inlet manifold screw 5.2 - 6.6 lb ft (7 - 9 Nm)

Crankcase - crankshaft

- First remove the following units:

Driving pulley Driven pulley

Final reduction greasing

Oil pump Flywheel with stator

Cylinder-piston-head unit

Starter motor with cables.

See alsoRemoving the driving pulleyRemovalRemoving the driven pulleyRemoving the cylinder - piston assy.Removing the starter motorRemoving the stator

Splitting the crankcase halves

- Remove the ten crankshaft coupling screws.

-Separate the crankcase halves keeping the half

casing driving shaft engaged on the transmission

side.

- Remove the crankshaft.CAUTIONIF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC-CIDENTALLY FALL.

- Remove the oil guard on the flywheel side.CAUTION

THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT. DO NOT WASH WITH SOL-VENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT. A CENTRIFUGALOIL FILTER'S LIFE IS THE SAME AS THE ENGINE'S AND IS MAINTENANCE FREE.


ENG - 121

- Check the axial clearance on the connecting rod.

Fitting clearanceStandard connecting rod axial clearance0.005906 - 0.011811 in (0.15 - 0.30 mm) Max. connectingrod clearance 0.019685 in (0.5 mm)

- Check the correct radial clearance of the con-

necting rod by holding the driving shaft with your

hands and, with a dial gauge fitted to the rod small

end, measuring the clearance, move the connect-

ing rod vertically as shown in the figure.

Fitting clearanceConnecting rod radial - standard clearance0.000236 - 0.000709 in (0.006 - 0.018 mm) Connectingrod max. - radial clearance 0.000984 in (0.025 mm)

- Check that the half shaft surfaces are not scored

and with the aid of a gauge check the driving shaft

width as indicated in the figure.

CharacteristicStandard measure1.771654 in (45 mm)

Removing the crankshaft bearings

- Remove the flywheel bearing fitted on the driving

shaft using the specific tool.

Specific tooling004499Y Camshaft bearing extractor

004499Y001 Bearing extractor bell

004499Y002 Bearing extractor screw

004499Y006 Bearing extractor ring

004499Y034 Bearing extractor part


ENG - 122

Refitting the crankshaft bearings

- Support the crankcase on a surface and place it

with the driving shaft axle in a vertical position.

- Warm the crankcase at ~ 250°F (~ 120°C) with a

thermal gun (and support).

- Fit the punch with guide and adaptor, place the

bearing on the punch using grease (to keep it from

falling).

-Insert the bearing in the crankcase; if needed, use

a mallet but do so with extreme care so as not to

damage the engine crankcase limit stop.

Specific tooling020359Y 42x47-mm Adaptor

020364Y 25-mm guide



- Warm a new main bearing in an oil bath at 250°

F (120°C).

- Place the driving shaft on the support base and

insert the bearing with the aid of an adequate piece

of tube if necessary.N.B.USE A NEW BEARING WHEN REFITTINGWARNINGTHE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEELAXLE SHAFT. DO NOT WASH WITH SOLVENTS OR BLOWCOMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT.

Specific tooling020265Y Bearing fitting base

008119Y009 Tube to assemble shafts andaxles


ENG - 123

Inspecting the crankshaft alignment

To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated

in figure.N.B.IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC-TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-SERTING A WOODEN WEDGE BETWEEN THE HALFSHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-DED. IF EVEN AFTER THIS OPERATION THE VALUES ARENOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.

CharacteristicOff-line maximum admitted - A0.005906 in (0.15 mm)

Off-line maximum admitted - B0.000787 in (0.02 mm)

Off-line maximum admitted - C0.000787 in (0.02 mm)

Off-line maximum admitted - D0.003937 in (0.10 mm)

- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded

tangs are in good working order.

- In case of failures, replace the crankshaft.

Specific tooling020074Y Support base for checking crankshaft alignment

Refitting the crankcase halves

-Be careful to place the two centring dowels pref-

erably on the flywheel side half casing.

-Insert the crankshaft on the half casing on the

transmission side.


ENG - 124

- Fit the gasket recommended for surfaces on the

half casing on the transmission side after greasing

the two faying surfaces carefully.

-Insert the flywheel half casing.

- Fit the 10 screws and tighten them to the pre-

scribed torque.N.B.WHEN FITTING THE HALF CASING AND THE CRANK-SHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREA-DED TANGS.

Recommended productsLoctite 510 Liquid sealantGasket

Locking torques (N*m)Crankcase half union screw 5.9 - 7.4 lb ft (8 - 10 Nm)

- Fit a new O-Ring on the mesh oil filter and on the

filling cap; lubricate the rings.

- Insert the filter on the engine and lock the cap to

the prescribed torque.

Locking torques (N*m)Engine oil pre-filter cover 18.4 - 20.6 lb ft (25 - 28 Nm)

Lubrication

Crankshaft oil seals

Removal

- Extract the flywheel oil seal from the crankcase

being careful not to damage or score the crank-

case.


ENG - 125

- Check that the chain contrast pad is not worn.

-Otherwise, replace the pad or fit it inverted to

make it work on the other side.

- Any operation on the chain cover oil seal should

be carried out placing the cover on the workbench

on the covering plate side of the oil pump chain.

- Remove the oil seal with a Ø 1.18 in (Ø30 mm) -

MAX diameter Ø 1.26 in (Ø 32 mm) tube section.

Refitting

- Fit a new oil seal on the outer rim with the help of

the specific tools below.

- Fit a new O-ring and lubricate it with grease.

- Install the cover on the engine crankcase, insert

the three screws and place the cover in its position.

- Tighten the 3 screws to the prescribed torque.



