677691 EN
Typhoon 50 4t 4v
Typhoon 50 4t 4v
The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of each model should be checked at the official PIAGGIO sales network. Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy www.piaggio.com
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 TOOLING MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE SUSPENSIONS BRAKING SYSTEM CHASSIS PRE-DELIVERY
CHAR TOOL MAIN TROUBL ELE SYS ENG VE ENG SUSP BRAK SYS CHAS PRE DE
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
Typhoon 50 4t 4v
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.
CHAR - 6
Typhoon 50 4t 4v
Characteristics
Vehicle identification
VEHICLE IDENTIFICATION
Specification Chassis prefix Engine prefix Desc./Quantity ZAPC50 C37CM
Engine
DATI TECNICI MOTORE
Specification Motore Distribuzione Cilindrata Alesaggio per corsa Gioco Valvole Transmission Clutch Desc./Quantity Monocilindrico 4 tempi, 4 valvole raffreddato ad aria monoalbero a camme in testa a 4 valvole 3,03 in (49,0 cc) 1,54 x 1,63 in (39 x 41,35 mm) aspirazione: 0,006 in (0,15 mm) scarico: 0,006 in (0,15 mm) Automatic continuous variator Automatic centrifugal dry clutch
CHAR - 7
Characteristics
Typhoon 50 4t 4v
Desc./Quantity Wet crankcase forced air circulation Starter and kick starter KEIHIN NCV 20 Unleaded petrol 90 (M+R) /2 minimum octane NGK ER9EH-6N
Transmission
TRANSMISSION
Specification Transmission Desc./Quantity With automatic expandable pulley variator, torque server, Vbelt, automatic clutch, gear reduction unit.
Capacities
CAPACITY
Specification Fuel tank capacity Hub oil Engine oil Desc./Quantity ~1.5 gal (including 0.4 gal reserve) ~ 7 litres (including 1.5 l reserve) ~ 0.0225 gal (~ 85 cc) ~0.225 gal (~850 cc)
Electrical system
ELECTRICAL COMPONENTS
1 2 3 4 5 Specification Ignition advance Spark plug Battery Fuses Generator Desc./Quantity reference in table NGK ER9EH-N 12V - 9Ah 1 15A - 1 10A - 1 7.5A single-phase alternating current
STATOR - PICKUP - Power: 120 W. - Resistance between BLUE cable and GROUND CONNECTION: 1 ohm. - Resistance between green cable and ground connection: approximately 170 Ohm.
CHAR - 8
Typhoon 50 4t 4v
Characteristics
- Primary resistance: 0.5 to 0.6 Ohm - Resistance between primary and ground connection: infinite - Resistance between primary and HV output: 3 to 3.6 kOhm - Shielded cap: 5000 Ohm
Brakes
BRAKES
Specification Front brake Rear brake Desc./Quantity Disc brake 8.6 in (220 mm) with hydraulic control (lever on the far right of the handlebar) and floating calliper. Drum 5.51 in ( 140 mm)
Tightening Torques
ENGINE ASSEMBLY
Name Ignition spark plug Floating head cover screws Head-cylinder stud bolt nuts Head nut tightening (only for stud bolt replacement) Screws fixing head and cylinder to crankcase Chain tensioner pad screw Timing chain tensioner central screw Torque in Nm 7.4 - 11 lb ft (10 - 15 Nm) 4.4 - 5.2 lb ft (6 - 7 Nm) 4.4 - 5.2 lb ft + 90 + 90 (6 - 7 Nm + 90 + 90) 4.4 - 5.2 lb ft + 135 + 90 (6-7 Nm + 135 + 90) 5.9 - 7.4 lb ft (8 - 10 Nm) 3.7 - 5.2 lb ft (5 - 7 Nm) 3.7 - 4.4 lb ft (5 - 6 Nm)
CHAR - 9
Characteristics
Typhoon 50 4t 4v
Name Camshaft pulley screw Rocking lever axle and camshaft bearing screw Rocker adjusting nuts Engine oil pre-filter cover Engine oil drainage cap Flywheel nut Stator screws Pick-up screws Oil pump bulkhead screw Timing chain/oil pump compartment cover screws Oil decantation labyrinth sheet screws Oil pump sprocket gear screw Screws fixing oil pump to the crankcase Oil sump screws Inlet manifold screw Carburettor/manifold clamp screw Screws fixing cables to starter motor Starter motor screws Transmission cover screws Start-up lever screw Crankcase cooling cover screw Clutch assembly nut Crankshaft pulley nut Driven pulley shaft nut Hub oil drainage screw Rear hub cap screws Crankcase half union screw
Torque in Nm 8.8 - 10.3 lb ft (12 - 14 Nm) 2.2 - 2.9 lb ft (3 - 4 Nm) 5.2 - 6.6 lb ft (7 - 9 Nm) 18.4 - 20.6 lb ft (25 - 28 Nm) 29.5 - 32.4 lb ft (40 - 44 Nm) 2.2 - 2.9 lb ft (3 - 4 Nm) 2.2 - 2.9 lb ft (3 - 4 Nm) 2.2 - 2.9 lb ft (3 - 4 Nm) 2.9 - 3.7 lb ft (4 - 5 Nm) 2.9 - 3.7 lb ft (4 - 5 Nm) 5.2 - 5.9 lb ft (7 - 8 Nm) 5.9 - 7.4 lb ft (8 - 10 Nm) 3.7 - 4.4 lb ft (5 - 6 Nm) 5.9 - 7.4 lb ft (8 - 10 Nm) 5.2 - 6.6 lb ft (7 - 9 Nm) 0.9 - 1.1 lb ft (1.2 - 1.5 Nm) 0.9 - 1.1 lb ft (1.2 - 1.5 Nm) 8.1 - 9.6 lb ft (11 - 13 Nm) 8.1 - 9.6 lb ft (11 - 13 Nm) 8.1 - 9.6 lb ft (11 - 13 Nm) 1.5 - 1.8 lb ft (2 - 2.5 Nm) 40.5 - 44.2 lb ft (55 - 60 Nm) 13.3 - 14.8 lb ft + 90 (18 - 20 Nm + 90) 29.5 - 32.4 lb ft (40 - 44 Nm) 2.2 - 3.7 lb ft (3 - 5 Nm) 8.1 - 9.6 lb ft (11 - 13 Nm) 5.9 - 7.4 lb ft (8 - 10 Nm)
STEERING ASSEMBLY
Name Steering upper ring nut Steering lower ring nut Headstock handlebar Torque in Nm 27.7 lb ft (37.5 Nm) 9.6 lb ft (13 Nm) 38.7 lb ft (52.5 Nm)
CHASSIS ASSEMBLY
Name Engine side swinging arm Chassis side swinging arm Passenger handle Centre stand pin Saddle plate fixing nut Mirror fixing spacer Chassis fuel tank retainer screws Handlebar brake pump Torque in Nm 31.3 lb ft (42.5 Nm) 31.3 lb ft (42.5 Nm) 15.1 lb ft (20.5 Nm) 31.3 lb ft (42.5 Nm) 7.4 lb ft (10 Nm) 18.4 lb ft (25 Nm) 7.4 lb ft (10 Nm) 5.9 lb ft (8 Nm)
FRONT SUSPENSION
Name Plate fork stanchions Sleeve fork stanchions Front wheel axle hub Fork wheel axle Torque in Nm 29.5 lb ft (40 Nm) 22.1 lb ft (30 Nm) 7.3 lb ft (10 Nm) 34.3 lb ft (46.5 Nm)
REAR SUSPENSION
Name Shock absorber upper part Shock absorber lower part Rear wheel hub Torque in Nm 27.3 lb ft (37 Nm) 27.3 lb ft (37 Nm) 87.8 lb ft (115 Nm)
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Typhoon 50 4t 4v
Characteristics
Name Rear brake adjustment nut Brake fluid hose-pump fitting Oil bleed screw *with Loctite 243
Torque in Nm 3.69 lb ft (5 Nm) 14.75 - 18.44 lb ft (20-25 Nm) 5.9 - 8.8 lb ft (8-12 Nm)
Overhaul data
CHAR - 11
Characteristics
Typhoon 50 4t 4v
Name Piston 2nd oversize Piston 2nd oversize Cylinder 3rd oversize Cylinder 3rd oversize Piston 3rd oversize Piston 3rd oversize N.B.
Initials C2 D2 A3 B3 C3 D3
Cylinder 1.551457 - 1.551732 in (39.407 - 39.414 mm) 1.551732 - 1.552008 in (39.414 - 39.421 mm) 1.558780 - 1.559055 in (39.593 - 39.600 mm) 1.559055 - 1.559331 in (39.600 - 39.607 mm) 1.559331 - 1.559006 in (39.607 - 39.614 mm) 1.559006 - 1.559882 in (39.614 - 39.621 mm)
Piston 1.549921 - 1.550197 in (39.368 - 39.375 mm) 1.5590197 - 1.550472 in (39.375 - 39.382 mm) 1.557244 - 1.557520 in (39.554 - 39.561 mm) 1.557520 - 1.557795 in (39.561 - 39.568 mm) 1.557795 - 1.558071 in (39.568 - 39.575 mm) 1.558071 - 1558346 in (39.575 - 39.582 mm)
Play on fitting 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm) 0.00126 - 0.001811 in (0.032 - 0.046 mm)
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS. - Measure the outer diameter of the gudgeon pin.
Characteristic
Pin outside diameter 0.511811 +0 -0.000157 in (13 +0 -0.004 mm) Minimum admissible diameter gudgeon pin 0.511417 in (12.990 mm)
Characteristic
Pin seat diameter 0.511811 +0.000197 +0.000394 in (13 +0.005 +0.010 mm)
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS
Characteristic
Standard clearance 0.000197 - 0.000551 in (0.005 - 0.014 mm) - Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
N.B.
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Typhoon 50 4t 4v
Characteristics
MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE SECOND SEAL RING SIDE.
ASSEMBLY CLEARANCES
Name Top piston ring Top piston ring Middle piston ring Middle piston ring scraper ring scraper ring Description standard coupling clearance maximum admissible clearance after use standard coupling clearance maximum admissible clearance after use standard coupling clearance maximum admissible clearance after use Dimensions 0.001181 - 0.002559 in (0.03 - 0.065 mm) 0.002756 in (0.07 mm) 0.000787 - 0.002165 in (0.02 - 0.055 mm) 0.002362 in (0.06 mm) 0.001575 - 0.006299 in (0.04 - 0.16 mm) 0.006693 in (0.17 mm) Initials Quantity
- Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out 0.001 in (0.05 mm)
CHAR - 13
Characteristics
Typhoon 50 4t 4v
Piston rings
- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis. - Measure the opening, see figure, of the sealing rings using a thickness gauge. - If any measurements are greater than specified, replace the piston rings.
