Piaggio Typhoon 50 2T MY2010 Service Station Manual ENG

MANUALE STAZIONE DI SERVIZIO
665497(IT)-665498(EN)-665499(FR)-677200
(DE)-677201(ES)-677202(NL)-677203(PT)-677204
(EL)
Typhoon 50 2T (MY2010)
MANUALE
STAZIONE DI
SERVIZIO
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of each
model should be checked at the official Piaggio sales network.
"© Copyright 2010 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
www.piaggio.com
MANUALE STAZIONE DI
SERVIZIO
Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari
e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli
Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei
veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate
attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non
si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale
riguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
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
TIME TIME
INDEX OF TOPICS
CHARACTERISTICS CHAR
Typhoon 50 2T (MY2010) Characteristics
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.
CHAR - 7
Characteristics Typhoon 50 2T (MY2010)
Vehicle identification
Chassis prefix LBMC501

Engine prefix C421M
Dimensions and mass
WEIGHTS AND DIMENSIONS

Specification Desc./Quantity
Maximum length 1947
Overall width 730
Maximum height 1130 mm
Wheelbase 1355
Kerb weight 99±5 Kg
CHAR - 8
Engine
ENGINE
Engine type Single cylinder 2-stroke
Bore x stroke 40 X 39.3 mm
Engine capacity 49.38 cm³
Compression ratio 10.3:1 (±0.5)
carburettor DELL'ORTO PHVA 17.5
CO adjustment 3.5% ± 0.5
Engine idle speed 1800 ± 100 rpm
Air filter Sponge, soaked in a mixture (50% AGIP Filter Oil and 50%
unleaded petrol).
Starting system electric starter/kick starter
Lubrication With blend and variable oil variable according to the engine
revolutions and the throttle valve opening by means of a pump
controlled by the crankshaft with toothed belt.
Fuel system With vacuum operated cock, lead-free gasoline (with 95 octane
minimum) by means of the carburettor.
Cooling Forced-circulation air cooling.
Maximum power 3.98 kW at 7500 rpm
Maximum torque 5.20 Nm at 7000 rpm
Transmission
TRANSMISSION
Transmission With automatic expandable pulley variator, torque server, V-
belt, automatic clutch, gear reduction unit.
CHAR - 9
Capacities
CAPACITY
Fuel tank In plastic, with a capacity of 7.0 litres (approximate value) in-
cluding reserve ~ 1.5 litres
Oil mixer tank In plastic, with a capacity of 1.5 lit. (including reserve ~0.500
lit).
Rear hub oil Quantity: ~80cc
Electrical system
ELECTRICAL SYSTEM
Ignition type Capacitive discharge electronic ignition, with incorporated HV
coil
Ignition advance (before TDC) Fixed 17° ±1 at 4,000 rpm
Spark plug electrode gap 0.6 mm
spark plug NGKR BR8ES
CHAMPION RN2C (alternative)
Battery 12V-9Ah
Main fuse 10 A
Alternator (permanent magnet type) 88 W
Frame and suspensions
CHASSIS AND SUSPENSION

Chassis type Welded tubular steel chassis with stamped sheet reinforce-
ments
Front suspension hydraulic telescopic fork
Trail 73 mm
Front suspension stroke 58 mm
Rear suspension With coaxial spring and hydraulic shock absorber. Chassis to
engine support with swinging arm.
Brakes
BRAKES
Front brake Disc D=220 mm with hydraulic control, operated by right brake
lever on handlebars.
Rear brake Drum D=110 mm with expansion brake shoes, mechanically
controlled by the left brake lever on the handlebars.
Wheels and tyres
WHEELS AND TYRES

Front tyre Tubeless, 120/80-12"
Front wheel rim Die-cast aluminium alloy, 3.50x10"
Rear tyre Tubeless, 120/80-12"
Rear wheel rim Die-cast aluminium alloy, 3.50x10"
Front tyre pressure 1.5 bar
CHAR - 10
Rear tyre pressure 1.8 bar
Rear tyre pressure (rider and luggage) 2.0 bar
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES
Carburettor
50cc Version
Dell'Orto
DELL'ORTO CARBURETTOR
Type PHVA 17.5 RD
Diffuser diameter Ø 17.5
Regulation reference number 8423
Maximum nozzle: 53
Maximum air nozzle (on the body): Ø 1.5
Tapered pin stamped code: A22
Pin position (notches from above): 1
Diffuser: 209 HA
Minimum nozzle: 32
Minimum air nozzle (on the body): Free
Secondary minimum air hole Ø 2.5
Initial minimum mix screw opening: 1 1/2
Starter nozzle 50
Starter air nozzle (on the body): Ø 1.5
Stroke of starter pin: 11 mm
Petrol inlet hole Ø 1.5
Tightening Torques
ENGINE
Name Torque in Nm
Ignition spark plug 18 Nm
Cylinder head nuts (*) 10 ÷ 11
Start-up lever screw 12-13
Flywheel air duct screw 3 to 4
Mixer clamping screws 3÷4
Nut fixing silencer to cylinder head 16 to 18
Head intake manifold screw 11 to 13
Rear brake cam tightening screw 11 to 13
Engine-crankcase coupling screws 11 to 13
Starter screws 11 to 13
Silencer to crankcase fixing screws 24 to 27
(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.
TRANSMISSION
Name Torque in Nm
Drive pulley nut 18 - 20 Nm + 90° rotation
Transmission cover screw 11 to 13
Driven pulley shaft nut 40 ÷ 44
Rear hub cap screws 24 to 27
Clutch unit nut on driven pulley 40 ÷ 44
CHAR - 11
FLYWHEEL
Name Torque in Nm
Flywheel hood fixing screws 3÷4
Flywheel fan screws 3 to 4
Stator screws (°) 3 to 4
Flywheel nut 40 ÷ 44
Pick-up screw 3 to 4
(°) Apply LOCTITE 243 threadlock
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 30 to 36
Lower steering ring nut 10 - 13 (loosen by 90°)
Handlebar fixing screw 45 to 50
Mirror fastening spacer 25
CHASSIS ASSEMBLY
Name Torque in Nm
Engine-swinging arm pin 45,5
Centre stand screws on engine 18.5 to 19
Chassis-side swinging arm retaining nut 52.5 Nm
FRONT SUSPENSION
Name Torque in Nm
Front wheel axle nut (safety fasteners) 45 to 50 Nm
Wheel axle clamp screw 6 ÷ 7 Nm
Lower leg screw 15 to 20 N·m
Hydraulic cartridge stem nut 15 to 18 Nm
FRONT BRAKE
Name Torque in Nm
Brake fluid hose-pump fitting 20 to 25
Brake fluid pipe-calliper fitting 20 to 25
Calliper to fork tightening screw 20 to 25
Disc tightening screw 8 to 12
Oil bleed screw 8 to 12
Pump U bolt screw 8
Brake pad fastening screw 15 to 20
REAR SUSPENSION
Name Torque in Nm
Rear wheel axle 115
Shock absorber nut 22.5
FUEL TANK UNIT

Name Torque in Nm
Fuel tank to chassis fixing screw 10
SADDLE UNIT
Name Torque in Nm
Saddle plate fixing nut 10
BODYWORK UNIT
Name Torque in Nm
Helmet compartment fixing screw 3
Rear grab handle fixing screw 20.5
Battery cover fixing screw 6
Front wheel housing to chassis fixing screw 6
Front wheel housing to leg shield back plate fixing screw 3
CHAR - 12
Name Torque in Nm
Front mudguard fixing screw 6
Footrest fixing screw 6
Screw fixing leg shield back plate to chassis 6
Leg shield back plate to leg shield fixing screw 3
Footrest spoiler fixing screw 6
Passenger footrest protection fixing screw 3
Passenger footrest to side body panel fixing screw 6
Rear mudguard fixing screw 6
Rear brake adjustment nut 5
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND CYLINDER

Name Initials Cylinder Piston Play on fitting
Standard coupling M 40.005 - 40.012 39.943 - 39.95 0.055 - 0.069
Standard coupling N 40.012 - 40.019 39.95 - 39.957 0.055 - 0.069
Standard coupling O 40.019 - 40.026 39.957 - 39.964 0.055 - 0.069
Standard coupling P 40.026 - 40.033 39.964 - 39.971 0.055 - 0.069
Coupling 1st oversize M1 40.205 - 40.212 40.143 - 40.15 0.055 - 0.069
Coupling 1st oversize N1 40.212 - 40.219 40.15 - 40.157 0.055 - 0.069
Coupling 1st oversize O1 40.219 - 40.226 40.157 - 40.164 0.055 - 0.069
Coupling 1st oversize P1 40.226 - 40.233 40.164 - 40.171 0.055 - 0.069
Coupling 2nd oversize M2 40.405 - 40.412 40.343 - 40.35 0.055 - 0.069
Coupling 2nd oversize N2 40.412 - 40.419 40.35 - 40.357 0.055 - 0.069
Coupling 2nd oversize O2 40.419 - 40.426 40.357 - 40.364 0.055 - 0.069
Coupling 2nd oversize P2 40.426 - 40.433 40.364 - 40.371 0.055 - 0.069
Piston rings
SEALING RINGS
Name Description Dimensions Initials Quantity
Compression ring 40 A 0.10 to 0.25
Compression ring 1st 40.2 A 0.10 to 0.25
oversize
Compression ring 2nd 40.4 A 0.10 to 0.25
Oversize
CHAR - 13
Crankcase - crankshaft - connecting rod
CRANKSHAFT - CONNECTING ROD AXIAL CLEARANCE

Characteristic Code Value (mm) Fitting clearance E Fitting clearance F
(mm) (mm)
Connecting rod A 11.75 (+0;-0.05) 0.25 - 0.50 -
thrust washer G 0.5±0.03 0.25 - 0.50 -
Transmissionside half-shaft C 13.75 (-0.005;-0.04) 0.25 - 0.50 -
Flywheel-side halfshaft D 13.65 (-0.005;-0.04) 0.25 - 0.50 -
Spacer tool H 40.46 0.25 - 0.50 -
Cage B 11.8 (+0;-0.05) - 0.20 - 0.90
thrust washer G 0.5±0.03 - 0.20 - 0.90
Transmissionside half-shaft C 13.75 (-0.005;-0.04) - 0.20 - 0.90
Flywheel-side halfshaft D 13.65 (-0.005;-0.04) - 0.20 - 0.90
Spacer tool H 40.46 - 0.20 - 0.90
CHAR - 14
Slot packing system
- Fit the cylinder without installing the basic gasket.

