Beruflich Dokumente
Kultur Dokumente
633507
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WORKSHOP MANUAL
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The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. " Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited." PIAGGIO & C. S.p.A. - After-Sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
WORKSHOP MANUAL
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This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS TOOLING MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE SUSPENSIONS BRAKING SYSTEM COOLING SYSTEM CHASSIS PRE-DELIVERY TIME
CHAR TOOL MAIN TROUBL ELE SYS ENG VE ENG SUSP BRAK SYS COOL SYS CHAS PRE DE TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
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Characteristics
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, 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. - For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling members and tools may damage the scooter. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.
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Characteristics
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Vehicle identification
VEHICLE IDENTIFICATION
Specification Frame prefix Engine prefix Desc./Quantity ZAPC2700000001001 C271M
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Characteristics
Engine
ENGINE
Specification Motor Engine capacity Bore x stroke Compression ratio Supply. Desc./Quantity Fluid-cooled, two-cycle, single-cylinder. 49 cm 40 X 39.3 mm 11.3 12.8 : 1 With high-octane, 95 N.O.R. lead-free petrol mix - oil via carburettor, automatic mixer (with variable capacity depending on the engine speed and opening of throttle valve) petrol pump. By means of a compression valve on the casing PHVA 17.5 Engine lubrication (piston, cylinder, crankshaft, main bearings) with mixer oil.
Transmission
TRANSMISSION
Specification Transmission Desc./Quantity With automatic expandable pulley variator, torque server, V belt, automatic clutch, gear reduction unit.
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Characteristics
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Capacities
CAPACITIES
Specification Fuel tank Oil mixer tank Rear hub oil Desc./Quantity Plastic, capacity ~ 9 lt. (including reserved ~ 1.2 lt.). In plastic, of capacity ~ 1.3 lt. (including reserve ~ 0.500 lt.) ~ 85 cc
Electrical system
ELECTRICAL SYSTEM
Specification Electronic ignition Spark advance (Before T.D.C.) Spark plug Battery Main fuse Generator Desc./Quantity A capacitor discharge microprocessor device, with built-in HV coil. 201 at 4000 rpm CHAMPION RN1C 12V-4Ah 7.5 A In alternate current with three output sections
Brakes
BRAKES
Specification Front brake Rear brake Desc./Quantity 240 mm dia. disc brake with hydraulic control activated from handlebar with right lever 200 mm dia. disc brake with hydraulic control activated from handlebar with left lever
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Characteristics
Secondary air
To clean the sponge filters of the secondary air system, proceed as follows: Unscrew the two studs ( 2) of the aluminium lid of the secondary air box to access the polyurethane sponge contained inside the box; after cleaning with water and neutral soap, dry the sponge with a clean cloth and reassemble the system, checking that the steel blade is not warped and/or does not guarantee the seal on its strike surface; replace if necessary.
N.B. UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMINIUM COVERS. CAUTION DURING THE OPERATION, CHECK THE INTEGRITY AND SEAL OF THE TWO SLEEVES (3) IN RUBBER LOCATED AT THE ENDS OF THE SECONDARY AIR HOSE; IF NECESSARY, REPLACE THEM USING NEW CLAMPS TO FASTEN.
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Characteristics
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Tightening Torques
STEERING ASSEMBLY
Name Upper steering ring nut (safety locks) Lower steering ring nut (safety locks) Handlebar fixing pin (safety locks) Torque in Nm 35 to 40 Nm 8 to 10 Nm 45 to 50 Nm
FRAME ASSEMBLY
Name Swinging arm-engine pin (safety locks) Swinging arm-frame pin (safety locks) Shock absorber - frame nut (safety locks) Shock absorber-engine pin (safety locks) Rear wheel axis (safety locks) Bolt holding stand to the engine Side stand fixing screw Side stand bracket fixing screw Rear rim fixing screw Torque in Nm 33 to 41 Nm 64 to 72 Nm 20 to 25 Nm 33 to 41 Nm 104 to 126 Nm 18 to 19 Nm 12 20 15 20 2025
FRONT SUSPENSION
Name Front wheel axle Wheel axle clamp screw Lower leg screw Hydraulic cartridge stem nut Torque in Nm 45 50 6 7 Nm 15 to 20 Nm 15 to 18 Nm
FRONT BRAKE
Name Viti fissaggio coperchio pompa freno Brake pump support fixing screw Brake fluid pump - hose fitting Brake fluid tube - calliper fitting Calliper tightening screw Disc tightening screw (safety locks - lock with LOCTITE THREADLOCK MEDIUM TYPE 243) Oil bleed screw Calliper coupling screw Torque in Nm 1,5 2 Nm 7 to 10 Nm 13 to 18 Nm 20 to 25 Nm 20 to 25 Nm 6 7 Nm 7 to 10 Nm 20 to 25 Nm
REAR BRAKE
Name Fastening screws calliper to the crankcase Brake reservoir cover fixing screw Brake pump support fixing screw Brake fluid pump - hose fitting Brake fluid tube - calliper fitting Oil bleed screw Torque in Nm 20 - 25 24 Nm (Grimeca) - 0,81,5 Nm (Brembo) - 1,52 Nm (Hengtong) 7 to 10 Nm 13 to 18 Nm 20 to 25 Nm 7 to 10 Nm
ENGINE ASSEMBLY
Name Clutch bell nut Clutch lock ring nut nut locking driving pulley on the crankshaft Start-up lever screw Flywheel nut Flywheel fan screws Half-crank case joint bolts Bolts holding exhaust pipe to the crankcase Screws holding the filter box to the crank case Head nuts Starter screws Torque in Nm 40 to 44 Nm 55 60 40 to 44 Nm 12 13 40 to 44 Nm 34 12 13 22 24 45 10 11 12 13
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Characteristics
Name Ignition spark plug Hub oil drainage cap Oil hub level dipstick Rear hub cap screws Transmission cover screws Inlet manifold screws Flywheel hood fixing screws Cylinder hood fixing screws Stator clamping screws Pick-Up clamping screw Mixer clamping screws Screw fixing brake lever to the journal on the engine
Piston rings
SEALING RINGS
Name Compression ring Compression ring 1st oversize Compression ring 2nd Oversize Description Dimensions 40 40.2 40.4 Initials A A A Quantity 0.10 to 0.25 0.10 to 0.25 0.10 to 0.25
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Characteristics
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13.75+0.040
13.75+0.040
40.64
11.800-0.35
Specific tooling
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Characteristics
Products
TABLE OF RECOMMENDED PRODUCTS
Product AGIP ROTRA 80W-90 AGIP CITY HI TEC 4T Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Oil to lubricate flexible transmissions Oil for 2-stroke engines: SAE 5W-40, API (brake, throttle control and mixer, odomSL, ACEA A3, JASO MA eter) Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness Mixer oil synthetic oil for 2-stroke engines: JASO FC, ISO-L-EGD Grease for brake levers, throttle White calcium complex soap-based spray grease with NLGI 2; ISO-L-XBCIB2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-LXBCHB2, DIN KF2K-20 Brake fluid FMVSS DOT 4 Synthetic fluid Grease for driven pulley shaft adjusting Grease with molybdenum disulphide ring and movable driven pulley housing Grease for the steering bearings, pin White anhydrous-calcium based grease seats and swinging arm to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2. coolant Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16 Description Rear hub oil
AGIP FILTER OIL AGIP CITY TEC 2T AGIP GP 330 AGIP GREASE SM 2
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INDEX OF TOPICS
TOOLING
TOOL
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Tooling
TOOLS
Stores code 001330Y Description Tool for fitting steering seats
001467Y006
001467Y007
001467Y009
001467Y013
001467Y014
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Tooling
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001467Y021
002465Y
006029Y
020004Y
020209Y
Spring hook
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Tooling
020074Y
020150Y
020151Y
Air heater
020162Y
Flywheel extractor
020163Y
TOOL - 19
Tooling
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020165Y
020166Y
020167Y
020168Y
020169Y
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Tooling
020261Y
020262Y
020265Y
020325Y
020329Y
TOOL - 21
Tooling