N.B. BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
SEALING RINGS
Name 1st Compression ring 2nd Compression ring Oil scraper ring 1st Compression ring 1st Oversize 2nd Compression ring 1st Oversize Oil scraper ring 1st Oversize 1st Compression ring 2nd Oversize 2nd Compression ring 2nd Oversize Oil scraper ring 2nd Oversize Description Dimensions 1.535433 x 0.03937 in (39 x 1 mm) 1.535433 x 0.03937 in (39 x 1 mm) 1.535433 x 0.07874 in (39 x 2 mm) 1.543307 x 0.03937 in (39.2 x 1 mm) 1.543307 x 0.03937 in (39.2 x 1 mm) 1.543307 x 0.07874 in (39.2 x 2 mm) 1.551181 x 0.03937 in (39.4 x 1 mm) 1.551181 x 0.03937 in (39.4 x 1 mm) 1.551181 x 0.07874 in (39.4 x 2 mm) Initials A A A A A A A A A Quantity 0.003150 - 0.007874 in (0.08 - 0.20 mm) 0.001969 - 0.007874 in (0.05 - 0.20 mm) 0.007874 - 0.027559 in (0.20 - 0.70 mm) 0.003150 - 0.007874 in (0.08 - 0.20 mm) 0.001969 - 0.007874 in (0.05 - 0.20 mm) 0.007874 - 0.027559 in (0.20 - 0.70 mm) 0.003150 - 0.007874 in (0.08 - 0.20 mm) 0.001969 - 0.007874 in (0.05 - 0.20 mm) 0.007874 - 0.027559 in (0.20 - 0.70 mm)
CHAR - 14
Typhoon 50 4t 4v
Characteristics
Name 1st Compression ring 3rd Oversize 2nd Compression ring 3rd Oversize Oil scraper ring 3rd Oversize
Description
Dimensions 1.559055 x 0.03937 in (39.6 x 1 mm) 1.559055 x 0.03937 in (39.6 x 1 mm) 1.559055 x 0.07874 in (39.6 x 2 mm)
Initials A A A
Quantity 0.003150 - 0.007874 in (0.08 - 0.20 mm) 0.001969 - 0.007874 in (0.05 - 0.20 mm) 0.007874 - 0.027559 in (0.20 - 0.70 mm)
Characteristic
Clearance between crankshaft and connecting rod A = 0.005906 - 0.011811 in (A = 0.15 - 0.30 mm)
CHAR - 15
Characteristics
Typhoon 50 4t 4v
Characteristic
Crankshaft bearing, transmission side 0.787402 -0.000472 -0.000984 in (20 -0.012 -0.025 mm) Crankshaft bearing, flywheel side 0.669291 +0 +0.000276 in (17 +0 +0.007 mm)
- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order. - In case of failures, replace the crankshaft.
Specific tooling
020074Y Support base for checking crankshaft alignment
CHAR - 16
Typhoon 50 4t 4v
Characteristics
To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure.
N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE DETECTED, TRY STRAIGHTENING THE CRANKSHAFT BY INSERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEEDED. IF EVEN AFTER THIS OPERATION THE VALUES ARE NOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.
Characteristic
Off-line maximum admitted - A 0.005906 in (0.15 mm) Off-line maximum admitted - B 0.000787 in (0.02 mm) Off-line maximum admitted - C 0.000787 in (0.02 mm) Off-line maximum admitted - D 0.003937 in (0.10 mm) - Using a bore gauge, measure the connecting rod small end diameter.
N.B. IF THE CONNECTING ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Characteristic
Rod small end diameter 0.511811 +0.000591 +0.000984 in (13 +0.015 + 0.025 mm) Max. diameter admitted: Connecting rod small end check-up 0.512992 in (13.030 mm) Calculate the coupling clearance between pin and rod small end
Characteristic
Pin - connecting rod clearance 0.000591 - 0.001142 in (0.015 - 0.029 mm)
CHAR - 17
Characteristics
Typhoon 50 4t 4v
Products
RECOMMENDED PRODUCTS TABLE
Product eni i-Ride PG 5W-40 AGIP GEAR SAE 80W-90 AGIP FORK 7.5 W AGIP BRAKE 4 Description Synthetic based lubricant for high-performance four-stroke engines. Lubricant for gearboxes and transmissions. Oil for fork. Brake fluid. Specifications JASO MA, MA2 - API SL - ACEA A3 API GL-4
Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4 AGIP FILTER OIL Special product for the treatment of foam filters. NEUTRAL GREASE OR PETROLEUM Battery poles Neutral grease or petroleum jelly JELLY Loctite 510 Liquid sealant Gasket Loctite 243 Medium-strength threadlock Medium Loctite 243 threadlock AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide. AGIP GREASE MU3 Yellow-brown, lithium-base, medium-fi- ISO L-X-BCHA 3 - DIN 51 825 K3K -20 bre multipurpose grease.
CHAR - 18
INDEX OF TOPICS
TOOLING
TOOL
Tooling
Typhoon 50 4t 4v
SPECIFIC TOOLS
Stores code 001330Y Description Tool for fitting steering seats
001467Y009
001467Y013
001467Y029
008119Y009
002465Y
TOOL - 20
Typhoon 50 4t 4v
Tooling
Description Bearing extractor. Fitted with: 1 Bell, 2 Sleeve, 3 Screw, 6 Ring, 7 Half rings, 27 Half rings, 34 Half rings
005095Y
Engine support
006029Y
020004Y
020055Y
020150Y
020151Y
Air heater
TOOL - 21
Tooling
Typhoon 50 4t 4v
020171Y
020193Y
020201Y 020265Y
020271Y
020288Y
TOOL - 22
Typhoon 50 4t 4v
Tooling
020306Y
020329Y
020330Y
020331Y
Digital multimeter
TOOL - 23
Tooling
Typhoon 50 4t 4v
020334Y
020335Y
020363Y
20-mm guide
020364Y
25-mm guide
TOOL - 24
Typhoon 50 4t 4v
Tooling
020412Y
15-mm guide
020428Y
020431Y
020439Y
17-mm guide
020444Y
TOOL - 25
Tooling
Typhoon 50 4t 4v
020450Y
020451Y
020452Y
020565Y
TOOL - 26
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
Typhoon 50 4t 4v
Maintenance chart
SCHEDULED MAINTENANCE TABLE
I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R:REPLACE, A: ADJUST, L:LUBRICATE * Replace every 2 years 0.6 1.9 3.7 5.6 7.5 9.3 11. 13 14. 16. 18. 20. 22. 24. 26. 28 29. 31. 33. 35. 37. 2 2 9 8 6 5 4 2 1 8 7 6 4 3 km x 1,000 1 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 Safety fasteners I I I I I I Spark plug R R R R R R R R R R Drive belt I R I R I R I R I R Throttle control A A A A A A Tyre condition and I I I I I wear Air filter C C C C C Oil filter (mesh) C C C C C C C C C C Solenoid filter C C C C C C C C C C Valve clearance I I I I I I Electrical system I I I I I I I I I I I and battery Cylinder ventilaI I tion system Brake levers L L L L L L Brake oil level (*) I I I I I I I I I I I Hub oil level R I R I R I R I R I R Engine oil R I R I R I R I R I R I R I R I R I R I R Brake Pads/Shoes I I I I I I I I I I I Tyre pressure I I I I I I I I I I I Headlight A A A A A Vehicle road test I I I I I I I I I I I Idle speed A A A A A A Odometer gear L L L L L CVT rollers I R I R I R I R I R Suspension I I I I I Steering A A A A A A Transmission L L L L L Operation time 90' 10' 60' 10' 13 10' 60' 10' 18 10' 60' 10' 16 10' 60' 10' 18 10' 60' 10' 13 0' 0' 5' 0' 0' N.B. mi x 1.000
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.
Carburettor
The carburettor features a solenoid valve "A" that, via an ECU, manages an extra flow of air. It is connected to the carburettor via flexible pipes as shown in the figure. The valve is positioned under the helmet compartment. The piping is joined to a filter positioned inside the body. The solenoid filter should be cleaned ac-
MAIN - 28
Typhoon 50 4t 4v
Maintenance
- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condition. -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
1. Needle valve - 2. Idle adjustment screw - 3. Max jet - 4. Accelerating pump - 5. Tapered pin - 6. Jet holder - 7. Float - 8. Reservoir - 9. Starter device - 10. Depression valve - 11. Cover - 12. Minimum jet.
Spark plug
Remove the rear central cover.
MAIN - 29
Maintenance
Typhoon 50 4t 4v
Disconnect the spark plug HV wire cap; Remove the wire cap.
- Check the conditions of the spark plug, make sure the insulation is intact, that the electrodes are not excessively worn or sooty, the conditions of the washer, and measure the distance between the electrodes using the appropriate feeler gauge. -Adjust the distance, if necessary, by bending the side electrode very carefully. In case of anomaly (as described before), replace the spark plug with another of the recommended type.
- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it. MAIN - 30
Typhoon 50 4t 4v
Maintenance
- Refit the cover. - Place the cap fully over the spark plug, and tie down the cable to the bracket. - Carry out refit operations.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD.THE SPARK PLUG MUST BE REPLACED EVERY 20,000 KM. THE USE OF NON CONFORMING ELECTRONIC IGNITION CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Electrode gap 0.028 - 0.031 in (0.7 - 0.8 mm) Spark plug NGK ER9EH-6N
See also
Chassis
- Remove the dipstick/cover and check that the oil level is between MIN and MAX. - If the level is below the MIN value, restore the proper amount of oil in the hub. - Screw the oil dipstick back and check it is locked.
MAIN - 31
Maintenance
Typhoon 50 4t 4v
Replacement
- Remove the oil dipstick/cover.
- Remove the rear wheel. - Prepare an adequately sized container. - Unscrew the oil drainage plug and drain out all the oil.
Screw the drainage cap back on and fill the hub with the prescribed oil.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions. API GL-4
Characteristic
Hub oil ~ 0.0225 gal (~ 85 cc)
Air filter
Remove the cap of the air cleaner, unscrewing the screws and the fixing knob. Take out the filtering element.
MAIN - 32
Typhoon 50 4t 4v
Maintenance
Cleaning: Wash with water and neutral soap. Dry with a clean cloth and short blasts of compressed air. Saturate with a 50% mixture of petrol and oil. Drip dry the filtering element and then squeeze it with your hands without wringing. Let it dry and refit it.
CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WILL RESULT IN AN EXCESSIVE CYLINDER AND PISTON WEAR AND ALSO IN CARBURETTOR DAMAGE.
Recommended products
AGIP FILTER OIL Special product for the treatment of foam filters. FILTER BOX REMOVAL Undo the screws indicated.
- Loosen the indicated clamps and slide off the filter box.
Engine oil
MAIN - 33
Maintenance
Typhoon 50 4t 4v
Replacement
Change oil and replace filter as indicated in the scheduled maintenance table. The engine must be emptied by draining off the oil through the drainage plug of the mesh pre-filter, flywheel side; furthermore, to facilitate oil drainage, loosen or remove the cap/dipstick. Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter and remove it. To carry out this operation the complete exhaust must be removed. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from oil dipstick/cover. Then start up the vehicle, leave it running for a few minutes and switch it off: After about five minutes, check the level and, if necessary, top-up but never exceeding the MAX level reference mark. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.
N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
Recommended products
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3
Characteristic
Engine oil ~0.225 gal (~850 cc)
See also
Engine oil filter MAIN - 34
Typhoon 50 4t 4v
Maintenance
Check
This operation must be carried out with the engine cold and following the procedure below: - Place the vehicle on its centre stand and on flat ground. - Undo cap/dipstick, dry it off with a clean cloth and reinsert it, screwing down completely. - Remove the cap/dipstick again and check that the level is between the MIN and MAX reference marks; top up if necessary. The MAX level mark indicates a quantity of around 0.225 gal (850 cc) of engine oil. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level. Engine oil top-up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoration of the level from MIN to MAX requires approximately 0.053 gal (200 cc).