- Apply a centimetre dial gauge on the special tool
and zero it on the ground plane
- Fit the tool to the top of the cylinder fixing it with
two nuts to the studbolts and take the piston to the
T.D.C.
- The thickness of the gasket to fit will change de-
pending on the value detected. For this purpose,
there are three with different thicknesses
Specific tooling
020272Y Piston position check tool
SHIMMING SYSTEM
Name Measure A Thickness
SHIMMING 2.80 ÷ 3.04 0.4
SHIMMING 3.04 ÷ 3.24 0.6
SHIMMING 3.25 ÷ 3.48 0.8
Products
RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
AGIP GP 330 Grease for brake lever, gas White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
AGIP GREASE SM 2 Grease for the C-ring of the tone wheel Soap-based lithium grease containing
NLGI 2 Molybdenum disulphide; ISO-L-
XBCHB2, DIN KF2K-20
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
MONTBLANC MOLYBDENUM Grease for driven pulley shaft adjusting Grease with molybdenum disulphide
GREASE ring and movable driven pulley housing
AGIP GREASE PV2 Grease for steering bearings, pin seats White anhydrous-calcium based grease
and swinging arm to protect roller bearings; temperature
range between -20 C and +120 C; with
NLGI 2; ISO-L-XBCIB2.
CHAR - 15
INDEX OF TOPICS
TOOLING TOOL
Typhoon 50 2T (MY2010) Tooling
TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y009 Driver for OD 42-mm bearings
001467Y013 Calliper to extract ø 15-mm bearings
001467Y017 Bell for bearings, OD 39 mm
001467Y021 Extraction pliers for ø 11 mm bearings
001467Y029 Bell for bearings, O.D. 38 mm
TOOL - 17
Tooling Typhoon 50 2T (MY2010)

002465Y Calliper for circlips
004499Y001 Bearing extractor bell
004499Y002 Bearing extractor screw
004499Y006 Bearing extractor ring
004499Y007 Half rings
005095Y Engine support
006029Y Punch for fitting fifth steering bearing on

steering tube
TOOL - 18

020004Y Punch for removing steering bearings
from headstock
020055Y Wrench for steering tube ring nut
020074Y Support base for checking crankshaft

alignment
020150Y Air heater mounting
020151Y Air heater
020162Y Flywheel extractor
TOOL - 19

020163Y Crankcase splitting plate
020164Y Driven pulley assembly sheath
020165Y Start-up sprocket lock
020166Y Pin lock fitting tool
020171Y Punch for Ø 17 mm roller bearing
020201Y Spacer bushing driving tube

020261Y Starter spring fitting
TOOL - 20

020265Y Bearing fitting base
020325Y Pliers for brake-shoe springs
020329Y Mity-Vac vacuum-operated pump
020330Y Stroboscopic light to check timing
020331Y Digital multimeter
TOOL - 21

020332Y Digital rpm indicator
020334Y Multiple battery charger
020335Y Magnetic mounting for dial gauge
020340Y Flywheel and transmission oil seals fitting

punch
TOOL - 22

020350Y Electrical system check instrument
020357Y 32x35-mm Adaptor

020360Y Adaptor 52x54 mm

020362Y 12 mm guide
020363Y 20-mm guide
020364Y 25-mm guide
TOOL - 23

020375Y 28 x 30 mm adaptor
020376Y Adaptor handle
020412Y 15-mm guide
020439Y 17-mm guide
020444Y Tool for fitting/ removing the driven pulley

clutch
020451Y Starting ring gear lock
TOOL - 24

020452Y Tube for removing and refitting the driven
pulley shaft
020456Y Ø 24 mm adaptor
020477Y 37 mm adaptor
020483Y 30-mm guide
020565Y Flywheel lock calliper spanner
020625Y Kit for sampling gas from the exhaust

manifold
TOOL - 25
INDEX OF TOPICS
MAINTENANCE MAIN
Typhoon 50 2T (MY2010) Maintenance
Maintenance chart
SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Check level every 500 km
** Replace every 2 years
*** Replace every 4 years
Km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Safety fasteners I I I I I I I I I I I I I
Spark plug I R R R R R R R R R R R R
Transmission cables and controls I I I I I I I I I I I I I
Mixer belt R R R
Drive belt I R I R I R I R
Air filter C C C C C C C C C C C C C
SAS filter box C C C C
Rear brake shoes I I I I I I I I I I I I
Electrical system and battery I I I I I I I I I I I I I
Braking systems I I I I I I I I I I I I I
Light circuit I I I I I I I I I I I I I
Brake fluid ** I I I I I I I I I I I I I
Exhaust muffler/ silencer I I I I I I I I I I I I
Mixer I I I I I I I I I I I I I
Hub oil R I R I R I R I R I R I R
Mixer oil* I I I I I I I I I I I I I
Rear brake cam pin L L L L L L L L L L L L
Headlight A A A A A
Vehicle and brake test - test ride I I I I I I I I I I I I I
Brake pads I I I I I I I I I I I I I
Electric starter gear pins L L L L L L
Wheels/ tyres I I I I I I I I I I I I I
CVT rollers / Sliding shoes R R R R R R
Idle speed A A A A A A A
Suspension I I I I I I I I I I I I
Steering I I I I I I I I I I I I I
Braking system pipes*** I I I I I I I I I I I I I
Mixer oil pipes I I I I I I I
Fuel pipes *** I I I I I I I I I I I I I
Carburettor
Check the idle at the intervals indicated in the

maintenance table.
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS
AND IN ORDER TO AVOID BURNS, LEAVE ENGINE AND
SILENCER TO COOL OFF TO AMBIENT TEMPERATURE.
• Operate on the indicated screw until the pre-set idle speed is obtained.
Characteristic
Idle speed
MAIN - 27
Maintenance Typhoon 50 2T (MY2010)
1800 ± 100 rpm
Checking the spark advance
-Check to be made at over 4000 rpm with strobo-

scopic gun. The advanced ignition measured must
be 17° before the TDC.
- This value is correct when the reference mark on
the flywheel hood is aligned with the reference
mark on the cooling fan and the phase shifter on
the stroboscopic gun is set on 17°.
N.B.
IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS
PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK
THE CORRECT KEYING OF THE FLYWHEEL ON THE
CRANKSHAFT.
Specific tooling
020330Y Stroboscopic light to check timing
Spark plug
Place the vehicle on its central stand

- Remove the central cover by undoing the four
clamping screws indicated in the figure;
MAIN - 28
- Undo the fixing screw (1) and remove the coil,

leaving it connected to the system;
- Disconnect the cap (2) of the spark plug HV wire;
-Undo the spark plug using the socket wrench;
- Examine the condition of the spark plug, check
that the insulating material is whole and measure
the distance between the electrodes using a feeler
gauge.
-Adjust the distance, if necessary, by bending the
side electrode very carefully.
In the case of defects, replace the spark plug with
one of the specified type;
- Engage the spark plug with the due inclination
and screw it right down by hand, then do it up with
the wrench at the prescribed torque;
-Fit the cap on the spark plug as far as it will go;
- Refit the central flap.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE EN-
GINE IS COLD. THE SPARK PLUG MUST BE REPLACED
EVERY 5,000 KM. USE OF STARTERS NOT CONFORMING
OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERI-
OUSLY DAMAGE THE ENGINE.
Characteristic
spark plug
NGKR BR8ES
CHAMPION RN2C (alternative)
Spark plug electrode gap
0.6 mm
Locking torques (N*m)

Ignition spark plug 18 Nm
Hub oil
MAIN - 29
Check
Do the following to check the correct level:

- Ride a few kilometres until the regular working
temperature is reached, then shut off the engine.
- Park the vehicle on level ground and rest it on the
centre stand.
- Unscrew the oil filler dipstick (A), dry it with a
clean cloth and reinsert it.
- Remove the dipstick and make sure that the oil
level reaches the indicated reference notch.
- Screw up the oil dipstick back in and make sure
it is locked properly in place.
CAUTION
DO NOT RIDE THE MOTORCYCLE WITH INSUFFICIENT
LUBRICATION OR WITH CONTAMINATED OR INCOR-
RECT LUBRICANTS AS THIS ACCELERATES THE WEAR
AND TEAR OF THE MOVING PARTS AND CAN CAUSE IR-
RETRIEVABLE DAMAGE.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Replacement
- Ride a few kilometres until the regular working

temperature is reached, then shut off the engine.
- Park the vehicle on level ground and rest it on the
centre stand.
- Remove the oil dipstick (A).
- Unscrew the oil drainage plug (B) and drain out
all the oil.
- Screw the oil drainage plug (B) back and fill up
the hub with the required oil.
Characteristic
Rear hub oil
Quantity: ~80cc
MAIN - 30
- Check the level.

- Screw the oil filler dipstick (A) back into place
completely.

Hub oil drainage cap 3 ÷ 5
Air filter
-Remove the cap of the purifier, unscrewing the six

clamping screws and removing the filter.
Cleaning:
-Wash with water and neutral soap.
- Dry with a clean cloth and short blasts of com-
pressed air.
-Saturate with a 50% mixture of gasoline and oil.
-Drip dry the filter and then squeeze it between the
hands without wringing.
-Let it dry and refit it again.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE
PISTON AND CYLINDER.
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased ad-
hesiveness
FILTER BOX REMOVAL

- Undo the two screws indicated.
MAIN - 31
- Cut the tie.
transmissions
Put the vehicle in gear and regulate the idling by

turning the adjustment screw on the carburettor.
Adjust the control cables:
Handlebar control: remove the front handlebar
cover and regulate the cable adjustment in such a
way that it causes a minimum clearance on the
throttle.
Carburettor control: remove the rubber hood and

regulate the cable adjustment in such a way that
the sheath has a minimum clearance.
See also
Carburettor
MAIN - 32
Oil mixer control: remove the cap on the trans-

mission cover and regulate the adjustment in such
a way that with the throttle released, the reference
mark on the rotating plate is lined up with the ref-
erence mark on the mixer body as indicated in the
figure.
Bring the throttle a couple of times to the end of
the stroke and check that the adjustments have
been made properly, then tighten them all up.
See also
Carburettor
CAUTION
IN CASE OF DISMANTLING OF THE OIL RESERVOIR OR
THE MIXER OR RUNNING OUT OF OIL IN THE RESERVOIR
BLEED THE MIXER AS FOLLOWS:
- FILL THE FUEL TANK WITH 3 LITER OF 2% MIXTURE
MADE WITH THE RECOMMENDED OIL;
- FILL THE OIL RESERVOIR;
- WITH THE MIXER ON THE VEHICLE AND THE ENGINE
OFF, DISCONNECT THE MIXER PIPE FROM THE CARBU-
RETTOR AND LOOSEN THE BLEED SCREW (SHOWN IN
THE FIGURE) UNTIL OIL STARTS FLOWING OUT;
- TIGHTEN THE SCREW, START THE ENGINE AND WAIT
UNTIL OIL COMES OUT FROM THE (PREVIOUSLY DIS-
CONNECTED) DELIVERY PIPE TO THE CARBURETTOR;
- RECONNECT THE DELIVERY PIPE TO THE CARBURET-
TOR AND FIX IT IN PLACE WITH THE RELEVANT METAL
CLIP.
MAIN - 33
AGIP CITY TEC 2T Mixer oil
synthetic oil for 2-stroke engines: JASO FC, ISO-
L-EGD
See also
Carburettor
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:
- Undo the two screws and remove the cover with
the seal.
- Top-up using only the fluid specified, without ex-
ceeding the maximum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR

EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
CAUTION
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE
SURE THAT IT DOES NOT COME INTO CONTACT WITH
THE PAINTWORK.
CAUTION
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS
MOISTURE FROM THE SURROUNDING AIR. IF THE CON-
TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A
CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.
MAIN - 34
NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY

USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID
MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EV-
ERY TWO YEARS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO
THE CHANGING OF BRAKE FLUID AND THE BLEEDING
OF AIR FROM THE CIRCUITS.
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Headlight adjustment
Proceed as follows:
1. Place the vehicle in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10 m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the 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.
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 COUNTRY
WHERE THE VEHICLE IS USED.
CO check
This test must be carried out after washing all carburettor parts accurately, the air filter must be clean
and the ignition spark plug in good condition.
MAIN - 35
- Warm up the vehicle at a speed of 45 Km/h for about 10 min., enough time for the automatic starter
to exclude its circuit.
- Switch off the vehicle for the time strictly necessary for carrying out the following operations.
- Connect the exhaust gas analyser to the silencer.
- Make sure the silencer and the exhaust gas analyser pipe are adequately connected and tight.
- Start the engine.
- Switch on the low beam light.
- Wait until the idle speed stabilises for one minute.
- Without operating the accelerator again and using the flow screw rev the engine at 1800 ± 100
rpm.
- Adjust the flow screw so that the "CO" value is equal to 3.5%±0.5%.
- Slowly operate the throttle accelerating the engine until it reaches 4000 rpm and then set throttle back
to close position; check that the idle speed remains at the above set value; if not, repeat the procedure.
Specific tooling
020332Y Digital rpm indicator
SAS filters inspection and cleaning
Undo the two fixing screws and remove the sec-

ondary air box cover. Detach the housing cover
and remove the filtering element made of sponge.
Wash the sponge with water and neutral soap,
then dry with a clean cloth and short blasts of com-
pressed air. While cleaning the filter, check the
condition of the reed valve on the cover, and fit it
back in place on the housing.
Before closing the cover of the SAS housing,
check the good condition of the sealing O-ring; re-
place it if damaged or deformed.
N.B.
The reed valve can be inserted in only one direction on the
SAS housing
MAIN - 36
MAIN - 37
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Typhoon 50 2T (MY2010) Troubleshooting
This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Defective fuel cock or vacuum hose damaged. Replace the cock or the control hose.
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Fuel filter on the tank outlet fitting dirty or clogged Clean the fitting filter
Excess of scales in the combustion chamber Remove the encrustations
Lack of compression: wear of the piston rings or cylinder Check the worn parts and replace them
Silencer clogged due to excessive encrustations Replace the silencer and check the carburation and mixer timer
Air filter blocked or dirty. Clean according to the procedure
Starter inefficient (stays on) Check the mechanical sliding, continuity of the circuit, the pres-
ence of power and electrical wiring
Clutch slipping Check the centrifugal brake shoe assembly and /or clutch
housing and replace if necessary
Defective mobile pulley sliding Check the parts, change the faulty parts and lubricate only the
sliding seat of the driven pulley with specific grease.
Drive belt worn Replace
Roller wear; Presence of oil; Dirt Clean the speed variator, replace the rollers if worn out
Rear wheel spins at idle
REAR WHEEL
Idling rpm too high Check the idling speed and, if necessary, adjust the C.O.
Clutch fault Check the spring/friction mass and the clutch housing
Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged
Starting difficulties
DIFFICULTY STARTING
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Defective fuel cock or vacuum hose damaged. Replace the cock or the control hose.
Inefficient Starter Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Flat battery Check the state of the battery. If it shows signs of sulphation
replace it and bring the new battery into service charging it for
eight hours at a current of 1/10 of the capacity of the battery
itself
Engine flooded Start the vehicle keeping the throttle fully open alternately mak-
ing the engine run for approx. five seconds and stopping for
other five seconds. If however it does not start, remove the
spark plug, the engine over with the throttle open being careful
to keep the cap in contact with the spark plug and the spark
plug grounded but away from its hole. Refit a dry spark plug
and start the vehicle.
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Defective spark plug or with incorrect electrode gap Remove the encrustation, restore the plug gap or replace being
sure to use the types of spark plug recommended at all times.
TROUBL - 39
Troubleshooting Typhoon 50 2T (MY2010)

Bear in mind that many problems engines have, derive from
the use of the wrong spark plug
Intake joint cracked or with a bad seal Replace the intake joint and check its tightness on the crank-
case and on the carburettor
Purifier-carburettor fitting damaged Replace
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Excess of scales in the combustion chamber Remove the encrustations
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air
Dirty carburettor Wash the carburettor with solvent and dry with compressed air
Water in the carburettor Empty the tank through the appropriate bleed nipple.
Air filter dirty Clean or replace
Defective floating valve Check the proper sliding of the float and the functioning of the
valve
Tank breather hole obstructed Restore the proper reservoir aeration
Engine tends to cut-off at idle
ENGINE STOP IDLING

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air
Starter that stays open Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Reed valve does not close Check / replace the reed pack
Wrong idling adjustment Correctly adjust the engine idling and check the level of the
C.O.
Spark plug defective or faulty Replace the spark plug with one with the specified degree and
check the plug gap
Excessive exhaust noise
INCREASED NOISINESS
Secondary metal air pipe deteriorated Check the seal of the piping on the crankcase and on the hous-
ing, check the piping between the housing and the silencer.
Good condition of the missing secondary air circuit components Check the individual components and the piping, check the
precision of the fitting. Replace the damaged components
High fuel consumption
HIGH FUEL CONSUMPTION

Air filter blocked or dirty. Clean according to the procedure
TROUBL - 40

Inefficient Starter Check: electric wiring, circuit continuity, mechanical sliding and
power supply
SAS malfunctions
SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE SI-
LENCER
Secondary air reed blocking Replace
Secondary air filter clogging Clean the filter and the housing
Blockage of the secondary air fitting on the silencer Remove the encrustations from the joint being careful not to let
the debris fall into the silencer
Transmission and brakes
Clutch grabbing or performing inadequately
CLUTCH
Slippage or irregular functioning Check that the masses open and return normally
Check that there is no grease on the masses
Check that the clutch masses' contact surface with the clutch
housing is mainly in the middle with characteristics equivalent
on the three masses
Check that the clutch housing is not scored or worn abnormally
Never operate the engine without the clutch housing
Insufficient braking
BRAKING SYSTEM MALFUNCTION

INSUFFICIENT BRAKING The rear (drum type) brake is adjusted by regulating the special
adjustment (on the wheel) bearing in mind that, with the control
levers in the rest position, the wheels must turn freely.
The braking action should begin when the brake levers are
pressed by about a third.
Check the brake pad wear.
If it is not possible to remove any problems by simply adjusting
the transmissions, check the brake pads and front brake disc,
the brake shoes and the rear drum. If you encounter excessive
wear or scoring, make the necessary replacements.
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 Elastic fittings, piston seals or brake pump breakdown, replace
The brake fluid has lost its properties Replace the front brake fluid and top up to the correct level in
the pump
Defective sliding of the cables in their sheathes Lubricate or substitute
Brake noise Check the wear of the brake pads and/or shoes
Brakes overheating
BRAKE OVERHEAT
Defective piston sliding Check calliper and replace any damaged part.
TROUBL - 41
Troubleshooting Typhoon 50 2T (MY2010)

Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the
wheel correctly fitted or the concentricity of the rear drum.
Electrical system
Battery
BATTERY
Battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. If the
vehicle is not used for some time (1 month or more) the battery
needs to be recharged periodically. The battery runs down
completely in the course of 5 to 6 months. If the battery is fitted
on a motorcycle, be careful not to invert the connections, keep-
ing in mind that the black ground cable is connected to the
negative terminal while the red cable is connected to the ter-
minal marked +. Follow the instructions in the ELECTRICAL
SYSTEM chapter for the recharging of the batteries.
Steering and suspensions
Rear wheel
POOR ROAD HOLDING

Faulty suspension Check that the rear shock absorber and/or the front fork is/are
in good working order. Replace or overhaul the front fork and/
or replace the rear shock absorbers in case of malfunction
Tyres deflated or damaged Check the correct pressure of the tyres and the condition of the
tread. Inflate to the correct pressure or replace.
Loosen the anchorage points of the front and/or rear suspen- Check the tightness between the frame, swinging arm and en-
sion unit. gine and the fixing of the wheels to the hub and/or the axle.
Check the correct tightening of the steering ring nut.
Heavy steering
STEERING HARDENING
Torque not conforming Check the tightening of the top and bottom ring nuts.
If irregularities continue in turning the steering even after mak-
ing the above adjustments, check the seats in which the ball
bearings rotate: replace if they are recessed.
Excessive steering play
EXCESSIVE STEERING CLEARANCE

Excessive steering clearance Check the tightening of the top and bottom ring nuts.
If irregularities continue in turning the steering even after mak-
ing the above adjustments, check the seats in which the ball
bearings rotate: replace if they are recessed.
TROUBL - 42
Noisy suspension
NOISY SUSPENSION
Components of the front suspension damaged. Check the quiet operation in the compression or release pha-
ses of the fork and if necessary overhaul it. Check that there is
no noise or seizing during the wheel rotation; if there is, change
the wheel bearing.
Components of the rear suspension damaged. Check the absence of noise in the compression or release of
the suspension, if necessary check the proper tightness to the
swinging arm unit and the absence of rust or replace the entire
shock absorber. Check that there is no noise or seizing during
the wheel rotation; if there is noise or seizing overhaul the final
reduction assembly.
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION

Shock absorbers malfunctioning Replace the complete shock absorption unit
Hydraulic cartridge in the fork damaged. Replace the hydraulic cartridge
TROUBL - 43
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Typhoon 50 2T (MY2010) Electrical system
Key
1. Multiple connectors
2. Horn
3. Horn button
4. Oil level warning light
5. Instrument panel lighting bulbs
6. High beam warning light
7. Turn indicator warning light
8. Fuel level instrument
9. Instrument panel
10. Fuel level transmitter
11. Light switch
12. Key switch
13. Turn indicator switch
14. Starter button
15. Front stop switch
16. Rear stop switch
17. Rear left turn indicator
18. Rear light
19. License plate light
ELE SYS - 45
Electrical system Typhoon 50 2T (MY2010)
20. Rear right turn indicator

21. Start-up relay
22. Starter motor
23. Battery
24. Main fuse
25. Ignition coil
26. Spark plug
27. Pick-up
28. Generator
29. Regulator
30. Automatic starter
31.Oil reserve warning light
32. Front right turn indicator
33. High beam light
34. Daylight running light
35. Low beam light
36. Front left turn indicator
37. Front headlamp
38. Low fuel warning light
39. Ground point on chassis
40. License plate cables
41. Heater control device
42. Heater
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
ELE SYS - 46
Components arrangement
1. Instrument panel - To reach the connector, re-

move the front handlebar cover.
2. Ignition switch
3. Regulator
4. Turn indicators
Remove the leg shield back plate to reach it.
ELE SYS - 47
5. Horn - Remove the leg shield back plate to re-

move it.
6. Ignition coil - Remove the rear central cover to

reach it.
7. Pick-Up/Current generator - The connector is

located on the right-hand side of the engine.
8. Starter motor - The starter motor is located un-

der the engine.
ELE SYS - 48
9. Automatic starter - Heater- To reach the con-

nector, remove the helmet compartment inspec-
tion lid.
10. Start-up solenoid- Remove the side fairings

to reach it.
11. Fuel level transmitter - Located on the fuel

tank.
12. Mixer oil reserve indicator - Remove the side

fairings to reach it.
ELE SYS - 49
13. Battery - 14. Main fuse - Remove the specific

cover under the saddle to reach it.
Ground points
- On the vehicle there is a chassis ground point,

beneath the rear central cover.
- On the engine there is a ground point fixed under

the starter motor. remove the centre stand togeth-
er with its support to reach it.
Conceptual diagrams
ELE SYS - 50
Ignition
Key
12. Key switch
23. Battery
24. Main fuse
25. Ignition coil
26. Spark plug
27. Pick-up
28. Generator
ELE SYS - 51
Battery recharge and starting
Key
12. Key switch
14. Starter button
18. Rear light
21. Start-up relay
22. Starter motor
23. Battery
24. Main fuse
28. Generator
29. Regulator
ELE SYS - 52
Level indicators and enable signals section
Key
4. Oil level warning light
8. Fuel level instrument
10. Fuel level transmitter
12. Key switch
23. Battery
24. Main fuse
29. Regulator
31.Oil reserve warning light
38. Low fuel warning light
ELE SYS - 53
Instruments and warning lights control board
A= High beam warning light;

B = Oil pressure warning light;
C= Turn indicator warning light;
D= Low fuel warning light;
E = Odometer;
F= Rpm indicator;
G= Fuel gauge
LIGHT BULBS TABLE

1 High/low beam light bulb Type: Halogen (H8)
Power: 12V - 35W
Quantity: 2
2 Front side light bulb Type: All glass
Power: 12V 3W
Quantity: 2
3 Instrument panel bulb, indicator warning lights, mixer oil Type: All glass
reserve and high beams Power: 12V - 1.2W
Quantity: 5
4 Front turn indicator light bulb Type: SPHERICAL (amber colour)
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
5 Rear turn indicator light bulb Type: SPHERICAL (amber colour)
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
6 Stop light/rear daylight running light bulb Type: ALL GLASS (twin-filament)
Power: 12V - 21/5W
Quantity: 1
7 License plate bulb Type: All glass
Power: 12V - 3W
Quantity: 1
ELE SYS - 54
Devices and accessories
Key
2. Horn
3. Horn button
12. Key switch
23. Battery
24. Main fuse
29. Regulator
41. Heater control device
42. Heater
ELE SYS - 55
Lights and turn indicators
Key
5. Instrument panel lighting bulbs
6. High beam warning light
7. Turn indicator warning light
9. Instrument panel
11. Light switch
13. Turn indicator switch
17. Rear left turn indicator
18. Rear light
19. License plate light
29. Regulator
32. Front right turn indicator
33. High beam light
34. Daylight running light
35. Low beam light
ELE SYS - 56
36. Front left turn indicator