Locking torques (N*m)Timing chain/oil pump compartment coverscrews 2.9 - 3.7 lb ft (4 - 5 Nm)

Oil pump

Removal

- Remove the chain compartment cover undoing

the 3 fixing screws indicated in the figure.

- Take out the cover using the appropriate fusion

couplings on the cover with a pair of pliers


ENG - 126

- Undo the 2 clamping screws in the figure and re-

move the cover over the pump control crown gear.

- Block the rotation of the oil pump control gear with

a screwdriver inserted through one of its pump

holes.

- Remove the central screw and the belleville

washer

- Remove the chain with the crown gear.

- Remove the crankshaft control pinion.

- Remove the oil pump by undoing the 2 screws

indicated in the figure.

- Remove the oil pump seal.N.B.IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-SURE THAT THE INITIAL DIRECTION OF ROTATION ISMAINTAINED.

Inspection

- Remove the two screws and the oil pump cover.

- Remove the clip retaining the innermost rotor.

- Remove and wash the rotors thoroughly with a

degreasing solvent and compressed air.

- Reassemble the rotors in the pump body, keep-

ing the two reference marks visible Replace the

clip.

- Measure distance between rotors (inner rotor/

outer rotor) with a thickness gauge in the position

shown in the picture.

CharacteristicAdmissible maximum clearance 10.005906 in (0.15 mm)


ENG - 127

Measure the distance between the outer rotor and

the pump body (see figure).


- Check the axial clearance of the rotors using a

trued bar as reference as shown in the figure.N.B.MAKE SURE THE TRUED BAR IS POSITIONED PROPERLYON THE TWO POINTS ON THE PUMP BODY.


Refitting

- Check there are no signs of wear on the oil pump

shaft or body.

- Check there are no signs of scoring or wear on

the oil pump cover.

- If you detect non-conforming measurements or

scoring, replace the faulty parts or the assembly.

- Fit the cover on the pump being careful to align

the holes (2 on the cover and 2 on the pump body)

fixing the oil pump on the crankcase.

- Fit the oil pump on the crankcase by tightening

the two screws to the prescribed torque.

- Fit the pulley on the pump, the central screw to

the specified torque and the belleville washer.

- Check that there is no seizing and/or friction dur-

ing the pulley rotation.N.B.FIT THE CUP WASHER SO THAT ITS OUTER (CURVED)RIM TOUCHES THE PULLEY.

Locking torques (N*m)


ENG - 128

Timing chain/oil pump compartment coverscrews 2.9 - 3.7 lb ft (4 - 5 Nm) Screws fixing oilpump to the crankcase 3.7 - 4.4 lb ft (5 - 6 Nm)

Removing the oil sump

- Remove the oil filling cap, the transmission cover,

the complete driving pulley assembly with belt and

pinion.

- Unscrew the oil drainage plug «A» shown in the

figure and drain out all the oil from the sump.

- Remove the 6 screws indicated in the figure.

Refitting the oil sump

- Clean and grease the faying surfaces.

- Apply LOCTITE 510 on the sump surface and

tighten the 6 fixing screws to the specified torque.

- Refit the driving pulley assembly, the belt, the

pinion and the transmission cover.WARNINGWHEN TESTING THE LUBRICATION SYSTEM, REFER TOTHE "CRANKCASE AND CRANKSHAFT" CHAPTER, RE-GARDING LUBRICATION OF THE CRANKSHAFT ANDCONNECTING ROD

Locking torques (N*m)Oil sump screws 5.9 - 7.4 lb ft (8 - 10 Nm)

Fuel supply

- Disconnect the fuel supply and the suction taking

pipe from the carburettor.

- Check that there are no fuel leaks between the

two tubes.

- Close the fuel outlet pipe.

- Using a MITIVAC pump, apply 1.45 psi (0.1 bar)

vacuum bar on the cock.

- Make sure that the suction is kept stable and that

and that there are no fuel leaks.

- Reconnect the vacuum pipe to the manifold.


ENG - 129

- Position the fuel pipe with the outlet at the point

of the tap.

- Turn the engine by using the starter motor for five

seconds with the carburettor at minimum.

- Take up the fuel by means of a graded burette.N.B.THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-RECT NUMBER OF REVS OR BY THE WRONG POSITIONOF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB-TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-LET ON THE MANIFOLD HAS A SECTION INTENTIONALLYREDUCED FOR THE PURPOSE OF ENHANCING THE SUC-TION PULSATION AND THEREBY GUARANTEE A CON-STANT TAP FLOW RATE.

Specific tooling020329Y Mity-Vac vacuum-operated pump

CharacteristicMinimum flow rate0.676 fl oz in 5 sec (20 cc in 5 sec)

- Completely empty the fuel tank.

- Remove the petrol delivery pipe and the low-

pressure pipe.

- Loosen the clip and remove the cock.

- Clean the tank and the filter of the cock with a

specific solvent.

- Refit the cock making sure that there is an O-

Ring.

- Turn the cock to the direction it had before it was

removed and block the clip.N.B.THE FILTER CAN BE UNSCREWED FROM THE COCK TOFACILITATE CLEANING.


ENG - 130

Removing the carburettor

- To detach the carburettor from the engine, re-

move the two clamps anchoring the carburettor to

the inlet manifold and the air intake coupling to the

filter.

- Remove the fuel supply pipe.

- Disconnect the starter connection.

- Detach the accelerator cable with the sheath that

connects the plate and the support.

- Remove the carburettor.

- Remove the protection, the bracket and the start-

er undoing the screw shown in the figure.CAUTIONTHE CARBURETTOR FEATURES AN ANTI-VIBRATIONRUBBER BUFFER FITTED ON THE LOWER SUPPLEMENTOF THE ACCELERATING PUMP BODY. UPON REFITTINGTHE CARBURETTOR ON THE ENGINE, MAKE SURE THISBUFFER IS PRESENT SO THAT THE PETROL IN THE TANKDOES NOT EMULSIFY.