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020331Y
Digital multimeter
020332Y
020334Y
TOOL - 22
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Tooling
020350Y
020357Y 020359Y
020376Y
Adaptor handle
020412Y
15 mm guide
TOOL - 23
Tooling
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Description 24 mm adaptor
020483Y
30 mm guide
020565Y
TOOL - 24
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
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Maintenance chart
EVERY 2 YEARS
Action Brake fluid - change Coolant - change
AT 1000 KM OR 4 MONTHS
50'
Action Hub oil - change Oil mixer/throttle linkage - adjustment Steering - adjustment Brake control levers - greasing Coolant level - check Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test
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Maintenance
AT 30000 KM
130'
Action Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idling speed (*) - adjustment Oil mixer/throttle linkage - adjustment Driving belt - replacement Variable speed rollers - replacement Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Flexible brake tubes - replacement Brake fluid level - check Transmission elements - lubrication
MAIN - 27
Maintenance
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Action Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check SAS box (sponge) (**) - cleaning Vehicle and brake test - road test (**) See the regulations of the "Secondary air system" section
AT 60000 KM
160'
Action Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idling speed (*) - adjustment Oil mixer/throttle linkage - adjustment Driving belt - replacement Variable speed rollers - replacement Mixer belt - replacement Coolant level - check Radiator - external cleaning/ check Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Flexible brake tubes - replacement Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check SAS box (sponge) (**) - cleaning Vehicle and brake test - road test (**) See the regulations of the "Secondary air system" section
Specific tooling
020330Y Stroboscopic light to check timing MAIN - 28
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Maintenance
Spark plug
-Put the vehicle on its centre stand; -Disconnect the cap of the spark plug HV lead; -Unscrew the spark plug using a pipe spanner; -Examine the conditions of the spark plug, make sure its isolation is not damaged, measure the distance between the electrodes using the specific feeler gauge. -Adjust the distance if necessary carefully bending the side electrode. If the spark plug is defective replace it with the prescribed type; - Insert the spark plug with the correct inclination, screw it down by hand, then lock with a spanner to the prescribed torque; -Put the cap tightly back on the spark plug;
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5000 KM. USE OF STARTERS NOT CONFORMING OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Electrode gap 0.6 0.7 mm Spark plug CHAMPION RN1C
Hub oil
MAIN - 29
Maintenance
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Check
To check the hub oil level, proceed as follows: 1. Place the scooter on its stand on a level surface; 2. Unscrew the dipstick A, dry it with a clean rag and then reinsert it, screwing it tightly into place; 3. Unscrew the dipstick again and check that the oil level barely reaches the 2nd notch from the bottom; 4. Screw the dipstick back into place completely. The screw B is the hub oil drainage tap.
CAUTION
USING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH THE WRONG LUBRICANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY CAUSE SERIOUS DAMAGE. CAUTION
USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOR OIL REPLACEMENT, CONTACT AN AUTHORISED SERVICE CENTRE, WHICH IS EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY. N.B. THE NOTCHES ON THE HUB OIL LEVEL DIPSTICK, EXCEPT THOSE INDICATING THE MAXIMUM AND MINIMUM LEVELS, REFER TO OTHER MODELS BY THE MANUFACTURER, AND HAVE NO SPECIFIC FUNCTION FOR THIS MODEL.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Characteristic
Rear hub oil Quantity: approx. 85 cc
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Maintenance
Replacement
- Remove oil filler cap A. - Loosen oil draining cap B and allow for the system to drain completely. - Refit the draining cap and refill the hub with the prescribed oil.
Characteristic
Rear hub oil ~ 85 cc
Air filter
-Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter. Cleaning: -Wash with water and neutral soap. - Dry with a clean cloth and short blasts of compressed air. -Saturate with a 50% mixture of gasoline and oil. -Drip dry the filter and then squeeze it between the hands without wringing. -Let it dry and refit it again.
CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.
Recommended products
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness
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Maintenance
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transmissions
During this phase the engine must be fuelled with a 2% mixture (at least 0.5 litres if the tank is empty). Remove the carburettor guard. Start the vehicle and adjust the idle using the adjusting screw A on the carburettor. Adjust the control wires: Handle control: remove the rubber cap and adjust the lead adjusting screw so that there is no play in the gas handle. Carburettor control: remove the rubber cap and adjust the lead adjusting screw so that there is no play in the shielding. Mixer control: remove the cap on the crankcase and adjust the adjusting screw so that when the gas handle is released the reference mark on the rotating plate is aligned with the reference mark on the mixer body as shown in the figure. Move the gas handle to the end of its stroke a few times and make sure the adjustments have been made correctly, then lock all the adjusting screws.
CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN THE RESERVOIR BLEED THE MIXER AS FOLLOWS: REFILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE MIXER PIPE FROM THE CARBURETTOR AND LOOSEN THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE) UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH THE RELEVANT METAL CLIP.
Recommended products
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO FC, ISOL-EGD
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Maintenance
Top-up
Proceed as follows: - Remove the tank cap by loosening the two screws, remove the gasket and top up using only the liquid specified without exceeding the maximum level.
CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK. CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS, IT ABSORBS MOISTURE FROM MAIN - 33
Maintenance
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THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS.
N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
Headlight adjustment
Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen; 2. Turn on the headlight and check that the borderline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and higher than 7/10; 3. If otherwise, adjust the right headlight with screw A.
N.B. 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.
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INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Troubleshooting
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This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given.
Starting difficulties
DIFFICULTY STARTING
Possible Cause Carburettor nozzles clogged or dirty Defective fuel pump or damaged depression line Starter inefficient Battery flat Operation Dismantle, wash with solvent and dry with compressed air Replace the pump or control lines Check: electric wiring, circuit continuity, mechanical sliding and power supply Check the state of the battery. If it shows signs of sulphation replace it and bring the new battery into service charging it for eight hours at a current of 1/10 of the capacity of the battery itself Start up keeping the throttle fully open alternating approximately five seconds of turning it with five seconds still. If however it does not start, remove the spark plug, the engine over with the throttle open being careful to keep the cap in contact with the spark plug and the spark plug grounded but away from its hole. Refit a dry spark plug and start the vehicle. Drain off the fuel no longer up to standard; then, refill Remove the encrustation, restore the plug gap or replace being sure to use the types of spark plug recommended at all times.