37. Front headlamp
40. License plate cables
Checks and inspections

Checks to be made in the case of ignition irregularities and/or no spark on the spark plug
1. Check the condition of the spark plug (clean it with a metal brush, remove the encrustations, blast
it with compressed air and, if necessary, replace it).
2. Without removing the stator, carry out the following checks:
After visually checking the electrical wiring, perform measurements on the loading reel, the pickup (see
chart) and the continuity using the appropriate tester.
If checks on the loading reel, pickup and continuity show abnormalities, replace the stator; otherwise
replace the central unit. Remember that the engine must be off to disconnect and replace the control
unit.
Specific tooling
CHECK ON THE PICK UP

1 Red and white cable 90±140 ohm
RECHARGE COIL CHECK UP

1 Yellow and blue cable 800±1100 ohm
ELE SYS - 57
CHECK CONTINUITY
1 White cable-frame Continuity
2 White cable-engine Continuity
Ignition circuit
All the control operations of the system that require

the disconnection of cables (checks of the con-
nections 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 dam-
aged.
Stator check
- Using a tester, check the resistance between the

stator wiring.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERA-
TURE LEADS TO VALUES HIGHER THAN THOSE STATED.
Electric characteristic
Stator: Grey ÷ Ground
~ 1 ohm
Stator: White ÷ Ground
~ 1 ohm
Stator: Green - Ground
~ 1Kohm
Stator: Blue ÷ Yellow
~ 1 ohm
Pick-Up: Red - Ground
~ 170 Ω (Pick-Up)
Voltage regulator check
A malfunction in the voltage regulator might cause the following problems depending on the type of
fault:
1. The lighting system bulbs burn out.
2. The lighting system bulbs stop working.
ELE SYS - 58
3. The battery overcharges (the main fuse blows).

4. Non-recharging of the battery.
5. Non functioning of the turn indicators.
Measures
FAULT 1
Replace the regulator because it is certainly inef-
ficient.
FAULT 2
Check the efficiency of the bulbs.
With the vehicle in gear, check the battery voltage
on the green cables of the light switch. If there is
no voltage check the presence of voltage between
the yellow-black cable on the regulator and
ground. If there is voltage here, the fault needs to
be sought in the wiring from the regulator to the
light switch or the correct supply of voltage to the
stator is to be checked: without disconnecting the
regulator connector and with the vehicle in gear,
using the tester for alternate voltage readings
check that the voltage supplied between the con-
nection of the yellow-grey cable (pin 2) and the
blue cable (pin 6) is within the values indicated. If
faults are detected, replace the stator.
If no faults are detected in the controls carried out,
replace the regulator.
If functioning is still not correct even when the reg-
ulator is replaced, check the connections of the
electrical system.
Specific tooling
Characteristic
Voltage distributed at 3000 rpms
25 to 30V
FAULT 3
After checking that there are no short circuits in the system towards the earth, replace the regulator
because it is certainly inefficient and replace it with a protective fuse.
Following the replacement, measure the current and the recharging voltage on the battery end.
ELE SYS - 59
FAULT 4
Put the vehicle in gear and check when the tester
for the detection of alternate voltages put between
the blue cable connection and the yellow cable
connection on the stator, the voltage distributed by
the generator is within the values indicated. In the
case of malfunction, check the continuity of the
stator or continue with the tests.
Insert an ammeter between the stator (blue cable)
and the battery and check, with the tester, that the
current is properly distributed at 3000 rpm and the
battery is kept between 12 and 13V as indicated.
If the values detected are lower than those speci-
fied, replace the regulator; otherwise replace the
battery.
N.B.
BEFORE CARRYING OUT THE CHECKS ON THE REGU-
LATOR AND RELATIVE SYSTEM, IT IS ALWAYS GOOD
PRACTICE TO CHECK THAT THERE IS CONTINUITY BE-
TWEEN THE BLACK CABLE AND THE GROUND.
N.B.
TO KEEP THE BATTERY BETWEEN 12 AND 13V, CAUSING
CURRENT ABSORPTION BY THE SYSTEM, A 12V - 35W
BULB CONNECTED BETWEEN THE + BATTERY AND
GROUND CAN BE USED.
Specific tooling
Characteristic
Distributed current
1.5 to 2A
Voltage distributed at 3000 rpms
25 to 30V
FAULT 5
If the turn indicators do not work, do the following:
• With the engine off, remove the regu-

lator connector, and insert the ends of
the tester between contact 5 and the
ground.
• Move the ignition switch to ON and
check there is battery voltage. If no
voltage is detected, check the wiring
ELE SYS - 60
and the contacts on the ignition switch

and on the battery.
• Repeat the same procedure with the

ends of the tester inserted between
contact 5 (+) and 6 (-) and check the
presence of the battery voltage with the
ignition switch at on. If this does not
happen, check the regulator's ground
cable.
• If these last two tests have a positive result replace the regulator because it is certainly not
functioning properly.
Specific tooling
Turn signals system check

WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
Check that bulb operates properly.
Check continuity of the Blue-Black cable between the regulator 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.
Fuses
The electrical system is protected by a fuse con-

nected on the left-hand side of the helmet com-
partment next to the battery. For access it is
necessary to remove the battery cover and the
transparent protection over the fuse block. The ig-
nition system, headlight and the rear tail light are
not fuse-protected.
CAUTION
BEFORE REPLACING THE BLOWN FUSE, SEARCH AND
SOLVE THE PROBLEM THAT CAUSED IT TO BLOW.
NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE
OF A DIFFERENT RATING THAN THAT SPECIFIED OR US-
ING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF
ELECTRICAL WIRE).
Characteristic
ELE SYS - 61
Fuse
10 A
Sealed battery
Commissioning sealed batteries
INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT

1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
-Constant voltage equal to 14.40÷14.70V
-Initial charge voltage equal to 0.3÷0.5 for nominal capacity
-Duration of the charge: 10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the battery
-Duration of the charge: 5 h
WARNING
-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF
RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CON-
TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Dry-charge battery
If available
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO
CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN.
AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
ELE SYS - 62
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR

CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
Commissioning dry-charged batteries:
1) - Remove the short closed tube and the plugs,
then pour sulphuric acid into the cells using the
type specified for batteries with a specific gravity
of 1.26, corresponding to 30 Bé at a minimum tem-
perature of 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 27, corresponding to 31 Be, 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 freed
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VE-
HICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE
(WITH CLOSED END) NEAR THE + POSITIVE TERMINAL
WITH THE CORRESPONDING LONG TUBE (WITH OPEN
END), THAT YOU FIND FITTED TO THE VEHICLE, TO EN-
SURE THAT THE GASES THAT FORM CAN ESCAPE
PROPERLY.
Specific tooling
020333Y Single battery charger
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
ELE SYS - 63
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
After topping-up the electrolyte level, check its density using an appropriate densitometer (see figure).
When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific
weight of 1.26 to 1.28 at a temperature of no lower than 15° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
If the 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 THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.
LACK OF PROPER CHARGING OF THE BATTERY BEFORE FIRST USE AT LOW ELECTROLYTE
LEVEL, CAN LEAD TO PREMATURE BATTERY LIFE.
Specific tooling
020333Y Single battery charger
Battery installation
If available
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)
ELE SYS - 64
WARNING
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO
CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN.
AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quick-
ly as possible to run the subsequent activation
phases.
2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulfuric
acid.
3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
to break the seals. The electrolyte should start to
flow inside the battery.
Note: Do not tilt the container to prevent the flow
of electrolyte from pausing or stopping.
4) Control the flow of electrolyte
Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.
Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container
two or three times. Do not remove the container from the battery.
ELE SYS - 65
5) Take out the container.

Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte
remains in the container. Now, gently pull the container out from the battery, only do this when the
container is completely empty, and proceed immediately to the next point.
6) Battery closing.
Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure
that the strip is levelled with the top part of the battery.
Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Place the battery down for 1 to 2 hours prior to the charging from the battery.
7) Recharging the new battery

With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeop-
ardising its useful life on vehicle.
The dry charge battery MF like the completely loa-
ded YTX, must have a no-load voltage between
12.8 - 13.15 V Bring the battery to full charge, us-
ing the 020648Y battery charger:
a - select the type of battery with the red switch on
the left of the panel battery charger panel
b - select NEW on the yellow timer
c - connect the clamps of the battery charger to the
battery poles (black clamp to negative pole (-) and
red clamp to positive pole (+)).
ELE SYS - 66
d - Press the red button, as shown in figure.
e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-
ure.
f - Check the ignition of the green LED indicated

with a red arrow in figure.
g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED
has taken place
ELE SYS - 67
h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less
than 12.8 V, proceed with a new recharge of the
battery starting from point c of the recharge pro-
cedure of the new battery, otherwise go to point i
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,
disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
ELE SYS - 68
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle Typhoon 50 2T (MY2010)
Exhaust assy. Removal
- Position the vehicle on centre stand.

- Undo and remove the two screws that fix the ex-
haust manifold to the engine.
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERA-
TIONS, LET THE ENGINE AND THE SILENCER TO COOL
OFF AT AMBIENT TEMPERATURE TO AVOID POTENTIAL
BURNS.

Screws fixing silencer to cylinder head 16 to 18
- Remove the clamp on the SAS box pipe.
- Undo and remove the screws indicated.
- Remove the silencer.
CAUTION
UPON REFITTING, REPLACE THE GASKET BETWEEN
THE EXHAUST MANIFOLD AND THE SILENCER WITH A
NEW ONE.

Screws fixing silencer to the crankcase 24 to 27
Removal of the engine from the vehicle
• Rest the vehicle on its stand.

• Remove the side panels
• Slide off the tube from the spark plug.
• Disconnect the alternator connector.
• Release the starter motor cable, by
cutting the indicated clamp.
• Disconnect the power connector and
the ground cable from the starter mo-
tor.
ENG VE - 70
Typhoon 50 2T (MY2010) Engine from vehicle
• Remove the air duct pipe from the car-

burettor cover.
• Remove the carburettor cover.
• Remove the fuel pipes.
• Undo the screw and remove from the

carburettor the gas cable.
ENG VE - 71
Engine from vehicle Typhoon 50 2T (MY2010)
• Disconnect the automatic starter and

the heater connectors.
• Removing the lower mixer oil reservoir

pipe.
• Remove the mixer control cable.
ENG VE - 72
Typhoon 50 2T (MY2010) Engine from vehicle
• Undo the rear brake set screw and the

indicated screw and then free the en-
gine from the rear brake transmission.
CAUTION
SUPPORT THE VEHICLE ADEQUATELY.

• Undo the shock absorber lower screw.

• Remove the entire silencer assembly.

• Undo and remove the engine-rod ful-
crum nut.
• Operating on the chassis, lift the vehi-
cle rear part.
• Slide off the engine-rod fulcrum pin.
• Slide off the engine towards the back.

Engine-swinging arm pin 42.5
ENG VE - 73
INDEX OF TOPICS
ENGINE ENG
Typhoon 50 2T (MY2010) Engine
Automatic transmission
Transmission cover
- Loosen the 14 screws and remove the transmis-

sion cover with the aid of a mallet.
N.B.
THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT
FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY
AND THE BEARING HOUSED ON THE CRANKCASE.
- To refit tighten the screws to the prescribed tightening torque.

Transmission cover screws 11 ÷ 13
Kickstart
- Remove the screws shown in the figure and re-

move the engine starting lever.
- For the assembly, work in reverse and tighten the
screws to the prescribed torque..