- Remove the 2 fixing screws indicated in the fig-

ure, the vacuum chamber cover and the spring.

- Remove the vacuum valve together with the di-

aphragm; the pin, the spring and its plastic guide.WARNINGDURING THE REMOVAL OF THE COVER TAKE SPECIALCARE NOT TO RELEASE THE SPRING ACCIDENTALLY.

- Remove the 3 fixing screws and the chamber with

the gasket.


ENG - 131

- Remove the chamber components following the

procedure below.

- Undo the 2 screws fixing the intake pump dia-

phragm cover.

- Remove the cover being careful with the spring

below, then remove the spring, take out the rubber

protection and the diaphragm together with the

pipe O-Ring.

-Remove the accelerating pump jet together with

the ball spring.

- Remove the screw indicated in the figure fixing

the float pin.

- Remove the float and the plunger.

-Remove the maximum nozzle.

-Remove diffuser.


ENG - 132

-Remove the minimum nozzle.

- Remove the sprayer tilting the carburettor body.N.B.THIS OPERATION IS NECESSARY TO AVOID LOSINGSPRAYER PARTS WHEN CLEANING THE CARBURETTORBODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DONOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM-AGE IT.

- Remove the idle flow screw with the O-ring and

the spring.

CAUTION

DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS:FUEL SUPPLY PIPE, PIN SEATING, STARTER NOZZLE, THROTTLE VALVE CONTROL VALVESHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWSARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT.


ENG - 133

Refitting the carburettor

- Before refitting, wash the carburettor body accu-

rately with a degreasing solvent and compressed

air.

- Pay special attention to the fuel supply pipe and

the plunger seat.

- For the minimum circuit, make sure the following

points are properly cleaned: air gauging, exhaust

section controlled by flow screw, progression

holes near the throttle valve.

- For the starter circuit, blow the connection pipe

properly with the jet. This is necessary because

the nozzle support hides other inaccessible inter-

nal calibrations.

- Blow the intake nozzle properly.

The acceleration nozzle outlet is extremely small

and is oriented to the throttle valve.

- Check that the carburettor body has the closing ball for the idle circuit pipe.

- Check that the coupling surfaces, the chamber and the diaphragm are not dented.

-Check that the depression valve housing pipe is not scratched.

- Check that the throttle valve and the shaft do not show abnormal wear.

- Check that the plunger seat does not show abnormal wear.

- Replace the carburettor in case of irregularities.N.B.

TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.


ENG - 134

- Wash and blow the minimum nozzle properly and

reassemble it.

- Accurately wash and blow the components of the

maximum circuit, the sprayer, the diffuser and the

nozzle.

- Introduce the sprayer in the carburettor body with

the bigger cylindrical part directed to the diffuser.

- Fit the diffuser.

-Assemble the maximum nozzle.

- Check that the tapered pin does not show signs

of wear on the sealing surfaces of the shock ab-

sorber pin and the return clamp.

- Replace the rod if worn out.

- Check that the float is not worn on the pin housing

or on the contact plate with the rod and that there

are no fuel infiltrations.

- Replace it in case of failures.

- Fit the float together with the pin and rod in its

position and lock it with its screw.N.B.INTRODUCE THE RETURN SPRING ON THE FLOATPLATE ADEQUATELY

- Insert the ball in the corresponding accelerating

pump.

- Fit the spring.

- Fit the accelerating pump nozzle.WARNINGWHEN REFITTING, PAY SPECIAL ATTENTION TO THECOMPONENTS AS THEY ARE SMALL.


ENG - 135

- Check the diaphragm is in good conditions and

remove the remaining components of the acceler-

ating pump following these steps:

- Insert the O-Ring in the pipe.

- Insert the diaphragm together with the pin and its

spring.N.B.REPLACE THE DIAPHRAGM IF THERE ARE SIGNS OF UN-DULATIONS, CRACKS OR HARDENING.

- Fit the accelerating pump diaphragm cover and

tighten the 2 fixing screws making sure the spring

below is correctly positioned.

- Fit the rubber bellows protecting the pin in the

upper part of the accelerating pump.

Level check

- Tilt the carburettor so that the needle valve at the

fuel supply is closed and the float weight does not

affect it.

- Check that the diaphragm closing line and the

float central line are parallel as shown in the figure.

- Blow air in to the tank and then assembly it and

its gasket on the carburettor body with the 3 fixing

screws.N.B.-ALWAYS USE NEW RINGS AND GASKETS FOR REFIT-TING.WARNINGTHE SCREW IN THE TANK BOTTOM IS A BLEEDING ONEAND CONSEQUENTLY IT ONLY REQUIRES CLEANING.


ENG - 136

- Insert the diaphragm into the throttle valve.

- Insert the tapered pin together with the plastic

support and the contrast spring into the throttle

valve.N.B.PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETHFACING THE INNER SIDE OF THE MEMBRANE TO BEABLE TO FIT THE LOWER END OF THE THROTTLE VALVESPRING.

- Fit the vacuum chamber cover with the 2 fixing

screws paying special attention to the spring.

Inspecting the automatic choke device

- Check that the automatic starter piston is not de-

formed or rusty.

- Check that the piston slides freely in its seating.

- Check that the piston sealing O-Ring is not de-

formed.

- The starter must be more or less functional de-

pending on the ambient temperature.

- Measure the protrusion of the piston as shown in

the figure and check its corresponding value.

- Make sure that the starter is adjusted for the am-

bient temperature.