- Engine flooded.
Altered fuel characteristics Defective spark plug or with incorrect electrode gap
TROUBL - 36
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Troubleshooting
Possible Cause
Operation Bear in mind that many problems engines have, derive from the use of the wrong spark plug Replace the intake joint and check its tightness on the crankcase and on the carburettor Replace
TROUBL - 37
Troubleshooting
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Operation Check: electric wiring, circuit continuity, mechanical sliding and power supply
Engine overheating
ENGINE OVERHEATING
Possible Cause Lack of liquid in the cooling circuit. Incorrect air bleeding Thermostat remains closed Liquid leak from the radiator Liquid leak from the system Bearings shaft support impeller blocked Breakage of mixer belt Operation Restore the level and check the absence of losses from the circuit Repeat the operation Replace Replace radiator Overhaul of the system Replace the bearings and the shaft with impeller Replace the belt and check that the thermal unit has not been damaged
SAS malfunctions
SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUFFLER
Possible Cause Secondary air reed blocking Secondary air filter clogging Blockage of the secondary air fitting on the muffler Operation Replace Clean the filter and the housing Remove the encrustations from the joint being careful not to let the debris fall into the muffler
Check that the masses open and return normally Check that there is no grease on the masses Check that the clutch masses' contact surface with the clutch bell is mainly in the middle with characteristics equivalent on the three masses Check that the clutch bell is not scored or worn abnormally Never operate the engine without the clutch bell
Insufficient braking
INSUFFICIENT BRAKING
Possible Cause Inefficient braking system Operation Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the front brake calliper moves in axis with the disc.
TROUBL - 38
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Troubleshooting
Brakes overheating
OVERHEATING BRAKES
Possible Cause Brake disc slack or distorted Operation 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.
Heavy steering
STEERING HARDENING
Possible Cause Torque not conforming Operation
Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the above adjustments, check TROUBL - 39
Troubleshooting
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Possible Cause
Operation
the seats in which the ball bearings rotate: replace if they are recessed.
Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.
Noisy suspension
NOISY SUSPENSION
Possible Cause Components of the front suspension damaged. Operation Check the quiet operation in the compression or release phases of the fork and if necessary overhaul it. Check that there is no noise or seizing during the wheel rotation; if there is, change the wheel bearing. Check the absence of noise in the compression or release of the suspension, if necessary check the proper tightness to the swinging arm unit and the absence of rust or replace the entire shock absorber. Check that there is no noise or seizing during the wheel rotation; if there is noise or seizing overhaul the final reduction assembly.
TROUBL - 40
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
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1. Electronic ignition device 2. Spark plug 3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 8. Starter motor 9. Starter relay 10. Starter button 11. Stoplight switch on rear brake 12. Stoplight switch on front brake 13. Turn signal switch 14. Low-oil warning light sender 15. Automatic choke 16. Thermal switch 17. Antitheft LED pre-wiring 18. Antitheft box pre-wiring 19. Phonic wheel encoder 20. Fuel level sender ELE SYS - 42
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Electrical system
21. Blinker switch 22. Headlight switch 23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight 24. Headlight A. Turn signal light bulb B. Low-beam light bulb C. High-beam light bulb 25. Horn button 26. Horn 27. Dashboard assy. A. Low-oil warning light B. Dashboard light bulbs 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
Conceptual diagrams
ELE SYS - 43
Electrical system
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Ignition
ELE SYS - 44
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Electrical system
3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 15. Automatic choke 21. Blinker switch 22. Headlight switch 23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight 24. Headlight A. Turn signal light bulb B. Low-beam light bulb C. High-beam light bulb 27. Dashboard assy. A. Low-oil warning light
ELE SYS - 45
Electrical system
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3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 8. Starter motor 9. Starter relay 10. Starter button 11. Stoplight switch on rear brake 12. Stoplight switch on front brake 14. Low-oil warning light sender 23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight 27. Dashboard assy. A. Low-oil warning light ELE SYS - 46
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Electrical system
3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 14. Low-oil warning light sender 16. Thermal switch 19. Phonic wheel encoder 20. Fuel level sender 27. Dashboard assy. A. Low-oil warning light B. Dashboard light bulbs
ELE SYS - 47
Electrical system
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3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 13. Turn signal switch 23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight 24. Headlight A. Turn signal light bulb B. Low-beam light bulb C. High-beam light bulb 25. Horn button 26. Horn 27. Dashboard assy. A. Low-oil warning light
ELE SYS - 48
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Electrical system
INSTRUMENT UNIT CONNECTOR 1. Rpm signal 2. Fuel signal 3. Water temperature signal 4. Spare 5. Earth 6. Phonic wheel signal 7. Oil level 8. Parking lights 9. Oil check 10. Phonic wheel supply 11. Under key positive 12. Battery positive 13. Phonic wheel earth 14. Left turn indicator 15. Right turn indicator 16. High beam lamp
Electrical system
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1. Rpm counter 2. Fuel warning lamp 3. Oil mix warning lamp 4. Parking light lamp 5. High beam lamp 6. Turn indicator lamp 7. Temperature indicator 8. Fuel level indicator 9. Speedometer 10. Odometer 11. Digital display buttons
After visually checking the electrical wiring, perform measurements on the loading reel, the pickup (see chart) and the continuity using the appropriate tester. If checks on the loading reel, pickup and continuity show abnormalities, replace the stator; otherwise replace the central unit. Remember that disconnections due to replacement of the central unit must be done with the engine off.
Specific tooling
020331Y Digital multimeter
ELE SYS - 50
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Electrical system
CHECK CONTINUITY
1 2 Specification White cable-frame White cable-engine Desc./Quantity continuity continuity
Ignition circuit
All the control operations of the system that require the disconnection of cables (checks of the connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irreparably damaged.
Stator check
- Using a tester, check the resistance between the red-ground and green-ground terminal.
N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE LEADS TO VALUES HIGHER THAN THOSE STATED.
Electric characteristic
Stator : green - ground ~ 1 (Stator) Pick-Up: red - ground approx. 170 (Pick-Up)
ELE SYS - 51
Electrical system
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Specific tooling
020331Y Digital multimeter
Characteristic
Voltage distributed at 3000 rpms 25 to 30V FAULT 3 After checking that there are no short circuits in the system towards the earth, replace the regulator because it is certainly inefficient and replace it with a protective fuse. Following the replacement, measure the current and the recharging voltage on the battery end. ELE SYS - 52
DNA 50
Electrical system
FAULT 4 Start the vehicle and make sure that when the tester is placed between the connection of the red wire and yellow one on the stator, the voltage delivered by the generator is within the indicated value. In the event of a fault check the continuity of the stator or continue with the checks. Insert an ammeter between the stator (red wire) and the battery and use a tester to make sure that the current delivered at 3000 rpm and the battery maintained between 12 and 13 V is as indicated. If the measured values are lower than those prescribed, replace the regulator otherwise replace the battery.
