Service Station Manual: Typhoon 50 4t 4v

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 CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
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 connec-
tions.
CHAR - 6
Typhoon 50 4t 4v Characteristics
Vehicle identification
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Chassis prefix ZAPC50
Engine prefix C37CM
Dimensions and mass
WEIGHTS AND DIMENSIONS

Maximum length 76.38 in (1940 mm)
Overall width 28.35 in (720 mm)
Max. height to the windshield 44.69 in (1135 mm)
Wheelbase 53.15 in (1350 mm)
Kerb weight 242 lbs (110 Kg)
Engine
DATI TECNICI MOTORE

Motore Monocilindrico 4 tempi, 4 valvole raffreddato ad aria
Distribuzione monoalbero a camme in testa a 4 valvole
Cilindrata 3,03 in³ (49,0 cc)
Alesaggio per corsa 1,54 x 1,63 in (39 x 41,35 mm)
Gioco Valvole aspirazione: 0,006 in (0,15 mm)
scarico: 0,006 in (0,15 mm)
Transmission Automatic continuous variator
Clutch Automatic centrifugal dry clutch
CHAR - 7
Lubrication Wet crankcase
Cooling forced air circulation
Electric Starter and kick starter
Carburatore KEIHIN NCV Ø 20
Fuel Unleaded petrol 90 (M+R) /2 minimum octane
Spark plug NGK ER9EH-6N
Transmission
TRANSMISSION
Transmission With automatic expandable pulley variator, torque server, V-
belt, automatic clutch, gear reduction unit.
Capacities
CAPACITY
Fuel tank capacity ~1.5 gal (including 0.4 gal reserve) ~ 7 litres (including 1.5 l
reserve)
Hub oil ~ 0.0225 gal (~ 85 cc)
Engine oil ~0.225 gal (~850 cc)
Electrical system
ELECTRICAL COMPONENTS
1 Ignition advance reference in table
2 Spark plug NGK ER9EH-N
3 Battery 12V - 9Ah
4 Fuses 1 15A - 1 10A - 1 7.5A
5 Generator 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
- Primary resistance: 0.5 to 0.6 Ohm

- Resistance between primary and ground con-
nection: infinite
- Resistance between primary and HV output: 3 to
3.6 kOhm
- Shielded cap: 5000 Ohm
Frame and suspensions
FRAME AND SUSPENSION

Frame Tubular steel frame with sheet metal reinforcements
Front suspension Hydraulic telescopic fork; Ø 1,36 in (Ø 32) - 2.99 (76 mm)
rear suspension Hydraulic single shock absorber and spring adjustable to 4 po-
sitions at preloading; travel: 3.40 in (86.5 mm).
Brakes
BRAKES
Front brake Disc brake Ø 8.6 in (220 mm) with hydraulic control (lever on
the far right of the handlebar) and floating calliper.
Rear brake Drum Ø 5.51 in (Ø 140 mm)
Wheels and tyres
WHEELS AND TYRES

Wheel rims Die-cast aluminium alloy
Front wheel rim 3.00 x 14"
Rear wheel rim 3.50 x 14
Tyre type Without inner tube (Tubeless)
Front tyre 120/70 - 14" 55 P
Rear tyre 120/70 - 14" 55 P
Standard front tyre pressure [with passenger] 23 psi (1.6 bar) [29 psi (2.0 bar)]
Standard rear tyre pressure [with passenger] 29 psi (2.0 bar) [32 psi (2.2 bar)]
Tightening Torques
ENGINE ASSEMBLY
Name Torque in Nm
Ignition spark plug 7.4 - 11 lb ft (10 - 15 Nm)
Floating head cover screws 4.4 - 5.2 lb ft (6 - 7 Nm)
Head-cylinder stud bolt nuts 4.4 - 5.2 lb ft + 90° + 90° (6 - 7 Nm + 90° + 90°)
Head nut tightening (only for stud bolt replacement) 4.4 - 5.2 lb ft + 135° + 90° (6-7 Nm + 135° + 90°)
Screws fixing head and cylinder to crankcase 5.9 - 7.4 lb ft (8 - 10 Nm)
Chain tensioner pad screw 3.7 - 5.2 lb ft (5 - 7 Nm)
Timing chain tensioner central screw 3.7 - 4.4 lb ft (5 - 6 Nm)
CHAR - 9
Name Torque in Nm
Camshaft pulley screw 8.8 - 10.3 lb ft (12 - 14 Nm)
Rocking lever axle and camshaft bearing screw 2.2 - 2.9 lb ft (3 - 4 Nm)
Rocker adjusting nuts 5.2 - 6.6 lb ft (7 - 9 Nm)
Engine oil pre-filter cover 18.4 - 20.6 lb ft (25 - 28 Nm)
Engine oil drainage cap 29.5 - 32.4 lb ft (40 - 44 Nm)
Flywheel nut 2.2 - 2.9 lb ft (3 - 4 Nm)
Stator screws 2.2 - 2.9 lb ft (3 - 4 Nm)
Pick-up screws 2.2 - 2.9 lb ft (3 - 4 Nm)
Oil pump bulkhead screw 2.9 - 3.7 lb ft (4 - 5 Nm)
Timing chain/oil pump compartment cover screws 2.9 - 3.7 lb ft (4 - 5 Nm)
Oil decantation labyrinth sheet screws 5.2 - 5.9 lb ft (7 - 8 Nm)
Oil pump sprocket gear screw 5.9 - 7.4 lb ft (8 - 10 Nm)
Screws fixing oil pump to the crankcase 3.7 - 4.4 lb ft (5 - 6 Nm)
Oil sump screws 5.9 - 7.4 lb ft (8 - 10 Nm)
Inlet manifold screw 5.2 - 6.6 lb ft (7 - 9 Nm)
Carburettor/manifold clamp screw 0.9 - 1.1 lb ft (1.2 - 1.5 Nm)
Screws fixing cables to starter motor 0.9 - 1.1 lb ft (1.2 - 1.5 Nm)
Starter motor screws 8.1 - 9.6 lb ft (11 - 13 Nm)
Transmission cover screws 8.1 - 9.6 lb ft (11 - 13 Nm)
Start-up lever screw 8.1 - 9.6 lb ft (11 - 13 Nm)
Crankcase cooling cover screw 1.5 - 1.8 lb ft (2 - 2.5 Nm)
Clutch assembly nut 40.5 - 44.2 lb ft (55 - 60 Nm)
Crankshaft pulley nut 13.3 - 14.8 lb ft + 90° (18 - 20 Nm + 90°)
Driven pulley shaft nut 29.5 - 32.4 lb ft (40 - 44 Nm)
Hub oil drainage screw 2.2 - 3.7 lb ft (3 - 5 Nm)
Rear hub cap screws 8.1 - 9.6 lb ft (11 - 13 Nm)
Crankcase half union screw 5.9 - 7.4 lb ft (8 - 10 Nm)
STEERING ASSEMBLY
Name Torque in Nm
Steering upper ring nut 27.7 lb ft (37.5 Nm)
Steering lower ring nut 9.6 lb ft (13 Nm)
Headstock handlebar 38.7 lb ft (52.5 Nm)
CHASSIS ASSEMBLY
Name Torque in Nm
Engine side swinging arm 31.3 lb ft (42.5 Nm)
Chassis side swinging arm 31.3 lb ft (42.5 Nm)
Passenger handle 15.1 lb ft (20.5 Nm)
Centre stand pin 31.3 lb ft (42.5 Nm)
Saddle plate fixing nut 7.4 lb ft (10 Nm)
Mirror fixing spacer 18.4 lb ft (25 Nm)
Chassis fuel tank retainer screws 7.4 lb ft (10 Nm)
Handlebar brake pump 5.9 lb ft (8 Nm)
FRONT SUSPENSION
Name Torque in Nm
Plate fork stanchions 29.5 lb ft (40 Nm)
Sleeve fork stanchions 22.1 lb ft (30 Nm)
Front wheel axle hub 7.3 lb ft (10 Nm)
Fork wheel axle 34.3 lb ft (46.5 Nm)
REAR SUSPENSION
Name Torque in Nm
Shock absorber upper part 27.3 lb ft (37 Nm)
Shock absorber lower part 27.3 lb ft (37 Nm)
Rear wheel hub 87.8 lb ft (115 Nm)
FRONT AND REAR BRAKE