CharacteristicProtrusion value0.452756 in (11.5 mm)

Ambient temperature75.2°F (24°C)


ENG - 137

- The starter should disconnect progressively by

means of electric heating.

- Check the starter resistance when adjusted to the

ambient temperature.

CharacteristicAmbient temperature75.2°F (24°C)

Electric characteristicAutomatic starter resistance20 Ω ± 5 %

- Use battery to power the automatic starter and

check that piston protrudes as much as possible.

- The correct warm up time depends on the ambi-

ent temperature.

- If protrusion, resistance or timing values are dif-

ferent from the ones prescribed, replace the start-

er.

CharacteristicBattery12V-9Ah

Max. protrusion0.590551 in (15 mm)

max. time15 min

- Fit the starter, the support bracket and the pro-

tection with the screw indicated in the figure.


ENG - 138

- Insert rubber pipes for chamber ventilation.

- Insert the O-Ring, the washer, the spring and the

idle flow screw in their seats.

- Refit the carburettor on the engine and connect

again the accelerator cable with the sheath and the

support plate and the electrical connection of the

starter.

- Reconnect the fuel supply pipe and tighten the 2

clamping screw fixing the carburettor to the inlet

manifold and the air inlet coupling to the filter.

Adjusting the idle

- The engine does not require frequent idle speed

adjustments, but it is essential to strictly follow cer-

tain rules when adjusting the idle speed.

- Before adjusting the carburettor make sure to re-

spect requirements on lubrication, valve clear-

ance, and complying timing; spark plug should be

in optimum conditions, air filter clean and sealed,

and the exhaust system tight.

- Connect the tester thermometer to the sump, using a cover with oil expressly prepared for probes.

- Start the engine and before adjusting the idle speed, make sure that the oil temperature is between

158 to 176°F (70 to 80°C)

Specific tooling020331Y Digital multimeter


ENG - 139

- Using the rpm indicator in the analyser or a sep-

arate one, adjust the idle screw.N.B.THE WASTED SPARK IGNITION SYSTEM OFFERS RE-MARKABLE POWER. READINGS MAY NOT BE ACCU-RATE IF INADEQUATE RPM INDICATORS ARE USED.

Specific tooling020332Y Digital rpm indicator

CharacteristicIdle speedabout 1900/2000 rpm


ENG - 140

INDEX OF TOPICS

SUSPENSIONS SUSP

Front

Removing the front wheel

- Loosen the wheel axle lock nut, by keeping the

wheel axle blocked on the opposite side.

Loosen the wheel axle safety screws on the fork

leg, on the odometer gear side.

Suspensions Typhoon 50 4t 4v

SUSP - 142

- Pull out the wheel axle.

Remove the front wheel.

Slide off the odometer gear from the wheel hub.CAUTIONDO NOT ACT ON THE FRONT BRAKE LEVER ONCE THERELATIVE WHEEL IS REMOVED. BY DOING SO, THE CAL-LIPER PISTONS COULD COME OUT FROM THEIR HOUS-ING AND BRAKE FLUID LEAKAGE MIGHT ALSO OCCUR.

Front wheel hub overhaul

Check that the wheel bearings do not show signs

of wear.

If necessary, replace the wheel bearings, proceed-

ing as follows:

Lock the bearing puller in the bearing on the side

the odometer detects movement.

Specific tooling001467Y013 Pliers to extract ø 15-mm bearings

001467Y005 Screw

001467Y004 Lug / Taper pin

Insert the bell and the relative nut and remove the

bearing.

Specific tooling001467Y003 Nut

001467Y009 Bell for OD 42-mm bearings

Typhoon 50 4t 4v Suspensions

SUSP - 143

Remove the spacer from inside the hub.

Use handle, adaptor and guide, place the wheel

on supports and hit with a mallet on the brake side

to extract the bearing.



020412Y 15-mm guide

When refitting heat the brake side bearing seat

with an appropriate heater gun.



SUSP - 144

Use adaptor, handle and guide to drive the bearing

into its seat.



020412Y 15-mm guide

Fit the external spacer.

Fit the internal spacer.

With an appropriate heater gun heat the seat of the

bearing on the side the odometer detects move-

ment.



SUSP - 145

Use adaptor, handle and guide to drive the bearing

into its seat.



020412Y 15-mm guide

Refitting the front wheel

First shift by 90° the inner stop of the odometer

drive with respect to the one on the wheel.

Insert the wheel axle after greasing it from the

brake disc opposite side, centring the retainer on

the fork leg onto the projecting parts of the odom-

eter drive.

Holding the wheel axle, lock the nut on the oppo-

site side to the specified torque.


SUSP - 146

Screw in the wheel axle locking screws.

Make the fork travel to adjust the fork legs on the

wheel axle. Tighten the safety screws on the fork

leg to the specified torque with the "external-inter-

nal-external" sequence.

Locking torques (N*m)Front wheel axle hub 7.3 lb ft (10 Nm) Fork wheelaxle 34.3 lb ft (46.5 Nm)

Handlebar

Removal

- Remove the front and rear handlebar covers.

- Detach the front brake pump from the handlebar.

- Disconnect the rear brake, throttle control and

odometer control cables.

- Remove the screw fixing the handlebar to the

steering tube.

- Remove the handlebar.

See alsoFront handlebar coverRear handlebar coverFrontbrake pump

Refitting

Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on the

handlebar with that on the steering tube as shown in the figure.

Tighten the handlebar fixing screw on the steering tube to the specified torque.

Locking torques (N*m)Headstock handlebar 38.7 lb ft (52.5 Nm)


SUSP - 147

(*) Lubricate the nut with engine oil before instal-

lation

Front fork

Removal

REMOVING THE STANCHIONS

- Remove the legshield.

