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SERVICE STATION MANUAL

677691 EN

Typhoon 50 4t 4v

SERVICE STATION MANUAL

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

SERVICE STATION MANUAL


Typhoon 50 4t 4v
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.

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

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

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

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

Dimensions and mass

WEIGHTS AND DIMENSIONS


Specification Maximum length Overall width Max. height to the windshield Wheelbase Kerb weight Desc./Quantity 76.38 in (1940 mm) 28.35 in (720 mm) 44.69 in (1135 mm) 53.15 in (1350 mm) 242 lbs (110 Kg)

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

Specification Lubrication Cooling Electric Carburatore Fuel Spark plug

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

Frame and suspensions


FRAME AND SUSPENSION
Specification Frame Front suspension rear suspension Desc./Quantity Tubular steel frame with sheet metal reinforcements Hydraulic telescopic fork; 1,36 in ( 32) - 2.99 (76 mm) Hydraulic single shock absorber and spring adjustable to 4 positions at preloading; travel: 3.40 in (86.5 mm).

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)

Wheels and tyres


WHEELS AND TYRES
Specification Wheel rims Front wheel rim Rear wheel rim Tyre type Front tyre Rear tyre Standard front tyre pressure [with passenger] Standard rear tyre pressure [with passenger] Desc./Quantity Die-cast aluminium alloy 3.00 x 14" 3.50 x 14 Without inner tube (Tubeless) 120/70 - 14" 55 P 120/70 - 14" 55 P 23 psi (1.6 bar) [29 psi (2.0 bar)] 29 psi (2.0 bar) [32 psi (2.2 bar)]

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)

FRONT AND REAR BRAKE


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

CHAR - 10

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

Assembly clearances Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDER


Name Cylinder Cylinder Piston Piston Cylinder 1st oversize Cylinder 1st oversize Piston 1st oversize Piston 1st oversize Cylinder 2nd oversize Cylinder 2nd oversize Initials A B C D A1 B1 C1 D1 A2 B2 Cylinder 1.535157 - 1.535433 in (38.993 - 39.000 mm) 1.535433 - 1.535709 in (39.000 - 39.007 mm) 1.535709 - 1.535984 in (39.007 - 39.014 mm) 1.535984 - 1.536260 in (39.014 - 39.021 mm) 1.543031 - 1.543307 in (39.193 - 39.200 mm) 1.543307 - 1.543583 in (39.200 - 39.207 mm) 1.543583 - 1.543858 in (39.207 - 39.214 mm) 1.543858 - 1.544134 in (39.214 - 39.221 mm) 1.550906 - 1.551181 in (39.393 - 39.400 mm) 1.551181 - 1.551457 in (39.400 - 39.407 mm) Piston 1.533622 - 1.533898 in (38.954 - 38.961 mm) 1.533898 - 1.534173 in (38.961 - 38.968 mm) 1.534173 - 1.534449 in (38.968 - 38.975 mm) 1.534449 - 1.534724 in (38.975 - 38.982 mm) 1.541496 - 1.541772 in (39.154 - 39.161 mm) 1.541772 - 1.542047 in (39.161 - 39.168 mm) 1.542047 - 1.542323 in (39.168 - 39.175 mm) 1.542323 - 1.542598 in (39.175 - 39.182 mm) 1.549370 - 1.549646 in (39.354 - 39.361 mm) 1.549646 - 1.549921 in (39.361 - 39.368 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) 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)

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)

- Measure the diameter of the bearings on the piston.

Characteristic
Pin seat diameter 0.511811 +0.000197 +0.000394 in (13 +0.005 +0.010 mm)

- Calculate the piston pin coupling clearance.


N.B.

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, 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.

CHAR - 12

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)

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE


Name Half-shaft, transmission side Flywheel-side half shaft Connecting rod Spacer tool Description Dimensions 0.551181 +0 -0.000197 in (14 +0 -0.005 mm) 0.629921 +0 -0.000197 in (16 +0 -0.005 mm) 0.582677 + 0.001969 in (14.8 +0,05 mm) 1.771654 in / Fitting clearance D = 0.005906 - 0.011811 in (45.00 mm / Fitting clearance Initials A B C E Quantity

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

Measure the bearings along X and Y axes

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

Slot packing system


Characteristic
Compression ratio 11.5 to 12 : 1

PISTON PROTRUSION CHECK


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

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.

UNIT OF MEASURE - CONVERSION - ENGLISH SYSTEM TO INTERNATIONAL SYSTEM (IS).


Specification 1 Inch (in) 1 Foot (ft) 1 Mile (mi) 1 US Gallon (USgal) 1 Pound (lb) 1 Cubic inch (in) 1 Foot pound (lb ft) 1 Miles per hour (mi/h) 1 Pound per square inch (PSI) 1 Fahrenheit (F) Desc./Quantity 25.4 Millimetres (mm) 0.305 Meter (m) 1.609 Kilometre (km) 3.785 Litre (l) 0.454 Kilogram (kg) 16.4 Cubic centimetres (cm) 1,356 Newton meter (Nm) 1.602 Kilometres per hour (km/h) 0.069 (bar) 32+(9/5) Celsius (C)

CHAR - 18

INDEX OF TOPICS

TOOLING

TOOL

Tooling

Typhoon 50 4t 4v

SPECIFIC TOOLS
Stores code 001330Y Description Tool for fitting steering seats

001467Y009

Bell for OD 42-mm bearings

001467Y013

Pliers to extract 15-mm bearings

001467Y029

Bell for bearings, O.D. 38 mm

008119Y009

Tube to assemble shafts and axles

002465Y

Pliers for circlips

TOOL - 20

Typhoon 50 4t 4v

Tooling

Stores code 004499Y

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

Punch for fitting fifth steering bearing on steering tube

020004Y

Punch for removing fifth wheels from headstock

020055Y

Wrench for steering tube ring nut

020150Y

Air heater support

020151Y

Air heater

TOOL - 21

Tooling

Typhoon 50 4t 4v

Stores code 020162Y

Description Flywheel extractor

020171Y

Punch for 17 mm roller bearing

020193Y

Oil pressure check gauge

020201Y 020265Y

Spacer bushing driving tube Bearing fitting base

020271Y

Tool for removing-fitting silent bloc

020288Y

Fork to assemble piston on cylinder

TOOL - 22

Typhoon 50 4t 4v

Tooling

Stores code 020291Y

Description Valve fitting/ removal tool

020306Y

Punch for assembling valve seal rings

020329Y

Mity-Vac vacuum-operated pump

020330Y

Stroboscopic light to check timing

020331Y

Digital multimeter

TOOL - 23

Tooling

Typhoon 50 4t 4v

Stores code 020332Y

Description Digital rpm indicator

020334Y

Multiple battery charger

020335Y

Magnetic support for dial gauge

020363Y

20-mm guide

020364Y

25-mm guide

TOOL - 24

Typhoon 50 4t 4v

Tooling

Stores code 020376Y

Description Adaptor handle

020412Y

15-mm guide

020428Y

Piston position check mounting

020431Y

Valve oil seal extractor

020439Y

17-mm guide

020444Y

Tool for fitting/ removing the driven pulley clutch

TOOL - 25

Tooling

Typhoon 50 4t 4v

Stores code 020448Y

Description Pin lock fitting tool

020450Y

Camshaft fitting/removal tool

020451Y

Starting ring gear lock

020452Y

Tube for removing and refitting the driven pulley shaft

020565Y

Flywheel lock calliper spanner

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

cording to the kilometres travelled as instructed in the scheduled maintenance chart.

- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good 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

Undo the central cover fixing screws and remove it.

Disconnect the spark plug HV wire cap; Remove the wire cap.

Unscrew the spark plug.

- Check the conditions of the spark plug, make sure the insulation is intact, that the electrodes are not excessively worn or sooty, the conditions of the washer, and measure the distance between the electrodes using the appropriate feeler gauge. -Adjust the distance, if necessary, by bending the side electrode very carefully. In case of anomaly (as described before), replace the spark plug with another of the recommended type.

- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it. MAIN - 30

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

Hub oil Check


- Park the vehicle on flat ground and rest it on the centre stand. - Unscrew the oil dipstick/cover, dry it with a cloth and reinsert it screwing it in thoroughly.

- Remove the dipstick/cover and check that the oil level is between MIN and MAX. - If the level is below the MIN value, restore the proper amount of oil in the hub. - Screw the oil dipstick back and check it is locked.

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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.

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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

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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).

Engine oil filter


Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

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

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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

Checking the ignition timing


-Remove the flywheel fan. -Rotate the flywheel until the reference (arrow) matches the crankcase operation end as shown in the figure (TDC). Make sure that the 2V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference mark is opposite the indicator on the head, make the crankshaft turn once more. -The TDC reference mark is repeated also between the flywheel cooling fan and the flywheel cover.

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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.

Checking the valve clearance


-To check valve clearance, centre the reference marks of the timing system. - Use a feeler gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve clearance values, intake and exhaust respectively, are different from the ones indicated below, adjust them by loosening the lock nut and operate on the set screw with a screwdriver. Intake: 0.006 in (0.15 mm) (when cold) Exhaust: 0.006 in (0.15 mm) (when cold)

Braking system Level check


Proceed as follows: - Rest the vehicle on its centre stand with the handlebars perfectly horizontal; - Check the fluid level through the corresponding sight glass. A certain lowering of the level is caused by wear on the brake pads.

Top-up
Proceed as follows: - Remove the front handlebar cover. - Remove the reservoir cap by loosening the two screws, remove the gasket and top-up using only the fluid specified without exceeding the maximum level. MAIN - 37

Maintenance

Typhoon 50 4t 4v

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; 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.

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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

Engine Poor performance


POOR PERFORMANCE
Possible Cause Air filter blocked or dirty Operation 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 it and replace, if necessary Replace the worn parts Check for causes and fill to reach the correct level Descale the cylinder, the piston, the head and the valves Time the system again or replace the worn parts Replace Check the rollers and the pulley movement, replace the damaged parts and lubricate the movable guide of the driven pulley with grease. Adjust the valve clearance properly Remove the head and the valves, grind or replace the valves Replace the head unit Replace the piston cylinder assembly or just the piston rings

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.

Fuel pump fault

Excessive oil consumption/Exhaust smoke


EXCESSIVE CONSUMPTION
Possible Cause Operation Wrong valve adjustment Adjust the valve clearance properly Overheated valves Remove the head and the valves, grind or replace the valves Misshapen/worn valve seats Replace the head unit Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings fitted properly Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal Worn valve oil guard Replace the valve oil seal Worn valve guides Check and replace the head unit if required

TROUBL - 41

Troubleshooting

Typhoon 50 4t 4v

Insufficient lubrication pressure


POOR LUBRICATION PRESSURE
Possible Cause By-Pass remains open Oil pump with excessive clearance Oil filter too dirty Oil level too low Operation Check the By-Pass and replace if required. Carefully clean the By-Pass area. Perform the dimensional checks on the oil pump components Replace the cartridge filter Restore the level adding the recommended oil type

Transmission and brakes Clutch grabbing or performing inadequately


IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause Slippage or irregular functioning Operation Check that there is no grease on the masses. Check that the faying surface between the clutch masses and the clutch housing is mainly in the middle and with equivalent specifications on the three masses. Check that the clutch housing is not scored or worn abnormally

Insufficient braking
INEFFICIENT OR NOISY 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.

Defective piston sliding

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.

Steering and suspensions Heavy steering


STEERING HARDENING
Possible Cause Steering hardening 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 the seats in which the ball bearings rotate: if they are recessed or if the balls are squashed, replace them.

Excessive steering play


EXCESSIVE STEERING CLEARANCE
Possible Cause Excessive steering clearance Operation Check the tightening of the top ring nut. 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 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.

Suspension oil leakage


OIL LEAKAGE FROM SUSPENSION
Possible Cause Faulty or broken seals Operation Replace the shock absorber Check the condition of wear of the steering covers and the adjustments.

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

Ve = Green Vi = Violet Gr = Grey

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

13. HORN Remove the footrests to reach it.

14. VOLTAGE REGULATOR - 15. SPARK PLUG - 16. SIS VALVE Remove the rear central cover to reach it.

17. PTC HEATER - 18. AUTOMATIC STARTER - 19. STARTER MOTOR - 20. ENGINE 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.

There is a ground point on the vehicle on the voltage regulator.

Electrical system installation

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

Conceptual diagrams Ignition

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

Battery recharge and starting

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

Level indicators and enable signals section

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

Instruments and warning lights control board

Key A - Low fuel warning light; B - Fuel level indication; C - Turn indicator warning light; D - Speedometer; E - High-beam warning light; F - Low beam warning light G - Odometer.

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

Front turn indicator light bulb

Rear turn indicator light bulb

Stop/position light bulb

12V - 1.2W warning light bulb

ELE SYS - 56

Typhoon 50 4t 4v

Electrical system

Specification 6 License plate light

Desc./Quantity Quantity: 6 12V - 5W

Devices and accessories

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

Lights and turn indicators

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

Checks and inspections Ignition circuit


All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected to the Pick-Up by the chassis and the engine ground lead. To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.

