2006-2009 Piaggio Typhoon 50 Service & Repair Manual

SERVICE STATION MANUAL 633665 - . . . - 633672 Typhoon 50

SERVICE STATION MANUAL Typhoon 50 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 2008 - 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. - After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL Typhoon 50 This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, completely satisfactory work cannot be carried out without the necessary equipment and tools. It is therefore advisable to read the sections of this manual relating to appropriate tools, along with the appropriate tool catalogue. N.B. Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of 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

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 connections. Characteristics Typhoon 50 CHAR - 6

Vehicle identification Chassis prefix ZAPC29 xxxx xxxxxxx Engine prefix C216M xxxx Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Maximum length 1820 Maximum width 730 Maximum height 1160 Lead 1260 Kerb weight 84 Kg Typhoon 50 Characteristics CHAR - 7

Engine ENGINE Specification Desc./Quantity Engine type Two-stroke, single cylinder Piaggio Hi-PER2 Bore x stroke 40 X 39.3 mm Cubic capacity 49.40 cc Compression ratio 9.4 to 10.4 :1 Carburettor DELL'ORTO PHVA 17.5 CO adjustment 3.5% ± 0.5 Engine idle speed 1800 to 2000 r.p.m. Air filter Sponge, soaked in a mixture (50% SELENIA Air 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 driving shaft with toothed belt. Fuel supply With vacuum operated cock, lead-free gasoline (with 95 octane minimum) by means of the carburettor. Cooling Forced air circulation. Transmission TRANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V- belt, automatic clutch, gear reduction unit. Capacities CAPACITY Specification Desc./Quantity Petrol tank In plastic, with a capacity of 5.5 lit. (approximate value) including reserve ~ 2 lit. Oil mixer tank In plastic, with a capacity of 1.5 lit. (including reserve ~0.500 lit). Rear hub oil Quantity: approx. 80 cm³ Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Ignition type Capacitive discharge electronic ignition, with incorporated HV coil Ignition advance (before TDC) Fixed 17° ± 1 Recommended spark plug CHAMPION RN3C Battery 12V-4Ah Main fuse 7.5 A Generator In alternate current with three output sections Characteristics Typhoon 50 CHAR - 8

Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Type of chassis Welded tubular steel chassis with stamped sheet reinforce- ments. Front suspension upside-down hydraulic telescopic fork. Front stroke 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 Specification Desc./Quantity Front brake Disc D=190 / 200 mm with hydraulic control, operated by right brake lever on the 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 Specification Desc./Quantity Front tyre Tubeless 120/90 x -10'' Rear tyre Tubeless 120/90 x -10'' Wheels with 3.50x10" wheel rims in light alloy. Carburettor 50cc Version Dell'Orto ORTO CARBURETTOR Specification Desc./Quantity 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 jet 50 Starter air nozzle (on the body): Ø 1.5 Stroke of starter pin: 11 mm Gasoline inlet hole Ø 1.5 Typhoon 50 Characteristics CHAR - 9

Tightening Torques STEERING ASSEMBLY Name Torque in Nm Upper steering ring nut (safety locks) 35 to 40 Nm Lower steering ring nut (safety locks) 8 to 10 Nm Handlebar fixing pin (safety locks) 45 to 50 Nm FRAME ASSEMBLY Name Torque in Nm Swinging arm-engine pin (safety locks) 33 to 41 Nm Swinging arm-frame pin (safety locks) 64 to 72 Nm Shock absorber - frame nut (safety locks) 20 to 25 Nm Shock absorber-engine pin (safety locks) 33 to 41 Nm Rear wheel axis (safety locks) 104 to 126 Nm Bolt holding stand to the engine 18 to 19 Nm FRONT SUSPENSION Name Torque in Nm Front wheel axle nut (safety locks) 45 to 50 Nm Wheel axle clamp screw 6 ÷ 7 Nm Lower leg screw 15 to 20 Nm Hydraulic cartridge stem nut 15 to 18 Nm FRONT BRAKE Name Torque in Nm Viti fissaggio coperchio pompa freno 1,5 ÷ 2 Nm Brake pump support fixing screw 7 to 10 Nm Brake fluid pump - hose fitting 13 to 18 Nm Brake fluid tube - calliper fitting 20 to 25 Nm Calliper tightening screw 20 to 25 Nm Disc tightening screw (safety locks - lock with LOCTITE THREADLOCK MEDIUM TYPE 243) 6 ÷ 7 Nm Oil bleed screw 7 to 10 Nm Calliper coupling screw 20 to 25 Nm ENGINE ASSEMBLY Name Torque in Nm Clutch bell nut 40 to 44 Nm Clutch lock ring nut 55 ÷ 60 nut locking driving pulley on the crankshaft 40 to 44 Nm Start-up lever screw 12 ÷ 13 Flywheel nut 40 to 44 Nm Flywheel fan screws 3 to 4 Half-crank case joint bolts 12 ÷ 13 Bolts holding exhaust pipe to the crankcase 22 ÷ 24 Screws holding the filter box to the crank case 4 ÷ 5 Head nuts 10 ÷ 11 Starter screws 12 ÷ 13 Ignition spark plug 25 ÷ 30 Hub oil drainage cap 3 ÷ 5 Oil hub level dipstick Manual Rear hub cap screws 12 ÷ 13 Transmission cover screws 12 ÷ 13 Inlet manifold screws 8 ÷ 9 Flywheel hood fixing screws 1 ÷ 2 Cylinder hood fixing screws 3.5 ÷ 5 Stator clamping screws 3 ÷ 4 Pick-Up clamping screw 4 ÷ 5 Mixer clamping screws 3 ÷ 4 Screw fixing brake lever to the journal on the engine 12 ÷ 13 Characteristics Typhoon 50 CHAR - 10

2006-2009 Piaggio Typhoon 50 Service & Repair Manual

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