Name Torque in Nm
Brake disc 6.6* lb ft (9* Nm)
Front brake calliper to fork 18.8 lb ft (25.5 Nm)
Brake pad fastening screw 11-14.7 lb ft (15-20 Nm)
CHAR - 10
Name Torque in Nm
Rear brake adjustment nut 3.69 lb ft (5 Nm)
Brake fluid hose-pump fitting 14.75 - 18.44 lb ft (20-25 Nm)
Oil bleed screw 5.9 - 8.8 lb ft (8-12 Nm)
*with Loctite 243
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND CYLINDER

Name Initials Cylinder Piston Play on fitting
Cylinder A 1.535157 - 1.535433 in 1.533622 - 1.533898 in 0.00126 - 0.001811 in
(38.993 - 39.000 mm) (38.954 - 38.961 mm) (0.032 - 0.046 mm)
Cylinder B 1.535433 - 1.535709 in 1.533898 - 1.534173 in 0.00126 - 0.001811 in
(39.000 - 39.007 mm) (38.961 - 38.968 mm) (0.032 - 0.046 mm)
Piston C 1.535709 - 1.535984 in 1.534173 - 1.534449 in 0.00126 - 0.001811 in
(39.007 - 39.014 mm) (38.968 - 38.975 mm) (0.032 - 0.046 mm)
Piston D 1.535984 - 1.536260 in 1.534449 - 1.534724 in 0.00126 - 0.001811 in
(39.014 - 39.021 mm) (38.975 - 38.982 mm) (0.032 - 0.046 mm)
Cylinder 1st oversize A1 1.543031 - 1.543307 in 1.541496 - 1.541772 in 0.00126 - 0.001811 in
(39.193 - 39.200 mm) (39.154 - 39.161 mm) (0.032 - 0.046 mm)
Cylinder 1st oversize B1 1.543307 - 1.543583 in 1.541772 - 1.542047 in 0.00126 - 0.001811 in
(39.200 - 39.207 mm) (39.161 - 39.168 mm) (0.032 - 0.046 mm)
Piston 1st oversize C1 1.543583 - 1.543858 in 1.542047 - 1.542323 in 0.00126 - 0.001811 in
(39.207 - 39.214 mm) (39.168 - 39.175 mm) (0.032 - 0.046 mm)
Piston 1st oversize D1 1.543858 - 1.544134 in 1.542323 - 1.542598 in 0.00126 - 0.001811 in
(39.214 - 39.221 mm) (39.175 - 39.182 mm) (0.032 - 0.046 mm)
Cylinder 2nd oversize A2 1.550906 - 1.551181 in 1.549370 - 1.549646 in 0.00126 - 0.001811 in
(39.393 - 39.400 mm) (39.354 - 39.361 mm) (0.032 - 0.046 mm)
Cylinder 2nd oversize B2 1.551181 - 1.551457 in 1.549646 - 1.549921 in 0.00126 - 0.001811 in
(39.400 - 39.407 mm) (39.361 - 39.368 mm) (0.032 - 0.046 mm)
CHAR - 11
Name Initials Cylinder Piston Play on fitting

Piston 2nd oversize C2 1.551457 - 1.551732 in 1.549921 - 1.550197 in 0.00126 - 0.001811 in
(39.407 - 39.414 mm) (39.368 - 39.375 mm) (0.032 - 0.046 mm)
Piston 2nd oversize D2 1.551732 - 1.552008 in 1.5590197 - 1.550472 0.00126 - 0.001811 in
(39.414 - 39.421 mm) in (39.375 - 39.382 mm) (0.032 - 0.046 mm)
Cylinder 3rd oversize A3 1.558780 - 1.559055 in 1.557244 - 1.557520 in 0.00126 - 0.001811 in
(39.593 - 39.600 mm) (39.554 - 39.561 mm) (0.032 - 0.046 mm)
Cylinder 3rd oversize B3 1.559055 - 1.559331 in 1.557520 - 1.557795 in 0.00126 - 0.001811 in
(39.600 - 39.607 mm) (39.561 - 39.568 mm) (0.032 - 0.046 mm)
Piston 3rd oversize C3 1.559331 - 1.559006 in 1.557795 - 1.558071 in 0.00126 - 0.001811 in
(39.607 - 39.614 mm) (39.568 - 39.575 mm) (0.032 - 0.046 mm)
Piston 3rd oversize D3 1.559006 - 1.559882 in 1.558071 - 1558346 in 0.00126 - 0.001811 in
(39.614 - 39.621 mm) (39.575 - 39.582 mm) (0.032 - 0.046 mm)
N.B.
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 pis-

ton.
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
MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE
SECOND SEAL RING SIDE.
ASSEMBLY CLEARANCES
Name Description Dimensions Initials Quantity
Top piston ring standard coupling clear- 0.001181 - 0.002559 in
ance (0.03 - 0.065 mm)
Top piston ring maximum admissible 0.002756 in (0.07 mm)
clearance after use
Middle piston ring standard coupling clear- 0.000787 - 0.002165 in
ance (0.02 - 0.055 mm)
Middle piston ring maximum admissible 0.002362 in (0.06 mm)
clearance after use
scraper ring standard coupling clear- 0.001575 - 0.006299 in
ance (0.04 - 0.16 mm)
scraper ring maximum admissible 0.006693 in (0.17 mm)
clearance after use
- 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 catego-
ries based on their diameter. The coupling is car-
ried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out
0.001 in (0.05 mm)
CHAR - 13
Piston rings
- Alternately insert the three sealing rings into the