No spark plug
Once the lack of power to the spark plug has been detected you can proceed as follows: - Check the Pick-Up. The check includes the Pick-Up and its power line. Disconnect the control unit connector and 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

WARNING THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK.

Electric characteristic
High voltage coil voltage value High voltage coil voltage value: > 100 Volt

Battery recharge circuit


The charging circuit consists of three-phase alternator and a permanent magneto flywheel. The generator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 20A main protection fuse. This system therefore requires no connection to the ignition switch. The three-phase alternator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed.

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

TURN INDICATOR 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.

Voltage regulator check


With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 14.5 Volt. In case higher voltages are detected, replace the regulator. In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.

Recharge system voltage check


Connect the ammeter induction clamp to the voltage regulator positive terminal (Red/Orange), measure the battery voltage and turning on the vehicle lights with the engine off, wait for the voltage to settle at about 12 Volt. Start the engine and measure the current generated by the system with the lights on and a high running engine.

ELE SYS - 63

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.

Turn signals system check


WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. Check that bulb operates properly. Check continuity of the Blue-Black cable between the 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

Fuse no. 2 Fuse No. 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

HIGH BEAM CONNECTOR 1. Vi - Light switch control. 2. Ne - Ground.

BATTERY POSITIVE TERMINAL 1. Rs - Positive starter relay/Positive 15A fuse

BATTERY NEGATIVE TERMINAL 1. Ne - Chassis ground

HV COIL CONNECTOR 1. Vi - Command from electronic ignition device. 2. Ne - Negative from electronic ignition device.

HORN CONNECTOR 1. Ne - Ground. 2. GrNe - Command from horn button.

IGNITION SWITCH CONNECTOR 1. Ar - Positive with key on for secondary fuses and voltage regulator. 2. RsBL - Positive from 15A fuse. 3. Ne - Ground. 4. BL - Ground with key on for electronic ignition device and stop engine switch. TURN INDICATOR SWITCH CONNECTOR 1. BLNe - Power supply from voltage regulator. 2. BiBL - Command for right side turn indicators and for emergency flashers on warning light. 3. Ro - Command for left side turn indicators and for emergency flashers on warning light.

ELE SYS - 71

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.

VOLTAGE REGULATOR GROUND- Ne

CHASSIS GROUND - Ne

DIAGNOSTICS SOCKET CONNECTOR 1. Not connected. 2. Ne - Ground. 3. RsNe - Connection to electronic ignition device. STARTER BUTTON CONNECTOR 1. BiNe - Positive after stop button. 2. VeNe - Starter relay control.

HORN BUTTON CONNECTOR 1. Bi - Power from 7.5A fuse. 2. GrNe - Horn control.

FRONT BRAKE STOP BUTTON CONNECTOR 1. BiNe - Brake pressed signal for stop light and starter consent. 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.

NTC TEMPERATURE SENSOR CONNECTOR GiRo - Signal to electronic ignition device.

LOW FUEL WARNING LIGHT CONNECTOR 1. Bi - Positive from 7.5A fuse. 2. GrVe - Low fuel signal from fuel level 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

ENGINE FROM VEHICLE

ENG VE

Engine from vehicle

Typhoon 50 4t 4v

Exhaust assy. Removal


Remove the fixing nuts from the manifold to the head.

Remove the exhaust fixing screws to the crankcase, then remove the exhaust.

Removal of the engine from the vehicle


CAUTION

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

Engine from vehicle

Remove the rear brake transmission bracket fixing screws indicated in the photograph.

Disconnect the rear brake transmission by unscrewing the adjuster screw.

Disconnect the magneto flywheel cable harness connector.

Disconnect the starter motor connector from the relay and the ground.

ENG VE - 79

Engine from vehicle

Typhoon 50 4t 4v

Remove the accelerator cable.

Remove the accelerator cable supporting clamp.

Remove the S.I.S. valve piping. Disconnect the fuel piping and the depression piping.

Disconnect the throttle body sensor (PTC) and the automatic starter pins, moving the protective sheaths and removing the clamps.

ENG VE - 80

Typhoon 50 4t 4v

Engine from vehicle

Remove the nut connecting the crankcase to the rear shock absorber.

Remove the pin connecting the engine to the chassis.

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

Removing the driven pulley shaft bearing


- Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.
N.B. IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DIAMETER EXTRACTOR CAN BE USED.

Refitting the driven pulley shaft bearing


Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside.
N.B.

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


CAUTION

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

Removing the driven pulley


- Lock the clutch housing with the specific tool. - Remove the nut, the clutch housing and the whole of the driven pulley assembly.
N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.

Specific tooling
020565Y Flywheel lock calliper spanner

ENG - 84

Typhoon 50 4t 4v

Engine

Inspecting the clutch drum


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

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)

Removing the clutch


- Equip the tool with long pins screwed into position A from the outside, insert the entire driven pulley in the tool and have the central screw make contact.
CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW IS TIGHTENED UP TOO FAR.

- Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw by undoing spring of the driven pulley unit - Separate the components.

Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch

ENG - 85

Engine

Typhoon 50 4t 4v

Inspecting the clutch


- Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.
N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic
Check minimum thickness 0.03937 in (1 mm)

Pin retaining collar


- Remove the collar with the aid of 2 screwdrivers.

- Remove the three guide pins and the mobile half pulley.

ENG - 86

Typhoon 50 4t 4v

Engine

Removing the driven half-pulley bearing


- Remove the roller bearing with the special extractor inserted from the bottom of the fixed halfpulley.
CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLIERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEAL RING.

Specific tooling
001467Y029 Bell for bearings, O.D. 38 mm - Remove the ball bearing retention snap ring. - Expel the ball bearing from the side of the clutch housing by means of the special tool.
N.B. PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVE BELT

Specific tooling
020376Y Adaptor handle 020363Y 20-mm guide

Inspecting the driven fixed half-pulley


- Check that there are no signs of wear on the work surface of the belt. If there are, replace the halfpulley.. - Make sure the bearings do not show signs of unusual wear. - Measure the outside diameter of the pulley bushing.

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

Inspecting the driven sliding half-pulley


- Remove the 2 inner sealing rings and the two Orings. - Measure the inside diameter of the mobile halfpulley bushing.

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. -

Refitting the driven half-pulley bearing


- Fit a new ball bearing with the specific tool. - Fit the ball bearing retention snap ring. - Fit the new roller bearing with the wording visible from the outside.
CAUTION PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED.

Specific tooling
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

Inspecting the clutch spring


- Check that the contrast spring of the driven pulley does not show signs of deformation - Measure the free length of the spring

Characteristic
Standard length 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)

Refitting the clutch


- Preassemble the driven pulley group with spring, sheath and clutch. - Position the spring with the sheath - Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded shank.