Recommended products
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3
MAIN - 35
Maintenance
Typhoon 50 4t 4v
transmissions
Proceed as follows: Rest the vehicle on its centre stand and lift the saddle (as described in the Saddle opening section). Undo screw A in order to remove the helmet compartment cover.
To adjust the idle speed, start the engine, then loose or tighten the screw B until you reach the recommended idle speed taking care the engine does not make the rear wheel move.
WARNING
ADJUST IDLE SPEED WHEN THE ENGINE IS FAIRLY HOT AND HAS BEEN RUNNING FOR AT LEAST FIVE MINUTES. BEFORE THIS OPERATION, MAKE SURE THAT THE THROTTLE GRIP HAS THE RECOMMENDED BACKLASH. IF BACKLASH IN THE THROTTLE CONTROL TRANSMISSION NEEDS ADJUSTING TAKE YOUR SCOOTER TO AN AUTHORISED DEALER OR SERVICE CENTRE.
Characteristic
Engine idle speed 1700 - 1900
MAIN - 36
Typhoon 50 4t 4v
Maintenance
To use this reference mark, remove the spark plug and turn the engine in the opposite direction to the normal direction of rotation using a compass spanner applied to the camshaft drive sprocket housing.
N.B. TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.
Top-up
Proceed as follows: - Remove the front handlebar cover. - Remove the reservoir cap by loosening the two screws, remove the gasket and top-up using only the fluid specified without exceeding the maximum level. MAIN - 37
Maintenance
Typhoon 50 4t 4v
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; DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS.
CAUTION
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLUID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4
Headlight adjustment
Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen; 2. Turn on the headlight and check that the borderline 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 vehicle's headlamp; 3. Otherwise, adjust the headlight by turning the knobs of the body inside the wheel housing. - Tighten the screw (clockwise) to raise the light beam; - undo the screw (anticlockwise) to lower the light beam.
N.B.
MAIN - 38
Typhoon 50 4t 4v
Maintenance
THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.
MAIN - 39
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Typhoon 50 4t 4v
Troubleshooting
Excessive drive belt wear Lack of compression: parts, cylinder and valves worn Oil level exceeds maximum Excess of scales in the combustion chamber Incorrect timing or worn timing system elements Muffler obstructed Inefficient automatic transmission
Wrong valve adjustment Overheated valves Valve seat distorted Worn cylinder, Worn or broken piston rings
Starting difficulties
DIFFICULTY STARTING UP
Possible Cause Flat battery Operation Check the state of the battery. If it shows signs of sulphation, replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1/10 of the capacity of the battery itself. Replace the spark plug Inspect the head and/or restore the correct clearance Check starter motor. Drain off the fuel no longer up to standard; then, refill Remove the sponge, wash with water and car shampoo, then soak it in a mixture of 50% petrol and 50% specific oil. Press with your hand without squeezing, allow it to drip dry and refit. Check the pump.
Faulty spark plug Incorrect valve sealing or valve adjustment Starter motor and start-up system fault Altered fuel characteristics Air filter obstructed or dirty.
TROUBL - 41
Troubleshooting
Typhoon 50 4t 4v
Insufficient braking
INEFFICIENT OR NOISY BRAKING
Possible Cause Worn brake pads or shoes Front brake disk loose or deformed Operation Replace the brake pads or shoes and check for brake disk or drum wear conditions. Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Carefully bleed the hydraulic braking system, (there must be no flexible movement of the brake lever). Failing elastic fittings, plunger or brake pump seals, replace Adjust the clearance with the appropriate adjuster located on the back part of the crankcase.
Air bubbles inside the hydraulic braking system Fluid leakage in hydraulic braking system Excessive clearance in the rear brake control cable
Brakes overheating
BRAKES OVERHEATING
Possible Cause Rubber gaskets swollen or stuck Compensation holes on the pump clogged Brake disc slack or distorted Operation Replace gaskets. Clean carefully and blast with compressed air Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Check calliper and replace any damaged part.
Electrical system
TROUBL - 42
Typhoon 50 4t 4v
Troubleshooting
Battery
BATTERY
Possible Cause Battery Operation 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, keeping in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+. Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries.
Noisy suspension
NOISY SUSPENSION
Possible Cause NOISY SUSPENSION Operation If the front suspension is noisy, check: That the shock absorber works properly inside the stanchions and that the steering ball bearings are in good condition. Finally, check the locking torque of the wheel axle nut, the brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly.
TROUBL - 43
Troubleshooting
Typhoon 50 4t 4v
TROUBL - 44
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
Typhoon 50 4t 4v
Electrical system list of components: 1 12V-9Ah Battery 2 Ground point on chassis 3 Starter relay 4 Starter motor 5 15A Fuse 6 7.5A Fuse 7 10A Fuse 8 Starter button 9 Ignition switch 10 Voltage regulator 11 Magneto flywheel 12 Low fuel warning light ELE SYS - 46
Typhoon 50 4t 4v
Electrical system
13 Fuel gauge instrument 14 Fuel level transmitter 15 S.I.S. solenoid valve 16 Horn button 17 Horn 18 Stop light 19 Front stop switch 20 Rear stop switch 21 Engine stop 22 PTC heater 23 Left rear turn indicator 24 Left front turn indicator 25. Turn indicator signal warning light 26 Right front turn indicator 27 Right rear turn indicator 28. Turn indicator switch 29 Spark plug 30 HV coil 31 NTC temperature sensor 32 External lighting on relay 33 Diagnostics socket 34 Electronic ignition device 35 Light switch 36 Automatic starter 37 Headlight 38 Instrument panel 39. License plate light 40 >. Tail light Cable colour: Az = Sky blue Bi = White Ar = Orange Gi = Yellow BL = Blue Ma = Brown Ne = Black Rs = Red Ro = Pink ELE SYS - 47
Electrical system
Typhoon 50 4t 4v
Components arrangement
ELE SYS - 48
Typhoon 50 4t 4v
Electrical system
1. FRONT STOP SWITCH - 2. REAR STOP SWITCH - 3. LIGHTING RELAY - 4. IGNITION SWITCH - 5. ELECTRONIC IGNITION DEVICE Remove the legshield and the front handlebar cover to reach them.
6. STARTER BUTTON - 7. ENGINE STOP SWITCH Remove the front and rear handlebar covers to reach it.
8. HORN BUTTON - 9. TURN INDICATOR SWITCH - 10. LIGHT SWITCH Remove the front and rear handlebar covers to reach it.
11. 10 A - 12 FUSE. 7.5 A FUSE Open the glove compartment door in the leg shield back plate to reach them.
ELE SYS - 49
Electrical system
Typhoon 50 4t 4v
14. VOLTAGE REGULATOR - 15. SPARK PLUG - 16. SIS VALVE Remove the rear central cover to reach it.
17. PTC HEATER - 18. AUTOMATIC STARTER - 19. STARTER MOTOR - 20. ENGINE TEMPERATURE SENSOR Remove the helmet compartment to reach it.
21. GROUND POINT ON CHASSIS - 22. STARTER RELAY - 23. HV COIL - 24. MAGNETO FLYWHEEL AND PICK-UP Remove the right fairing to reach it.
ELE SYS - 50
Typhoon 50 4t 4v
Electrical system
25. BATTERY - 26. 15 A - 27 FUSE. DIAGNOSTICS SOCKET - 28. FUEL LEVEL TRANSMITTER Lift the saddle and remove the cover to access it.
Ground points
There is a ground point on the vehicle under the right fairing.
ELE SYS - 51
Electrical system
Typhoon 50 4t 4v
Front side
1. Starter button connector 2. Front right turn indicator connector 3. Right hand stop switch 4. Engine stop switch connector 5. Low fuel warning light connector 6. Instrumentation connector 7. Horn connector 8. Front left turn indicator connector 9. Turn indicator switch connector 10. Light switch connector 11. Left hand stop switch 12. Ignition switch 13. Lighting relay 14. High beam connectors 15. Electronic ignition device 16. Low beam connector 17. Auxiliary fuses 18. Cable harness section toward handlebar 19. Main cable harness 20. Horn
Back side
21. Main cable harness 22. Automatic starter connector 23. PTC connector 24. S.I.S. Valve 25. Voltage regulator 26. Engine temperature sensor 27. HV coil 28. Starter relay 29. Starter motor cabling 30. Battery connectors 31. Main fuse 32. Diagnostic connector 33. Fuel gauge connector
ELE SYS - 52
Typhoon 50 4t 4v
Electrical system
List of components 1 12V-9Ah Battery 2 Ground point on chassis 5 15A Fuse 7 10A Fuse 9 Ignition switch 10 Voltage regulator 11 Magneto flywheel 14 Pickup 21 Engine stop 29 Spark plug 30 HV coil 34 Electronic ignition device
ELE SYS - 53
Electrical system
Typhoon 50 4t 4v
List of components 1 12V-9Ah Battery 2 Ground point on chassis 3 Starter relay 4 Starter motor 5 15A Fuse 6 7.5A Fuse 7 10A Fuse 8 Starter button 9 Ignition switch 10 Voltage regulator 11 Magneto flywheel 19 Front stop switch 20 Rear stop switch 21 Engine stop 22 PTC heater 29 Spark plug 30 HV coil 32 External lighting on relay 34 Electronic ignition device ELE SYS - 54
Typhoon 50 4t 4v
Electrical system
36 Automatic starter
List of components 1 12V-9Ah Battery 2 Ground point on chassis 5 15A Fuse 6 7.5A Fuse 9 Ignition switch 10 Voltage regulator 11 Magneto flywheel 12 Low fuel warning light 13 Fuel gauge instrument 14 Fuel level transmitter 15 S.I.S. solenoid valve 31 NTC temperature sensor 34 Electronic ignition device
ELE SYS - 55
Electrical system
Typhoon 50 4t 4v
Key A - Low fuel warning light; B - Fuel level indication; C - Turn indicator warning light; D - Speedometer; E - High-beam warning light; F - Low beam warning light G - Odometer.
BULBS
1 Specification High beam/low beam bulb Desc./Quantity Type: Halogen H8 Power: 12V - 35W Quantity: 2 Type: Amber spherical Power: 12V - 10W Quantity: 1 RHS + 1 LHS Type: Amber spherical Power: 12V - 10W Quantity: 1 RHS + 1 LHS Type: Twin-filament Power: 12V - 21/5W Quantity: 1 Type: ALL GLASS Application: 1 Turn indicator warning light - 1 High beam warning light - 1 Low beam warning light - 2 Instrument illumination warning lights - 1 Low fuel warning light
ELE SYS - 56
Typhoon 50 4t 4v
Electrical system
List of components 1 12V-9Ah Battery 2 Ground point on chassis 5 15A Fuse 6 7.5A Fuse 7 10A Fuse 9 Ignition switch 16 Horn button 17 Horn 33 Diagnostics socket 34 Electronic ignition device
ELE SYS - 57
Electrical system
Typhoon 50 4t 4v
List of components 1 12V-9Ah Battery 2 Ground point on chassis 5 15A Fuse 6 7.5A Fuse 7 10A Fuse 9 Ignition switch 10 Voltage regulator 18 Stop light 19 Front stop switch 20 Rear stop switch 23 Left rear turn indicator 24 Left front turn indicator 25. Turn indicator signal warning light 26 Right front turn indicator 27 Right rear turn indicator 28. Turn indicator switch 32 External lighting on relay 34 Electronic ignition device 35 Light switch ELE SYS - 58
Typhoon 50 4t 4v
Electrical system
37 Headlight 38 Instrument panel 39. License plate light 40 >. Tail light
No spark plug
Once the lack of power to the spark plug has been detected you can proceed as follows: - Check the Pick-Up. The check includes the Pick-Up and its power line. Disconnect the control unit connector and measure the resistance between terminal No. 10 (Blue/ Yellow) and terminal No. 12 (Blue). If the value measured is incorrect, repeat the check directly on the component. Disconnect the pick-up connector on the engine and measure the resistance between the pin corresponding to the Blue-Yellow cable of the wiring and the ground connection on the engine. If correct values are detected, check that the cable is not interrupted.