Start-up lever screw 12-13
- Upon refitting, apply the recommended grease to

the bushing, to the spring and along the toothed
sector.
- Use the special tool for the charging of the spring,
as shown in the figure.
- Refit the seeger ring after checking that it is in
good condition.
Specific tooling
020261Y Starter spring fitting
ENG - 75
Engine Typhoon 50 2T (MY2010)
AGIP GREASE MU3 Grease for odometer

transmission gear case
Soap-based lithium grease with NLGI 3; ISO-L-
XBCHA3, DIN K3K-20
- Remove the seeger ring located on the exterior

of the crankshaft.
- Dismantle the dog gear from its seat, slackening
the tension that the toothed sector applies to it by
means of the spring; to do this, it is necessary to
rotate the toothed sector slightly (see the figure).
CAUTION
WHILE REMOVING THE TOOTHED SECTOR, BE VERY
CAREFUL OF THE SPRING TENSION: IT COULD CONSTI-
TUTE A HAZARD FOR THE OPERATOR.
Removing the driven pulley shaft bearing
- Slightly heat the crankshaft from the inside side

to avoid damaging the coated surface and use the
driven pulley shaft or a pin of the same diameter
to remove the bearing.
N.B.
IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-
AMETER EXTRACTOR CAN BE USED.
Refitting the driven pulley shaft bearing
-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.
N.B.
WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.
CAUTION
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED
SURFACE.
ENG - 76
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 DRIVING
PULLEY MOUNTED.
Specific tooling
Inspecting the clutch drum
- Check that the clutch housing is not worn or dam-

aged.
- Measure the inner diameter of the clutch housing.
Characteristic
clutch housing diameter/standard value
Ø 107+0.2 +0 mm
clutch housing diameter/max. value allowed
after use
Ø 107.5 mm
Eccentricity measured /max.
0.20 mm
Removing the clutch
- Equip the tool with long pins screwed into position

«A» from the outside, insert the entire driven pulley
in the tool and have the central screw make con-
tact.
CAUTION
THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW
IS TIGHTENED UP TOO FAR.
ENG - 77
- 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 tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
Inspecting the clutch
- Check the thickness of the clutch mass friction

material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
ENG - 78
- Remove the three guide pins and the mobile half

pulley.
Removing the driven half-pulley bearing
- Remove the roller bearing with the special ex-

tractor inserted from the bottom of the fixed half-
pulley.
CAUTION
POSITION THE HOLDING EDGE OF THE EXTRACTION PLI-
ERS BETWEEN THE END OF THE BEARING AND THE
BUILT IN SEAL RING.
Specific tooling
001467Y029 Bell for bearings, O.D. 38 mm
- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch
housing by means of the special tool.
N.B.
PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO
DEFORM THE SLIDING SURFACE OF THE DRIVE BELT
Specific tooling
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 external diameter of the pulley bush-
ing.
Characteristic
ENG - 79
Stationary driven half-pulley/Standard diame-

ter
Ø 33.965 to 33.985 mm
Stationary driven half-pulley / Minimum diam-
eter admitted after use
Ø 33.96 mm
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.
Characteristic
Mobile driven half-pulley/ Maximum diameter
allowed
Ø 34.08 mm
- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile
half-pulley.
- Fitting the half-pulley on the bushing.
AGIP GREASE SM 2 Grease for the C-ring of
the tone wheel
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This
operation must be done through one of the holes inside the bushing until grease comes out of the
opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.
AGIP GREASE SM 2 Grease for the C-ring of the tone wheel
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
ENG - 80
Refitting the driven half-pulley bearing
- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.
- Fit the new roller bearing with the wording visible
from the outside.
CAUTION
PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT
DAMAGE TO THE THREADED END WHILE THE BEARINGS
ARE BEING FITTED.
Specific tooling
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
Characteristic
Standard length
118 mm
Minimum length allowed after use
113 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 - 81
- Reassemble the nut securing the clutch and tight-

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

Nut locking clutch unit on pulley 55 to 60 Nm
Refitting the driven pulley
-Refit the driven pulley assembly, the clutch hous-

ing and the nut, using the specific tool.
Specific tooling

Clutch unit nut on driven pulley 40 ÷ 44
Drive-belt
- Make sure the drive belt is not damaged and does not show abnormal wear.
- Replace as indicated in the scheduled maintenance table.
Removing the driving pulley
- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer,
then remove the drive and the plastic fan.
- Remove the stationary half-pulley.
- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the
rollers and contrast plate fitted loosely on it do not come off.
Specific tooling
ENG - 82
Mixer gears and belt
- Remove the mixer oil pump.

- Remove gear and belt.
CAUTION
PAY PARTICULAR ATTENTION TO NOT TOUCHING OR
BENDING THE BELT BECAUSE THIS COULD BREAK SUD-
DENLY DURING OPERATION.
CAUTION
ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET
INTO THE INNER BUSHING OF THE MIXER CONTROL
GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON
THE CRANKCASE PIN.
N.B.
REPLACE THE BELT AS INDICATED IN THE SCHEDULED
MAINTENANCE TABLE.
See also
Lubrication
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.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHING.
Characteristic
Driving pulley / Maximum diameter:
ENG - 83
20.12 mm
Driving pulley/ Standard diameter:
20.021 mm
Driving pulley bushing/ Diameter maximum:
XXX mm
Driving pulley bushing/ Standard diameter:
20 -0.020/-0.041mm
Refitting the driving pulley
- Manually move the movable driven half-pulley

away by pulling it towards the clutch unit and insert
the belt observing the direction of rotation of the
first fitting.
N.B.
IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO
THAT THE WORDS CAN BE READ IN CASE IT DOES NOT
SHOW A FITTING SIDE.
- Refit the components of the assembly (roller

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 20
Nm and then perform a final 90° locking in order to
prevent the rotation of the driving pulley.
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
CAUTION
UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-
MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN
ORDER TO AVOID WRONG TIGHTENING AND CONSE-
QUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling

Drive pulley nut 18 - 20 Nm + 90° rotation
End gear
ENG - 84
Removing the hub cover
- Drain the rear hub oil

- Remove driven pulley
- Remove the rear brake shoes
- Remove the 5 screws fixing the cover to the
crankcase
- Remove the cover with the wheel axle and pull it
out
- Remove the intermediate gear with the appropri-
ate shim washers
Removing the wheel axle bearings
- Remove the oil seal and the seeger ring.

- Fix the hub cover properly to avoid damaging the
sealing surface with the housing
- Remove the wheel axle bearing using the specific
tool
Specific tooling
020363Y 20-mm guide
020477Y 37 mm adaptor
ENG - 85
Removing the driven pulley shaft bearing
- Remove the seeger ring

- Heat the engine crankcase but do not direct the
hot air towards the bearing
- Extract the driven pulley shaft together with the
bearing with a few mallet blows
- Remove the bearing off the driven pulley shaft

using the specific tool and a press
N.B.
USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALL-
ER INTERNAL DIAMETER
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
ENG - 86
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
seatings or in the pulley shaft capacities
Inspecting the hub cover
- Check that the fitting surface is not dented or dis-

torted.
- If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing
- Support the inner track of the bearing from the

outside of the hub cover with the specific tool posi-
tioned under the press and insert the driven pulley
axle.
- Refit the oil seal flush with the cover.
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
ENG - 87
• Heat the hub cover and insert the bearing with

the specific punch.
• Fit the snap ring with the concave or radial part
on the bearing side.
N.B.
FIT THE BALL BEARING WITH THE SHIELD FACING THE
OIL SEAL.
Specific tooling
020151Y Air heater
020439Y 17-mm guide
Refitting the wheel axle bearing
- Support the hub cover on a wooden surface

- Heat up the hub cover using the thermal gun.
- Preassemble the bearing on the specific punch
using grease and then insert the bearing in its
seating
- Refit the seeger ring and the oil seal using the 42
x 47 mm adaptor
N.B.
POSITION THE OIL SEAL WITH THE SEALING LIP FACING
THE HUB INTERNAL SIDE
Specific tooling
020150Y Air heater mounting
020151Y Air heater
020363Y 20-mm guide
ENG - 88
Refitting the hub bearings
- Remove the wheel axle on the cover and pay at-

tention not to damage the sealing lip of the oil seal
- Apply a thin layer of grease on the two shim
washers of the intermediate gear and fit one on the
cap so that it does not interfere with the wheel axle
gear when placing the transmission shaft
Refitting the ub cover
- Apply product recommended for surfaces on the

hub cap and refit cap on the crankcase
- Fit the 5 screws and tighten them to the specified
torque.
N.B.
CLEAN THE CONTACT SURFACES OF THE HUB COVER
AND THE HALF CRANKCASE OF RESIDUE FROM PREVI-
OUS GASKETS BEFORE APPLYING A NEW ONE.
Loctite 510 Liquid sealant
Gasket

Hub cover screws 24 - 27
Flywheel cover
Cooling hood
- Remove the four fixings shown in the figure.

- Remove the fan cover
ENG - 89
- Remove the oil piping retention band from the

hood
- Remove the 2 screws shown in the picture
Cooling fan
- Remove the cooling fan by acting on the three

fixings indicated in the figure.
Removing the stator
- Remove the three stator fixings shown in the

photo
- Remove the two pick-up fixings shown in the
photo
- Remove the stator with the wiring
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to
the specified torque.
N.B.
THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE
CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM-
BLY.
ENG - 90
Pick-up screws 3 to 4 Stator screws 3 to 4
Flywheel and starting
Removing the starter motor
• Remove the centre stand by unscrew-

ing the four clamping screws (two per
side) of the engine block
• Remove the two clamps shown in the
figure
Removing the flywheel magneto
- Lock the rotation of the flywheel using the calliper

spanner.
- Remove the nut.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
ENG - 91
- Extract the flywheel with the extractor.
Specific tooling
020162Y Flywheel extractor
Inspecting the flywheel components
- Check the condition of the flywheel and any dis-

tortions that might cause rubbing on the stator and
on the Pick-Up.
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key

properly.
- Lock the flywheel nut at the prescribed torque
- Check the Pick-Up air gap.
- The air gap may not be modified in the fitting of
the Pick-Up.
- Other values derive from deformations visible on
the Pick-Up support.
N.B.
A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO
A VARIATION IN THE IGNITION ADVANCE SUCH AS TO
CAUSE PINGING, KNOCKING ETC.

Flywheel nut 40 to 44 N.m
ENG - 92
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.

- Fit the starter motor on the crankcase and lock
the 2 screws to the prescribed torque.
N.B.
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.

Starter screws 11 to 13
Cylinder assy. and timing system
Removing the intake manifold
Use an anti-tampering TORX spanner to remove

the two clamping screws of the intake manifold
Removing the cylinder head
Remove the 4 screws shown in the figure
ENG - 93
Removing the cylinder - piston assy.
Remove the cylinder very carefully
Remove the snap rings and remove the pin

CAUTION
AFTER EACH REMOVAL OPERATION REPLACE THE PIN
RETENTION SNAP RINGS
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 DIAMETER ALLOWED,
SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE
THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE
AND CRANKSHAFT" CHAPTER".
Characteristic
Rod small end: standard diameter
17 +0.011-0.001
Rod small end: maximum allowable diameter
17.060 mm
ENG - 94
Inspecting the wrist pin
- Check the wrist pin external diameter using a mi-

crometer
Characteristic
Wrist pin: standard diameter
12 +0.005 +0.001 mm
Inspecting the piston
- Measure the bearings on the piston using a bore

meter
- Calculate the piston-pin coupling clearance.
Characteristic
Wrist pin housing: standard diameter
12 +0.007 +0.012
Wrist pin housing: standard clearance
0.002 ÷ 0.011 mm
- Measure the outer diameter of the piston, per-

pendicular to the pin axis.
- Take the measurement in the position shown in
the figure
To classify the cylinder-piston fitting, check the ap-
propriate table
See also
ENG - 95
Inspecting the cylinder
- Check that the cylinder does not show seizures.