ENG - 89

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

Locking torques (N*m)


Clutch assembly nut 40.5 - 44.2 lb ft (55 - 60 Nm)

Refitting the driven pulley


-Refit the driven pulley assembly, the clutch bell and the nut, using the specific tool.

Specific tooling
020565Y Flywheel lock calliper spanner

Locking torques (N*m)


Driven pulley shaft nut 29.5 - 32.4 lb ft (40 - 44 Nm)

Drive-belt
- Make sure the drive belt is not damaged and does not have cracks in the toothed grooves. - Check the width of the belt.

Characteristic
Drive belt/Minimum width 0.688976 in (17.5 mm)

ENG - 90

Typhoon 50 4t 4v

Engine

Removing the driving pulley


- Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.

Specific tooling
020451Y Starting ring gear lock

Inspecting the rollers case


1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation. 2) Check the roller running tracks on the contact pulley; there must not be signs of wear and check the condition of the contact surface of the belt on the half-pulleys (mobile and stationary). 3) Check that the rollers do not show signs of marked facetting on the sliding surface and that the metallic insert does not come out of the plastic shell borders. 4) Check the integrity of the sliding shoes of the contact plate. - Check that the internal bushing shown in the 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: 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)

Refitting the driving pulley


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

- Refit the components of the assembly (roller housing assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive, washer and nut). - With the specific tool, tighten the lock nut to 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

Locking torques (N*m)


Crankshaft pulley nut 13.3 - 14.8 lb ft + 90 (18 - 20 Nm
+ 90)

ENG - 92

Typhoon 50 4t 4v

Engine

Refitting the transmission cover


- Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and its seating in the crankcase and the return spring. - Remove the damaged components. - Grease the spring. - Remove the toothed sector and load the spring with an appropriate tool. - Refit the washer, the Seeger and the Kick-start lever.

Recommended 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.

Locking torques (N*m)


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

End gear

ENG - 93

Engine

Typhoon 50 4t 4v

Removing the hub cover


Remove the transmission cover Remove the clutch assembly Discharge the rear hub oil. Remove the 5 screws indicated in the figure. Remove the hub cover with driven pulley shaft.

See also
Refitting the clutch

Removing the wheel axle


- Remove the intermediate gear and the complete gear wheel axle. - When removing the intermediate gear pay attention to the various shim adjustments.

Removing the wheel axle bearings


- Remove the oil seal and the Seeger ring. - Remove the bearing by pushing from the outside towards the inside of the gear compartment, using the appropriate punch.

Specific tooling
020363Y 20-mm guide 020376Y Adaptor handle 020358Y 37x40-mm Adaptor

ENG - 94

Typhoon 50 4t 4v

Engine

Removing the driven pulley shaft bearing


- Remove the Seeger ring inside the cover. - Remove the oil seal from the outside. - Remove the centring dowels and position the cover on a plane. - Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press.

Specific 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

Inspecting the hub shaft


- Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - If faults are found, replace the damaged components. - Check capacity (A) of the transmission gear (wear, deformations, etc.) - Check the pulley shaft seating: Superficial wear (B) may indicate irregularities in the crankcase seats or in the pulley shaft capacities

Inspecting the hub cover


- Check that the fitting surface is not dented or distorted. - If faults are found, replace the hub cover.

ENG - 95

Engine

Typhoon 50 4t 4v

Refitting the driven pulley shaft bearing


- Support the inner track of the bearing from the outside of the hub cover with the specific tool positioned under the press and insert the driven pulley axle. - Refit the oil seal flush with the cover.

Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft 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

Refitting the wheel axle bearing


- Heat the half crankcase on the transmission side using a thermal gun. - After lubricating its outer strip, insert the bearing with the special adapter with the aid of a hammer. - Refit the Seeger ring and the oil seal using the 42 x 47 mm adapter and the handle.

Specific tooling
020151Y Air heater 020376Y Adaptor handle 020363Y 20-mm guide 020359Y 42x47-mm Adaptor

ENG - 96

Typhoon 50 4t 4v

Engine

Refitting the ub cover


- Refit the whole wheel axle. - Refit the intermediate gear paying attention to the two shim washers. - Apply LOCTITE 510 for surfaces to the hub covers and refit the same with driven pulley shaft. - Refit the 5 screws and tighten them to the specified torque.
N.B. CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF RESIDUE FROM PREVIOUS GASKETS BEFORE APPLYING A NEW ONE.

Locking torques (N*m)


Rear hub cap screws 8.1 - 9.6 lb ft (11 - 13 Nm)

Flywheel cover Cooling hood


- Remove the manifold and the carburettor undoing the 2 fixing screws on the head - Remove the fastening clamp of the secondary air pipe and disconnect it - Remove the 4 front coupling screws (1 of them is a knob) and the side fixing screw at the crankcase base. - Remove the 4 side screws - Extract the 3 covers - Remove the cover sealing gaskets on the head - For refitting, repeat the removal steps but in reverse order
CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. N.B. WHEN REFITTING THE COVER, TAKE CARE NOT TO DAMAGE THE STATOR WIRING.

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.

Removing the stator


- Remove the 2 Pick-Up screws and the 2 stator fixing screws indicated in the figure. - Remove the stator and its wiring.

ENG - 98

Typhoon 50 4t 4v

Engine

Refitting the stator


- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
N.B. THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEMBLY.

Locking torques (N*m)


Pick-up screws 2.2 - 2.9 lb ft (3 - 4 Nm) Stator screws 2.2 - 2.9 lb ft (3 - 4 Nm)

Flywheel and starting Removing the starter motor


- Undo the screw on the power positive contact and disconnect the cable - Undo the 2 screws fixing the starter motor to the crankcase and recover the power wiring.

ENG - 99

Engine

Typhoon 50 4t 4v

Removing the flywheel magneto


- Lock the rotation of the flywheel using the calliper spanner. - Remove the nut.
CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS

- Extract the flywheel with the extractor.

Specific tooling
020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor

Inspecting the flywheel components


- Check that the flywheel internal magnets are in good conditions. - Check that the flywheel splines exhibit no loosening. - Check there are no deformations that may cause rubbing on the stator and the Pick-Up. - Check that the stator winding, its ferromagnetic support and the pick-up are in good conditions.

ENG - 100

Typhoon 50 4t 4v

Engine

Starter gear rim


- Check the toothing is level and in good conditions

Intermediate gear
- Check that the keying toothing on the crown and the starter motor are in good conditions. - Check that the Bendix opens and returns adequately.