- Remove the brake calliper.

- Remove the front wheel.

- Remove circlip «7», the two screws «8» and slide

off the stanchion.

- Unscrew the upper cap «6».

- Remove the components including the spring.

- Drain the oil into a collecting container.


SUSP - 148

- Undo screw «3», remove the stanchion and the

piston.

See alsoLegshieldRemovalRemoving the front wheel

Overhaul

STANCHION INSPECTION

- Check the sliding surface for scorings and/or

scratches.

- If the scorings are deep, replace the stanchion.

SLEEVE INSPECTION

- Check that it is not damaged and/or cracked.

- If there are signs of excessive wear or damage,

replace the affected component.

- Replace the oil seal «4» and the dust gaiter «5»

and fit it once you have lubricated their seat.

- Replace the O-ring on the inner cap «1»

- Replace sealing washer «2».

Refitting

Refit the stem and the pumping member and tight-

en screw «3» with its washer «2» to the specified

torque.

Pour the recommended quantity of specific oil into

the stanchion unit.

Insert the spring and components.

Tighten the upper cap «6» to the specified torque.


SUSP - 149

Introduce the stanchion in the bottom yoke and in-

stall the circlip «7».

Push on the upper cap «6» until the circlip touches

the bottom yoke. Tighten the screws «8» to the

specified torque.

Recommended productsAGIP FORK 7.5 W Oil for fork.-

CharacteristicFork stem (oil level height without spring, com-pressed fork)3.35 in (85 mm)

Locking torques (N*m)Plate fork stanchions 29.5 lb ft (40 Nm) Sleeve forkstanchions 22.1 lb ft (30 Nm)

Steering column

Removal


SUSP - 150

Park the vehicle on its centre stand.

Place a support under the vehicle so that the wheel

can move freely and the vehicle does not fall.

Remove the handlebar.

- Remove the front shield.

Remove the front brake calliper.

Release the fork from the odometer cable and from

the front brake calliper pipe.

Loosen the upper ring nut «1» and collect the shim

washer «2».

Specific tooling020055Y Wrench for steering tube ring nut

Locking torques (N*m)Steering upper ring nut 27.7 lb ft (37.5 Nm)

Remove the upper ring (or lower ring nut) «3» of

the upper bearing «A».

Slide the fork and collect the cage with the balls

«4» of the upper bearing «A».

Locking torques (N*m)Steering lower ring nut 9.6 lb ft (13 Nm)

When the specified torque of the lower ring nut is reached, loosen by 90°.

See alsoRemovalLegshieldRemoval

- Remove the balls retainer «7» of the lower bear-

ing «B» from the steering tube.

- Wash carefully all the parts removed.

- To refit, carry out the removal operations but in reverse order.

- Appropriately lubricate the bearings with recommended products.


SUSP - 151

BEARING SEAT REPLACEMENT ON CHASSIS

- Only remove the seats if it is strictly necessary.

- Using the special tool remove the upper bearing

«A» seat «5» by putting the special tool into the

lower part of the headstock as indicated in the fig-

ure.

- Remove the lower bearing «B» seat «6» on the

headstock by inserting the punch from the top on

the headstock.

Specific tooling020004Y Punch for removing fifth wheels fromheadstock

- Using the special tool, refit the upper «A» and

lower «B» bearing seats on the headstock.

Specific tooling001330Y Tool for fitting steering seats

LOWER BEARING SEAT REPLACEMENT ON

FORK

Check the condition of the lower bearing «B» seat

«8» on the fork (steering tube). Replace if there are

faults.

- Support the fork properly.

- Using the special tool, remove the seat «8» on

the steering tube as shown in the photograph by

applying small mallet blows.

Specific tooling020004Y Punch for removing fifth wheels fromheadstock


SUSP - 152

Always use a new seat on refitting.

- Using the special tool, refit the seat «8» with the

aid of a few mallet blows and bring it as far as the

stop shown in the photo.

Specific tooling006029Y Punch for fitting fifth steering bearingon steering tube

Steering bearing

CHECKING THE BEARINGS CLEARANCE

To check the steering, it is necessary to:

- Position the vehicle on the centre stand.

- Place a support under the motorcycle in such a

way that the front wheel is able to move freely and

the vehicle does not fall.

When carrying out this operation, pay attention not

to mistake the centre stand clearance with that of

the steering. Repeat this test many times before

deciding if the steering clearance must be adjus-

ted.

- Hold the fork sleeves and pull the fork forwards

and backwards, with the steering in forward posi-

tion.

- There should be no clearance forward or back-

ward If there is clearance, the steering must be

adjusted.

ADJUSTING THE BEARING CLEARANCE


- Loosen the upper ring nut «1» using the specific

wrench.

- Screw in the lower ring nut «3» until the bearing

clearance is totally eliminated.CAUTIONDO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT«3» BECAUSE THE STEERING BEARINGS COULD GETDAMAGED.

Keep the lower ring nut «3» in position, by using a specific wrench and tighten the upper ring nut «1»

to the specified torque. Check again the bearings clearance.


SUSP - 153

Specific tooling020055Y Wrench for steering tube ring nut

Locking torques (N*m)Steering lower ring nut 9.6 lb ft (13 Nm) Steering upper ring nut 27.7 lb ft (37.5 Nm)

See alsoLegshield

Rear

Removing the rear wheel

- Position the vehicle on the centre stand.

- Remove the silencer.

- Use a screwdriver to remove the plastic cap.

- Remove the cotter pin.

- Remove the cap.

Pull the rear brake and hold it in.

Unscrew the wheel fixing nut and collect the wash-

er.

Take out the wheel from its housing.

See alsoExhaust assy. Removal


SUSP - 154

Refitting the rear wheel

To refit, carry out the removal operations but in reverse order, be careful to use a new split pin.