Otherwise, replace it or adjust it respecting the al-
lowable increases
- Measure the internal diameter of the cylinder with
a bore meter, according to the directions given in
the figure
- Check that the fitting surface with the head is not
dented or distorted.
To classify the cylinder-piston fitting, check the ap-
propriate table
See also
Inspecting the piston rings
- Alternatively insert the two sealing rings in the

cylinder
Using the piston, insert the seals perpendicularly
to the cylinder axis.
- Measure the opening of the sealing rings using a
feeler gauge as shown in the photograph
- If the values are higher than the values prescri-
bed in the chart, substitute the rings
See also
Piston rings
Removing the piston
- Place the circlip in the component 1 with the opening straddling the arrow printed on the tool.
- Push component 2 into component 1 until at stop and extract component 2.
- Insert component 3 into component 1, position the unit in the circlip fitting area and push fully home
the component 3.
N.B.
REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM
THE REMOVAL OPERATIONS
Specific tooling
020166Y Pin lock fitting tool
Locking head nuts: 10 to 11 N·m
ENG - 96
- Use new wrist pin snap rings.

- Use new cylinder base gasket.
- Before refitting carefully clean all the surfaces.
- Use oil to be mixed during the fitting of the piston
and the cylinder.
CAUTION
POSITION THE ARROW PRINTED ON THE PISTON
CROWN TOWARDS THE EXHAUST OPENING.
THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON
THE PISTON WITH THE SPECIFIC TOOL
AGIP CITY TEC 2T Oil
Recommended oil
ENG - 97
Inspecting the timing system components

CAUTION
CHECK THE CORRECT REED UNIT SEAL; NO LIGHT
MUST PASS BETWEEN THE SUPPORT AND LAMELLA.
Crankcase - crankshaft
Splitting the crankcase halves
Remove the eight crankcase union fasteners.
Install the special strip on the half crankcase on

the flywheel side and separate the half crankcase
on the flywheel side from the transmission side
Specific tooling
ENG - 98
Removing the crankshaft
- Install the specific tool on the half crankcase on

the transmission side using four M6 screws of an
adequate length.
- Remove the crankshaft from the transmission
side half crankcase
Specific tooling
Removing the crankshaft bearings
The bearings can stay on either the half crankcase

or the crankshaft indifferently
- Using the special tool, remove any bearings that
have been left on the crankshaft
N.B.
The half rings must be inserted on the bearings with a few mal-
let blows.
Specific tooling
004499Y001 Bearing extractor bell
004499Y006 Bearing extractor ring
004499Y002 Bearing extractor screw
004499Y007 Half rings
- Using the specific tool remove any bearings left
on the half crankcase
Specific tooling
001467Y006 Pliers to extract 20 mm bearings
ENG - 99
Refitting the crankshaft bearings
Heat the bearings in an oil bath at around 150°C

and fit them on the crankshaft, if necessary using
a section of tube that acts on the bearing's inner
track
Specific tooling
020265Y Bearing fitting base
Inspecting the crankshaft alignment
With the specific tool shown check that the eccen-

tricity of the surfaces of diam. «A»-«B»-« C» are
within 0.03 mm. (reading limit on the dial gauge);
in addition, check the eccentricity of diam. «D», for
which a maximum reading of 0.02 mm is permitted.
In the case where eccentricity is not much above
prescribed levels, straighten the shaft by acting
on the counterweights with a shim or tighten them
in a clamp (with an aluminium bushing) as re-
quired..
Specific tooling
020074Y Support base for checking crankshaft
alignment
Refitting the crankshaft
- Position the transmission side half crankcase on

two wooden supports
- Using a thermal gun, heat the bearing seat to
about 120°
ENG - 100
- Firmly insert the crankshaft until the bearing rea-

ches the end-of-stroke stop
- Let the temperature of the half crankcase settle

at the temperature of the crankshaft.
- Again install the special crankcase separation
plate NOT installing the crankshaft protection
- During the assembly phase keep the central
thrust screw loose.
- Take the four clamping screws to the end of the
stroke and loosen them again with the same angle
(e.g. 90°)
- When the temperature has settled, preload the
thrust screw of the tool manually until the ball bear-
ing clearance is cancelled out.
Specific tooling
Refitting the crankcase halves
- Prepare the coupling surface with LOCTITE 510

applying a thin layer of it after degreasing the sur-
face using a suitable solvent (e.g. trichloroethy-
lene)
- Heat the flywheel-side half crankcase with a ther-
mal gun.
Loctite 510 Liquid sealant
Gasket
ENG - 101
- Keeping the half crankcase on the transmission

side, insert the flywheel side half crankcase with a
clean precise movement
- Insert at least three clamping screws and tighten
up rapidly
- Insert the other 5 screws and tighten them to the
specified torque.

crankcase coupling screws 11 - 13
- Move the crankcase separation plate in a position
back from the one indicated in the figure
- Install the special magnetic support with dial
gauge at the end of the crankshaft
- Check the axial clearance of the crankshaft
If this is not within the maximum limit allowed, re-
peat the crankcase coupling procedure
Specific tooling
Characteristic
Axial clearance with warm crankcase
0.10 ÷ 0.12 mm
Axial clearance with cold crankcase
0.06 to 0.08 mm
Limit value with cold crankcase
0.02 ÷ 0.03 mm
Lubrication
Crankshaft oil seals
ENG - 102
Refitting
- Install a new flywheel-side oil seal only with the

special tool's punch
The flywheel-side oil seal is recognised by its
smaller diameter
N.B.
THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE
WITH THE FITTED WRENCH
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
- Install a new transmission side oil seal using the
special tool with adapter ring.
The transmission-side oil seal is recognised by the
larger diameter
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
Oil pump
Removal
- Remove the 2 screws shown in the figure
ENG - 103
Remove the tube passage seal from the crank-

case shown in the figure
Refitting
To refit, perform the steps in the reverse direction

to disassembly
Remember to drain after refitting using the screw
shown in the figure

Mixer clamping screws 3 - 4 Nm
See also
transmissions
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.
- By means of the MITYVAC pump apply 0.1 bar
of suction to the tap.
- Make sure that the suction is kept stable and that
and that there are no fuel leaks.
- Reconnect the vacuum pipe to the manifold.
- 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.
ENG - 104
N.B.
THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-
RECT NUMBER OF REVS OR BY THE WRONG POSITION
OF 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 INTENTIONALLY
REDUCED FOR THE PURPOSE OF ENHANCING THE SUC-
TION PULSATION AND THEREBY GUARANTEE A CON-
STANT TAP FLOW RATE.
Specific tooling
Characteristic
Minimum flow rate
20 cc
- 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 TO
FACILITATE CLEANING.
Removing the carburettor
- Follow the instructions mentioned in "Removing the engine from the vehicle".
See also
Removal of the engine from the
vehicle
ENG - 105
CARBURETTOR CHECK Disassemble the car-

burettor 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.
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE
GASKETS TO AVOID PETROL LEAKS
Key
2. Idle air set screw
3. Idle speed set screw
4. Throttle valve spring
5. Throttle valve tapered pin
6. Throttle valve
7. Carburettor body
8. Pin
9. Min. jet
10. Float
11. Max. jet
12. Float chamber
ENG - 106
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions Typhoon 50 2T (MY2010)
Front
Removing the front wheel
- Loosen the wheel axle lock nut, by keeping the

wheel axle blocked on the opposite side.
- Loosen the two wheel axle safety screws on the

fork leg, on the odometer gear side.
- Pull out the wheel axle.
SUSP - 108
Typhoon 50 2T (MY2010) Suspensions
- Remove the front wheel.

- Slide off the odometer gear from the wheel hub.
CAUTION
DO NOT ACT ON THE FRONT BRAKE LEVER ONCE THE
FRONT WHEEL IS REMOVED. BY DOING SO, THE CAL-
LIPER PISTONS COULD COME OUT FROM THEIR HOUS-
ING AND ALSO THE BRAKE FLUID MIGHT SPILL OUT.
Front wheel hub overhaul
Check that the wheel bearings do not show signs

of wear.
If you have to replace the wheel bearings, proceed
as follows:
- Remove the bearing on the odometer drive side
using the pliers 14 and the bell detail 9.
Specific tooling
001467Y013 Calliper to extract ø 15-mm bear-
ings
SUSP - 109
- Remove the internal spacer.
- Support the front wheel with two wooden shims

that make it possible to avoid scratching in the
case of contact with the rim.
- Insert the punch (consisting of adaptor handle,
24 mm adaptor and 15 mm guide) from the odom-
eter drive side to permit the removal of the brake
disc side bearing and the spacer bushing.
Specific tooling
020412Y 15-mm guide
SUSP - 110
- Heat the bearing seat on the side the brake disc

with the heat gun.
- Grease one side of the new bearing to make it

stay together with the adaptor.
- Insert the bearing using the punch consisting of

adaptor handle, 42x47 mm adaptor and 15 mm
guide, and drive it up to the stop.
- Reinsert the spacer bushing on the brake disc

side using the appropriate tool and take it to the
stop.
Specific tooling
020412Y 15-mm guide
020201Y Spacer bushing driving tube
SUSP - 111
- Turn the wheel upside-down and insert the inner

spacer.
- Heat the bearing seat on the odometer drive side with the heat gun.
- Grease one side of the new bearing to make it

stay together with the adaptor.
- Insert the new bearing on the odometer drive side

by using a punch consisting of adaptor handle,
32x35 adaptor and 15 mm guide and drive it fully
home.
Specific tooling
020412Y 15-mm guide
SUSP - 112
WHEEL RIM INSPECTION

- Make sure that the rim is not deformed or
cracked. Replace it if necessary.
- Check wheel eccentricity. If tolerance limits are
exceeded, check the wheel rim and the bearings.
If necessary, replace the wheel.
Characteristic
Eccentricity limits:
Vertical: 2 mm
Horizontal: 2 mm
- Check the wheel balance.

- Check wheel on the wheel balancer and turn it several times, paying attention to its position when it
stops. If the wheel is steadily balanced, it will not always stop at the same point. If it always stops at the
same point, the wheel is not balanced and must be balanced. Place weights on the lightest part of the
wheel so that it does not stop any more at a particular point after being turned several times.
SUSP - 113
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 op-
posite side to the specified torque.
SUSP - 114
- Make the fork travel to adjust the fork legs on the

wheel axle.
- Lock the two safety screws located on the fork
leg to the specified torque, according to the se-
quence 1-2-1.

Front wheel axle nut 45 - 50 Safety screw on fork
leg 6 - 7
Handlebar
Removal
- Remove the front and rear handlebar cover.

- 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 also
Front handlebar cover
Rear handlebar cover
Front
brake 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 prescribed torque.

Handlebar fixing screw (*) 45 to 50
SUSP - 115
(*) Lubricate the nut with engine oil before instal-

lation
Front fork
Removal
REMOVING THE STANCHIONS

- Remove the legshield.
- Remove the brake calliper.
- 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 - 116
- Undo screw «3», remove the stanchion and the

piston.
See also
Legshield
Removal
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 stanchion and the piston and tighten

screw «3» with its washer «2» to the specified tor-
que.
- Pour the recommended quantity of specific oil in-
to the stanchion unit.
- Insert the spring and the components.
- Tighten the upper cap «6» to the specified torque.
- Introduce the stanchion in the bottom yoke and
install the circlip «7».
SUSP - 117
- Push on the upper cap «6» until the circlip touch-

es the bottom yoke.
- Tighten the screws «8» to the prescribed torque.
Characteristic
Fork stem (oil level height without spring, com-
pressed fork)
85 mm

Fork clamp screw 20 to 25 Fork stanchion upper
cap 15 ÷ 30 Piston tightening fork lower screw
25 - 35
Steering column
Removal
SUSP - 118

- Set a support under the vehicle in such a way that
the wheel is able to move freely and the vehicle
does not fall.
- Remove the handlebar.
- 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 tooling

Upper steering ring nut 30 to 36
- 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».