N.B. BEFORE CARRYING OUT THE CHECKS ON THE REGULATOR AND RELATIVE SYSTEM, IT IS ALWAYS GOOD PRACTICE TO CHECK THAT THERE IS CONTINUITY BETWEEN THE BLACK CABLE AND THE GROUND. N.B. TO KEEP THE BATTERY BETWEEN 12 AND 13V, CAUSING CURRENT ABSORPTION BY THE SYSTEM, A 12V - 35W BULB CONNECTED BETWEEN THE + BATTERY AND GROUND CAN BE USED.
Specific tooling
020331Y Digital multimeter
Characteristic
Distributed current 1.5 to 2A Voltage distributed at 3000 rpms 25 to 30V FAULT 5 If the turn indicators do not work, do the following: Without removing the connector from the voltage regulator, move the keycontrolled switch to ON and verify the presence of intermittent voltage between contact 7 and the ground. If there is voltage, the failure must be attributed to the flashing indicator switch
ELE SYS - 53
Electrical system
DNA 50
or the wiring, otherwise carry on with tests. With the engine off, remove the regulator connector, and insert the ends of the tester between contact 5 and the ground. Move the key controlled switch to ON and check there is battery voltage. If no voltage is detected, check the wiring and the contacts on the key switch and on the battery. Repeat the same procedure with the ends of the tester inserted between contact 5 (+) and 6 (-) and check the presence of the battery voltage with the key switch at on. If this does not happen, check the regulator's ground cable.
If these last two tests have a positive result replace the regulator because it is certainly not functioning properly.
Specific tooling
020331Y Digital multimeter
Fuses
The electrics are protected by a fuse located on the right side next to the battery well. To replace it, remove the transparent protection mounted on the fuse holder. The ignition system, front headlight and rear taillight are not protected by fuses.
CAUTION
BEFORE REPLACING THE BLOWN FUSE, SEARCH AND ELIMINATE THE BREAKDOWN THAT HAS LED TO THE BLOW OUT. NEVER TRY TO REPLACE A FUSE USING DIFFERENT MATERIAL (FOR EXAMPLE A PIECE OF ELECTRIC WIRE) OR A FUSE FOR A HIGHER AMPERAGE THAN THE INDICATED ONE.
Electric characteristic
ELE SYS - 54
DNA 50
Electrical system
Fuse 7.5 A
Sealed battery
Putting the watertight battery into operation INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a normal tester. - If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge. - If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 2) Constant voltage battery charge mode -Constant voltage equal to 14.4014.70V -Initial charge voltage equal to 0.30.5 for nominal capacity -Duration of the charge: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode -Charge current equal to 1/10 of the nominal capacity of the battery -Duration of the charge: 5 h
WARNING
-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Dry-charge battery
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF REACH OF CHILDREN Use of dry-cell batteries : 1. Having removed the short, closed tube and removed the caps, put into the elements sulphuric acid of the type for specific weight 1.26 accumulators corresponding to 30 B at a temperature of no less than 15, until you reach the upper level. ELE SYS - 55
Electrical system
DNA 50
2. Leave to stand for at least 2 hours; afterwards top-up to the level with sulphuric acid. 3. Within twenty four hours, recharge with the special (single or multiple) battery charger that recharges at an intensity the same as approximately 1/10 the rated capacity of the said battery. At the end of the charge, make sure that the density of the acid is around 1.27, 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 in the vehicle ensuring that it is wired up properly..
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
020333Y Single battery charger 020334Y Multiple battery charger 1 Hold the vertical tube 2 Look at the level 3 The float must be freed
Battery maintenance The battery is an electrical device which requires careful monitoring and diligent 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 it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear. 2)Load status check After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). When the battery is charged, you should detect a density of 30 to 32 B corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15 C. A density reading of less than 20 B indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. ELE SYS - 56
DNA 50
Electrical system
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 removing the negative clamp first. The normal bench charging must be carried out with the specific (single or multiple) battery charger, placing the battery charger selector on the type of battery to be recharged. The connections to the power supply must be made by connecting to the corresponding poles (+ with+ and -with -). 4) Battery cleaning The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
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.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Specific tooling
020334Y Multiple battery charger 020333Y Single battery charger
ELE SYS - 57
INDEX OF TOPICS
ENG VE
DNA 50
ENG VE - 59
DNA 50
ENG VE - 60
INDEX OF TOPICS
ENGINE
ENG
Engine
DNA 50
Kickstart
- Upon refitting, apply the recommended grease to the bushing, to the spring and along the toothed sector. - Use the special tool for the charging of the spring, as shown in the figure. - Refit the seeger ring after checking that it is in good condition.
Specific tooling
020261Y Starter spring fitting
Recommended products
AGIP GREASE MU3 Grease for odometer transmission gear case Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20
ENG - 62
DNA 50
Engine
- Remove the screws shown in the figure and remove the engine starting lever. - For the assembly, work in reverse and tighten the screws to the prescribed torque..
- Remove the seeger ring located on the exterior of the crankshaft. - Dismantle the dog gear from its seat, slackening the tension that the toothed sector applies to it by means of the spring; to do this, it is necessary to rotate the toothed sector slightly (see the figure).
CAUTION WHILE REMOVING THE TOOTHED SECTOR, BE VERY CAREFUL OF THE SPRING TENSION: IT COULD CONSTITUTE A HAZARD FOR THE OPERATOR.
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED SURFACE.
ENG - 63
Engine
DNA 50
Specific tooling
020565Y Flywheel lock calliper spanner
Characteristic
Clutch bell diameter/standard value 107+0.2 +0 mm Clutch bell diameter/max. value allowed after use 107.5 mm Eccentricity measured /max. 0.20 mm
ENG - 64
DNA 50
Engine
- Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw thereby undoing the driven pulley unit - Separate the components.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch
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 TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness 1 mm
ENG - 65
Engine
DNA 50
- Remove the three guide pins and the mobile half pulley.
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 DRIVING BELT
Specific tooling
020376Y Adaptor handle 020363Y 20 mm guide
Characteristic
ENG - 66
DNA 50
Engine
Stationary driven half-pulley/Standard diameter 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diameter admitted after use 33.96 mm
Characteristic
Mobile driven half-pulley/ Maximum diameter allowed 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 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 - Make sure the pins and collar are not worn, reassemble the pins and collar. - Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
ENG - 67
Engine
DNA 50
Specific tooling
020376Y Adaptor handle 020456Y 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for 17 mm roller case
Characteristic
Standard length 118 mm Minimum length allowed after use XXXX
ENG - 68
DNA 50
Engine
- 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 driving belt is not damaged and does not have cracks in the toothed grooves. - Check the width of the belt.
Characteristic
Transmission belt/Minimum width 17.5 mm
ENG - 69
Engine
DNA 50
- 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
DNA 50
Engine
4) Check the integrity of the sliding blocks of the contact plate. - Check that the internal bushing shown in the figure is not abnormally worn and measure inside diameter A. - Measure outside diameter B of the pulley sliding bushing shown in the figure.
CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING.
Characteristic
Driving pulley / Maximum diameter: 20.12 mm Driving pulley/ Standard diameter: 20.021 mm Driving pulley bushing/ Diameter maximum: XXX mm Driving pulley bushing/ Standard diameter: 20 -0.020/-0.041mm
- Refit the components of the assembly (roller container assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive, washer and nut). - With the specific tool, tighten the lock nut to 20 Nm and then perform a final 90 locking in order to prevent the rotation of the driving pulley.