Locking torques (N*m)Rear wheel hub 87.8 lb ft (115 Nm)

Swing-arm

Removal

Rest the vehicle on its centre stand.

Support the engine adequately.

Unscrew the nut on the left-hand side of the frame

and remove the pin from the opposite side.

Unscrew the nut on the left-hand side of the engine

and remove the pin from the opposite side.

Overhaul

Regularly check the clearance of the swinging arm

retainer pins. To carry out these operations, pro-

ceed as follows:

- Position the vehicle on centre stand.

- Hold the rear wheel firmly and try to move it per-

pendicularly to the travel direction.

- If there is any clearance, check all the fastening

elements that connect the swinging arm to the en-

gine and chassis as well as the condition of the

silent block.


SUSP - 155

Refitting

For refitting, follow the previous operations but in reverse order.

Locking torques (N*m)Engine side swinging arm 31.3 lb ft (42.5 Nm) Chassis side swinging arm 31.3 lb ft (42.5 Nm)

Shock absorbers

Removal

- Remove the side fairings.

- Support the vehicle adequately.

- Undo the inner nut and slide off the shock-ab-

sorber to chassis upper fixing screw.

Undo the inner nut and slide off the shock-absorber to engine lower fixing screw.

Remove the shock absorber.

To refit tighten the screws to the prescribed tightening torque.

Locking torques (N*m)Shock absorber lower part 27.3 lb ft (37 Nm) Shock absorber upper part 27.3 lb ft (37 Nm)

See alsoSide fairings

Centre-stand

Remove the stand return spring.CAUTIONSUPPORT THE VEHICLE ADEQUATELY.CAUTIONTO PREVENT INJURY AND DAMAGE THE SPRING MUSTBE REMOVED WITH THE CENTRE STAND UP.


SUSP - 156

Undo the nut shown in the figure.

Remove the pin from the right side.

Remove the stand.

FITTING

On refitting tighten the nut to the specified torque.

Locking torques (N*m)Centre stand pin 31.3 lb ft (42.5 Nm)


SUSP - 157

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Front brake calliper

Removal

- Check that the brake piping, gasket and fitting are

in good condition. If you see any oil on the brake

calliper and/or the components of the system, it is

necessary to replace them.

- Detach the oil brake pipe from the calliper; pour

the fluid inside a container.

- Remove the two clamps shown in the figure.

- Remove the brake calliper from the fork.

Refitting

Refit the calliper on the support and tighten the

screws to the specified torque.

Refit the tube complete with fitting with new copper

gaskets.

Place the tube joint in the original position and

tighten it to the specified torque.

Bleed the air from the system.

Locking torques (N*m)Front brake calliper to fork 18.8 lb ft (25.5 Nm)

See alsoFront

Front brake disc

Typhoon 50 4t 4v Braking system

BRAK SYS - 159

Removal

Proceed as follows:

- remove the front wheel.

- Loosen the disc fixing screws.

- Remove the brake disc.

Refitting

When refitting, position the disc correctly making

sure that it rotates in the direction indicated on the

disc itself.

Locking torques (N*m)Brake disc 6.6* lb ft (9* Nm)

* With Loctite 243

Disc Inspection

- Check the disc thickness.

CharacteristicDisc minimum thickness0.1378 in (3.5 mm)

Braking system Typhoon 50 4t 4v

BRAK SYS - 160

• Using the appropriate tool, measure

how much the disc protrudes when the

wheel is fitted properly. The protrusion,

measured near the external edge of

the disc, must be less than 0.0039 in

(0.1 mm).

• If a value other than that prescribed is

detected, remove the front wheel and

check how much the disc protrudes.

The size measured must be within

0.0039 in (0.1 mm). If it is greater re-

place the disc and conduct the test

again.

• If the problem persists, check and re-

place the wheel rim if necessary.

Specific tooling020335Y Magnetic support for dial gauge

See alsoRemoving the front wheel

Front brake pads

Removal

Remove the brake calliper.


BRAK SYS - 161

Undo the screws indicated in the figure.

Remove the pads.

Remove the inside spring.CAUTIONAFTER REMOVING THE PADS, DO NOT OPERATE THEBRAKE LEVER OR THE CALLIPER PLUNGERS COULDGO OUT OF THEIR SEATS RESULTING IN BRAKE FLUIDLEAKAGE.

- Check the thickness of the friction material. If

thinner than the minimum value, replace it.

CharacteristicMinimum friction material thickness0.0591 in (1.5 mm)

- In case of uneven wear, replace the brake pads

when the friction material thickness difference is

0.0197 in (0.5 mm).CAUTIONALWAYS REPLACE BOTH PADS AND MAKE SURE THEYARE CORRECTLY POSITIONED INSIDE THE CALLIPER.


BRAK SYS - 162

Refitting

To refit, carry out the disassembly operations in

the inverse order, fitting the inner spring correctly

and tightening the fixing screws to the specified

torque.

Locking torques (N*m)Brake pad fastening screw 11-14.7 lb ft (15-20 Nm)

Fill

FrontN.B.

IF THERE IS AIR IN THE HYDRAULIC SYSTEM, THE WATER WILL ABSORB MOST OF THEPOWER OF THE BRAKE MAIN CYLINDER AND THEREFORE, IT WILL REDUCE THE CALLIPERPERFORMANCE WHEN BRAKING. THE PRESENCE OF AIR IS SIGNALLED BY THE 'SPONGI-NESS' OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY.CAUTION

CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARYTO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REG-ULAR MAINTENANCE OPERATIONS.

- To access the brake fluid reservoir the right rear-

view mirror must be removed. Remove the reser-

voir protection and undo the indicated screws.