Electric characteristic
Pick-up resistance value ELE SYS - 59
Electrical system
Typhoon 50 4t 4v
~ 170 Ohm - HV primary coil check Disconnect the control unit connector and check that the cable between terminal No. 4 (White/Violet) and terminal No. 12 (Blue) is not interrupted (see figure). If non-conforming values are measured, check again the HV coil primary directly on the positive and negative terminals. If the values are correct, repair the cable harness or reset the connections; otherwise, replace the HV coil
Electric characteristic
High voltage coil primary resistance value High voltage coil primary resistance value: ~ 0.5 Ohm - HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.
Electric characteristic
High voltage coil secondary resistance value High voltage coil secondary resistance value: ~ 3000 300 Ohm - HV coil With the control unit and HV coil connected to the circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor and connect the positive terminal to the ground one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit. ELE SYS - 60
Typhoon 50 4t 4v
Electrical system
Electric characteristic
High voltage coil voltage value High voltage coil voltage value: > 100 Volt
Specific tooling
020334Y Multiple battery charger
Switches check
To check buttons and switches, check that, according to their position, the continuity of contacts is correct as indicated in the following charts. KEY Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple STARTER BUTTON
ELE SYS - 61
Electrical system
Typhoon 50 4t 4v
LIGHT SWITCH
HORN BUTTON
Stator check
Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.
Electric characteristic
Ohm value: 1 1 Ohm
ELE SYS - 62
Typhoon 50 4t 4v
Electrical system
Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.
ELE SYS - 63
Electrical system
Typhoon 50 4t 4v
In case the generated current value is lower than 8A, repeat the test using a new regulator and/stator alternatively.
Characteristic
Distributed current 13A at 6000 rpm
Starter motor
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If it does not work: - Check the continuity of the Green/Red cable between the 7.5A fuse (B) and stop buttons. - Check the continuity between the starter button Green/Red cable and the stop button Green/Yellow cables. - Check continuity between the Yellow/Red cable between the starter button and the start-up solenoid. - Check that the Red cable between the battery and the start-up solenoid, and the latter and the starter motor are not interrupted. - Check the start-up solenoid. - Check the contacts of the ignition switch, the starter button and the stop buttons. - Check the efficiency of the fuses. - Check that the starter motor is grounded. - If all the tests are positive, replace the starter motor.
ELE SYS - 64
Typhoon 50 4t 4v
Electrical system
Horn control
KEY 1. Battery 2. Main fuse (A) 20A 3. Ignition switch contacts 4. Secondary fuse (C) 15A 5. Horn button 6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If the horn does not work: - Check the efficiency of the fuses. - Check the ignition switch and the horn button contacts. - If the components are not damaged, check wiring for continuity. - Check the continuity of the Green cable which connects the horn button to 15A fuse (C). - Check the continuity of the Grey cable which connects the switch to the horn. - If all the tests are positive, replace the horn.
ELE SYS - 65
Electrical system
Typhoon 50 4t 4v
Choke Inspection
Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If no voltage is detected, connect the multimeter negative probe to the ground lead and the positive probe to the automatic starter Yellow cable; with the ignition switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the ignition switch. If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start up the engine and keep it at idle speed and check there is voltage when the multimeter positive terminal is connected to terminal No. 9 (Green/Red) and the negative one to terminal No. 11 (Green/Black). Replace the control unit if there is no voltage; otherwise, check the wiring connections between the starter and the control unit.
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 CDI control unit and the turn indicators switch. Check that the turn indicator switch works properly. Check continuity of the Red and Blue cables which connect the switch to the bulbs.
level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
ELE SYS - 66
Typhoon 50 4t 4v
Electrical system
If faults are detected: - With a multimeter, check resistance values between the Grey-Green cable and the Blue cable of the fuel level transmitter by moving the arm with the float. - If the transmitter operates correctly but the indication on the instrument panel is not exact, check that the cable harnesses between them are not interrupted. - Check continuity of the Green cable which connects the instrument panel to the 15A secondary fuse (C). - Check continuity of the Grey/Green cable which connects the instrument panel to the probe checking fuel level.
Electric characteristic
Resistance value when the tank is full ~ 7.4 Resistance value when the tank is empty ~ 101
Fuses
The electrical system is protected by a main fuse (A) connected on the left-hand side of the helmet compartment next to the battery. The battery cover must be removed to reach it.
ELE SYS - 67
Electrical system
Typhoon 50 4t 4v
Starter circuit, light circuit, horn and instrument panel are protected by two secondary fuses (B) and (C) located inside the glove-box.
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 USING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).
FUSES
1 Specification Fuse No. 1 Desc./Quantity Capacity: 15 A Protected circuits: general, recharge battery, starter relay Capacity: 10 A Protected circuits: live: electronic ignition device Capacity: 7.5 A Protected circuits: live: minimum circuit heater (PTC), low fuel warning light, horn, fuel level indicator, front and rear stop buttons, voltage regulator, engine stop switch
2 3
Dry-charge battery
Where provided
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC 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. 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 PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN
ELE SYS - 68
Typhoon 50 4t 4v
Electrical system
Use of dry-cell batteries: 1) - Remove the short closed tube and the caps, then pour sulphuric acid into the cells, using the type specified for batteries with a specific gravity of 0.0455 lb/in3 (1.26 Kg/l), corresponding to 30 B, at a minimum temperature of 59F (15C). 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 capacity until fully charged; check that the acid density is about 0.0459 lb/in3 (1.27 Kg/l), corresponding to 31 B, 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 performed, 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 VEHICLE 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 ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.
Specific tooling
020334Y Multiple 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 The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If water topping is required too often, check the vehicle electrical system: the battery works overcharged and is subject to quick wear. 2)Load status check ELE SYS - 69
Electrical system
Typhoon 50 4t 4v
After topping-up the electrolyte level, check its density using an appropriate densitometer (see figure). With the battery charged, a density of 30-32 B, corresponding to a specific weight of 0.0455 - 0.0462 lb/in3 (1.26 - 1.28 Kg/l) must be at a minimum temperature of 59 F (15 C). A density reading of less than 20 B 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 connected to the clamp marked with the +positive sign. 3) Recharging the battery Remove the battery from the vehicle disconnecting the negative terminal first. Regular bench charging must be carried out with the specific battery charger, (single) or (multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connecting the corresponding poles (+ to+ and - to -). 4) Cleaning the battery The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. THE USE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VEHICLE 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
020334Y Multiple battery charger
Connectors
LOW BEAM CONNECTOR 1. Ma - Light switch control. 2. Ne - Ground.
ELE SYS - 70
Typhoon 50 4t 4v
Electrical system
HV COIL CONNECTOR 1. Vi - Command from electronic ignition device. 2. Ne - Negative from electronic ignition device.
IGNITION SWITCH CONNECTOR 1. Ar - Positive with key on for secondary fuses and voltage regulator. 2. RsBL - Positive from 15A fuse. 3. Ne - Ground. 4. BL - Ground with key on for electronic ignition device and stop engine switch. TURN INDICATOR SWITCH CONNECTOR 1. BLNe - Power supply from voltage regulator. 2. BiBL - Command for right side turn indicators and for emergency flashers on warning light. 3. Ro - Command for left side turn indicators and for emergency flashers on warning light.
ELE SYS - 71
Electrical system
Typhoon 50 4t 4v
"A" ELECTRONIC IGNITION DEVICE CONNECTOR 1. Ne - Negative for high voltage regulator. 2. BL - Ground after ignition key switch. 3. Vi - High coil and lights relay. "B" ELECTRONIC IGNITION DEVICE CONNECTOR 1. ArNe - 7.5A fused power supply with key on. 2. BiNe - PTC heater control. 3. Ve - Lights relay control. 4. Ne - Ground. 5. Ma - S.I.S. solenoid valve control 6. GiRo - NTC temperature sensor signal. 7. Az - Lights relay control. 8. RsNe - Diagnostics. 8. RsNe - Diagnostics. LIGHT SWITCH CONNECTOR 1. Vi - High beam control and high beams on. 2. GiNe - Lights relay power supply. 3. Ma - Low beam control and low beams on. 4. GiNe - Jumper with pin 2. SIS SOLENOID VALVE CONNECTOR 1. Ma - Command from electronic ignition device. 2. Bi - 10A fused positive with key on.
TAILLIGHT CONNECTOR 1. BiNe - Stop light control. 2. GiNe - Rear tail light control. 3. Ne - Ground. 15 A FUSE CONNECTOR 1. Rs - Positive from battery. 2. RsBL - Positive to ignition key switch.
SECONDARY FUSES CONNECTOR 1. Ar - Live positive lead 2. ArNe - Electronic ignition device power supply (10A). ELE SYS - 72
Typhoon 50 4t 4v
Electrical system
3. Ar - Live positive lead 4. Bi - Services power supply (7.5A). INSTRUMENT PANEL CONNECTOR 1. Vi - High beams on warning light control. 2. Ma - Low beams on warning light control. 3. Not connected. 4. GiNe - Instrument lighting control. 5. BiBL - Right side flashers warning light control. 6. Ne - Ground. 7. Ro - Left side flashers warning light control. 8. Bi - Positive lead for fuel level indicator gauge. 9. BiVe - Signal from fuel level transmitter. LICENCE PLATE LIGHTING CONNECTOR 1. Ne - Ground. 2. GiNe - Lights relay power supply control.
Engine stop switch connector 1. Ne - Ground. 2. BL - Ground from ignition key switch. 3. GiRs - Starter relay control. FRONT RIGHT TURN INDICATOR CONNECTOR 1. BiBL - Command from flashers control switch. 2. Ne - Ground. FRONT LEFT TURN INDICATOR CONNECTOR 1. Ro - Command from flashers control switch. 2. Ne - Ground.
REAR RIGHT TURN INDICATOR CONNECTOR 1. BiBL - Command from flashers control switch. 2. Ne - Ground.
ELE SYS - 73
Electrical system
Typhoon 50 4t 4v
REAR LEFT TURN INDICATOR CONNECTOR 1. Ro - Command from flashers control switch. 2. Ne - Ground.
CHASSIS GROUND - Ne
DIAGNOSTICS SOCKET CONNECTOR 1. Not connected. 2. Ne - Ground. 3. RsNe - Connection to electronic ignition device. STARTER BUTTON CONNECTOR 1. BiNe - Positive after stop button. 2. VeNe - Starter relay control.