Refitting the flywheel magneto


- Refit the stator and the pick-up being careful to pass the wiring through the appropriate crankcase couplings. - Refit the flywheel to the crankshaft being careful to respect the keying, then lock rotation with the specific tool and tighten the nut to the prescribed torque.
N.B. A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING, KNOCKING ETC.

Specific tooling
020565Y Flywheel lock calliper spanner

Locking torques (N*m)


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

ENG - 101

Engine

Typhoon 50 4t 4v

Refitting the starter motor


- Install the starter motor in its seating in the crankcase. - Tighten the screw on the head side but do not lock it, screw the second screw inserting the earth cable (black), then tighten the 2 screws at the prescribed torque. - Tighten the locking screw of the positive cable (red) on the side contact.
N.B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS.

Locking torques (N*m)


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

Cylinder assy. and timing system Removing the rocker-arms cover


- Remove the cooling covers - Remove the 4 retainers of the tappet cover - Remove the cover and the O-ring - Remove the 3 screws and then remove the Blowby cover - Clean the nozzle labyrinth and the membrane (replace it, if necessary), then remove the cover unit.

ENG - 102

Typhoon 50 4t 4v

Engine

Removing the timing system drive


- Temporarily loosen the tensioner central screw and remove it together with the spring. - Unscrew the 2 retainers indicated in the figure and remove the chain tightener support being careful to recover the sealing gasket.
N.B. SHOULD THE GASKET NOT BE IN GOOD CONDITIONS, REPLACE IT AFTER CAREFULLY CLEANING THE FAYING SURFACE IN ORDER TO AVOID ENGINE OIL LEAKS

- Remove the driving pulley - Remove the oil pump chain - Remove the tappet cover - Remove the central screw and the belleville washer indicated in the figure and lock the 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

Removing the cam shaft


- Remove the limit screw of the rocking lever pins shown in the figure. - Remove the Seeger ring retaining the camshaft bearing. - Remove pins and rocking levers. - Remove the calibrated pads
N.B. MARK THE ASSEMBLY POSITION OF THE ROCKING LEVERS IN ORDER TO AVOID MISPLACING THE INTAKE AND DISCHARGE ENDS.

- Remove the entire camshaft with bearing using the specific tool shown in the figure. - Take out the camshaft bearing with the aid of the specific tool, being careful to mount a screw on the camshaft in order to protect its thread.
N.B. IF A BEARING SEPARATES FROM THE CAMSHAFT, IT 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

Removing the cylinder head


- Remove the cooling covers, the timing control, the camshaft and the rocking levers. - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two alignment dowels and the gasket.
N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS AND ROCKING LEVERS WITHOUT REMOVING THE DRIVING PULLEY UNIT. REMEMBER TO HOLD THE TIMING CHAIN WITH A PIECE OF METAL CABLE AND TO ADJUST THE CHAIN TIGHTENER UPON REFITTING.

Removing the valves


- Using the specific tool fitted with the part shown in the figure, remove cotters, caps and valve springs.

- Remove the oil seals with the appropriate tool.

Specific tooling
020431Y Valve oil seal extractor 020382Y Valve cotters equipped with part 012 removal tool

ENG - 105

Engine

Typhoon 50 4t 4v

Removing the cylinder - piston assy.


- Remove the cylinder paying attention to the 2 cylinder centring dowels in the housing. - Remove the cylinder base gasket. To avoid damaging the piston, keep it fixed while removing the cylinder.

- Remove the two stop rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston.
N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.

Inspecting the small end


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

IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM 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

Inspecting the wrist pin


- Measure the outer diameter of the gudgeon pin.

ENG - 106

Typhoon 50 4t 4v

Engine

For the dimensions see the SPECIFICATIONS chapter

Inspecting the piston


- Measure the diameter of the bearings on the piston. For the dimensions see the SPECIFICATIONS chapter

- Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
N.B.

MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE SECOND SEAL RING SIDE. For the dimensions see the SPECIFICATIONS chapter

ENG - 107

Engine

Typhoon 50 4t 4v

Inspecting the cylinder

- Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).

Characteristic
Maximum allowable run-out 0.001 in (0.05 mm)

Inspecting the piston rings


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

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

Removing the piston


- Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Fit the pin retainer ring onto the appropriate tool.

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.

Refitting the piston rings


- Fit the oil scraper ring starting from the spring, taking care that the spring ends do not superimpose. Fit the two piston rings so that their gaps and that of the oil scraper ring are never aligned. - Fit the 2nd sealing ring with the identifying letter T facing towards the piston crown. - Fit the 1st sealing ring with the reference letter T facing towards the piston crown. - Misalign the lining openings at 120 as shown in the figure. - Lubricate the components with engine oil.
N.B. IN ORDER TO OBTAIN A GOOD BEDDING, THE 2 SEALING PISTON RINGS ARE MADE OF CONE SHAPED CONTACT SECTION TO THE CYLINDER. AS A RESULT IT IS IMPORTANT TO RESPECT THE FITTING INSTRUCTION TO ASSEMBLY THE RINGS WITH THE "T" MARK FACING UPWARDS.

ENG - 110

Typhoon 50 4t 4v

Engine

Refitting the cylinder


- Insert the cylinder base gasket. - Fit the cylinder as shown in the figure. - The piston can be kept out of the housing plane using the appropriate tool.
N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER LINER.

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.

Locking torques (N*m)


Head nut tightening (only for stud bolt replacement) 4.4 - 5.2 lb ft + 135 + 90 (6-7 Nm + 135 + 90)

Inspecting the cylinder head


- Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn. - It is advisable to replace the head if any failure is found.

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)

Inspecting the timing system components


- Check that the guide slider and the tensioner slider are not worn out. - Ensure that the camshaft drive pulley, the chain assembly and the sprocket wheel are not worn. - If sings of wear are found, replace the parts. if the chain, pinion or pulley are worn, replace the whole assembly. - Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole unit.

ENG - 112

Typhoon 50 4t 4v

Engine

Inspecting the valve sealings


- Remove any carbon deposits from the valve seats. - Check the width of the mark on the valve seat V with Prussian blue.

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.

Inspecting the valves


VALVE STANDARD LENGTH
Specification Inlet: standard length Outlet: standard length Desc./Quantity 2.948919 in (74.9 mm) 2.927165 in (74.35 mm)

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)

MINIMUM ADMISSIBLE DIAMETER


Specification Intake Exhaust Desc./Quantity 0.155827 in (3.958 mm) 0.155315 in (3.945 mm)

- Calculate the clearance between valve and valve guide. - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the V shaped support.