N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UTMOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN
ENG - 71
Engine
DNA 50
ORDER TO AVOID WRONG TIGHTENING AND CONSEQUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling
020451Y Starting ring gear lock
See also
Refitting the clutch
ENG - 72
DNA 50
Engine
Specific tooling
020363Y 20 mm guide 020376Y Adaptor handle 020358Y 37x40-mm adaptor
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 - 73
Engine
DNA 50
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
ENG - 74
DNA 50
Engine
Specific tooling
020151Y Air heater 020376Y Adaptor handle 020363Y 20 mm guide 020359Y 42x47-mm adaptor
Flywheel cover
ENG - 75
Engine
DNA 50
ENG - 76
DNA 50
Engine
Keeping the flywheel connector rubber clamp on the coolant inlet hose, refit the flywheel cover paying attention in inserting the strap in the groove.
Tighten the 4 studs, noting that the two longer golden screws are inserted in the 2 top holes and are also responsible for restraining the secondary airbox.
ENG - 77
Engine
DNA 50
Specific tooling
020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor
ENG - 78
DNA 50
Engine
ENG - 79
Engine
DNA 50
ENG - 80
DNA 50
Engine
Characteristic
Rod small end: standard diameter 17 +0.011-0.001 Rod small end: maximum allowable diameter 17,060 mm
Characteristic
Wrist pin: standard diameter 12 +0.005 +0.001 mm
Characteristic
Wrist pin housing: standard diameter 12 +0.007 +0.012 Wrist pin housing: standard clearance 0.002 0.011 mm
ENG - 81
Engine
DNA 50
- Measure the outer diameter of the piston, perpendicular to the pin axis. - Take the measurement in the position shown in the figure To classify the cylinder-piston fitting, check the appropriate table
See also
Cylinder - piston assy.
See also
Cylinder - piston assy.
ENG - 82
DNA 50
Engine
REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM THE REMOVAL OPERATIONS
Specific tooling
020166Y Pin lock fitting tool
POSITION THE ARROW PRINTED ON THE PISTON CROWN TOWARDS THE EXHAUST OPENING. THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON THE PISTON WITH THE SPECIFIC TOOL
Recommended products
AGIP CITY TEC 2T Oil Recommended oil
ENG - 83
Engine
DNA 50
ENG - 84
DNA 50
Engine
Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side
Specific tooling
020163Y Crankcase splitting plate
Specific tooling
020163Y Crankcase splitting plate
Specific tooling
004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring 004499Y002 Bearing extractor screw 004499Y007 Half rings
ENG - 85
Engine
DNA 50
- Using the specific tool remove any bearings left on the half crankcase
Specific tooling
001467Y007 Driver for OD 54 mm bearing 001467Y006 Pliers to extract 20 mm bearings
Specific tooling
020265Y Bearing fitting base
ENG - 86
DNA 50
Engine
Specific tooling
020335Y Magnetic support for dial gauge 020074Y Support base for checking crankshaft alignment
- Firmly insert the crankshaft until the bearing reaches the end-of-stroke stop
- Let the temperature of the half crankcase settle at the temperature of the crankshaft. - Again install the special crankcase separation plate NOT installing the crankshaft protection - During the assembly phase keep the central thrust screw loose. - Take the four clamping screws to the end of the stroke and loosen them again with the same angle (e.g. 90) - When the temperature has settled, preload the thrust screw of the tool manually until the ball bearing clearance is cancelled out.
Specific tooling
ENG - 87
Engine
DNA 50
Recommended products
Loctite 510 Liquid sealant Gasket - Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement - Insert at least three clamping screws and tighten up rapidly - Insert the other 5 screws and tighten them to the specified torque.
Specific tooling
ENG - 88
DNA 50
Engine
Characteristic
Axial clearance with warm crankcase 0.10 0.12 mm Axial clearance with cold crankcase 0.06 to 0.08 mm Limit value with cold crankcase 0.02 0.03 mm
THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE WITH THE FITTED WRENCH
Specific tooling
020340Y Flywheel and transmission oil seals fitting punch - Install a new transmission side oil seal using the special tool with adapter ring. The transmission-side oil seal is recognised by the larger diameter
Specific tooling
020340Y Flywheel and transmission oil seals fitting punch
Oil pump
ENG - 89
Engine
DNA 50
Removal
- Remove the 2 screws shown in the figure
Remove the tube passage seal from the crankcase shown in the figure
Refitting
To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure
ENG - 90
DNA 50
Engine
Fuel supply
The vehicle comes with a membrane pump controlled by the depression that is generated in the intake manifold. Therefore, the tank has an intake in the lowest point that sends the fuel to the pump and from here to the carburettor. To determine the correct functioning of the pump, the following measurements can be made on the amounts distributed: 1) Start up the engine, bring it to normal operating temperature and then shut it off. 2) Disconnect the fuel adduction line on the carburettor and insert it into a graduated tube. 3) Start up the engine without the accelerator and keep it idle. 4) After the engine is started, count to 10 and then turn it off. 5) Check that the quantity of fuel is not less than the prescribed value.
Characteristic
Fuel distributed ~100cc X 10"
ENG - 91
INDEX OF TOPICS
SUSPENSIONS
SUSP
DNA 50
Suspensions
Sospensioni anteriore This section is devoted to operations that can be carried out on the suspension.
Handlebar
SUSP - 93
Suspensions
DNA 50
Removal
- Remove the drives and disconnect the electrical terminals. - Remove the bracket using the four screws.
SUSP - 94
DNA 50
Suspensions
Disassembling the complete fork - Remove the front wheel. - Remove the front brake calliper. Take out the brake hose and the speedometer lead from the support bracket anchored on the lower plate. - Remove the handlebar support bracket and bring the handlebar forward without disconnecting the drives. - Loosen the four front cover support screws on the fork legs. - Loosen the two pump unit set screws on the upper plate, remove ring nut A and pull out the upper plate. - Remove ring nut B, extract the rubber protection and the washer. - Remove the complete fork from the bottom being careful to support the cover only with the brackets anchored to the fork legs. - Use the extractor to remove the bearing from the seat in the chassis. - Remove the roller bearing and sealing ring of the lower plate
See also
Front brake calliper Handlebar
SUSP - 95
Suspensions
DNA 50
Refitting
For the assembly proceed in the opposite order of the disassembly making sure to lubricate the seats and bearing with recommended grease.
Specific tooling
020055Y Wrench for steering tube ring nut
Recommended products
AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2
SUSP - 96
DNA 50
Suspensions
Refitting
When refitting, tighten the shock absorber/frame anchorage nut and the shock absorber/engine pin at the prescribed torque.
Centre-stand
Extracting the pin securing the stand to the bracket - Remove the stand support bracket from the engine. - Drill a 5 mm hole in the bracket so that the pin P can come out. Assembly and caulking stand pin to the bracket - Caulk the end of the pin P between the two punches shown in the figure. - After caulking it must be possible for the stand to turn freely.