HORN BUTTON CONNECTOR 1. Bi - Power from 7.5A fuse. 2. GrNe - Horn control.
FRONT BRAKE STOP BUTTON CONNECTOR 1. BiNe - Brake pressed signal for stop light and starter consent. 2. Bi - Power from 7.5A fuse. STOP BUTTON ON REAR BRAKE CONNECTOR 1. BiNe - Brake pressed signal for stop light and starter consent. 2. Bi - Power from 7.5A fuse.
ELE SYS - 74
Typhoon 50 4t 4v
Electrical system
VOLTAGE REGULATOR CONNECTOR 1. Gi - Positive lead for lights relay. 2. Ne - Ground. 3. Ar - Live positive lead 4. BL - Positive lead for turn indicators. 5. BLNe - Signal from magneto flywheel. MAGNETO FLYWHEEL CONNECTOR 1. Ve - Engine speed sensor for electronic ignition device. 2. Not connected. 3. Bl - Signal for voltage regulator. 4. Not connected. 5. Not connected. 6. Not connected. PTC heater connector 1. Bi - Power from 7.5A fuse. 2. BiNe - Negative from electronic ignition device.
LOW FUEL WARNING LIGHT CONNECTOR 1. Bi - Positive from 7.5A fuse. 2. GrVe - Low fuel signal from fuel level transmitter. AUTOMATIC STARTER CONNECTOR 1. Ne - Ground. 2. GiNe - Lights relay power supply control.
LIGHTS RELAY CONNECTOR 85. Vi - Command from electronic ignition device. 86. Az - Command from electronic ignition device. 87. GiNe - Positive lead for external lighting. 30. Gi - Positive lead from voltage regulator.
ELE SYS - 75
Electrical system
Typhoon 50 4t 4v
FUEL LEVEL TRANSMITTER CONNECTOR 1. BiVe - Signal for fuel level indicator gauge. 2. Ne - Ground. 3. GrVe - Signal for low fuel warning light.
ELE SYS - 76
INDEX OF TOPICS
ENG VE
Typhoon 50 4t 4v
Remove the exhaust fixing screws to the crankcase, then remove the exhaust.
SUITABLY SUPPORT THE VEHICLE AND THE ENGINE TO AVOID ACCIDENTAL FALL. - Disconnect the battery. - Remove the helmet compartment. - Remove the lower cover. - Slide the HV wire cap off the spark plug. - Disconnect the engine temperature sensor.
ENG VE - 78
Typhoon 50 4t 4v
Remove the rear brake transmission bracket fixing screws indicated in the photograph.
Disconnect the starter motor connector from the relay and the ground.
ENG VE - 79
Typhoon 50 4t 4v
Remove the S.I.S. valve piping. Disconnect the fuel piping and the depression piping.
Disconnect the throttle body sensor (PTC) and the automatic starter pins, moving the protective sheaths and removing the clamps.
ENG VE - 80
Typhoon 50 4t 4v
Remove the nut connecting the crankcase to the rear shock absorber.
ENG VE - 81
INDEX OF TOPICS
ENGINE
ENG
Typhoon 50 4t 4v
Engine
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- Remove the 12 fixing screws. - Remove the oil filling cap and then slide out the cover. If this operation is carried out directly on the vehicle, it is necessary to remove the transmission cooling coupling and the air filter housing retainers.
N.B. USE A MALLET ON THE APPROPRIATE COUPLINGS TO REMOVE THE COVER.
Kickstart
-To remove the start up pinion push the starter lever to facilitate extracting the pinion. -Remove the kick-start screw and lever. -Remove the Seeger ring and the washer indicated in the figure. -Pull out the toothed sector.
WARNING THE SECTOR KEEPS THE SPRING SET, BE CAREFUL SO AS NOT TO CAUSE ANY ACCIDENTS
Air duct
- To remove the intake throat on the transmission cover, just remove the three fixing screws indicated in the figure.
ENG - 83
Engine
Typhoon 50 4t 4v
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE COVER PAINTED SURFACE.
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 84
Typhoon 50 4t 4v
Engine
Characteristic
clutch housing diameter/standard value 4.212598 + 0.007874 + 0 in ( 107+0.2 +0 mm) Clutch housing diameter/maximum admissible value 4.232283 in ( 107.5 mm) Eccentricity measured /max. 0.007874 in (0.20 mm)
- 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
ENG - 85
Engine
Typhoon 50 4t 4v
Characteristic
Check minimum thickness 0.03937 in (1 mm)
- Remove the three guide pins and the mobile half pulley.
ENG - 86
Typhoon 50 4t 4v
Engine
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
020376Y Adaptor handle 020363Y 20-mm guide
Characteristic
Stationary driven half-pulley/Standard diameter 1.337205 - 1.337992 in ( 33.965 - 33.985 mm) Stationary driven half-pulley / Minimum diameter admitted after use 1.337008 in ( 33.96 mm)
ENG - 87
Engine
Typhoon 50 4t 4v
Characteristic
Mobile driven half-pulley/ Maximum diameter admissible 1.341732 in ( 34.08 mm) - Check the belt contact surfaces. - Insert the new oil seal and O-rings on the mobile half-pulley. - Fitting the half-pulley on the bushing.
Recommended products
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide. - Make sure the pins and collar are not worn, reassemble the pins and collar. - Using a curved-spout grease gun, lubricate the driven pulley unit with approximately 0.013 lb (6 grams) of grease. Apply grease through one of the holes in the bushing until it comes out through the hole on the opposite side. This procedure is necessary to prevent the presence of grease beyond the O-ring.
Recommended products
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide. -
Specific tooling
020376Y Adaptor handle
ENG - 88
Typhoon 50 4t 4v
Engine
020456Y 24-mm adaptor 020362Y 12 mm guide 020171Y Punch for 17 mm roller bearing
Characteristic
Standard length 4.645669 in (118 mm)
- Check the thickness of the clutch mass friction material. -The masses must not show traces of lubricants; otherwise, check the driven pulley unit.
N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT 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 SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Minimum thickness permitted: 0.03937 in (1 mm)
ENG - 89
Engine
Typhoon 50 4t 4v
- Reassemble the nut securing the clutch and tighten to the prescribed torque.
CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCKET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE NUT IN CONTACT WITH THE CLUTCH
Specific tooling
020565Y Flywheel lock calliper spanner
Drive-belt
- Make sure the drive belt is not damaged and does not have cracks in the toothed grooves. - Check the width of the belt.
Characteristic
Drive belt/Minimum width 0.688976 in (17.5 mm)
ENG - 90
Typhoon 50 4t 4v
Engine
- 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
020451Y Starting ring gear lock
Characteristic
Driving pulley / Maximum diameter: ENG - 91
Engine
Typhoon 50 4t 4v
0.792126 in (20.12 mm) Driving pulley/ Standard diameter: 0.788228 in (20.021 mm) Driving pulley bushing/ Standard diameter: 0.787402 -0.000787 -0.001614 in (20 -0.020 -0.041mm)
- Refit the components of the assembly (roller housing assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive, washer and nut). - With the specific tool, tighten the lock nut to 14.75 lbft (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 UTMOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN ORDER TO AVOID WRONG TIGHTENING AND CONSEQUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling
020451Y Starting ring gear lock
ENG - 92
Typhoon 50 4t 4v
Engine
Recommended products
AGIP GREASE MU3 Yellow-brown, lithiumbase, medium-fibre multipurpose grease. ISO L-X-BCHA 3 - DIN 51 825 K3K -20 - Insert the pinion in its seating by pushing the starter lever. - Fit the intake throat and tighten the 3 screws. -Make sure the oil sump presents centring dowels and sealing gaskets. - Replace the cover tightening the 12 screws to the prescribed torque. -Refit the oil filling cap.
End gear
ENG - 93
Engine
Typhoon 50 4t 4v
See also
Refitting the clutch
Specific tooling
020363Y 20-mm guide 020376Y Adaptor handle 020358Y 37x40-mm Adaptor
ENG - 94
Typhoon 50 4t 4v
Engine
Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft - Position the special tube on the internal raceway of the bearing and from the shaft toothed side as indicated in the figure. Expel the driven pulley shaft with the aid of a press.
Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft
ENG - 95
Engine
Typhoon 50 4t 4v
Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft 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 020376Y Adaptor handle 020439Y 17-mm guide 020358Y 37x40-mm Adaptor
Specific tooling
020151Y Air heater 020376Y Adaptor handle 020363Y 20-mm guide 020359Y 42x47-mm Adaptor
ENG - 96
Typhoon 50 4t 4v
Engine
ENG - 97
Engine
Typhoon 50 4t 4v
Cooling fan
- Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.
ENG - 98
Typhoon 50 4t 4v
Engine
ENG - 99
Engine
Typhoon 50 4t 4v
Specific tooling
020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor
ENG - 100
Typhoon 50 4t 4v
Engine
Intermediate gear
- Check that the keying toothing on the crown and the starter motor are in good conditions. - Check that the Bendix opens and returns adequately.
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 101
Engine
Typhoon 50 4t 4v
ENG - 102
Typhoon 50 4t 4v
Engine
- Remove the driving pulley - Remove the oil pump chain - Remove the tappet cover - Remove the central screw and the belleville washer indicated in the figure and lock the camshaft crown with the specific tool.
N.B. TO FACILITATE REMOVING THE HEAD COMPONENTS, SET THE CRANKSHAFT TO THE TIMING POINT (TDC OF THE COMPRESSION END).
Specific tooling
020565Y Flywheel lock calliper spanner - Remove the camshaft control pulley and the washer below. - Remove the pinion of the crankshaft timing control - To remove the chain lower guiding pad, remove the head by pulling it upwards
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE DIRECTION OF ROTATION IS MAINTAINED.
See also
Removing the rocker-arms cover Removal Removing the driving pulley ENG - 103
Engine
Typhoon 50 4t 4v
- Remove the entire camshaft with bearing using the specific tool shown in the figure. - Take out the camshaft bearing with the aid of the specific tool, being careful to mount a screw on the camshaft in order to protect its thread.
N.B. IF A BEARING SEPARATES FROM THE CAMSHAFT, IT IS ESSENTIAL TO FIT A NEW BEAR.
Specific tooling
020450Y Camshaft fitting/removal tool 004499Y Camshaft bearing extractor 004499Y001 Bearing extractor bell 004499Y002 Bearing extractor screw 004499Y006 Bearing extractor ring 004499Y027 Bearing extractor part
ENG - 104
Typhoon 50 4t 4v
Engine
Specific tooling
020431Y Valve oil seal extractor 020382Y Valve cotters equipped with part 012 removal tool
ENG - 105
Engine
Typhoon 50 4t 4v
- Remove the two stop rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston.
N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.
IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ADMISSIBLE, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER". For the dimensions see the SPECIFICATIONS chapter
ENG - 106
Typhoon 50 4t 4v
Engine
- Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE SECOND SEAL RING SIDE. For the dimensions see the SPECIFICATIONS chapter
ENG - 107
Engine
Typhoon 50 4t 4v
- Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out 0.001 in (0.05 mm)
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
ENG - 108
Typhoon 50 4t 4v
Engine
SEALING RINGS
Name 1st Compression ring 2nd Compression ring Oil scraper ring 1st Compression ring 1st Oversize 2nd Compression ring 1st Oversize Oil scraper ring 1st Oversize 1st Compression ring 2nd Oversize 2nd Compression ring 2nd Oversize Oil scraper ring 2nd Oversize 1st Compression ring 3rd Oversize 2nd Compression ring 3rd Oversize Oil scraper ring 3rd Oversize Description Dimensions 1.535433 x 0.03937 in (39 x 1 mm) 1.535433 x 0.03937 in (39 x 1 mm) 1.535433 x 0.07874 in (39 x 2 mm) 1.543307 x 0.03937 in (39.2 x 1 mm) 1.543307 x 0.03937 in (39.2 x 1 mm) 1.543307 x 0.07874 in (39.2 x 2 mm) 1.551181 x 0.03937 in (39.4 x 1 mm) 1.551181 x 0.03937 in (39.4 x 1 mm) 1.551181 x 0.07874 in (39.4 x 2 mm) 1.559055 x 0.03937 in (39.6 x 1 mm) 1.559055 x 0.03937 in (39.6 x 1 mm) 1.559055 x 0.07874 in (39.6 x 2 mm) Initials A A A A A A A A A A A A Quantity 0.003150 - 0.007874 in (0.08 - 0.20 mm) 0.001969 - 0.007874 in (0.05 - 0.20 mm) 0.007874 - 0.027559 in (0.20 - 0.70 mm) 0.003150 - 0.007874 in (0.08 - 0.20 mm) 0.001969 - 0.007874 in (0.05 - 0.20 mm) 0.007874 - 0.027559 in (0.20 - 0.70 mm) 0.003150 - 0.007874 in (0.08 - 0.20 mm) 0.001969 - 0.007874 in (0.05 - 0.20 mm) 0.007874 - 0.027559 in (0.20 - 0.70 mm) 0.003150 - 0.007874 in (0.08 - 0.20 mm) 0.001969 - 0.007874 in (0.05 - 0.20 mm) 0.007874 - 0.027559 in (0.20 - 0.70 mm)
ENG - 109
Engine
Typhoon 50 4t 4v
Specific tooling
020448Y Pin lock fitting tool
- With the opening in the position indicated on the tool, set the lock ring into position in the tool with the punch. - Rest the tool on the piston paying attention that the 90chamfered side faces upwards as indicated in the figure. - Fit the gudgeon pin stop using the plug.
CAUTION USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING.
ENG - 110
Typhoon 50 4t 4v
Engine
Specific tooling
020288Y Fork to assemble piston on cylinder If the four cylinder stud bolts should be replaced in this kind of engine, it is necessary to tighten the head nuts strictly following the procedure below.
Characteristic
Maximum allowable run-out: 0.003937 in (0.1 mm)
ENG - 111
Engine
Typhoon 50 4t 4v
Measure the camshaft bearing seats and rocking lever support pins with a bore meter
HEAD CHECK
Specification Standard diameter in (mm) A Standard diameter in (mm) B Standard diameter in (mm) C Desc./Quantity 1.260433 - 1.260827 ( 32.015 - 32.025) 0.629921 - 0.63063 ( 16.0 - 16.018) 0.433071 - 0.43378 ( 11.0 - 11.018)
ENG - 112
Typhoon 50 4t 4v
Engine
Characteristic
Standard value: 0.03937 - 0.051181 in (1 - 1.3 mm) Admissible limit: 0.062992 in (1.6 mm) - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45 milling cutter and then grind. - In case of excessive wear or damage, replace the head. - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
ENG - 113
Engine
Typhoon 50 4t 4v
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
STANDARD DIAMETER
Specification Intake Exhaust Desc./Quantity 0.156299 - 0.156890 in (3.970 - 3.985 mm) 0.155906 - 0.156496 in (3.960 - 3.975 mm)
- Calculate the clearance between valve and valve guide. - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the V shaped support.
Characteristic
Admissible limit: 0.001181 in (0.03 mm)
- Check the deviation of the valve stem by resting it on a V shaped support and measuring the extent of the deformation using a dial gauge.
Characteristic
Limit values admitted: 0.003937 in (0.1 mm)
ENG - 114
Typhoon 50 4t 4v
Engine
- After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem.
INTAKE
Specification Standard clearance Admissible limit Desc./Quantity 0.000590 - 0.001654 in (0.015 - 0.042 mm) 0.002362 in (0.06 mm)
EXHAUST
Specification Standard clearance Admissible limit Desc./Quantity 0.000984 - 0.002047 in (0.025 - 0.052 mm) 0.002756 in (0.07 mm)
ENG - 115
Engine
Typhoon 50 4t 4v
- Fit the valves, the springs and the upper caps. - Using the appropriate tool, compress the springs and insert the cotters in their seats.
Characteristic
Standard diameter - Bearing A: 0.472441 +0.000079 +0.000394 in ( 12 +0.002 +0.010 mm) Standard diameter - Bearing B: 0.629921 -0.000591 -0.000906 in ( 16 -0.015 -0.023 mm) Minimum diameter admissible - Bearing A: 0.471654 in ( 11.98 mm) Minimum diameter admissible - Bearing B: 0.628346 in ( 15.96 mm) - Using a gauge, measure the height of the cams. Check the axial clearance of the camshaft
ENG - 116
Typhoon 50 4t 4v
Engine
- If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
N.B. A BALL BEARING IS FITTED ON BEARING A; CONSEQUENTLY, BEARING B IS THE MOST IMPORTANT AS IT WORKS DIRECTLY ON THE HEAD ALUMINIUM
Characteristic
Standard height - Inlet 0.960512 in (24.397 mm) Standard height - Outlet 0.944724 in (23.996 mm)
Fitting clearance
Maximum admissible axial clearance: 0.019685
(0.5 mm)
- Measure the outside diameter of the rocking lever pins - Check the rocking lever pins do not show signs of wear or scoring. - Measure the internal diameter of each rocker. - Check that the pad in contact with the cam is not worn.
Engine
Typhoon 50 4t 4v
- Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque.
Specific tooling
020450Y Camshaft fitting/removal tool - Fit pins, inlet rocking lever and discharge rocking lever. - Lubricate the 2 rocking levers through the holes.
N.B. IF A BEARING SEPARATES FROM THE CAMSHAFT, IT IS ESSENTIAL TO FIT A NEW BEARING.
- Screw up the limit screw of the rocking lever pins and tighten it to the prescribed torque. - Reposition the Seeger ring retaining the camshaft
- Finish the head tightening following the procedure below: screw the four head nuts to an initial torque at two crossed passes. Afterwards tighten the nuts with 2 turns of 90 each to be done at two crossed passes. -Finish the tightening of the head to the crankcase with the 2 side screws.
N.B. SHOULD THE CRANKCASE OR THE CYLINDER STUD BOLTS BE REPLACED, IT IS NECESSARY TO CARRY OUT AN INITIAL TIGHTENING PLUS OTHER 3 TURNS OF 90 EACH AT 3 CROSSED PASSES
ENG - 118
Typhoon 50 4t 4v
Engine
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 119
Engine
Typhoon 50 4t 4v
Camshaft pulley screw 8.8 - 10.3 lb ft (12 - 14 Nm) Floating head cover screws 4.4 - 5.2 lb ft (6 - 7 Nm) - Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the specified torque. - Insert the spring with the central screw and tighten it to the prescribed torque. - Fit the spark plug.
Characteristic
Electrode distance 0.023622 in (0.6 mm)
Electric characteristic
Spark plug NGK ER9EH-6N
ENG - 120
Typhoon 50 4t 4v
Engine
Crankcase - crankshaft
- First remove the following units: Driving pulley Driven pulley Final reduction greasing Oil pump Flywheel with stator Cylinder-piston-head unit Starter motor with cables.
See also
Removing the driving pulley Removal Removing the driven pulley Removing the cylinder - piston assy. Removing the starter motor Removing the stator
THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT. DO NOT WASH WITH SOLVENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT. A CENTRIFUGAL OIL FILTER'S LIFE IS THE SAME AS THE ENGINE'S AND IS MAINTENANCE FREE.
ENG - 121
Engine
Typhoon 50 4t 4v
Fitting clearance
Standard connecting rod axial clearance 0.005906 - 0.011811 in (0.15 - 0.30 mm) Max. connecting rod clearance 0.019685 in (0.5 mm)
- Check the correct radial clearance of the connecting rod by holding the driving shaft with your hands and, with a dial gauge fitted to the rod small end, measuring the clearance, move the connecting rod vertically as shown in the figure.
Fitting clearance
Connecting rod radial - standard clearance 0.000236 - 0.000709 in (0.006 - 0.018 mm) Connecting rod max. - radial clearance 0.000984 in (0.025 mm) - Check that the half shaft surfaces are not scored and with the aid of a gauge check the driving shaft width as indicated in the figure.
Characteristic
Standard measure 1.771654 in (45 mm)
Specific tooling
004499Y Camshaft bearing extractor 004499Y001 Bearing extractor bell 004499Y002 Bearing extractor screw 004499Y006 Bearing extractor ring 004499Y034 Bearing extractor part
ENG - 122
Typhoon 50 4t 4v
Engine
Specific tooling
020359Y 42x47-mm Adaptor 020364Y 25-mm guide 020376Y Adaptor handle 020360Y 52x55-mm Adaptor - Warm a new main bearing in an oil bath at 250 F (120C). - Place the driving shaft on the support base and insert the bearing with the aid of an adequate piece of tube if necessary.
N.B. USE A NEW BEARING WHEN REFITTING WARNING THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT. DO NOT WASH WITH SOLVENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT.
Specific tooling
020265Y Bearing fitting base 008119Y009 Tube to assemble shafts and axles
ENG - 123
Engine
Typhoon 50 4t 4v
Characteristic
Off-line maximum admitted - A 0.005906 in (0.15 mm) Off-line maximum admitted - B 0.000787 in (0.02 mm) Off-line maximum admitted - C 0.000787 in (0.02 mm) Off-line maximum admitted - D 0.003937 in (0.10 mm) - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order. - In case of failures, replace the crankshaft.
Specific tooling
020074Y Support base for checking crankshaft alignment
ENG - 124
Typhoon 50 4t 4v
Engine
- Fit the gasket recommended for surfaces on the half casing on the transmission side after greasing the two faying surfaces carefully. -Insert the flywheel half casing. - Fit the 10 screws and tighten them to the prescribed torque.
N.B. WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.
Recommended products
Loctite 510 Liquid sealant Gasket
ENG - 125
Engine
Typhoon 50 4t 4v
- Check that the chain contrast pad is not worn. -Otherwise, replace the pad or fit it inverted to make it work on the other side. - Any operation on the chain cover oil seal should be carried out placing the cover on the workbench on the covering plate side of the oil pump chain. - Remove the oil seal with a 1.18 in (30 mm) MAX diameter 1.26 in ( 32 mm) tube section.
Refitting
- Fit a new oil seal on the outer rim with the help of the specific tools below. - Fit a new O-ring and lubricate it with grease. - Install the cover on the engine crankcase, insert the three screws and place the cover in its position. - Tighten the 3 screws to the prescribed torque.
Specific tooling
020376Y Adaptor handle 020358Y 37x40-mm Adaptor
ENG - 126
Typhoon 50 4t 4v
Engine
- Undo the 2 clamping screws in the figure and remove the cover over the pump control crown gear. - Block the rotation of the oil pump control gear with a screwdriver inserted through one of its pump holes.