cylinder, in the area where it retains its original di-
ameter. Using the piston, insert the rings perpen-
dicularly 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
1st Compression ring 1.535433 x 0.03937 in A 0.003150 - 0.007874 in
(39 x 1 mm) (0.08 - 0.20 mm)
2nd Compression ring 1.535433 x 0.03937 in A 0.001969 - 0.007874 in
(39 x 1 mm) (0.05 - 0.20 mm)
Oil scraper ring 1.535433 x 0.07874 in A 0.007874 - 0.027559 in
(39 x 2 mm) (0.20 - 0.70 mm)
1st Oversize (39.2 x 1 mm) (0.08 - 0.20 mm)
Oil scraper ring 1st 1.543307 x 0.07874 in A 0.007874 - 0.027559 in
Oversize (39.2 x 2 mm) (0.20 - 0.70 mm)
2nd Oversize (39.4 x 1 mm) (0.08 - 0.20 mm)
Oil scraper ring 2nd 1.551181 x 0.07874 in A 0.007874 - 0.027559 in
Oversize (39.4 x 2 mm) (0.20 - 0.70 mm)
CHAR - 14

3rd Oversize (39.6 x 1 mm) (0.08 - 0.20 mm)
Oil scraper ring 3rd 1.559055 x 0.07874 in A 0.007874 - 0.027559 in
Oversize (39.6 x 2 mm) (0.20 - 0.70 mm)
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE

Half-shaft, transmission 0.551181 +0 -0.000197 A
side in (14 +0 -0.005 mm)
Flywheel-side half shaft 0.629921 +0 -0.000197 B
in (16 +0 -0.005 mm)
Connecting rod 0.582677 + 0.001969 in C
(14.8 +0,05 mm)
Spacer tool 1.771654 in / Fitting E
clearance D = 0.005906
- 0.011811 in (45.00
mm / Fitting clearance
Characteristic
Clearance between crankshaft and connecting rod
A = 0.005906 - 0.011811 in (A = 0.15 - 0.30 mm)
CHAR - 15
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
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 DETEC-
TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-
SERTING A WOODEN WEDGE BETWEEN THE HALF
SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-
DED. 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 EX-
CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANK-
SHAFT 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
Slot packing system
Characteristic
Compression ratio
11.5 to 12 : 1
PISTON PROTRUSION CHECK

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

Product Description Specifications
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per- JASO MA, MA2 - API SL - ACEA A3
formance four-stroke engines.
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis- API GL-4
sions.
AGIP FORK 7.5 W Oil for fork. -
AGIP BRAKE 4 Brake fluid. 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 disul-
phide.
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).

1 Inch (in) 25.4 Millimetres (mm)
1 Foot (ft) 0.305 Meter (m)
1 Mile (mi) 1.609 Kilometre (km)
1 US Gallon (USgal) 3.785 Litre (l)
1 Pound (lb) 0.454 Kilogram (kg)
1 Cubic inch (in³) 16.4 Cubic centimetres (cm³)
1 Foot pound (lb ft) 1,356 Newton meter (Nm)
1 Miles per hour (mi/h) 1.602 Kilometres per hour (km/h)
1 Pound per square inch (PSI) 0.069 (bar)
1 Fahrenheit (°F) 32+(9/5) Celsius (°C)
CHAR - 18
INDEX OF TOPICS
TOOLING TOOL
Tooling Typhoon 50 4t 4v
SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y009 Bell for OD 42-mm bearings
001467Y013 Pliers to extract ø 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

004499Y 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

020162Y Flywheel extractor
020171Y Punch for Ø 17 mm roller bearing
020193Y Oil pressure check gauge
020201Y Spacer bushing driving tube

020265Y Bearing fitting base
020271Y Tool for removing-fitting silent bloc
020288Y Fork to assemble piston on cylinder
TOOL - 22

020291Y 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

020332Y Digital rpm indicator
020334Y Multiple battery charger
020335Y Magnetic support for dial gauge
020363Y 20-mm guide
020364Y 25-mm guide
TOOL - 24

020376Y 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

020448Y 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
mi x 1.000 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 ventila- I 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.
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 compart-
ment.
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 condi-
tion.
-The throttle valve should move freely in the
chamber. Replace valve in case of wear due to
excessive clearance.
- If there are wear marks in the chamber causing
inadequate tightness or a free valve slide (even if
it is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit.
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE
GASKETS TO AVOID PETROL LEAKS
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
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
- 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.
MAIN - 31
Replacement
- Remove the oil dipstick/cover.
- Remove the rear wheel.

- Prepare an adequately sized container.
- Unscrew the oil drainage plug and drain out all
the oil.
Screw the drainage cap back on and fill the hub with the prescribed oil.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions.
API GL-4
Characteristic
Hub oil
~ 0.0225 gal (~ 85 cc)
Air filter
Remove the cap of the air cleaner, unscrewing the

screws and the fixing knob. Take out the filtering
element.
MAIN - 32
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.
AGIP FILTER OIL Special product for the treat-
ment of foam filters.
-
FILTER BOX REMOVAL

Undo the screws indicated.
- Loosen the indicated clamps and slide off the fil-

ter box.
Engine oil
MAIN - 33
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; further-
more, to facilitate oil drainage, loosen or remove
the cap/dipstick. Once all the oil has drained
through the drainage hole, unscrew the oil car-
tridge filter and remove it. To carry out this opera-
tion 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.
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
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 car-
ried out after the vehicle has been used, and there-
fore 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 rec-
ommended 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.
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
MAIN - 35
transmissions
Proceed as follows:
Rest the vehicle on its centre stand and lift the
saddle (as described in the «Saddle opening» sec-
tion).
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 TRANSMIS-
SION 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 be-
tween the flywheel cooling fan and the flywheel
cover.
MAIN - 36
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 span-
ner applied to the camshaft drive sprocket hous-
ing.
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 han-
dlebars perfectly horizontal;
- Check the fluid level through the corresponding
sight glass.
A certain lowering of the level is caused by wear
on the brake pads.
Top-up
Proceed as follows:
- 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
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 SURROUND-
ING 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 SCHED-
ULED 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.
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 bor-
derline of the projected light beam on the screen
is no higher than 9/10 or lower than 7/10 of the
distance from the ground to the centre of the ve-
hicle's headlamp;
3. Otherwise, adjust the headlight by turning the
knobs of the body inside the wheel housing.
- Tighten the screw (clockwise) to raise the light
beam;
- undo the screw (anticlockwise) to lower the light
beam.
N.B.
MAIN - 38
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
MAIN - 39
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Typhoon 50 4t 4v Troubleshooting
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Air filter blocked or dirty 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.
Excessive drive belt wear Check it and replace, if necessary
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Oil level exceeds maximum Check for causes and fill to reach the correct level
Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Muffler obstructed Replace
Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-
aged parts and lubricate the movable guide of the driven pulley
with grease.
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Valve seat distorted Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings
Starting difficulties
DIFFICULTY STARTING UP
Flat battery 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.
Faulty spark plug Replace the spark plug
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance
Starter motor and start-up system fault Check starter motor.
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Air filter obstructed or dirty. 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.
Fuel pump fault Check the pump.
Excessive oil consumption/Exhaust smoke
EXCESSIVE CONSUMPTION
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