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

Inspecting the valve stem guide clearance


Measure the valve guides

VALVE GUIDE DIAMETER


Specification Standard valve guide diameter Valve guide Maximum admissible diameter Desc./Quantity 0.15748 + 0.000472 in (4 + 0.012 mm) 0.15748 + 0.000866 in (4 + 0.022 mm)

- After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem.

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

Refitting the valves


- Lubricate the valve guides with graphite grease. - Place the lower caps of the valve spring on the head. - Use the punch to fit the 4 sealing rings one at a time.

- Fit the valves, the springs and the upper caps. - Using the appropriate tool, compress the springs and insert the cotters in their seats.

Inspecting the cam shaft


- Inspect the camshaft for signs of abnormal wear on the cams.

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.

DIAMETER OF PINS AND ROCKING LEVERS


Specification Rocking levers - Inside diameter Rocking levers - Pins diameter Desc./Quantity 0.433661 - 0.434449 in (11.015 - 11.035 mm) 0.432165 - 0.43248 in (10.977 - 10.985 mm)

Refitting the head and timing system components


- Fix the head on a workbench. - Screw the tool to fit the camshaft fully down on the bearing's inner track. - Fit the camshaft fully into its seating together with the bearing with the aid of a mallet. - Remove the tool. - Fit the head gasket after cleaning the faying surface carefully. ENG - 117

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

Locking torques (N*m)


Rocking lever axle and camshaft bearing screw 2.2 - 2.9 lb ft (3 - 4 Nm)

- 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

Locking torques (N*m)


Head-cylinder stud bolt nuts 4.4 - 5.2 lb ft + 90 + 90 (6 - 7 Nm + 90 + 90) Floating head cover screws 4.4 - 5.2 lb ft (6 - 7 Nm)

ENG - 118

Typhoon 50 4t 4v

Engine

Refitting the timing chain


- Insert the timing chain pads in their corresponding seatings, the screw and the spacer as indicated in the figure. - Tighten to the prescribed torque and check the tensioner pad moves adequately. - Insert the timing pinion in driving shaft with the chamfered side facing the insertion (towards the main bearing). - Loop the timing chain around the sprocket on the crankshaft.

Locking torques (N*m)


Chain tensioner pad screw 3.7 - 5.2 lb ft (5 - 7 Nm) - Refit the spacer on the camshaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - With this operation, insert the chain on the camshaft control pulley and make the reference notch coincide with the point on the head. - Fit the pulley onto the camshaft. - Fit the belleville washer so that the outer rim touches the pulley. - Bring the screw closer but without reaching its final locking point. - Push the tensioner pad lightly so as to check the correct timing. - Use the specific tool to lock the camshaft crown gear and tighten the screw. - Adjust valve clearance. - Replace the O-ring on the tappet cover. - Fit the tappet cover and lock it with the 4 fixing screws indicated in the figure.

Specific tooling
020565Y Flywheel lock calliper spanner

Locking torques (N*m)

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

Locking torques (N*m)


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

Refitting the rocker-arms cover


- Carry out the removal procedure but in reverse order and tighten the four fixing screws to the specified torque.
N.B. FIT A NEW O-RING ON THE TAPPET COVER.

Refitting the intake manifold


-Fit the cover sealing gaskets on the head. -Fit the 2 covers. - Fit the inlet manifold and do up the 2 screws to the specified torque. -Fit the carburettor on the inlet manifold and lock the clamp. -Fit the secondary air pipe and fix it with the appropriate clamp.
N.B.

ENG - 120

Typhoon 50 4t 4v

Engine

FIT THE CARBURETTOR THROUGH THE SUPPLEMENT ON THE MANIFOLD.

Locking torques (N*m)


Inlet manifold screw 5.2 - 6.6 lb ft (7 - 9 Nm)

Crankcase - crankshaft
- First remove the following units: Driving pulley Driven pulley Final reduction greasing Oil pump Flywheel with stator Cylinder-piston-head unit Starter motor with cables.

See also
Removing the driving pulley Removal Removing the driven pulley Removing the cylinder - piston assy. Removing the starter motor Removing the stator

Splitting the crankcase halves


- Remove the ten crankshaft coupling screws. -Separate the crankcase halves keeping the half casing driving shaft engaged on the transmission side. - Remove the crankshaft.
CAUTION IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL.

- Remove the oil guard on the flywheel side.


CAUTION

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

- Check the axial clearance on the connecting rod.

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)

Removing the crankshaft bearings


- Remove the flywheel bearing fitted on the driving shaft using the specific tool.

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

Refitting the crankshaft bearings


- Support the crankcase on a surface and place it with the driving shaft axle in a vertical position. - Warm the crankcase at ~ 250F (~ 120C) with a thermal gun (and support). - Fit the punch with guide and adaptor, place the bearing on the punch using grease (to keep it from falling). -Insert the bearing in the crankcase; if needed, use a mallet but do so with extreme care so as not to damage the engine crankcase limit stop.

Specific 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

Inspecting the crankshaft alignment


To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure.
N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE 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) - 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

Refitting the crankcase halves


-Be careful to place the two centring dowels preferably on the flywheel side half casing. -Insert the crankshaft on the half casing on the transmission side.

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

Locking torques (N*m)


Crankcase half union screw 5.9 - 7.4 lb ft (8 - 10 Nm) - Fit a new O-Ring on the mesh oil filter and on the filling cap; lubricate the rings. - Insert the filter on the engine and lock the cap to the prescribed torque.

Locking torques (N*m)


Engine oil pre-filter cover 18.4 - 20.6 lb ft (25 - 28 Nm)

Lubrication Crankshaft oil seals Removal


- Extract the flywheel oil seal from the crankcase being careful not to damage or score the crankcase.

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

Locking torques (N*m)


Timing chain/oil pump compartment cover screws 2.9 - 3.7 lb ft (4 - 5 Nm)

Oil pump Removal


- Remove the chain compartment cover undoing the 3 fixing screws indicated in the figure. - Take out the cover using the appropriate fusion couplings on the cover with a pair of pliers

ENG - 126

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.

Locking torques (N*m)

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)

Removing the oil sump


- Remove the oil filling cap, the transmission cover, the complete driving pulley assembly with belt and pinion. - Unscrew the oil drainage plug A shown in the figure and drain out all the oil from the sump. - Remove the 6 screws indicated in the figure.