N.B. UPON REFITTING USE NEW O-RING AND PIN, GREASE THE SPRING ATTACHMENTS AND THE PIN.
SUSP - 97
Suspensions
DNA 50
- Work on the screws shown in the figure. - When refitting, secure to the prescribed torque.
SUSP - 98
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
DNA 50
Overhaul
Proceed as follows: 1) remove the two male hexagonal screws (1) and take out the two pads (10); 2) remove the two male hexagonal screws (2) and remove the reaction plate (3); 3) take out the fixed plate (4) from the guide; 4) remove the internal elements from the floating body (5) with the help of short blows of compressed air through the brake fluid pipe in order to facilitate the expulsion of pistons (6). 5) Check: - that the plates and the body are whole and in good condition; - that the cylinder and the floating body of the calliper do not show signs of scratches or erosion, otherwise replace the entire calliper; - that the guides of the fixed plate are not scratched or eroded, otherwise replace the entire plate; - that the brake pad check spring works properly. Reassembly
DNA 50
Braking system
1) insert the pistons (6) and the sealing rings (7) in the body; 2) place the guide rubbers (8) and refit the fixed plate (4); 3) assemble the reaction plate (3) tightening the screws (2), insert the brake pad check spring (9) and then the pads, fixing them with the corresponding screws (1); 5) place the calliper on the disc and lock it to the strut by tightening the fixing screws; 6) fix the pipe joint on the calliper at the prescribed torque. Functioning This is a floating type calliper. It takes advantage of the action and reaction principle to obtain the thrust for both pads. The body and the reaction plate body work integrally and can move axially with respect of the fixed plate that is integral to the strut. The pistons, forced by pressure to push the pad to the disk, cause the reaction plate to push in turn the other pad towards the disc. The brake pad lock spring 1. Pad fixing screws 2. Reaction plate fixing screws 3. Reaction plate 4. Fixed plate 5. Floating body 6. Piston 7. Piston sealing rings 8. Guide protection rubbers 9. Brake pad check spring 10. Pads
CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED.
Braking system
DNA 50
Refitting
Refit the pincer on the support and tighten the screws at the prescribed torque. Refit the tube complete with fitting with new copper gaskets. Bleed the air from the system.
Refitting
-When refitting, position the disc correctly making sure that it rotates in the right direction.
Disc Inspection
Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring.
Characteristic
New rear disc thickness 4.0 mm Disc thickness at wear limit (front) BRAK SYS - 102
DNA 50
Braking system
3.5 mm Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm. If a value is measured other than the specified value, remove the front wheel (Front/Rear Suspension chapter) and check the protrusion of the disc. Maximum permissible out of true is 0.1 mm. If the value measured is greater, replace the disc and repeat the check. If the problem persists, check and replace the wheel hub if necessary.
Specific tooling
020335Y Magnetic support for dial gauge
Characteristic
Minimum value 1.5 mm
See also
Front brake calliper
Refitting
To fit, proceed as follows: - Insert the two pads in the callipers. BRAK SYS - 103
Braking system
DNA 50
- Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock
Fill
-Once the bleed valve is closed, fill the system with brake liquid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system. The operation is finished when just oil comes out of the bleed screws. -Do up the bleed screw. -When the operation is over, tighten up the oil bleed screw to the prescribed torque.
N.B.
IF AIR CONTINUES TO COME OUT DURING PURGING, 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
DNA 50
Braking system
- 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 MityVac vacuum-operated pump
Recommended products
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
Braking system
DNA 50
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
Cooling system
DNA 50
System bleed
1. Fill the circuit through the expansion tank to the maximum level. 2. Fasten the rubber line to the drain fitting on the head and thread it into the expansion tank mouth.. 3. Loosen the fitting and restore the tank level. 4. Start up the engine and wait until only coolant exits from the line, then tighten the fitting on the head.. 5. Turn off the engine, restore the level of liquid to the maximum level, then close the expansion tank.. 6. Heat up the engine to normal operating temperature in order to eliminate any air formation in the main lines.. 7. Stop the engine and let it cool, then check that the level of coolant in the expansion tank to the maximum;; refill it.
DNA 50
Cooling system
- Use a new oil seal to refit - Position the new oil seal on the special tool with the main lip facing the bearings as shown in the picture
- Lubricate the oil seal and push it home using the special tool as shown in the picture
Specific tooling
020168Y Water seal punch mount on halfcrankcase
- Insert the shaft, with bearings, into its housing by pushing and turning it at the same (turn anticlockwise for tightening) - Turn it rapidly to the end of the threading. - Should this operation prove difficult, do not carry on; instead, start over by reheating the crankcase
N.B. FAILURE TO OBSERVE THIS RULE MAY RESULT IN DAMAGE TO THE THREAD OF THE COPPER INSERT ON THE IMPELLER, OR SEPARATION OF THIS FROM THE IMPELLER ITSELF.
Specific tooling
020169Y Water pump crankshaft fitting and removal spanner Using the air heater, warm up the water pump bearing housing, without directing the air flow directly against the oil seal - Lubricate the end of the water pump shaft on the oil seal side, using the recommended product.
Recommended products
AGIP GREASE MU3 Grease for odometer transmission gear case
Cooling system
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- Remove the pick-up/coolant inlet hose clamp - Remove the transmission cover - Remove the mixer - Setup the special as shown in the picture
N.B. WHEN SECURING THE TOOL, PAY ATTENTION NOT TO OVERLOAD THE PLASTIC IMPELLER.
Specific tooling
020167Y Arrest key for impeller pump - Remove the mixer/water pump drive-belt with the two sprockets
- Remove the split ring from the shaft together with the bearings - Remove the steel washer
- Using the air heater, warm up the crankcase in the area around the water pump bearings as shown in the picture.
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Cooling system
- With the aid of the special tool, loosen the impeller shaft turning the spanner clockwise (left-handed thread) - As the thread is fully disengaged, extract the shaft with the aid of pliers.
Specific tooling
020169Y Water pump crankshaft fitting and removal spanner - Using the special hook, remove the sealing ring from its housing as shown in the picture.
Specific tooling
020209Y Spring hook
Thermostat Removal
Detach the coolant hose from the head, partially draining the system. Remove the cylinder head. Remove the two fixing screws and hence the thermostat.
Check
1) Visually check that the thermostat is not damaged. 2) Fill a metallic container with approx. 1 litre of water. Immerge the thermostat, and keep it in the centre of the bowl. Immerge the multimeter temperature probe, and keep it close to the thermostat. Heat up the bowl using the thermal gun. Check the thermostat opening start temperature: Heat up until the thermostat is completely open. COOL SYS - 111
Cooling system
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Specific tooling
020331Y Digital multimeter 020151Y Air heater
Characteristic
Thermostat check: Opening start temperature 602C
Refitting
Refit the thermostat onto the head, following the removal operations in the reverse order, and paying attention in inserting the groove on the thermostat on the reference on the head.
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
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Headlight assy.
- Remove the 9 screws shown in the figure. - Remove the rubber caps and disconnect the connectors from the bulbs. - Remove the headlamp unit set screws and pull the unit out from the top.
Taillight assy.
Remove the two screws and take out the whole unit.