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level adding the recommended oil type
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Slippage or irregular functioning 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

Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk or
drum wear conditions.
Front brake disk loose or deformed 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.
Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be
no flexible movement of the brake lever).
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Excessive clearance in the rear brake control cable Adjust the clearance with the appropriate adjuster located on
the back part of the crankcase.
Brakes overheating
BRAKES OVERHEATING
Rubber gaskets swollen or stuck Replace gaskets.
Compensation holes on the pump clogged Clean carefully and blast with compressed air
Brake disc slack or distorted 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.
Defective piston sliding Check calliper and replace any damaged part.
Electrical system
TROUBL - 42
Typhoon 50 4t 4v Troubleshooting
Battery
BATTERY
Battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. If the
vehicle is not used for some time (1 month or more) the battery
needs to be recharged periodically. The battery runs down
completely in the course of 5 to 6 months. If the battery is fitted
on a motorcycle, be careful not to invert the connections, keep-
ing in mind that the black ground 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
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities 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

Excessive steering clearance Check the tightening of the top ring nut. If irregularities continue
in turning the steering even after making the above adjust-
ments, check the seats in which the ball bearings rotate: re-
place if they are recessed.
Noisy suspension
NOISY SUSPENSION
NOISY SUSPENSION 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

Faulty or broken seals 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
Ve = Green
Vi = Violet
Gr = Grey
Components arrangement
ELE SYS - 48
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 cov-
er 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
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 TEMPER-
ATURE SENSOR
Remove the helmet compartment to reach it.
21. GROUND POINT ON CHASSIS - 22. START-

ER RELAY - 23. HV COIL - 24. MAGNETO FLY-
WHEEL AND PICK-UP
Remove the right fairing to reach it.
ELE SYS - 50
25. BATTERY - 26. 15 A - 27 FUSE. DIAGNOS-

TICS SOCKET - 28. FUEL LEVEL TRANSMIT-
TER
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 volt-

age regulator.
Electrical system installation
ELE SYS - 51
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
Conceptual diagrams
Ignition
List of components
1 12V-9Ah Battery
5 15A Fuse
7 10A Fuse
9 Ignition switch
11 Magneto flywheel
14 Pickup
21 Engine stop
29 Spark plug
30 HV coil
ELE SYS - 53
Battery recharge and starting
List of components
1 12V-9Ah Battery
3 Starter relay
4 Starter motor
5 15A Fuse
6 7.5A Fuse
7 10A Fuse
8 Starter button
9 Ignition switch
11 Magneto flywheel
20 Rear stop switch
21 Engine stop
22 PTC heater
29 Spark plug
30 HV coil
ELE SYS - 54
36 Automatic starter
Level indicators and enable signals section
List of components
1 12V-9Ah Battery
5 15A Fuse
6 7.5A Fuse
9 Ignition switch
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
ELE SYS - 55
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 High beam/low beam bulb Type: Halogen H8
Power: 12V - 35W
Quantity: 2
2 Front turn indicator light bulb Type: Amber spherical
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
3 Rear turn indicator light bulb Type: Amber spherical
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
4 Stop/position light bulb Type: Twin-filament
Power: 12V - 21/5W
Quantity: 1
5 12V - 1.2W warning light bulb Type: ALL GLASS
Application: 1 Turn indicator warning light - 1 High
beam warning light - 1 Low beam warning light - 2 In-
strument illumination warning lights - 1 Low fuel warning
light
ELE SYS - 56
Quantity: 6
6 License plate light 12V - 5W
Devices and accessories
List of components
1 12V-9Ah Battery
5 15A Fuse
6 7.5A Fuse
7 10A Fuse
9 Ignition switch
16 Horn button
17 Horn
33 Diagnostics socket
ELE SYS - 57
Lights and turn indicators
List of components
1 12V-9Ah Battery
5 15A Fuse
6 7.5A Fuse
7 10A Fuse
9 Ignition switch
18 Stop light
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
35 Light switch
ELE SYS - 58
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 im-
mediately 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 meas-
ure 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
~ 170 Ohm
- HV primary coil check

Disconnect the control unit connector and check
that the cable between terminal No. 4 (White/Vio-
let) 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
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 diagno-
sis, check the peak voltage with the multimeter
adaptor.
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 dur-
ing 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
WARNING
THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS
BLACK.
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 ach-
ieved between generated power and idle stability.
For this reason, it is very important that the idle speed is adjusted as prescribed.
Specific tooling
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
LIGHT SWITCH
TURN INDICATOR SWITCH
HORN BUTTON
Stator check
Disconnect the connector from the voltage regu-

lator and check there is continuity between any
yellow cable and the other two cables.
Ohm value:
1 ± 1 Ohm
ELE SYS - 62
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 rep-
etitions 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 volt-

age regulator positive terminal (Red/Orange),
measure the battery voltage and turning on the
vehicle lights with the engine off, wait for the volt-
age 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
In case the generated current value is lower than

8A, repeat the test using a new regulator and/sta-
tor 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
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
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
Choke Inspection
Refer to the engine section to check the resistance

and operating conditions of the component. As re-
gards voltage supply, keep the connector connec-
ted 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
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
DISCONNECTED.
ELE SYS - 66
If faults are detected:

- With a multimeter, check resistance values be-
tween 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 indi-
cation on the instrument panel is not exact, check
that the cable harnesses between them are not in-
terrupted.
- Check continuity of the Green cable which con-
nects the instrument panel to the 15A secondary
fuse (C).
- Check continuity of the Grey/Green cable which
connects the instrument panel to the probe check-
ing fuel level.
Resistance value when the tank is full
~ 7.4 Ω
Resistance value when the tank is empty
~ 101 Ω
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
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 US-
ING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF
ELECTRICAL WIRE).
FUSES
1 Fuse No. 1 Capacity: 15 A
Protected circuits: general, recharge battery, starter
relay
2 Fuse no. 2 Capacity: 10 A
Protected circuits: live: electronic ignition device
3 Fuse No. 3 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
Dry-charge battery
Where provided
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CON-
TACT 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
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°
Bé, at a minimum temperature of 59°F (15°C). until
the upper level is reached.
2) - Leave to rest for at least 2 hours; then, restore
the level with sulphuric acid.
3) - Within the following 24 hours, recharge using
the specific battery charger (single) or (multiple) at
a density of about 1/10 of the battery nominal ca-
pacity until fully charged; check that the acid den-
sity is about 0.0459 lb/in3 (1.27 Kg/l), correspond-
ing to 31° Bé, and that these values are stabilised.
4) - Once the charge is over, level the acid (by
adding distilled water). Close and clean carefully.
5) Once the above operations have been per-
formed, install the battery on the vehicle ensuring
that it is wired up properly.
1 Hold the vertical tube
2 Look at the level
3 The float must be freed
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VE-
HICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE
(WITH CLOSED END) NEAR THE + POSITIVE TERMINAL
WITH THE CORRESPONDING LONG TUBE (WITH OPEN
END), THAT YOU FIND FITTED TO THE VEHICLE, TO EN-
SURE THAT THE GASES THAT FORM CAN ESCAPE
PROPERLY.
Specific tooling
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
After topping-up the electrolyte level, check its density using an appropriate densitometer (see figure).
With the battery charged, a density of 30-32 Bé, 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 59º F (15° C).
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
If the vehicle is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
The battery runs down completely in the course of three months. If it is necessary to refit the battery in
the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked
(-) must be connected to the -negative clamp while the other two red wires marked (+) must be con-
nected to the clamp marked with the +positive sign.
3) Recharging the battery
Remove the battery from the vehicle disconnecting the negative terminal first.
Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),
setting the battery charger selector to the type of battery to be recharged. Connections to the power
supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).
4) Cleaning the battery
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN 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
Connectors
LOW BEAM CONNECTOR

1. Ma - Light switch control.
2. Ne - Ground.
ELE SYS - 70
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
"A" ELECTRONIC IGNITION DEVICE CONNEC-

TOR
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 CONNEC-

TOR
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

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 CONNEC-

TOR
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
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.
STOP BUTTON ON REAR BRAKE CONNEC-

TOR
1. BiNe - Brake pressed signal for stop light and
starter consent.
ELE SYS - 74
VOLTAGE REGULATOR CONNECTOR

1. Gi - Positive lead for lights relay.
2. Ne - Ground.
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

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 transmit-
ter.
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
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 crank-

case, 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 un-

screwing 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 chas-

sis.
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 vehi-
cle, it is necessary to remove the transmission
cooling coupling and the air filter housing retain-
ers.
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 indica-
ted 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 indica-
ted 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 DI-
AMETER EXTRACTOR CAN BE USED.
Refitting the driven pulley shaft bearing
Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.
N.B.
WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.
CAUTION
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE 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
ENG - 84
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
Ø 4.212598 + 0.007874 + 0 in (Ø 107+0.2 +0 mm)
Clutch housing diameter/maximum admissible
value
Ø 4.232283 in (Ø 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 con-
tact.
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
Inspecting the clutch
- Check the thickness of the clutch mass friction

material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
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
Removing the driven half-pulley bearing
- Remove the roller bearing with the special ex-

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

- Expel the ball bearing from the side of the clutch
housing by means of the special tool.
N.B.
PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO
DEFORM THE SLIDING SURFACE OF THE DRIVE BELT
Specific tooling
020363Y 20-mm guide
Inspecting the driven fixed half-pulley
- Check that there are no signs of wear on the work

surface of the belt. If there are, replace the half-
pulley..
- Make sure the bearings do not show signs of un-
usual wear.
- Measure the outside diameter of the pulley bush-
ing.
Characteristic
Stationary driven half-pulley/Standard diame-
ter
Ø 1.337205 - 1.337992 in (Ø 33.965 - 33.985 mm)
Stationary driven half-pulley / Minimum diam-
eter admitted after use
Ø 1.337008 in (Ø 33.96 mm)
ENG - 87
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two O-

rings.
- Measure the inside diameter of the mobile half-
pulley bushing.
Characteristic
Mobile driven half-pulley/ Maximum diameter
admissible
Ø 1.341732 in (Ø 34.08 mm)
- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile
half-pulley.
- Fitting the half-pulley on the bushing.
AGIP GREASE SM 2 Gray black smooth-tex-
tured 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.
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum di-
sulphide.
-
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
ENG - 88
020456Y Ø 24-mm adaptor

020362Y 12 mm guide
020171Y Punch for Ø 17 mm roller bearing
Inspecting the clutch spring
- Check that the contrast spring of the driven pulley

does not show signs of deformation
- Measure the free length of the spring
Characteristic
Standard length
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 CEN-
TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-
ENT 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
- Reassemble the nut securing the clutch and tight-

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

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
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
Inspecting the rollers case
1) Check that the bushing and the sliding rings of

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

ure is not abnormally worn and measure inside
diameter «A».
- Measure outside diameter «B» of the pulley slid-
ing bushing shown in the figure.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHING.
Characteristic
Driving pulley / Maximum diameter:
ENG - 91
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
lb·ft (20 N·m) and then perform a final 90° locking
in order to prevent the rotation of the driving pulley.
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
CAUTION
UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-
MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN
ORDER TO AVOID WRONG TIGHTENING AND CONSE-
QUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling

Crankshaft pulley nut 13.3 - 14.8 lb ft + 90° (18 - 20 Nm
+ 90°)
ENG - 92
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 re-
turn 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.
AGIP GREASE MU3 Yellow-brown, lithium-
base, 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.

Transmission cover screws 8.1 - 9.6 lb ft (11 - 13
Nm)
End gear
ENG - 93
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 atten-
tion 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
020358Y 37x40-mm Adaptor
ENG - 94
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
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 compo-
nents.
- Check capacity (A) of the transmission gear
(wear, deformations, etc.)
- Check the pulley shaft seating: Superficial wear
(B) may indicate irregularities in the crankcase
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
Refitting the driven pulley shaft bearing
- Support the inner track of the bearing from the

outside of the hub cover with the specific tool posi-
tioned under the press and insert the driven pulley
axle.
- Refit the oil seal flush with the cover.
Specific tooling
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
020439Y 17-mm guide
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
020363Y 20-mm guide
ENG - 96
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 cov-
ers and refit the same with driven pulley shaft.
- Refit the 5 screws and tighten them to the speci-
fied torque.
N.B.
CLEAN THE CONTACT SURFACES OF THE HUB COVER
AND THE HALF CRANKCASE OF RESIDUE FROM PREVI-
OUS GASKETS BEFORE APPLYING A NEW ONE.

Rear hub cap screws 8.1 - 9.6 lb ft (11 - 13 Nm)
Flywheel cover
Cooling hood
- Remove the manifold and the carburettor undo-

ing 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 re-
verse order
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL
CONNECTOR.
N.B.
WHEN REFITTING THE COVER, TAKE CARE NOT TO DAM-
AGE THE STATOR WIRING.
ENG - 97
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
Refitting the stator
- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers 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 COV-
ER ASSEMBLY.