- Remove the central screw and the belleville washer - Remove the chain with the crown gear. - Remove the crankshaft control pinion. - Remove the oil pump by undoing the 2 screws indicated in the figure. - Remove the oil pump seal.
N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover. - Remove the clip retaining the innermost rotor. - Remove and wash the rotors thoroughly with a degreasing solvent and compressed air. - Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the clip.
- Measure distance between rotors (inner rotor/ outer rotor) with a thickness gauge in the position shown in the picture.
Characteristic
Admissible maximum clearance 1 0.005906 in (0.15 mm)
ENG - 127
Engine
Typhoon 50 4t 4v
Measure the distance between the outer rotor and the pump body (see figure).
Characteristic
Admissible maximum clearance 2 0.007874 in (0.20 mm)
- Check the axial clearance of the rotors using a trued bar as reference as shown in the figure.
N.B. MAKE SURE THE TRUED BAR IS POSITIONED PROPERLY ON THE TWO POINTS ON THE PUMP BODY.
Characteristic
Admissible maximum clearance 3 0.003543 in (0.09 mm)
Refitting
- Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the assembly. - Fit the cover on the pump being careful to align the holes (2 on the cover and 2 on the pump body) fixing the oil pump on the crankcase. - Fit the oil pump on the crankcase by tightening the two screws to the prescribed torque. - Fit the pulley on the pump, the central screw to the specified torque and the belleville washer. - Check that there is no seizing and/or friction during the pulley rotation.
N.B. FIT THE CUP WASHER SO THAT ITS OUTER (CURVED) RIM TOUCHES THE PULLEY.
ENG - 128
Typhoon 50 4t 4v
Engine
Timing chain/oil pump compartment cover screws 2.9 - 3.7 lb ft (4 - 5 Nm) Screws fixing oil pump to the crankcase 3.7 - 4.4 lb ft (5 - 6 Nm)
Fuel supply
- Disconnect the fuel supply and the suction taking pipe from the carburettor. - Check that there are no fuel leaks between the two tubes. - Close the fuel outlet pipe. - Using a MITIVAC pump, apply 1.45 psi (0.1 bar) vacuum bar on the cock. - Make sure that the suction is kept stable and that and that there are no fuel leaks. - Reconnect the vacuum pipe to the manifold.
ENG - 129
Engine
Typhoon 50 4t 4v
- Position the fuel pipe with the outlet at the point of the tap. - Turn the engine by using the starter motor for five seconds with the carburettor at minimum. - Take up the fuel by means of a graded burette.
N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCORRECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUTLET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUCTION PULSATION AND THEREBY GUARANTEE A CONSTANT TAP FLOW RATE.
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Characteristic
Minimum flow rate 0.676 fl oz in 5 sec (20 cc in 5 sec)
- Completely empty the fuel tank. - Remove the petrol delivery pipe and the lowpressure 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 ORing. - 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.
ENG - 130
Typhoon 50 4t 4v
Engine
- Remove the 2 fixing screws indicated in the figure, the vacuum chamber cover and the spring. - Remove the vacuum valve together with the diaphragm; the pin, the spring and its plastic guide.
WARNING DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
- Remove the 3 fixing screws and the chamber with the gasket.
ENG - 131
Engine
Typhoon 50 4t 4v
- Remove the chamber components following the procedure below. - Undo the 2 screws fixing the intake pump diaphragm cover.
- Remove the cover being careful with the spring below, then remove the spring, take out the rubber protection and the diaphragm together with the pipe O-Ring.
-Remove the accelerating pump jet together with the ball spring.
- Remove the screw indicated in the figure fixing the float pin. - Remove the float and the plunger.
ENG - 132
Typhoon 50 4t 4v
Engine
- Remove the idle flow screw with the O-ring and the spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PIN SEATING, STARTER NOZZLE, THROTTLE VALVE CONTROL VALVE SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS ARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT.
ENG - 133
Engine
Typhoon 50 4t 4v
- For the minimum circuit, make sure the following points are properly cleaned: air gauging, exhaust section controlled by flow screw, progression holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly. The acceleration nozzle outlet is extremely small and is oriented to the throttle valve.
- Check that the carburettor body has the closing ball for the idle circuit pipe. - Check that the coupling surfaces, the chamber and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear. - Check that the plunger seat does not show abnormal wear. - Replace the carburettor in case of irregularities.
N.B.
ENG - 134
Typhoon 50 4t 4v
Engine
- Wash and blow the minimum nozzle properly and reassemble it.
- Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindrical part directed to the diffuser. - Fit the diffuser. -Assemble the maximum nozzle. - Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock absorber pin and the return clamp. - Replace the rod if worn out. - Check that the float is not worn on the pin housing or on the contact plate with the rod and that there are no fuel infiltrations. - Replace it in case of failures. - Fit the float together with the pin and rod in its position and lock it with its screw.
N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
- Insert the ball in the corresponding accelerating pump. - Fit the spring. - Fit the accelerating pump nozzle.
WARNING WHEN REFITTING, PAY SPECIAL ATTENTION TO THE COMPONENTS AS THEY ARE SMALL.
ENG - 135
Engine
Typhoon 50 4t 4v
- Check the diaphragm is in good conditions and remove the remaining components of the accelerating pump following these steps: - Insert the O-Ring in the pipe. - Insert the diaphragm together with the pin and its spring.
N.B. REPLACE THE DIAPHRAGM IF THERE ARE SIGNS OF UNDULATIONS, CRACKS OR HARDENING.
- Fit the accelerating pump diaphragm cover and tighten the 2 fixing screws making sure the spring below is correctly positioned. - Fit the rubber bellows protecting the pin in the upper part of the accelerating pump.
Level check
- Tilt the carburettor so that the needle valve at the fuel supply is closed and the float weight does not affect it. - Check that the diaphragm closing line and the float central line are parallel as shown in the figure.
- Blow air in to the tank and then assembly it and its gasket on the carburettor body with the 3 fixing screws.
N.B. -ALWAYS USE NEW RINGS AND GASKETS FOR REFITTING. WARNING THE SCREW IN THE TANK BOTTOM IS A BLEEDING ONE AND CONSEQUENTLY IT ONLY REQUIRES CLEANING.
ENG - 136
Typhoon 50 4t 4v
Engine
- Insert the diaphragm into the throttle valve. - Insert the tapered pin together with the plastic support and the contrast spring into the throttle valve.
N.B. PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH FACING THE INNER SIDE OF THE MEMBRANE TO BE ABLE TO FIT THE LOWER END OF THE THROTTLE VALVE SPRING.
- Fit the vacuum chamber cover with the 2 fixing screws paying special attention to the spring.
Characteristic
Protrusion value 0.452756 in (11.5 mm) Ambient temperature 75.2F (24C)
ENG - 137
Engine
Typhoon 50 4t 4v
- The starter should disconnect progressively by means of electric heating. - Check the starter resistance when adjusted to the ambient temperature.
Characteristic
Ambient temperature 75.2F (24C)
Electric characteristic
Automatic starter resistance 20 5 % - Use battery to power the automatic starter and check that piston protrudes as much as possible. - The correct warm up time depends on the ambient temperature. - If protrusion, resistance or timing values are different from the ones prescribed, replace the starter.
Characteristic
Battery 12V-9Ah Max. protrusion 0.590551 in (15 mm) max. time 15 min - Fit the starter, the support bracket and the protection with the screw indicated in the figure.
ENG - 138
Typhoon 50 4t 4v
Engine
- Insert rubber pipes for chamber ventilation. - Insert the O-Ring, the washer, the spring and the idle flow screw in their seats.
- Refit the carburettor on the engine and connect again the accelerator cable with the sheath and the support plate and the electrical connection of the starter. - Reconnect the fuel supply pipe and tighten the 2 clamping screw fixing the carburettor to the inlet manifold and the air inlet coupling to the filter.
Specific tooling
020331Y Digital multimeter
ENG - 139
Engine
Typhoon 50 4t 4v
- Using the rpm indicator in the analyser or a separate one, adjust the idle screw.
N.B. THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED.
Specific tooling
020332Y Digital rpm indicator
Characteristic
Idle speed about 1900/2000 rpm
ENG - 140
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
Typhoon 50 4t 4v
Loosen the wheel axle safety screws on the fork leg, on the odometer gear side.
SUSP - 142
Typhoon 50 4t 4v
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 RELATIVE WHEEL IS REMOVED. BY DOING SO, THE CALLIPER PISTONS COULD COME OUT FROM THEIR HOUSING AND BRAKE FLUID LEAKAGE MIGHT ALSO OCCUR.
Specific tooling
001467Y013 Pliers to extract 15-mm bearings 001467Y005 Screw 001467Y004 Lug / Taper pin Insert the bell and the relative nut and remove the bearing.
Specific tooling
001467Y003 Nut 001467Y009 Bell for OD 42-mm bearings
SUSP - 143
Suspensions
Typhoon 50 4t 4v
Use handle, adaptor and guide, place the wheel on supports and hit with a mallet on the brake side to extract the bearing.
Specific tooling
020376Y Adaptor handle 020456Y 24-mm adaptor 020412Y 15-mm guide
When refitting heat the brake side bearing seat with an appropriate heater gun.
Specific tooling
020151Y Air heater
SUSP - 144
Typhoon 50 4t 4v
Suspensions
Use adaptor, handle and guide to drive the bearing into its seat.
Specific tooling
020376Y Adaptor handle 020456Y 24-mm adaptor 020412Y 15-mm guide
With an appropriate heater gun heat the seat of the bearing on the side the odometer detects movement.
Specific tooling
020151Y Air heater
SUSP - 145
Suspensions
Typhoon 50 4t 4v
Use adaptor, handle and guide to drive the bearing into its seat.
Specific tooling
020376Y Adaptor handle 020456Y 24-mm adaptor 020412Y 15-mm guide
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 odometer drive. Holding the wheel axle, lock the nut on the opposite side to the specified torque.
SUSP - 146
Typhoon 50 4t 4v
Suspensions
Screw in the wheel axle locking screws. Make the fork travel to adjust the fork legs on the wheel axle. Tighten the safety screws on the fork leg to the specified torque with the "external-internal-external" sequence.
Handlebar Removal
- Remove the front and rear handlebar covers. - Detach the front brake pump from the handlebar. - Disconnect the rear brake, throttle control and odometer control cables. - Remove the screw fixing the handlebar to the steering tube. - Remove the handlebar.
See 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 specified torque.
SUSP - 147
Suspensions
Typhoon 50 4t 4v
REMOVING THE STANCHIONS - Remove the legshield. - Remove the brake calliper. - Remove the front wheel. - Remove circlip 7, the two screws 8 and slide off the stanchion. - Unscrew the upper cap 6. - Remove the components including the spring. - Drain the oil into a collecting container.
SUSP - 148
Typhoon 50 4t 4v
Suspensions
See also
Legshield Removal Removing the front wheel
Overhaul
STANCHION INSPECTION - Check the sliding surface for scorings and/or scratches. - If the scorings are deep, replace the stanchion. SLEEVE INSPECTION - Check that it is not damaged and/or cracked. - If there are signs of excessive wear or damage, replace the affected component. - Replace the oil seal 4 and the dust gaiter 5 and fit it once you have lubricated their seat. - Replace the O-ring on the inner cap 1 - Replace sealing washer 2.