Lower steering ring nut 10 - 13 **
When the specified torque of the lower ring nut is reached, loosen by 90°.
See also
Removal
Legshield
Removal
- 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.
SUSP - 119
- Appropriately lubricate the bearings with recommended products.
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 tooling
from headstock
- Using the special tool, refit the upper «A» and

lower «B» bearing seats on the headstock.
Specific tooling
001330Y 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 tooling
from headstock
SUSP - 120
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 tooling
006029Y Punch for fitting fifth steering bearing
on steering tube
Steering bearing
CHECKING THE BEARINGS CLEARANCE

To check the steering, it is necessary to:
- 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.
CAUTION
DO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT
«3» BECAUSE THE STEERING BEARINGS COULD GET
DAMAGED.
- Check clearance as described above. Make sure the front fork can move all long its stroke, from left
to right or vice versa, rotating freely and smoothly.
SUSP - 121
- 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.
Specific tooling

Lower steering ring nut 10 - 13 ** Upper steering ring nut 30 to 36
When the specified torque of the lower ring nut is reached, loosen by 90°.
See also
Legshield
Rear
Removing the rear wheel

- Remove the silencer.
- Use a screwdriver to remove the plastic cap.
- Remove the cotter pin.

- Remove the cap.
SUSP - 122
See also
Exhaust assy. Removal
- Pull the rear brake and keep it pulled with a

clamp.
- Unscrew the wheel fixing nut and collect the
washer.
- Take out the wheel from its housing.
- To refit, carry out the removal operations but in reverse order, be careful to use a new cotter pin.

Rear wheel axle 115
Swing-arm
Removal
The worn or damaged bushings on the rubber insulator may cause an annoying vibration and an unsafe
manoeuvrability. To check if the bushings are in good conditions, it is necessary to remove the engine
support axle.
- Remove the complete engine.
Place a support of suitable height under the chassis central part.
CAUTION
MAKE SURE THE MOTORCYCLE IS STABLE AND FIRM.
SUSP - 123
- Remove nut (1) and take out pin (2) fixing the chassis to the rod on the opposite side.
- Remove the entire rod (3).
- Check if silent-block (4) and buffer (5) are in good conditions, and replace them if damaged.

Chassis-side swinging arm retaining nut 52.5 Nm
Overhaul
Periodically check the pin, fulcrum, engine and

bearings clearance.
To carry out these operations, proceed as follows:
- Hold the wheel firmly and try to move it perpen-
dicularly to the stroke direction.
- If there is any clearance, check all the retainers
that connect the support.
Shock absorbers
SUSP - 124
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-ab-

sorber to engine lower fixing screw.
- Remove the shock absorber.
- To refit tighten the screws to the prescribed tight-
ening torque.

See also
Side fairings
Centre-stand
- Undo the screws highlighted in the figure on both

sides of the engine.
- When refitting, secure to the prescribed torque.
N.B.
WHEN REFITTING, GREASE THE SPRING ENDS AND THE
PIN.

Stand screws 18.5 to 19 Nm
SUSP - 125
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Typhoon 50 2T (MY2010) Braking system
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 cop-
per gaskets.
- Place the tube joint in the original position and
tighten it to the specified torque.
- Bleed the air from the system.

Brake fluid pipe-calliper fitting 20 to 25 Calliper
to fork tightening screw 20 to 25 Oil bleed
screw 8 to 12
See also
Front
Front brake disc
BRAK SYS - 127

Braking system Typhoon 50 2T (MY2010)
Removal
Proceed as follows:
- remove the front wheel.
- Undo the five screws fixing the disc.
- Remove the brake disc.
Refitting
When refitting, position the disc correctly, following

the direction indicated on the same disc.

Disc tightening screw 8 to 12
Disc Inspection
- Check the disc thickness.
Characteristic
Disc minimum thickness:
3.5 mm
BRAK SYS - 128

• 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 0.1 mm.
• If a value other than that prescribed is
detected, remove the front wheel and
check how much the disc protrudes.
Maximum permissible out of true is 0.1
mm. If the value measured is greater,
fit a new disc and repeat the check.
• If the problem persists, check and re-
place the wheel rim if necessary.
Specific tooling
See also
Front brake pads
Removal
- Remove the brake calliper.

- Undo and remove the two screws indicated.
- Remove the pads.

- Remove the inner spring.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE LEVER OR THE CALLIPER PLUNGERS COULD
GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID
LEAKAGE.
BRAK SYS - 129

See also
Front
brake calliper
- Check the thickness of the friction material. If

thinner than the minimum value, replace it.
Characteristic
Minimum friction material thickness
1.5 mm
- In case of uneven wear, replace the brake pads

when the friction material thickness difference is
0.5 mm.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY
ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
BRAK SYS - 130

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.

Brake pad fastening screw 15 to 20
Fill
Front
N.B.
IF THERE IS AIR IN THE HYDRAULIC SYSTEM, THE WATER WILL ABSORB MOST OF THE
POWER OF THE BRAKE MAIN CYLINDER AND THEREFORE, IT WILL REDUCE THE CALLIPER
PERFORMANCE 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 NECESSARY
TO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REG-
ULAR MAINTENANCE OPERATIONS.
- 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.
-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:
BRAK SYS - 131

IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAUL-

TY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS
SEALS ON THE PUMP AND CALLIPER PISTONS.
CAUTION
- DURING THE OPERATIONS, THE VEHICLE MUST BE ON
THE STAND AND LEVEL.
N.B.
DURING PURGING FREQUENTLY CHECK THE LEVEL TO
PREVENT AIR GETTING INTO THE SYSTEM THROUGH
THE 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 BE
REDUCED.
THEREFORE, ALWAYS USE FLUID FROM SEALED CON-
TAINERS.
UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS
YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS.
IF THE BRAKES ARE USED INTENSELY AND/OR IN
HARSH CONDITIONS, CHANGE THE FLUID MORE FRE-
QUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID
MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS
SEAT ON THE CALLIPER.
CAREFULLY DRY THE CALLIPER AND DEGREASE THE
DISC SHOULD THERE BE OIL ON IT.
Specific tooling
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid

Oil bleed screw 8 to 12
Front brake pump
- Remove the front and rear handlebar cover.

- Disconnect the tube, collecting the brake oil in a
container.
BRAK SYS - 132

- 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.

Brake fluid hose-pump fitting 20 to 25 Pump U
bolt screw 8
See also
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.
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 also
Removing the rear wheel
BRAK SYS - 133

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.
See also
Legshield
Footrest
- 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 activation point.

BRAK SYS - 134

BRAK SYS - 135

INDEX OF TOPICS
CHASSIS CHAS
Typhoon 50 2T (MY2010) Chassis
Seat
- Undo the four nuts indicated in the figure and

collect the washers.

Saddle plate fixing nut 10
Driving mirrors
- Lift the rubber cover.

- Loosen the indicated nut, keeping the lower
spacer blocked.
- Undo the mirror from the lower spacer.
- Remove the lower spacer, if necessary.
N.B.
THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCK-
WISE.

Mirror fastening spacer 25

- Undo the four screws indicated.
CHAS - 137
Chassis Typhoon 50 2T (MY2010)
- Disconnect the connectors of the instrument pan-

el and the odometer cable.
- Remove the handlebar cover together with the
instrument panel and controls.
See also
Instrument panel
- Remove the rear handlebar cover.

See also
CHAS - 138
- Remove the rear-view mirrors and the lower

spacers.
- Undo the front screw.

- Lift the upper edge to release and separate it from
the rear handlebar cover.
- Disconnect the turn indicators connections and
remove the front handlebar cover.
See also
Driving
mirrors
CHAS - 139
Headlight assy.

FRONT TURN INDICATORS

- Undo the three screws indicated.
See also
Legshield
Legshield
- Remove the leg shield back plate.

- Working from the front wheel housing internal
side, undo the two screws from both sides of the
vehicle.
CHAS - 140
- Undo the indicated screw, beneath the leg shield

lug.
- Move the leg shield forward, opening the lower

ends and detach the headlight bulb connections.
Knee-guard

- Undo the five side screws on the sides of the leg
shield back plate as shown.
CHAS - 141
- Undo the screw in the glove-box and the one un-

der 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 THE
GLOVE-BOX OPENING LEVER TO THE KEY-OPERATED
DEVICE.
See also
Front wheel housing

- Remove the front mudguard
- Undo the upper screw.

- Slide the housing off the fork stanchions.
See also
Legshield
Front mudguard
CHAS - 142
Footrest
- Remove the leg shield back plate.

- Remove the rear central cover.
- Undo the indicated screws and remove the pro-
tections.
- Remove the two rear screws.
See also
Knee-guard
Side fairings
CHAS - 143
Side fairings
- Remove the rear grab handle.

- Remove the rear central cover.
- Undo side screw from both sides of the vehicle.
- Undo the two screws on the helmet compartment.
- Undo the two upper screws.
CHAS - 144
- 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 also
Handles and top side fairings
Rear central cover
CHAS - 145
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.

- Remove the license plate support together with
the turn indicators.
See also
Side fairings
CHAS - 146
Rear mudguard
- Undo the rear screw.
- Undo the right-hand side screw.
Helmet bay
- Slide off the fuse box and free the helmet com-
partment from the cables.
- Remove the side fairings

- Remove the battery cover and the battery.
- Undo the two screws inside the helmet compart-
ment.
See also
Side fairings
CHAS - 147
Battery
spoiler
- Remove the footrest.

- Undo from both sides of the vehicle the screw

placed under the footrest.
See also
Footrest
Fuel tank
Remove the side fairings and the helmet compart-

ment.
- Detach the pipes from the vacuum-operated
cock.
CHAS - 148
- Undo the indicated screw on both sides of the

vehicle.
- Undo the central screw and loosen the two side

screws on the license plate support frame.
- Disconnect the fuel probe connector and detach

the breather pipe from the filler.

Fuel tank to chassis fixing screws 10
See also
Side fairings
Helmet bay
CHAS - 149
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.
See also
Seat
Front mudguard
- Operating from both sides of the vehicle, undo

the three indicated screws.
CHAS - 150
Mixture oil tank

- Remove the helmet compartment.
- Unscrew the mix oil reservoirs.
- Undo the two screws (1).
- Disconnect the mix oil level connector.
- Undo the lower screw (2) of the front tank.
- Undo the upper screw (3) of the front tank.

- Free the reservoirs from the pipes.
CHAS - 151
Handles and top side fairings
- Remove the three screws indicated in the figure

and collect the washers.
- Remove the rear handles.

Rear grab handle fixing screw 20.5
Battery
- Undo the three indicated screws and remove the

battery cover.
- Disconnect the negative and positive cables.