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
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
020162Y Flywheel extractor
Inspecting the flywheel components
- Check that the flywheel internal magnets are in

good conditions.
- Check that the flywheel splines exhibit no loos-
ening.
- 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
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 ade-
quately.
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

Flywheel nut 2.2 - 2.9 lb ft (3 - 4 Nm)
ENG - 101
Refitting the starter motor
- Install the starter motor in its seating in the crank-

case.
- 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 pre-
scribed 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.

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 Blow-
by cover
- Clean the nozzle labyrinth and the membrane
(replace it, if necessary), then remove the cover
unit.
ENG - 102
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 cam-
shaft 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
- 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 RO-
TATION IS MAINTAINED.
See also
Removing the rocker-arms cover
Removal
ENG - 103
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 LEV-
ERS 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
004499Y Camshaft bearing extractor
004499Y001 Bearing extractor bell
004499Y002 Bearing extractor screw
004499Y006 Bearing extractor ring
004499Y027 Bearing extractor part
ENG - 104
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 RE-
MOVING THE DRIVING PULLEY UNIT. REMEMBER TO
HOLD THE TIMING CHAIN WITH A PIECE OF METAL CA-
BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE-
FITTING.
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
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 DUR-
ING 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 DIAME-
TER 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

chapter
Inspecting the piston
- Measure the diameter of the bearings on the piston.

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.
chapter
ENG - 107
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 di-
ameter. 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
SEALING RINGS
(39 x 1 mm) (0.08 - 0.20 mm)
(39 x 1 mm) (0.05 - 0.20 mm)
Oil scraper ring 1.535433 x 0.07874 in A 0.007874 - 0.027559 in
(39 x 2 mm) (0.20 - 0.70 mm)
Oil scraper ring 1st 1.543307 x 0.07874 in A 0.007874 - 0.027559 in
Oversize (39.2 x 2 mm) (0.20 - 0.70 mm)
Oil scraper ring 2nd 1.551181 x 0.07874 in A 0.007874 - 0.027559 in
Oversize (39.4 x 2 mm) (0.20 - 0.70 mm)
Oil scraper ring 3rd 1.559055 x 0.07874 in A 0.007874 - 0.027559 in
Oversize (39.6 x 2 mm) (0.20 - 0.70 mm)
ENG - 109
Removing the piston
- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-
wards 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 90°chamfered 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 DAM-
AGE THE LOCKING HOUSING.
Refitting the piston rings
- Fit the oil scraper ring starting from the spring,

taking care that the spring ends do not superim-
pose. 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 IMPOR-
TANT TO RESPECT THE FITTING INSTRUCTION TO AS-
SEMBLY THE RINGS WITH THE "T" MARK FACING
UPWARDS.
ENG - 110
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.

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
Measure the camshaft bearing seats and rocking

lever support pins with a bore meter
HEAD CHECK
Standard diameter in (mm) A Ø 1.260433 - 1.260827 (Ø 32.015 - 32.025)
Standard diameter in (mm) B Ø 0.629921 - 0.63063 (Ø 16.0 - 16.018)
Standard diameter in (mm) C Ø 0.433071 - 0.43378 (Ø 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
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

Inlet: standard length 2.948919 in (74.9 mm)
Outlet: standard length 2.927165 in (74.35 mm)
ENG - 113
- Measure the diameter of the valve stems in the

three positions indicated in the diagram.
STANDARD DIAMETER
Intake 0.156299 - 0.156890 in (3.970 - 3.985 mm)
Exhaust 0.155906 - 0.156496 in (3.960 - 3.975 mm)
MINIMUM ADMISSIBLE DIAMETER

Intake 0.155827 in (3.958 mm)
Exhaust 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 ex-
tent of the deformation using a dial gauge.
Characteristic
Limit values admitted:
0.003937 in (0.1 mm)
ENG - 114
Inspecting the valve stem guide clearance
Measure the valve guides
VALVE GUIDE DIAMETER

Standard valve guide diameter 0.15748 + 0.000472 in (4 + 0.012 mm)
Valve guide Maximum admissible diameter 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
Standard clearance 0.000590 - 0.001654 in (0.015 - 0.042 mm)
Admissible limit 0.002362 in (0.06 mm)
EXHAUST
Standard clearance 0.000984 - 0.002047 in (0.025 - 0.052 mm)
Admissible limit 0.002756 in (0.07 mm)
ENG - 115
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:
Ø 0.472441 +0.000079 +0.000394 in (Ø 12 +0.002
+0.010 mm)
Standard diameter - Bearing B:
Ø 0.629921 -0.000591 -0.000906 in (Ø 16 -0.015
-0.023 mm)
Minimum diameter admissible - Bearing A:
Ø 0.471654 in (Ø 11.98 mm)
Minimum diameter admissible - Bearing B:
Ø 0.628346 in (Ø 15.96 mm)
- Using a gauge, measure the height of the cams.
Check the axial clearance of the camshaft
ENG - 116
- 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»; CONSE-
QUENTLY, 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

Rocking levers - Inside diameter 0.433661 - 0.434449 in (11.015 - 11.035 mm)
Rocking levers - Pins diameter 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
- Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque.
Specific tooling
- 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 cam-
shaft

Rocking lever axle and camshaft bearing
screw 2.2 - 2.9 lb ft (3 - 4 Nm)
- Finish the head tightening following the proce-

dure 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

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
Refitting the timing chain
- Insert the timing chain pads in their correspond-

ing seatings, the screw and the spacer as indica-
ted 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.

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 cam-
shaft 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
ENG - 119
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)
Spark plug
NGK ER9EH-6N

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 ap-
propriate clamp.
N.B.
ENG - 120
FIT THE CARBURETTOR THROUGH THE SUPPLEMENT

ON THE MANIFOLD.

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
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 AC-
CIDENTALLY FALL.
- Remove the oil guard on the flywheel side.

CAUTION
THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT. DO NOT WASH WITH SOL-
VENTS 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
- 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 con-

necting 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 connect-
ing 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
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 ~ 250°F (~ 120°C) 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
020364Y 25-mm guide
- Warm a new main bearing in an oil bath at 250°

F (120°C).
- 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
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 DETEC-
TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-
SERTING A WOODEN WEDGE BETWEEN THE HALF
SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-
DED. 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 pref-

erably on the flywheel side half casing.
-Insert the crankshaft on the half casing on the
transmission side.
ENG - 124
- 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 pre-
scribed torque.
N.B.
WHEN FITTING THE HALF CASING AND THE CRANK-
SHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREA-
DED TANGS.
Loctite 510 Liquid sealant
Gasket

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.