CHAS - 114
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Chassis
Side fairings
Rear side panels - Remove the saddle. - Remove the passenger footrest. - Remove the screws indicated in the photo and then the side panels.
Front side panels: Remove the screws shown in the photo and then disconnect the joint between the side panels and the lower central cover. When reassembling be sure to screw the shortest threaded screw in position A.
CHAS - 115
Chassis
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Lower central covering: - Remove the front side frames and the helmet compartment. - Remove the connectors A, rear brake hose B from the left brake pump, the accelerator control lead C, then pull it all out from the slot in the lower central cover.
Air filter
- Remove the protective crankcase of the carburettor by removing the four screws. - Remove the two screws shown in the photo then disconnect the air manifold at the carburettor and remove it. When refitting, be careful to correctly install the air manifold into the air filter housing.
Rear mudguard
Rimuovere il carter di protezione carburatore agendo sulle quattro viti. Rimuovere il parafango agendo sulle due viti indicate in figura.
CHAS - 116
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Chassis
Helmet bay
- Remove the saddle and the left rear side panel. - Open the helmet compartment, remove the expansion cap and the gas tank cover, then screw the cap back on. - Remove the two screws inside the helmet compartment indicated in the photo. - Remove the saddle opening drives on both sides using the two screws indicated in the photo. - Remove the five screws connecting the two compartment guards indicated in the photo. - Remove the fuel cap, separate the two guards enough to let the fuel intake pipe pass and then remove the compartment from the top.
CHAS - 117
Chassis
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Fuel tank
- Remove the helmet compartment. - Remove the from side frames and the lower central covering. - Remove the lower radiator support using the two screws and the pump guard indicated in the photo. Disconnect the three hoses A towards the engine unit, then remove the fuel pump using the two screws B indicated in the photo.
Remove the two expansion tank support screws, remove the two radiator set screws, and without draining the cooling system, pull the radiator out from the bottom and the expansion tank from the chassis unit.
CHAS - 118
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Chassis
Remove the four fuel tank set screws shown in the photo, then pull the tank out from the front.
When reassembling make sure to secure the splitter block support with the left front set screws of the tank.
Radiator fan
- Remove the front side panels and the lower central covering - Drain the coolant and then disconnect the four hoses A. - Remove the two screws B and pull the radiator out of its seat on the lower bracket.
CHAS - 119
Chassis
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Expansion tank
- Remove the helmet compartment. - Remove the tow support screws shown in the figure - Disconnect the two hoses collecting the coolant in a container
Battery
Remove the saddle, unscrew the screw indicated in the photo and remove the cover.
CHAS - 120
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
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Aesthetic inspection
Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt
Electrical system
Electrical system: - Main switch - Headlamps: high beam, low beam, position and parking lights and the respective warning lights - Adjusting the headlights according to the regulations currently in force - Rear light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel and temperature indicator - Instrument panel warning lights - Horn - Starter PRE DE - 122
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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 BATTERY LIFE.
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 SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE. IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GAS; 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 coolant 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 - 123
Pre-delivery
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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 check up: Braking system (hydraulic) - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Throttle travel check Others - Check documentation - Check the frame and engine numbers - Tool kit - License plate fitting - Check locks - Check tyre pressures - Installation of mirrors and any accessories
PRE DE - 124
INDEX OF TOPICS
TIME
TIME
Time
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This section is devoted to the time necessary to carry out repairs. The description and code for each operation is indicated.
Engine
ENGINE
Code 001001
Duration
TIME - 126
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Time
Crankcase
CRANKCASE
1 Code 001133 Action Engine crankcase - Replacement Duration
TIME - 127
Time
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Crankshaft
CRANKSHAFT
1 2 3 4 Code 001117 001118 001099 001100 Action Crankshaft - Replacement Main bearings - Replacement Oil seal, flywheel side - Replacement Oil seal, clutch side - Replacement Duration
TIME - 128
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Time
Cylinder assy.
CYLINDER / PISTON
1 2 Code 001002 001107 Action Cylinder piston - Replacement Cylinder / piston - Inspection / cleaning Duration
TIME - 129
Time
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HEAD ASSEMBLY
1 2 3 4 5 6 7 8 Code 001013 001056 001057 001093 001126 007010 001178 001083 Action Intake manifold - Replacement Head gasket - change Thermostat - Replacement Spark plug - Replacement Head - Replacement Bleed valve - Replacement Disc pack - Replacement Thermistor - Replacement Duration
TIME - 130
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Time
Driven pulley
DRIVEN PULLEY
1 2 3 4 Code 001110 001022 001155 001012 Action Driven pulley - Replacement Clutch - Replacement Clutch bell housing - Replacement Driven pulley - Service Duration
TIME - 131
Time
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Oil pump
TIME - 132
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Time
TIME - 133
Time
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Driving pulley
DRIVING PULLEY
1 2 3 4 5 Code 001011 001066 001017 001086 001177 Action Driving belt - Replacement driving pulley - Replacement Starter sprocket wheel - Replacement Driving half-pulley - replace Variator rollers / shoes - Replacement Duration
TIME - 134
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Time
Transmission cover
TRANSMISSION COVER
1 2 3 4 5 Code 001096 001131 001132 001135 004179 Action Transmission crankcase cover - Replacement Transmission air intake - Replacement Transmission air inlet pipe - Replacement Transmission cover bearing - Replacement Stand buffer - Replacement Duration
TIME - 135
Time
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Water pump
WATER PUMP
1 2 3 Code 001113 001062 007019 Action Water pump - Replacement Water pump command shaft - Replacement Connection water pump pipe / return pipe - Replacement Duration
TIME - 136
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Time
Starter motor
TIME - 137
Time
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Flywheel magneto
FLYWHEEL MAGNETO
1 2 3 4 Code 001058 001067 001173 001087 Action Flywheel - Replacement Stator - Replacement Rotor - Replacement Flywheel cover - Replacement Duration
TIME - 138
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Time
Brake shoes
BRAKE SHOES
1 Code 002002 Action Rear brake shoe(s) - Replacement Duration
TIME - 139
Time
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Carburettor
CARBURETTOR
1 2 3 Code 001063 007020 003058 Action Carburettor - Replacement Carburettor heating tubing - replacement Carburettor - Adjustment Duration
TIME - 140
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Time
CARBURETTOR INSPECTION
1 2 Code 001081 001008 Action Automatic choke - Replacement Carburettor - Inspection Duration
Exhaust pipe
TIME - 141
Time
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MUFFLER