- Slide off the breather pipe.
CHAS - 152
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery Typhoon 50 2T (MY2010)
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 and temperature indicator
- Instrument panel warning lights
- Horn
- Starter
PRE DE - 154
Typhoon 50 2T (MY2010) Pre-delivery
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT 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 TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE 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 CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
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
PRE DE - 155
Pre-delivery Typhoon 50 2T (MY2010)
Static test
Static control after the test ride:

- Starting when warm
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
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 DE - 156
INDEX OF TOPICS
TIME TIME
Time Typhoon 50 2T (MY2010)
This section is dedicated to the time necessary to

carry out repairs.
The description and code for each operation is in-
dicated.
Engine
ENGINE
Code Action Duration
1 001001 Engine to chassis - Replacement
TIME - 158
Typhoon 50 2T (MY2010) Time
Crankcase
CRANKCASE
1 001133 Engine crankcase - Replacement
TIME - 159
Crankshaft
CRANKSHAFT
1 001117 Crankshaft - Replacement
2 001118 Main bearings - Replacement
3 001099 Flywheel-side oil seal - Replacement
4 001100 Clutch-side oil seal - Replacement
TIME - 160
Cylinder assy.
CYLINDER / PISTON
1 001002 Cylinder / Piston - Replacement
2 001107 Cylinder / piston - Inspection / clean-
ing
TIME - 161
Cylinder head assy.
HEAD ASSEMBLY
1 001013 Intake manifold - change
2 001093 Spark plug - Replacement
3 001126 Head - Replacement
4 001097 Cooling hood - Replacement
5 001178 Disc pack - Replacement
6 001087 Flywheel cover - Replacement
TIME - 162
Driven pulley
DRIVEN PULLEY
1 001110 Driven pulley- Replacement
2 001022 Clutch - Replacement
3 001155 clutch housing - Replacement
4 001012 Driven pulley - overhaul
TIME - 163
Oil pump
OIL MIX PUMP

1 001018 Mixer - Replacement
2 001019 Mixer belt - replacement
3 001028 Mix movement gear socket - Re-
placement
TIME - 164
Final gear assy.
FINAL REDUCTION GEAR

1 001010 Geared reduction unit - Service
2 001156 Gear reduction unit cover - Replace-
ment
3 003065 Gear box oil - Replacement
4 004125 Rear wheel axle - Replacement
TIME - 165
Driving pulley
DRIVING PULLEY
1 001011 Drive belt - Replacement
2 001066 rear-view pulley - Replacement
3 001017 Start-up pinion - Replacement
4 001086 Driving half-pulley - Replacement
5 001177 CVT rollers / sliders - Replacement
TIME - 166
Transmission cover
TRANSMISSION COVER
1 001096 Transmission crankcase cover - Re-
placement
2 001131 Transmission air intake - Replace-
ment
3 001135 Transmission cover bearing - Re-
placement
4 004179 Stand bumper - Replacement
TIME - 167
Starter motor
STARTER MOTOR AND KICK STARTER

1 001020 Starter motor - Replacement
2 001021 Kick starter - Inspection
3 001084 Starter lever - Replacement
4 008008 Starter spring pack - Replacement
5 005045 Starter motor cable assembly - Re-
placement
TIME - 168
Flywheel magneto
MAGNETO FLYWHEEL
1 001058 Flywheel - Replacement
2 001067 Stator - Replacement
3 001173 Rotor - Replacement
4 001109 Cooling fan - Replacement
TIME - 169
Brake shoes
BRAKE SHOES
1 002002 Rear brake shoe(s) - Replacement
TIME - 170
Carburettor
CARBURETTOR INSPECTION
1 001081 Automatic choke - Replacement
2 001008 Carburettor - Inspection
TIME - 171
CARBURETTOR
1 001063 Carburettor - Replacement
2 003058 Carburettor - Adjustment
3 004177 Heating hood - Replacement
Exhaust pipe
SILENCER
1 001009 Silencer - Replacement
2 001095 Silencer heatshield - Replacement
3 001136 Exhaust emissions - Adjustment
TIME - 172
Air cleaner
AIR FILTER
1 001014 Air filter - Replacement / cleaning
2 001015 Air filter box - Replacement
3 004122 Air cleaner carburettor fitting - Re-
placement
TIME - 173
Frame
CHASSIS
1 001053 Stand pin - Replacement
2 004004 Stand - Replacement
3 004001 Chassis - Replacement
4 004015 Footrest - Replacement
5 004171 Stand support plate - Replacement
6 004143 Footrest support - Replacement
TIME - 174
Legshield spoiler
LEGSHIELD
1 004064 Legshield - Replacement
2 004065 Leg shield rear section - Replace-
ment
3 004178 Footrest - Replacement
4 004053 Spoiler - Replacement
TIME - 175
Side fairings
REAR COVERS
1 004011 Central chassis cover - Replacement
2 004085 Fairing (1) - Replacement
3 004012 Rear side panels (2) - Replacement
4 004096 Lock series - Replacement
TIME - 176
Underseat compartment
HELMET COMPARTMENT
1 004016 Helmet compartment - Replacement
2 005046 Battery cover - change
TIME - 177
Plate holder
LICENSE PLATE HOLDER

1 004136 License plate holder mounting - Re-
placement
2 004056 Upper rear light cover - Replacement
3 005048 number plate holder - Replacement
TIME - 178
Mudguard
REAR MUDGUARD
1 004009 Rear mudguard - Replacement
Fuel tank
TIME - 179
FUEL TANK
1 004005 Fuel tank - Replacement
2 005010 Tank float - Replacement
3 004072 Fuel filter - Replacement
4 004139 Fuel no return valve - Replacement
5 004112 Cock / carburettor hose - Replace-
ment
6 004109 Fuel tank breather - change
Tank oil
OIL TANK
1 004017 Oil reservoir - Replacement
2 005018 Oil reservoir float - Replacement
3 004095 Oil reservoir cock - Replacement
4 004091 Oil reservoir hose - Replacement
TIME - 180
Rear shock-absorber
REAR SHOCK ABSORBER

1 003007 Rear shock absorbers - Replace-
ment
TIME - 181
Steering column bearings
STEERING BEARING
1 003002 Steering bearing - Replacement
2 003073 Steering clearance - Adjustment
3 004119 Steering Bearing / upper steering
bearing - Replacement
TIME - 182
Handlebar components
HANDLEBAR COMPONENTS
1 002071 Left hand grip - Replacement
2 002037 Brake or clutch lever - Replacement
3 005017 Stop switch - Replacement
TIME - 183
HANDLEBAR COMPONENTS
1 004066 Driving mirror - Replacement
2 003001 Handlebar - Replacement
3 005017 Stop switch - Replacement
4 002037 Brake or clutch lever - Replacement
5 002059 Right hand grip - Replacement
TIME - 184
Seat
SADDLE
1 004003 Saddle - Replacement
TIME - 185
Instrument panel
INSTRUMENT PANEL AND HANDLEBAR COVER

1 005014 Odometer - Replacement
2 004018 Handlebar front section - Replace-
ment
3 004019 Handlebar rear section - Replace-
ment
4 005078 Odometer glass - Replacement
5 005076 Clock / Cell - Replacement
TIME - 186
Turn signal lights
FRONT HEADLAMP
1 005067 Front turn indicator bulb - Replace-
ment
2 005008 Headlight bulbs - Replacement
3 005002 Front headlamp - Replacement
4 005091 Turn indicator glass - Replacement
5 005012 Front turn indicator - Replacement
TIME - 187
REAR LIGHTS
1 005022 Rear turning indicators - Replace-
ment
2 005068 Rear turning indicator bulb - Re-
placement
3 005091 Turn indicator glass - Replacement
4 005028 Rear light assembly glass - Replace-
ment
5 005066 Rear light bulbs - Replacement
6 005005 Taillight - change
TIME - 188
Front wheel
FRONT WHEEL
1 002041 Front brake disc - Replacement
2 003040 Front wheel bearings - Replacement
3 003037 Front wheel rim - Replacement
4 003047 Front tyre - Replacement
5 004123 Front wheel - Replacement
6 003038 Front wheel axle - Replacement
7 002011 Odometer movement sensor - Re-
placement
Tone wheel or drive greasing

Please take note that the code has been intro-
duced:
900001 - Tone wheel / drive greasing - 15'.
Never mistake the codes 002011 (movement sen-
sor replacement) and 005089 (tone wheel replace-
ment) in the event of noise of the indicated
components. The grease recommended is TUTE-
LA MRM 2 (soap-based lithium grease with Mo-
lybdenum disulphide).
In the following points, the area to be greased is
indicated with an arrow (1 - Drive, 2 - Tone wheel)
TIME - 189
Rear wheel
REAR WHEEL
1 001071 Rear wheel rim - Replacement
2 001016 Rear wheel - Replacement
3 004126 Rear wheel tyre - Replacement
TIME - 190
Electric devices
BATTERY
1 005007 Battery - change
2 005024 Battery fuse - Replacement
3 005025 Fuse holder - Replacement
4 005011 Starter relay - Replacement
TIME - 191
ELECTRICAL SYSTEM
1 001023 Control unit - Replacement
2 001094 Spark plug cap - Replacement
3 005001 Electrical system - Replacement
4 005009 Voltage regulator - Replacement
TIME - 192
Electronic controls
ELECTRIC CONTROLS
1 005041 Starter button - Replacement
2 005040 Horn button - Replacement
3 005016 Key switch - Replacement
4 004096 Lock series - Replacement
5 004010 Anti-theft lock - Replacement
6 005003 Horn - Replacement
7 005006 Light or turning indicator switch - Re-
placement
8 005039 Lights switch - Replacement
9 005077 Emergency stop switch - Replace-
ment
TIME - 193
Transmissions
SPLITTER
1 002012 Splitter - Replacement
2 002058 Mix / splitter transmission complete -
Replacement
3 002057 Carburettor / splitter transmission
complete - Replacement
4 002054 Throttle or splitter transmission com-
plete - Replacement
TIME - 194
REAR BRAKE TRANSMISSION AND ODOMETER

1 002051 Odometer transmission assembly -
Replacement
2 002053 Rear brake transmission complete -
Replacement
TIME - 195
Front suspension
FORK
1 003010 Front suspension - Service
2 003051 Complete fork - Replacement
3 003048 Fork oil seal - Replacement
4 003041 Fork stanchion - Replacement
TIME - 196
Braking system
FRONT BRAKE
1 002103 Brake fluid reservoir - Replacement
2 002052 Front brake transmission - Replace-
ment
3 002025 Brake piping - Replacement
4 002021 Front brake piping - Replacement
5 002039 Front brake calliper - Replacement
6 002024 Front brake pump - Replacement
TIME - 197
A
Air filter: 31
B
Battery: 42, 52, 62, 64, 148, 152
Brake: 115, 127, 129, 130, 132, 133, 170
Bulbs:
C
Carburettor: 11, 27, 32–34, 105, 171
Checks: 57
E
Electric: 191
Engine stop:
F
Fuel: 40, 104, 148, 179
Fuses: 61
H
Headlight: 35, 140
Hub oil: 29
I
Identification: 8
Instrument panel: 138, 186
M
Maintenance: 7, 27
Mirrors: 137, 139
O
Odometer:
R
Recommended products:
S
Saddle:
Shock absorbers: 124
Spark plug: 28
Suspension: 43, 196
T
Tank: 148, 151, 179, 180
Transmission: 9, 41, 75, 167
Turn indicators: 56
Tyres: 10
V
Vehicle: 8, 70, 105

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MANUALE STAZIONE DI SERVIZIO

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

Chassis prefix LBMC501

Dimensions and mass

WEIGHTS AND DIMENSIONS

Frame and suspensions

CHASSIS AND SUSPENSION

Wheels and tyres

WHEELS AND TYRES

FUEL TANK UNIT

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDER

Crankcase - crankshaft - connecting rod

CRANKSHAFT - CONNECTING ROD AXIAL CLEARANCE

Slot packing system

- Fit the cylinder without installing the basic gasket.

RECOMMENDED PRODUCTS TABLE

001467Y009 Driver for OD 42-mm bearings

001467Y013 Calliper to extract ø 15-mm bearings

001467Y017 Bell for bearings, OD 39 mm

001467Y021 Extraction pliers for ø 11 mm bearings

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

Stores code Description

004499Y001 Bearing extractor bell

004499Y002 Bearing extractor screw

004499Y006 Bearing extractor ring

004499Y007 Half rings

005095Y Engine support

006029Y Punch for fitting fifth steering bearing on

Stores code Description

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crankshaft

020150Y Air heater mounting

020151Y Air heater

020162Y Flywheel extractor

Stores code Description

020164Y Driven pulley assembly sheath

020165Y Start-up sprocket lock

020166Y Pin lock fitting tool

020171Y Punch for Ø 17 mm roller bearing

020201Y Spacer bushing driving tube

Stores code Description

020325Y Pliers for brake-shoe springs

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

Stores code Description

020334Y Multiple battery charger

020335Y Magnetic mounting for dial gauge

020340Y Flywheel and transmission oil seals fitting

Stores code Description

020357Y 32x35-mm Adaptor

020360Y Adaptor 52x54 mm

020364Y 25-mm guide

Stores code Description

020376Y Adaptor handle

020412Y 15-mm guide

020439Y 17-mm guide