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 crank-
case.
ENG - 125
- 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 Ø 1.18 in (Ø30 mm) -
MAX diameter Ø 1.26 in (Ø 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

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
- Undo the 2 clamping screws in the figure and re-

move 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 EN-
SURE 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, keep-
ing 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
Measure the distance between the outer rotor and

the pump body (see figure).
Characteristic
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
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 dur-
ing the pulley rotation.
N.B.
FIT THE CUP WASHER SO THAT ITS OUTER (CURVED)
RIM TOUCHES THE PULLEY.
ENG - 128
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, RE-
GARDING LUBRICATION OF THE CRANKSHAFT AND
CONNECTING ROD

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
- 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 INCOR-
RECT NUMBER OF REVS OR BY THE WRONG POSITION
OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB-
TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-
LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY
REDUCED FOR THE PURPOSE OF ENHANCING THE SUC-
TION PULSATION AND THEREBY GUARANTEE A CON-
STANT TAP FLOW RATE.
Specific tooling
Characteristic
Minimum flow rate
0.676 fl oz in 5 sec (20 cc in 5 sec)
- Completely empty the fuel tank.

- Remove the petrol delivery pipe and the low-
pressure pipe.
- Loosen the clip and remove the cock.
- Clean the tank and the filter of the cock with a
specific solvent.
- Refit the cock making sure that there is an O-
Ring.
- Turn the cock to the direction it had before it was
removed and block the clip.
N.B.
THE FILTER CAN BE UNSCREWED FROM THE COCK TO
FACILITATE CLEANING.
ENG - 130
Removing the carburettor
- To detach the carburettor from the engine, re-

move 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 start-

er 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 fig-

ure, the vacuum chamber cover and the spring.
- Remove the vacuum valve together with the di-
aphragm; 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
- Remove the chamber components following the

procedure below.
- Undo the 2 screws fixing the intake pump dia-
phragm 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
-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 DAM-
AGE 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
Refitting the carburettor
- Before refitting, wash the carburettor body accu-

rately 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 inter-
nal 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
- 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 ab-
sorber 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
- Check the diaphragm is in good conditions and

remove the remaining components of the acceler-
ating 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 UN-
DULATIONS, 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 REFIT-
TING.
WARNING
THE SCREW IN THE TANK BOTTOM IS A BLEEDING ONE
AND CONSEQUENTLY IT ONLY REQUIRES CLEANING.
ENG - 136
- 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 de-

formed or rusty.
- Check that the piston slides freely in its seating.
- Check that the piston sealing O-Ring is not de-
formed.
- The starter must be more or less functional de-
pending 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 am-
bient temperature.
Characteristic
Protrusion value
0.452756 in (11.5 mm)
Ambient temperature
75.2°F (24°C)
ENG - 137
- The starter should disconnect progressively by

means of electric heating.
- Check the starter resistance when adjusted to the
ambient temperature.
Characteristic
Ambient temperature
75.2°F (24°C)
Automatic starter resistance
20 Ω ± 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 ambi-
ent temperature.
- If protrusion, resistance or timing values are dif-
ferent from the ones prescribed, replace the start-
er.
Characteristic
Battery
12V-9Ah
Max. protrusion
0.590551 in (15 mm)
max. time
15 min
- Fit the starter, the support bracket and the pro-

tection with the screw indicated in the figure.
ENG - 138
- 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 cer-
tain rules when adjusting the idle speed.
- Before adjusting the carburettor make sure to re-
spect requirements on lubrication, valve clear-
ance, 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 176°F (70 to 80°C)
Specific tooling
020331Y Digital multimeter
ENG - 139
- Using the rpm indicator in the analyser or a sep-

arate one, adjust the idle screw.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS RE-
MARKABLE POWER. READINGS MAY NOT BE ACCU-
RATE 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 CAL-
LIPER PISTONS COULD COME OUT FROM THEIR HOUS-
ING 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, proceed-
ing as follows:
Lock the bearing puller in the bearing on the side
the odometer detects movement.
Specific tooling
001467Y013 Pliers to extract ø 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
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
020412Y 15-mm guide
When refitting heat the brake side bearing seat

with an appropriate heater gun.
Specific tooling
020151Y Air heater
SUSP - 144
Use adaptor, handle and guide to drive the bearing

into its seat.
Specific tooling
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 move-
ment.
Specific tooling
020151Y Air heater
SUSP - 145
Use adaptor, handle and guide to drive the bearing

into its seat.
Specific tooling
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 odom-
eter drive.
Holding the wheel axle, lock the nut on the oppo-
site side to the specified torque.
SUSP - 146
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-inter-
nal-external" sequence.

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.

Headstock handlebar 38.7 lb ft (52.5 Nm)
SUSP - 147
(*) Lubricate the nut with engine oil before instal-

lation
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
- Undo screw «3», remove the stanchion and the

piston.
See also
Legshield
Removal
Overhaul
STANCHION INSPECTION
- Check the sliding surface for scorings and/or
scratches.
- If the scorings are deep, replace the stanchion.
SLEEVE INSPECTION
- Check that it is not damaged and/or cracked.
- If there are signs of excessive wear or damage,
replace the affected component.
- Replace the oil seal «4» and the dust gaiter «5»
and fit it once you have lubricated their seat.
- Replace the O-ring on the inner cap «1»
- Replace sealing washer «2».
Refitting
Refit the stem and the pumping member and tight-

en 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
Introduce the stanchion in the bottom yoke and in-

stall the circlip «7».
Push on the upper cap «6» until the circlip touches
the bottom yoke. Tighten the screws «8» to the
specified torque.
AGIP FORK 7.5 W Oil for fork.
-
Characteristic
Fork stem (oil level height without spring, com-
pressed fork)
3.35 in (85 mm)

Plate fork stanchions 29.5 lb ft (40 Nm) Sleeve fork
stanchions 22.1 lb ft (30 Nm)
Steering column
Removal
SUSP - 150
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

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».

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 bear-

ing «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
BEARING SEAT REPLACEMENT ON CHASSIS

- Only remove the seats if it is strictly necessary.
- Using the special tool remove the upper bearing
«A» seat «5» by putting the special tool into the
lower part of the headstock as indicated in the fig-
ure.
- Remove the lower bearing «B» seat «6» on the
headstock by inserting the punch from the top on
the headstock.
Specific tooling
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
headstock
SUSP - 152
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 adjus-
ted.
- Hold the fork sleeves and pull the fork forwards
and backwards, with the steering in forward posi-
tion.
- There should be no clearance forward or back-
ward If there is clearance, the steering must be
adjusted.
ADJUSTING THE BEARING CLEARANCE

- Loosen the upper ring nut «1» using the specific
wrench.
- Screw in the lower ring nut «3» until the bearing
clearance is totally eliminated.
CAUTION
DO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT
«3» BECAUSE THE STEERING BEARINGS COULD GET
DAMAGED.
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
Specific tooling

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 wash-
er.
Take out the wheel from its housing.
See also
Exhaust assy. Removal
SUSP - 154
Refitting the rear wheel
To refit, carry out the removal operations but in reverse order, be careful to use a new split pin.