Refitting the oil sump


- Clean and grease the faying surfaces. - Apply LOCTITE 510 on the sump surface and tighten the 6 fixing screws to the specified torque. - Refit the driving pulley assembly, the belt, the pinion and the transmission cover.
WARNING WHEN TESTING THE LUBRICATION SYSTEM, REFER TO THE "CRANKCASE AND CRANKSHAFT" CHAPTER, REGARDING LUBRICATION OF THE CRANKSHAFT AND CONNECTING ROD

Locking torques (N*m)


Oil sump screws 5.9 - 7.4 lb ft (8 - 10 Nm)

Fuel supply
- Disconnect the fuel supply and the suction taking pipe from the carburettor. - Check that there are no fuel leaks between the two tubes. - Close the fuel outlet pipe. - Using a MITIVAC pump, apply 1.45 psi (0.1 bar) vacuum bar on the cock. - Make sure that the suction is kept stable and that and that there are no fuel leaks. - Reconnect the vacuum pipe to the manifold.

ENG - 129

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

Removing the carburettor


- To detach the carburettor from the engine, remove the two clamps anchoring the carburettor to the inlet manifold and the air intake coupling to the filter. - Remove the fuel supply pipe. - Disconnect the starter connection. - Detach the accelerator cable with the sheath that connects the plate and the support. - Remove the carburettor. - Remove the protection, the bracket and the starter undoing the screw shown in the figure.
CAUTION THE CARBURETTOR FEATURES AN ANTI-VIBRATION RUBBER BUFFER FITTED ON THE LOWER SUPPLEMENT OF THE ACCELERATING PUMP BODY. UPON REFITTING THE CARBURETTOR ON THE ENGINE, MAKE SURE THIS BUFFER IS PRESENT SO THAT THE PETROL IN THE TANK DOES NOT EMULSIFY.

- 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.

-Remove the maximum nozzle. -Remove diffuser.

ENG - 132

Typhoon 50 4t 4v

Engine

-Remove the minimum nozzle.

- Remove the sprayer tilting the carburettor body.


N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.

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

CAUTION

DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PIN SEATING, STARTER NOZZLE, THROTTLE VALVE CONTROL 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

Refitting the carburettor


- Before refitting, wash the carburettor body accurately with a degreasing solvent and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat.

- For the minimum circuit, make sure the following points are properly cleaned: air gauging, exhaust section controlled by flow screw, progression holes near the throttle valve.

- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible 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.

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

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.

Inspecting the automatic choke device


- Check that the automatic starter piston is not deformed or rusty. - Check that the piston slides freely in its seating. - Check that the piston sealing O-Ring is not deformed. - The starter must be more or less functional depending on the ambient temperature. - Measure the protrusion of the piston as shown in the figure and check its corresponding value. - Make sure that the starter is adjusted for the ambient temperature.

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.

Adjusting the idle


- The engine does not require frequent idle speed adjustments, but it is essential to strictly follow certain rules when adjusting the idle speed. - Before adjusting the carburettor make sure to respect requirements on lubrication, valve clearance, and complying timing; spark plug should be in optimum conditions, air filter clean and sealed, and the exhaust system tight. - Connect the tester thermometer to the sump, using a cover with oil expressly prepared for probes. - Start the engine and before adjusting the idle speed, make sure that the oil temperature is between 158 to 176F (70 to 80C)

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

Front Removing the front wheel


- Loosen the wheel axle lock nut, by keeping the wheel axle blocked on the opposite side.

Loosen the wheel axle safety screws on the fork leg, on the odometer gear side.

SUSP - 142

Typhoon 50 4t 4v

Suspensions

- Pull out the wheel axle.

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.

Front wheel hub overhaul


Check that the wheel bearings do not show signs of wear. If necessary, replace the wheel bearings, proceeding as follows: Lock the bearing puller in the bearing on the side the odometer detects movement.

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

Remove the spacer from inside the hub.

Use handle, adaptor and guide, place the wheel on supports and hit with a mallet on the brake side to extract the bearing.

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

Fit the external spacer.

Fit the internal spacer.

With an appropriate heater gun heat the seat of the bearing on the side the odometer detects 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

Refitting the front wheel


First shift by 90 the inner stop of the odometer drive with respect to the one on the wheel.

Insert the wheel axle after greasing it from the brake disc opposite side, centring the retainer on the fork leg onto the projecting parts of the 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.

Locking torques (N*m)


Front wheel axle hub 7.3 lb ft (10 Nm) Fork wheel axle 34.3 lb ft (46.5 Nm)

Handlebar Removal
- Remove the front and rear handlebar covers. - Detach the front brake pump from the handlebar. - Disconnect the rear brake, throttle control and odometer control cables. - Remove the screw fixing the handlebar to the steering tube. - Remove the handlebar.

See 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.

Locking torques (N*m)


Headstock handlebar 38.7 lb ft (52.5 Nm)

SUSP - 147

Suspensions

Typhoon 50 4t 4v

(*) Lubricate the nut with engine oil before installation

Front fork Removal

REMOVING THE STANCHIONS - Remove the legshield. - Remove the brake calliper. - Remove the front wheel. - Remove circlip 7, the two screws 8 and slide off the stanchion. - Unscrew the upper cap 6. - Remove the components including the spring. - Drain the oil into a collecting container.

SUSP - 148

Typhoon 50 4t 4v

Suspensions

- Undo screw 3, remove the stanchion and the piston.

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)

Locking torques (N*m)


Plate fork stanchions 29.5 lb ft (40 Nm) Sleeve fork stanchions 22.1 lb ft (30 Nm)

Steering column Removal

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

Locking torques (N*m)


Steering upper ring nut 27.7 lb ft (37.5 Nm) Remove the upper ring (or lower ring nut) 3 of the upper bearing A. Slide the fork and collect the cage with the balls 4 of the upper bearing A.

Locking torques (N*m)


Steering lower ring nut 9.6 lb ft (13 Nm)

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

See 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

Locking torques (N*m)


Steering lower ring nut 9.6 lb ft (13 Nm) Steering upper ring nut 27.7 lb ft (37.5 Nm)

See also
Legshield

Rear Removing the rear wheel


- Position the vehicle on the centre stand. - Remove the silencer. - Use a screwdriver to remove the plastic cap.

- Remove the cotter pin. - Remove the cap.

Pull the rear brake and hold it in. Unscrew the wheel fixing nut and collect the washer. Take out the wheel from its housing.

See also
Exhaust assy. Removal

SUSP - 154

Typhoon 50 4t 4v

Suspensions

Refitting the rear wheel


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

Locking torques (N*m)


Rear wheel hub 87.8 lb ft (115 Nm)

Swing-arm Removal
Rest the vehicle on its centre stand. Support the engine adequately. Unscrew the nut on the left-hand side of the frame and remove the pin from the opposite side.

Unscrew the nut on the left-hand side of the engine and remove the pin from the opposite side.

Overhaul
Regularly check the clearance of the swinging arm retainer pins. To carry out these operations, 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.