Refitting
Refit the stem and the pumping member and tighten screw 3 with its washer 2 to the specified torque. Pour the recommended quantity of specific oil into the stanchion unit. Insert the spring and components. Tighten the upper cap 6 to the specified torque.
SUSP - 149
Suspensions
Typhoon 50 4t 4v
Introduce the stanchion in the bottom yoke and install the circlip 7. Push on the upper cap 6 until the circlip touches the bottom yoke. Tighten the screws 8 to the specified torque.
Recommended products
AGIP FORK 7.5 W Oil for fork. -
Characteristic
Fork stem (oil level height without spring, compressed fork) 3.35 in (85 mm)
SUSP - 150
Typhoon 50 4t 4v
Suspensions
Park the vehicle on its centre stand. Place a support under the vehicle so that the wheel can move freely and the vehicle does not fall. Remove the handlebar. - Remove the front shield. Remove the front brake calliper. Release the fork from the odometer cable and from the front brake calliper pipe. Loosen the upper ring nut 1 and collect the shim washer 2.
Specific tooling
020055Y Wrench for steering tube ring nut
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 bearing B from the steering tube.
- Wash carefully all the parts removed. - To refit, carry out the removal operations but in reverse order. - Appropriately lubricate the bearings with recommended products. SUSP - 151
Suspensions
Typhoon 50 4t 4v
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 figure. - Remove the lower bearing B seat 6 on the headstock by inserting the punch from the top on the headstock.
Specific tooling
020004Y Punch for removing fifth wheels 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
020004Y Punch for removing fifth wheels from headstock
SUSP - 152
Typhoon 50 4t 4v
Suspensions
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: - Position the vehicle on the centre stand. - Place a support under the motorcycle in such a way that the front wheel is able to move freely and the vehicle does not fall. When carrying out this operation, pay attention not to mistake the centre stand clearance with that of the steering. Repeat this test many times before deciding if the steering clearance must be adjusted. - Hold the fork sleeves and pull the fork forwards and backwards, with the steering in forward position. - There should be no clearance forward or backward If there is clearance, the steering must be adjusted. ADJUSTING THE BEARING CLEARANCE - Remove the front shield. - 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.
Keep the lower ring nut 3 in position, by using a specific wrench and tighten the upper ring nut 1 to the specified torque. Check again the bearings clearance. SUSP - 153
Suspensions
Typhoon 50 4t 4v
Specific tooling
020055Y Wrench for steering tube ring nut
See also
Legshield
Pull the rear brake and hold it in. Unscrew the wheel fixing nut and collect the washer. Take out the wheel from its housing.
See also
Exhaust assy. Removal
SUSP - 154
Typhoon 50 4t 4v
Suspensions
Swing-arm Removal
Rest the vehicle on its centre stand. Support the engine adequately. Unscrew the nut on the left-hand side of the frame and remove the pin from the opposite side.
Unscrew the nut on the left-hand side of the engine and remove the pin from the opposite side.
Overhaul
Regularly check the clearance of the swinging arm retainer pins. To carry out these operations, proceed as follows: - Position the vehicle on centre stand. - Hold the rear wheel firmly and try to move it perpendicularly to the travel direction. - If there is any clearance, check all the fastening elements that connect the swinging arm to the engine and chassis as well as the condition of the silent block. SUSP - 155
Suspensions
Typhoon 50 4t 4v
Refitting
For refitting, follow the previous operations but in reverse order.
Undo the inner nut and slide off the shock-absorber to engine lower fixing screw. Remove the shock absorber. To refit tighten the screws to the prescribed tightening torque.
See also
Side fairings
Centre-stand
Remove the stand return spring.
CAUTION SUPPORT THE VEHICLE ADEQUATELY. CAUTION TO PREVENT INJURY AND DAMAGE THE SPRING MUST BE REMOVED WITH THE CENTRE STAND UP.
SUSP - 156
Typhoon 50 4t 4v
Suspensions
Undo the nut shown in the figure. Remove the pin from the right side. Remove the stand.
SUSP - 157
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Typhoon 50 4t 4v
Braking system
Refitting
Refit the calliper on the support and tighten the screws to the specified torque. Refit the tube complete with fitting with new copper gaskets. Place the tube joint in the original position and tighten it to the specified torque. Bleed the air from the system.
See also
Front
Braking system
Typhoon 50 4t 4v
Removal
Proceed as follows: - remove the front wheel. - Loosen the disc fixing screws. - Remove the brake disc.
Refitting
When refitting, position the disc correctly making sure that it rotates in the direction indicated on the disc itself.
Disc Inspection
- Check the disc thickness.
Characteristic
Disc minimum thickness 0.1378 in (3.5 mm)
Typhoon 50 4t 4v
Braking system
Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.0039 in (0.1 mm).
If a value other than that prescribed is detected, remove the front wheel and check how much the disc protrudes. The size measured must be within 0.0039 in (0.1 mm). If it is greater replace the disc and conduct the test again.
If the problem persists, check and replace the wheel rim if necessary.
Specific tooling
020335Y Magnetic support for dial gauge
See also
Removing the front wheel
Braking system
Typhoon 50 4t 4v
- Check the thickness of the friction material. If thinner than the minimum value, replace it.
Characteristic
Minimum friction material thickness 0.0591 in (1.5 mm)
- In case of uneven wear, replace the brake pads when the friction material thickness difference is 0.0197 in (0.5 mm).
CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
Typhoon 50 4t 4v
Braking system
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.
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 'SPONGINESS' 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 REGULAR MAINTENANCE OPERATIONS. - To access the brake fluid reservoir the right rearview mirror must be removed. Remove the reservoir protection and undo the indicated screws. - Once the bleed valve is closed, fill the system with brake fluid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system. The operation is finished when just oil comes out of the bleed screws. -Do up the bleed screw.
Braking system
Typhoon 50 4t 4v
-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, EXAMINE ALL THE FITTINGS: IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, 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 ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. 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 FREQUENTLY. 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
020329Y Mity-Vac vacuum-operated pump
Recommended products
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4
Typhoon 50 4t 4v
Braking system
- 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.
See also
Front handlebar cover Rear handlebar cover
Braking system
Typhoon 50 4t 4v
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 Transmission replacement - Remove the front handlebar cover. - Remove the leg shield and the footrest. - Loosen the brake set screw - Release the transmission from its retainers to the engine.
Release the transmission from the retainers on chassis and from the control lever. Fit the new transmission, fixing and positioning it like the one replaced. Adjust the drum brake activation point.
Typhoon 50 4t 4v
Braking system
See also
Front handlebar cover Legshield Footrest
INDEX OF TOPICS
CHASSIS
CHAS
Typhoon 50 4t 4v
Chassis
Seat
Undo the nuts indicated in the figure and collect the washers.
Driving mirrors
Undo the screws indicated.
CHAS - 169
Chassis
Typhoon 50 4t 4v
- Disconnect the connectors of the instrument panel and the odometer cable. - Remove the handlebar cover together with the instrument panel and controls.
See also
Front handlebar cover
Instrument panel
Remove the rear handlebar cover. Undo the screws indicated.
See also
Rear handlebar cover
CHAS - 170
Typhoon 50 4t 4v
Chassis
Undo the front screw. Disconnect the connectors of the turn indicators.
See also
Driving mirrors
Headlight assy.
- Remove the front shield. Undo the screws indicated.
FRONT TURN INDICATORS Remove the front handlebar cover. Unscrew the indicated nuts.
See also
Legshield Front handlebar cover
CHAS - 171
Chassis
Typhoon 50 4t 4v
Legshield
Remove the shield back plate. Working from the front wheel housing internal side, undo the screws from both sides of the vehicle.
- Move the leg shield forward, opening the lower ends and detach the headlight bulb connections.
CHAS - 172
Typhoon 50 4t 4v
Chassis
Knee-guard
Remove the front handlebar cover. Undo the indicated screws on the sides of the leg shield back plate.
Undo the screw in the glove-box and the one under the chassis number lid. Before refitting the leg shield back plate, loosen the footrest fixing screws, so as to fit the two components 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 handlebar cover
CHAS - 173
Chassis
Typhoon 50 4t 4v
- Undo the upper screw. - Slide the housing off the fork stanchions.
See also
Legshield Front mudguard Removing the front wheel
Footrest
- Remove the shield back plate. - Remove the side fairings. - Undo the indicated screws and remove the protections.
CHAS - 174
Typhoon 50 4t 4v
Chassis
See also
Knee-guard Side fairings
Side fairings
Remove the rear handles. Remove the rear central cover. Undo the screws indicated.
- Undo side screw from both sides of the vehicle. Undo the screws on the helmet compartment.
CHAS - 175
Chassis
Typhoon 50 4t 4v
- 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 - 176
Typhoon 50 4t 4v
Chassis
- Undo the two screws indicated. - Remove the license plate support together with the turn indicators.
See also
Side fairings
CHAS - 177
Chassis
Typhoon 50 4t 4v
Rear mudguard
- Undo the right-hand side screw.
Helmet bay
Remove the side panels Remove the battery cover and the battery. Undo the two screws inside the helmet compartment.
- Disconnect the fuse box and free the helmet compartment from the cables.
See also
Side fairings CHAS - 178
Typhoon 50 4t 4v
Chassis
Battery
spoiler
Remove the footrest. Undo the screws indicated.
- Undo from both sides of the vehicle the screw placed under the footrest.
See also
Footrest
Fuel tank
CAUTION
BEFORE REMOVING THE FUEL TANK REMOVE THE FUEL FROM THE TANK ITSELF. Remove the side fairings and the helmet compartment. - Detach the pipes from the vacuum-operated cock.
CHAS - 179
Chassis
Typhoon 50 4t 4v
Disconnect the fuel probe connector and detach the breather pipe from the filler.
See also
Helmet bay Side fairings
CHAS - 180
Typhoon 50 4t 4v
Chassis
See also
Seat
Front mudguard
- Operating from both sides of the vehicle, undo the three indicated screws.
CHAS - 181
Chassis
Typhoon 50 4t 4v
Battery
Undo the indicated screws and remove the battery cover.
- Disconnect the negative and positive cables. - Slide off the breather pipe.
CHAS - 182
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
Typhoon 50 4t 4v
Aesthetic inspection
Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt
Electrical system
Electrical system: - Main switch - Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights - Adjusting the headlights according to the regulations currently in force - Rear light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel gauge - Instrument panel warning lights - Horn - Starter PRE DE - 184
Typhoon 50 4t 4v
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 NEGATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC 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. KEEP OUT OF THE REACH OF CHILDREN
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 - 185
Pre-delivery
Typhoon 50 4t 4v
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
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 - 186
A
Air filter: 32
B
Battery: 43, 54, 61, 68, 179, 182 Brake: 147, 159, 161, 165 Bulbs:
C
Carburettor: 28, 131, 134 Checks: 59
E
Engine oil: 33
F
Fuel: 129, 179 Fuses: 67
H
Headlight: 38, 171 Horn: 65 Hub oil: 31
I
Identification: 7 Instrument panel: 170
M
Maintenance: 6, 28 Mirrors: 169, 171
O
Oil filter: 34, 35
R
Recommended products:
S
Shock absorbers: 156 Spark plug: 29, 59 Suspension: 43
T
Tank: 179
V
Vehicle: 7, 78