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, pro-
ceed as follows:
- Position the vehicle on centre stand.
- Hold the rear wheel firmly and try to move it per-
pendicularly to the travel direction.
- If there is any clearance, check all the fastening
elements that connect the swinging arm to the en-
gine and chassis as well as the condition of the
silent block.
SUSP - 155
Refitting
For refitting, follow the previous operations but in reverse order.

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-ab-
sorber 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.

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
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.

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.

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.

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

• 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 re-
place the disc and conduct the test
again.
• If the problem persists, check and re-
place the wheel rim if necessary.
Specific tooling
020335Y Magnetic support for dial gauge
See also
Front brake pads
Removal
Remove the brake calliper.
BRAK SYS - 161

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

Refitting
To refit, carry out the disassembly operations in

the inverse order, fitting the inner spring correctly
and tightening the fixing screws to the specified
torque.

Brake pad fastening screw 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 'SPONGI-
NESS' OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY.
CAUTION
CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY
TO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REG-
ULAR MAINTENANCE OPERATIONS.
- To access the brake fluid reservoir the right rear-
view mirror must be removed. Remove the reser-
voir 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

-When the operation is over, tighten up the oil

bleed screw to the prescribed torque.
N.B.
IF AIR CONTINUES TO COME OUT DURING PURGING, EX-
AMINE ALL THE FITTINGS:
IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAUL-
TY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS
SEALS ON THE PUMP AND CALLIPER PISTONS.
CAUTION
- DURING THE OPERATIONS, THE VEHICLE MUST BE ON
THE STAND AND LEVEL.
N.B.
DURING PURGING FREQUENTLY CHECK THE LEVEL TO
PREVENT AIR GETTING INTO THE SYSTEM THROUGH
THE PUMP.
WARNING
- BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT AB-
SORBS HUMIDITY FROM THE SURROUNDING AIR.
IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX-
CEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE
REDUCED.
THEREFORE, ALWAYS USE FLUID FROM SEALED CON-
TAINERS.
UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS
YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS.
IF THE BRAKES ARE USED INTENSELY AND/OR IN
HARSH CONDITIONS, CHANGE THE FLUID MORE FRE-
QUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID
MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS
SEAT ON THE CALLIPER.
CAREFULLY DRY THE CALLIPER AND DEGREASE THE
DISC SHOULD THERE BE OIL ON IT.
Specific tooling
AGIP BRAKE 4 Brake fluid.
Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4
- ISO 4925 - CUNA NC 956 DOT 4

Oil bleed screw 5.9 - 8.8 lb ft (8-12 Nm)
BRAK SYS - 164

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.

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
Rear drum brake
Drum brake adjustment

Regulate the point where the rear drum brake in-
tervenes, using the adjustment indicated in the
figure.
With the brake lever at rest, the wheel must turn
freely.
BRAK SYS - 165

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 acti-
vation point.

Rear brake adjustment nut 3.69 lb ft (5 Nm)
BRAK SYS - 166

See also
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.

Saddle plate fixing nut 7.4 lb ft (10 Nm)
Driving mirrors

Mirror fixing spacer 18.4 lb ft (25 Nm)
Remove the front handlebar cover.

CHAS - 169
Chassis Typhoon 50 4t 4v
- Disconnect the connectors of the instrument pan-

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

See also
Remove the rear-view mirrors.

CHAS - 170
Undo the front screw.

Disconnect the connectors of the turn indicators.
See also
Driving
mirrors
Headlight assy.

FRONT TURN INDICATORS

Unscrew the indicated nuts.
See also
Legshield
CHAS - 171
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
Knee-guard

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 com-
ponents in the best conditions.
N.B.
WHILE REFITTING, PLEASE REMEMBER TO ATTACH THE
GLOVE-BOX OPENING LEVER TO THE KEY-OPERATED
DEVICE.
See also
CHAS - 173
Front wheel housing

Remove the front mudguard.
Remove the front wheel.
- Undo the upper screw.

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

- Undo the indicated screws and remove the pro-
tections.
CHAS - 174
See also
Knee-guard
Side fairings
Side fairings
Remove the rear handles.

Remove the rear central cover.
- Undo side screw from both sides of the vehicle.
Undo the screws on the helmet compartment.
CHAS - 175
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
License plate holder

- Disconnect the connections of the turn indicators
and of the license plate light.
- Undo the rear screw outside the license plate

support.
- Undo the two screws indicated.

- Remove the license plate support together with
the turn indicators.
See also
Side fairings
CHAS - 177
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 compart-
ment.
- Disconnect the fuse box and free the helmet

compartment from the cables.
See also
Side fairings
CHAS - 178
Battery
spoiler
Remove the footrest.

- 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 compart-
ment.
- Detach the pipes from the vacuum-operated
cock.
CHAS - 179
- 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.

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
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.

Passenger handle 15.1 lb ft (20.5 Nm)
CHAS - 181
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 NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
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

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SERVICE STATION MANUAL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

Dimensions and mass

WEIGHTS AND DIMENSIONS

DATI TECNICI MOTORE

- Primary resistance: 0.5 to 0.6 Ohm

Frame and suspensions

FRAME AND SUSPENSION

Wheels and tyres

WHEELS AND TYRES

FRONT AND REAR BRAKE

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDER

Name Initials Cylinder Piston Play on fitting

- Measure the diameter of the bearings on the pis-

- Calculate the piston pin coupling clearance.

- Carefully clean the seal housings.

- Using a bore meter, measure the inner cylinder

- Alternately insert the three sealing rings into the

Name Description Dimensions Initials Quantity

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE

Measure the bearings along X and Y axes

To install the crankshaft on the support and to

- Using a bore gauge, measure the connecting rod

Slot packing system

PISTON PROTRUSION CHECK

RECOMMENDED PRODUCTS TABLE

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

001467Y009 Bell for OD 42-mm bearings

001467Y013 Pliers to extract ø 15-mm bearings

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

008119Y009 Tube to assemble shafts and axles

002465Y Pliers for circlips

Stores code Description

005095Y Engine support

006029Y Punch for fitting fifth steering bearing on

020004Y Punch for removing fifth wheels from

020055Y Wrench for steering tube ring nut

020150Y Air heater support

020151Y Air heater

Stores code Description

020171Y Punch for Ø 17 mm roller bearing

020193Y Oil pressure check gauge

020201Y Spacer bushing driving tube

020271Y Tool for removing-fitting silent bloc

020288Y Fork to assemble piston on cylinder

Stores code Description

020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

Stores code Description

020334Y Multiple battery charger

020335Y Magnetic support for dial gauge

020363Y 20-mm guide

020364Y 25-mm guide