1 2 3 Code 001009 001095 001136 Action Muffler - Replacement Muffler guard - Replacement Exhaust emissions - Adjustment Duration
Air cleaner
AIR FILTER
1 2 3 Code 001014 001015 004122 Action Air filter - Replacement / cleaning Air filter box - Replacement Air cleaner carburettor fitting - Replacement Duration
TIME - 142
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Time
Frame
CHASSIS
1 2 3 4 5 6 Code 001053 004004 004001 004015 004171 004143 Action Stand bolt - Replacement Stand - Replacement Frame - replace Footrest - Replacement Stand support plate - Replacement Footrest support - replace Duration
TIME - 143
Time
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Legshield spoiler
FRONT SHIELD
1 2 3 4 5 Code 004065 004064 003087 004167 004176 Action Front shield rear section - Replacement Front shield - Replacement Wheel housing - Replacement Grill / radiator cover - Replacement Air vent - Replacement Duration
TIME - 144
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Time
Side fairings
CENTRAL COVER
1 2 3 Code 004053 004178 004011 Action Spoiler - Replacement Footrest - Replacement Central chassis cover - Replacement Duration
TIME - 145
Time
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Underseat compartment
HELMET COMPARTMENT
1 2 3 Code 004059 004016 005046 Action Spark plug inspection flap - Replacement Helmet compartment - Replacement Battery cover - Replacement Duration
TIME - 146
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Time
Plate holder
TIME - 147
Time
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Mudguard
MUDGUARDS
1 2 3 Code 004009 004052 004002 Action Rear mudguard - Replacement Bumper - Replacement Front mudguard - Replacement Duration
TIME - 148
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Time
Fuel tank
FUEL TANK
1 2 3 4 5 6 7 Code 004005 005010 004011 004072 004110 004168 004170 Action Fuel tank - Replacement Tank float - Replacement Central chassis cover - Replacement Fuel filter - Replacement Fuel tank hose - Replacement Fuel tank cap - Replacement Tank filler neck - Replacement Duration
TIME - 149
Time
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Tank oil
OIL TANK
1 2 3 4 Code 004017 005018 004095 004091 Action Oil reservoir - Replacement Oil reservoir float - Replacement Oil reservoir cock - Replacement Oil reservoir hose - Replacement Duration
TIME - 150
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Time
Rear shock-absorber
TIME - 151
Time
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TIME - 152
DNA 50
Time
Handlebar components
HANDLEBAR COMPONENTS
1 2 3 4 5 6 7 8 9 10 11 12 13 Code 003001 002060 002059 005017 003059 002024 002037 002047 003061 004066 002071 002067 002080 Action Handlebar - Replacement Complete throttle control - Replacement Right hand grip - Replacement Stop switch - Replacement Counterweight - Replacement Front brake pump - replace Brake or clutch lever - Replacement Front brake fluid and air bleeding system - Replacement Accelerator transmission - Adjustment Driving mirror - Replacement Left hand grip - Replacement Rear brake pump - Replacement Rear brake oil bleeding system - Replacement Duration
TIME - 153
Time
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Swing-arm
SWINGING ARM
1 Code 001072 Action Engine / frame swinging arm fitting Replacement Duration
TIME - 154
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Time
Seat
SEAT
1 2 3 Code 004003 004054 002083 Action Saddle - Replacement Seat lock hook - Replacement Saddle opening transmission - Replacement Duration
TIME - 155
Time
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Instrument panel
TIME - 156
DNA 50
Time
FRONT LIGHT
1 2 3 4 Code 005067 005008 005002 005012 Action Front turn indicator bulb - Replacement Front headlamp bulbs - Replacement Front headlamp - Replacement Front turn indicator - Replacement Duration
TIME - 157
Time
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Front wheel
FRONT WHEEL
1 2 3 4 5 6 7 Code 002041 003040 003037 003047 004123 003038 005089 Action Front brake disc - Replacement Front wheel bearings - Replacement Front wheel rim- Replacement Front tyre - replace Front wheel - Replacement Front wheel axle - Replacement Tone wheel - Replacement Duration
Grease tone wheel or drive Please take note that the code has been introduced: 900001 - Tone wheel / drive greasing - 15'. Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated components. The grease recommended is TUTELA MRM 2 (soap-based lithium grease with Molybdenum disulphide). In the following points we indicate with an arrow the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 158
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Time
Rear wheel
REAR WHEEL
1 2 3 4 5 Code 001071 001016 002070 004126 002028 Action Rear wheel rim - Replacement Rear wheel - Replacement Rear brake disc - Replacement Rear wheel tyre - Replacement Rear wheel hub - Replacement Duration
TIME - 159
Time
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Fuel pump
FUEL PUMP
1 2 3 Code 004073 004137 004086 Action Fuel pump - Replacement Pump / carburettor hose - Replacement Petrol pump depression tube - Replacement Duration
TIME - 160
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Time
Electric devices
BATTERY
1 2 3 4 Code 005007 005024 005025 005011 Action Battery - Replacement Battery fuse - Replacement Fuse holder - Replacement Start-up remote control switch - Replacement Duration
TIME - 161
Time
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ELECTRICS
1 2 3 4 5 6 Code 001023 001094 005001 005009 005136 005044 Action Control unit - Replacement Spark plug cap - Replacement Electrical system - Replacement Voltage regulator - Replacement Resistance - Replacement Front lights cable unit- Replacement Duration
TIME - 162
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Time
Electronic controls
ELECTRICAL COMMANDS
1 2 3 4 5 6 7 8 Code 005041 005040 005016 004096 004010 005003 005006 005039 Action Starter button - Replacement Horn button - Replacement Key switch - Replacement Lock series - Replacement Antitheft lock - replace Horn - Replacement Light switch or turn indicators - Replacement Headlight switch - Replacement Duration
TIME - 163
Time
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Transmissions
SPLITTER
1 2 3 4 Code 002012 002058 002057 002054 Action Splitter - Replacement Mix / splitter transmission complete Replacement Carburettor / splitter transmission complete - Replacement Throttle or splitter transmission complete - Replacement Duration
TIME - 164
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Time
Brake callipers
BRAKE CALLIPERS
1 2 3 4 5 6
Action Front brake pads - Replacement Front brake piping - Replacement Front brake calliper - Replacement Rear brake pads - Replacement Rear brake disc piping - Replacement Rear brake calliper - Replacement
Duration
TIME - 165
Time
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REAR COVERS
1 2 3 4 5 Code 004159 004056 004036 004085 004129 Action Plates / Stickers - Replacement Upper rear light cover - Replacement Lower chassis cover - Replacement Fairing (1) - Replacement Rear fairing - Replacement Duration
TIME - 166
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Time
Front suspension
FORK
1 2 3 4 Code 003010 003051 003048 003041 Action Front suspension - Service Complete fork - replace Fork oil seal - Replacement Fork stanchion - Replacement Duration
TIME - 167
Time
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Cooling system
COOLING SYSTEM
1 2 3 4 5 6 7 Code 007001 007002 001052 007024 007013 007003 001170 Action Expansion tank - Replacement Water cooling radiator - Replacement Coolant and air bleed - Replacement Expansion tank cap - Replacement Expansion tank / radiator connecting hose - Replacement Delivery line and coolant return - Replacement Air deflector - Replacement Duration
TIME - 168
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Time
TIME - 169
A
Air filter: 31, 116
B
Battery: 39, 46, 55, 120 Brake: 95, 100, 102, 103, 105, 106, 139, 165
C
Carburettor: 11, 140
E
Engine stop:
F
Fuel: 37, 91, 118, 149, 160 Fuses: 54
H
Headlight: 34, 114 Hub oil: 29
I
Identification: 8 Instrument panel: 49, 156
M
Maintenance: 7, 26
S
Shock absorbers: 96 Spark plug: 29
T
Tank: 118, 120, 149, 150 Transmission: 9, 38, 62, 135 Tyres: 10