Locking torques (N*m)


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

Shock absorbers Removal


- Remove the side fairings. - Support the vehicle adequately. - Undo the inner nut and slide off the shock-absorber to chassis upper fixing screw.

Undo the inner nut and slide off the shock-absorber to engine lower fixing screw. Remove the shock absorber. To refit tighten the screws to the prescribed tightening torque.

Locking torques (N*m)


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

See 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.

FITTING On refitting tighten the nut to the specified torque.

Locking torques (N*m)


Centre stand pin 31.3 lb ft (42.5 Nm)

SUSP - 157

INDEX OF TOPICS

BRAKING SYSTEM

BRAK SYS

Typhoon 50 4t 4v

Braking system

Front brake calliper Removal


- Check that the brake piping, gasket and fitting are in good condition. If you see any oil on the brake calliper and/or the components of the system, it is necessary to replace them. - Detach the oil brake pipe from the calliper; pour the fluid inside a container. - Remove the two clamps shown in the figure. - Remove the brake calliper from the fork.

Refitting
Refit the calliper on the support and tighten the screws to the specified torque. Refit the tube complete with fitting with new copper gaskets. Place the tube joint in the original position and tighten it to the specified torque. Bleed the air from the system.

Locking torques (N*m)


Front brake calliper to fork 18.8 lb ft (25.5 Nm)

See also
Front

Front brake disc

BRAK SYS - 159

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.

Locking torques (N*m)


Brake disc 6.6* lb ft (9* Nm)

* With Loctite 243

Disc Inspection
- Check the disc thickness.

Characteristic
Disc minimum thickness 0.1378 in (3.5 mm)

BRAK SYS - 160

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

Front brake pads Removal


Remove the brake calliper.

BRAK SYS - 161

Braking system

Typhoon 50 4t 4v

Undo the screws indicated in the figure.

Remove the pads. Remove the inside spring.


CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.

- 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.

BRAK SYS - 162

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.

Locking torques (N*m)


Brake pad fastening screw 11-14.7 lb ft (15-20 Nm)

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.

BRAK SYS - 163

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

Locking torques (N*m)


Oil bleed screw 5.9 - 8.8 lb ft (8-12 Nm)

BRAK SYS - 164

Typhoon 50 4t 4v

Braking system

Front brake pump


- Remove the front and rear handlebar cover. - Disconnect the tube, collecting the brake oil in a container.

- Operate on the two U bolt clamps (see figure). - On refitting, perform the operation in reverse. - Tighten the hydraulic line to the prescribed torque and then fill and purge the system.

Locking torques (N*m)


Brake fluid hose-pump fitting 14.75 - 18.44 lb ft (20-25 Nm) Handlebar brake pump 5.9 lb ft (8 Nm)

See also
Front handlebar cover Rear handlebar cover

Rear drum brake


Drum brake adjustment Regulate the point where the rear drum brake intervenes, using the adjustment indicated in the figure. With the brake lever at rest, the wheel must turn freely.

BRAK SYS - 165

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.

Locking torques (N*m)


Rear brake adjustment nut 3.69 lb ft (5 Nm)

BRAK SYS - 166

Typhoon 50 4t 4v

Braking system

See also
Front handlebar cover Legshield Footrest

BRAK SYS - 167

INDEX OF TOPICS

CHASSIS

CHAS

Typhoon 50 4t 4v

Chassis

Seat
Undo the nuts indicated in the figure and collect the washers.

Locking torques (N*m)


Saddle plate fixing nut 7.4 lb ft (10 Nm)

Driving mirrors
Undo the screws indicated.

Locking torques (N*m)


Mirror fixing spacer 18.4 lb ft (25 Nm)

Rear handlebar cover


Remove the front handlebar cover. 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

Front handlebar cover


Remove the rear-view mirrors. Undo the screws indicated.

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.

- Undo the indicated screw, beneath the leg shield lug.

- Move the leg shield forward, opening the lower ends and detach the headlight bulb connections.

CHAS - 172

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

Front wheel housing


- Remove the front shield. Remove the front mudguard. Remove the front wheel. Undo the screws indicated.

- 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

Undo the screws indicated.

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 the upper screws.

- Undo from both sides of the vehicle the screw placed under the footrest.

- Open the front ends of the side fairings to slide off the indicated upper inserts. - Disconnect the connections of the turn indicators and of the rear light unit.

See also
Handles and top side fairings Rear central cover

CHAS - 176

Typhoon 50 4t 4v

Chassis

License plate holder


- Remove the side fairings. - Disconnect the connections of the turn indicators and of the license plate light.

- Undo the rear screw outside the license plate support.

- Undo the two screws indicated. - Remove the license plate support together with the turn indicators.

See also
Side fairings

CHAS - 177

Chassis

Typhoon 50 4t 4v

Rear mudguard
- Undo the right-hand side screw.

Undo the screws indicated in the figure.

Helmet bay
Remove the side panels Remove the battery cover and the battery. Undo the two screws inside the helmet 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

- Undo the indicated screw on both sides of the vehicle.

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

Disconnect the fuel probe connector and detach the breather pipe from the filler.

Locking torques (N*m)


Chassis fuel tank retainer screws 7.4 lb ft (10 Nm)

See also
Helmet bay Side fairings

Rear central cover


- Remove the saddle. - Undo the four indicated screws and remove the cover by sliding it upwards so as to detach the locking tabs on the sides.

CHAS - 180

Typhoon 50 4t 4v

Chassis

See also
Seat

Front mudguard
- Operating from both sides of the vehicle, undo the three indicated screws.

Handles and top side fairings


Remove the three screws indicated in the figure and collect the washers. Remove the rear handles.

Locking torques (N*m)


Passenger handle 15.1 lb ft (20.5 Nm)

CHAS - 181

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

Tightening torques inspection


Lock check - Safety fasteners - Fixing screws Safety fasteners:
Rear shock absorber upper fixing Rear shock absorber lower fixing Front wheel axle nut Wheel hub nut Swinging arm - chassis pin Engine-swinging arm pin Engine arm pin - Chassis arm Handlebar lock nut Lower steering ring nut Upper steering ring nut

Electrical system
Electrical system: - Main switch - Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights - Adjusting the headlights according to the regulations currently in force - Rear light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel gauge - Instrument panel warning lights - Horn - Starter PRE 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

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.


CAUTION

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Functional inspection
Functional Checks: Braking system (hydraulic) - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Throttle travel check Others - Check documentation - Check the chassis and engine numbers - Tool kit - License plate fitting - Check locks - Check tyre pressures - Installation of mirrors and any accessories

PRE DE - 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

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

V
Vehicle: 7, 78