- Once the bleed valve is closed, fill the system

with brake fluid to the maximum level.

-Undo the bleed screw.

-Apply the tube of the special tool to the bleed

screws.

When bleeding it is necessary to fill the oil tank in

continuation while working with a MITYVAC pump

on the bleed screws until no more air comes out of

the system.

The operation is finished when just oil comes out

of the bleed screws.

-Do up the bleed screw.


BRAK SYS - 163

-When the operation is over, tighten up the oil

bleed screw to the prescribed torque.N.B.IF AIR CONTINUES TO COME OUT DURING PURGING, EX-AMINE ALL THE FITTINGS:IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAUL-TY, LOOK FOR THE AIR INPUT AMONG THE VARIOUSSEALS ON THE PUMP AND CALLIPER PISTONS.CAUTION- DURING THE OPERATIONS, THE VEHICLE MUST BE ONTHE STAND AND LEVEL.N.B.DURING PURGING FREQUENTLY CHECK THE LEVEL TOPREVENT AIR GETTING INTO THE SYSTEM THROUGHTHE PUMP.WARNING- BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT AB-SORBS HUMIDITY FROM THE SURROUNDING AIR.IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX-CEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BEREDUCED.THEREFORE, ALWAYS USE FLUID FROM SEALED CON-TAINERS.UNDER NORMAL DRIVING AND CLIMATIC CONDITIONSYOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS.IF THE BRAKES ARE USED INTENSELY AND/OR INHARSH CONDITIONS, CHANGE THE FLUID MORE FRE-QUENTLY.CAUTIONWHEN CARRYING OUT THE OPERATION, BRAKE FLUIDMAY LEAK FROM BETWEEN THE BLEED SCREW AND ITSSEAT ON THE CALLIPER.CAREFULLY DRY THE CALLIPER AND DEGREASE THEDISC SHOULD THERE BE OIL ON IT.

Specific tooling020329Y Mity-Vac vacuum-operated pump

Recommended productsAGIP BRAKE 4 Brake fluid.Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4

- ISO 4925 - CUNA NC 956 DOT 4

Locking torques (N*m)Oil bleed screw 5.9 - 8.8 lb ft (8-12 Nm)


BRAK SYS - 164

Front brake pump

- Remove the front and rear handlebar cover.

- Disconnect the tube, collecting the brake oil in a

container.

- Operate on the two U bolt clamps (see figure).

- On refitting, perform the operation in reverse.

- Tighten the hydraulic line to the prescribed torque

and then fill and purge the system.

Locking torques (N*m)Brake fluid hose-pump fitting 14.75 - 18.44 lb ft(20-25 Nm) Handlebar brake pump 5.9 lb ft (8 Nm)

See alsoFront handlebar coverRear handlebar cover

Rear drum brake

Drum brake adjustment

Regulate the point where the rear drum brake in-

tervenes, using the adjustment indicated in the

figure.

With the brake lever at rest, the wheel must turn

freely.


BRAK SYS - 165

Drum brake removal

- Remove the rear wheel.

- Hold the lower shoe and slide it out with the upper

one.

For fitting:

- First assembly two shoes and the springs then

place them on the pin and on the cam.

See alsoRemoving the rear wheel

Transmission replacement

- Remove the front handlebar cover.

- Remove the leg shield and the footrest.

- Loosen the brake set screw

- Release the transmission from its retainers to the

engine.

Release the transmission from the retainers on

chassis and from the control lever.

Fit the new transmission, fixing and positioning it

like the one replaced. Adjust the drum brake acti-

vation point.

Locking torques (N*m)Rear brake adjustment nut 3.69 lb ft (5 Nm)


BRAK SYS - 166

See alsoFront handlebar coverLegshieldFootrest


BRAK SYS - 167

INDEX OF TOPICS

CHASSIS CHAS

Seat

Undo the nuts indicated in the figure and collect

the washers.

Locking torques (N*m)Saddle plate fixing nut 7.4 lb ft (10 Nm)

Driving mirrors


Locking torques (N*m)Mirror fixing spacer 18.4 lb ft (25 Nm)

Rear handlebar cover

Remove the front handlebar cover.


Typhoon 50 4t 4v Chassis

CHAS - 169

- Disconnect the connectors of the instrument pan-

el and the odometer cable.

- Remove the handlebar cover together with the

instrument panel and controls.

See alsoFront handlebar cover

Instrument panel

Remove the rear handlebar cover.


See alsoRear handlebar cover

Front handlebar cover

Remove the rear-view mirrors.


Chassis Typhoon 50 4t 4v

CHAS - 170

Undo the front screw.

Disconnect the connectors of the turn indicators.

See alsoDrivingmirrors

Headlight assy.



FRONT TURN INDICATORS


Unscrew the indicated nuts.

See alsoLegshieldFront handlebar cover


CHAS - 171

Legshield

Remove the shield back plate.

Working from the front wheel housing internal side,

undo the screws from both sides of the vehicle.

- Undo the indicated screw, beneath the leg shield

lug.

- Move the leg shield forward, opening the lower

ends and detach the headlight bulb connections.


CHAS - 172

Knee-guard


Undo the indicated screws on the sides of the leg

shield back plate.

Undo the screw in the glove-box and the one under

the chassis number lid.

Before refitting the leg shield back plate, loosen

the footrest fixing screws, so as to fit the two com-

ponents in the best conditions.N.B.WHILE REFITTING, PLEASE REMEMBER TO ATTACH THEGLOVE-BOX OPENING LEVER TO THE KEY-OPERATEDDEVICE.

See alsoFront handlebar cover


CHAS - 173

Front wheel housing


Remove the front mudguard.

Remove the front wheel.


- Undo the upper screw.

- Slide the housing off the fork stanchions.

See alsoLegshieldFront mudguardRemoving the front wheel

Footrest

- Remove the shield back plate.


- Undo the indicated screws and remove the pro-

tections.


CHAS - 174


See alsoKnee-guardSide fairings

Side fairings

Remove the rear handles.

Remove the rear central cover.


- Undo side screw from both sides of the vehicle.

Undo the screws on the helmet compartment.


CHAS - 175

Undo the upper screws.

- Undo from both sides of the vehicle the screw

placed under the footrest.

- Open the front ends of the side fairings to slide off the indicated upper inserts.

- Disconnect the connections of the turn indicators

and of the rear light unit.

See alsoHandles and top side fairingsRear central cover


CHAS - 176

License plate holder


- Disconnect the connections of the turn indicators

and of the license plate light.

- Undo the rear screw outside the license plate

support.

- Undo the two screws indicated.

- Remove the license plate support together with

the turn indicators.



CHAS - 177

Rear mudguard

- Undo the right-hand side screw.

Undo the screws indicated in the figure.

Helmet bay

Remove the side panels

Remove the battery cover and the battery.

Undo the two screws inside the helmet compart-

ment.

- Disconnect the fuse box and free the helmet

compartment from the cables.



CHAS - 178

Battery

spoiler

Remove the footrest.


- Undo from both sides of the vehicle the screw

placed under the footrest.

See alsoFootrest

Fuel tankCAUTION

BEFORE REMOVING THE FUEL TANK REMOVE THE FUEL FROM THE TANK ITSELF.

Remove the side fairings and the helmet compart-

ment.

- Detach the pipes from the vacuum-operated

cock.


CHAS - 179

- Undo the indicated screw on both sides of the

vehicle.

Undo the screw (1) and loosen the screws (2).

Disconnect the fuel probe connector and detach

the breather pipe from the filler.

Locking torques (N*m)Chassis fuel tank retainer screws 7.4 lb ft (10 Nm)

See alsoHelmet baySide fairings

Rear central cover

- Remove the saddle.

- Undo the four indicated screws and remove the

cover by sliding it upwards so as to detach the

locking tabs on the sides.


CHAS - 180

See alsoSeat

Front mudguard

- Operating from both sides of the vehicle, undo

the three indicated screws.

Handles and top side fairings

Remove the three screws indicated in the figure

and collect the washers.

Remove the rear handles.

Locking torques (N*m)Passenger handle 15.1 lb ft (20.5 Nm)


CHAS - 181

Battery

Undo the indicated screws and remove the battery

cover.

- Disconnect the negative and positive cables.

- Slide off the breather pipe.


CHAS - 182

INDEX OF TOPICS

PRE-DELIVERY PRE DE

Aesthetic inspection

Appearance check:

- Paintwork

- Fitting of plastics

- Scratches

- Dirt

Tightening torques inspection

Lock check

- Safety fasteners

- Fixing screws

Safety fasteners:

Rear shock absorber upper fixing

Rear shock absorber lower fixing

Front wheel axle nut

Wheel hub nut

Swinging arm - chassis pin

Engine-swinging arm pin

Engine arm pin - Chassis arm

Handlebar lock nut

Lower steering ring nut

Upper steering ring nut

Electrical system

Electrical system:

- Main switch

- Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights

- Adjusting the headlights according to the regulations currently in force

- Rear light, parking light, stop light

- Front and rear stop light switches

- Turn indicators and their warning lights

- Instrument panel lights

- Instrument panel: fuel gauge

- Instrument panel warning lights

- Horn

- Starter

Pre-delivery Typhoon 50 4t 4v

PRE DE - 184

CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFOREIT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINALFIRST.CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-ATIVE ONE.WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FORABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER ORVEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARETO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKINGCLOSE TO BATTERIES.KEEP OUT OF THE REACH OF CHILDRENCAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USINGA FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSEA FIRE.

Levels check

Level check:

- Hydraulic braking system fluid level.

- Rear hub oil level

- Engine oil level

Road test

Test ride

- Cold start

- Instrument operations

- Response to the throttle control

- Stability on acceleration and braking

- Rear and front brake efficiency

- Rear and front suspension efficiency

- Abnormal noise

Typhoon 50 4t 4v Pre-delivery

PRE DE - 185

Static test

Static control after the test ride:

- Starting when warm

- Starter operation

- Minimum hold (turning the handlebar)

- Uniform turning of the steering

- Possible leaksCAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.CAUTION

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Functional inspection

Functional Checks:

Braking system (hydraulic)

- Lever travel

Braking system (mechanical)

- Lever travel

Clutch

- Proper functioning check

Engine

- Throttle travel check

Others

- Check documentation

- Check the chassis and engine numbers

- Tool kit

- License plate fitting

- Check locks

- Check tyre pressures

- Installation of mirrors and any accessories

Pre-delivery Typhoon 50 4t 4v

PRE DE - 186

AAir filter: 32

BBattery: 43, 54, 61, 68, 179, 182Brake: 147, 159, 161, 165Bulbs:

CCarburettor: 28, 131, 134Checks: 59

EEngine oil: 33

FFuel: 129, 179Fuses: 67

HHeadlight: 38, 171Horn: 65Hub oil: 31

IIdentification: 7Instrument panel: 170

MMaintenance: 6, 28Mirrors: 169, 171

OOil filter: 34, 35

RRecommended products:

SShock absorbers: 156Spark plug: 29, 59Suspension: 43

TTank: 179

Transmission: 8, 42, 83, 93Turn indicators: 58Tyres: 9

VVehicle: 7, 78

Documents

Piaggio Typhoon 50 4t 4v (EN)