Piaggio-Typhoon-50-EN _Service Manual

SERVICE STATION MANUAL 

633665 - . . . - 633672 

Typhoon 50

SERVICE STATION 

MANUAL 

Typhoon 50 

The descriptions and illustrations given in this publication are not binding. While the basic specifications 

as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at 

any time and without being required to update this publication beforehand, to make any changes to 

components, parts or accessories, which it considers necessary to improve the product or which are 

required for manufacturing or construction reasons. 

Not all versions/models shown in this publication are available in all countries. The availability of each 

model should be checked at the official Piaggio sales network. 

"© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication 

in whole or in part is prohibited." 

PIAGGIO & C. S.p.A. - After sales 

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL 


This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It 

is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical 

principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair 

operations will be communicated by updates to this manual. Nevertheless, completely satisfactory work cannot be carried out 

without the necessary equipment and tools. It is therefore advisable to read the sections of this manual relating to appropriate 

tools, along with the appropriate tool catalogue. 

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

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

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

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

injury. 

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle 

to prevent damaging the environment. 

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious 

damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS 

CHARACTERISTICS 

CHAR 

TOOLING 

TOOL 

MAINTENANCE 

MAIN 

TROUBLESHOOTING 

TROUBL 

ELECTRICAL SYSTEM 

ELE SYS 

ENGINE FROM VEHICLE 

ENG VE 

ENGINE 

ENG 

SUSPENSIONS 

SUSP 

BRAKING SYSTEM 

BRAK SYS 

CHASSIS 

CHAS 

PRE-DELIVERY 

PRE DE 

TIME 

TIME


CHARACTERISTICS 

CHAR

Characteristics Typhoon 50 

Rules 

This section describes general safety rules for any maintenance operations performed on the vehicle. 

Safety rules 

- If work can only be done on the vehicle with the engine running, make sure that the premises are well 

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust 

fumes are toxic. 

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is 

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water 

and seek immediate medical attention. 

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks 

or flames near the battery, especially when charging it. 

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working 

area, and avoid naked flames or sparks. 

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that 

you do not breathe in the dust produced by the wear of the friction material. Even though the latter 

contains no asbestos, inhaling dust is harmful. 

Maintenance rules 

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or 

non-conforming spares may damage the vehicle. 

- Use only the appropriate tools designed for this vehicle. 

- Always use new gaskets, sealing rings and split pins upon refitting. 

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all 

the work surfaces, except tapered couplings, before refitting these parts. 

- After refitting, make sure that all the components have been installed correctly and work properly. 

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, 

nuts and screws are not interchangeable with coupling members using English measurements. Using 

unsuitable coupling members and tools may damage the vehicle. 

- When carrying out maintenance operations on the vehicle that involve the electrical system, make 

sure the electrical connections have been made properly, particularly the ground and battery connections. 

CHAR - 6


Characteristics 

Vehicle identification 

Chassis prefix ZAPC29 xxxx xxxxxxx 

Engine prefix C216M xxxx 

Dimensions and mass 

WEIGHT AND DIMENSIONS 

Specification 

Desc./Quantity 

Maximum length 1820 

Maximum width 730 

Maximum height 1160 

Lead 1260 

Kerb weight 

84 Kg 

CHAR - 7


Engine 

Transmission 


Specification 


Engine type 

Two-stroke, single cylinder Piaggio Hi-PER2 

Bore x stroke 

40 X 39.3 mm 

Cubic capacity 

49.40 cc 

Compression ratio 9.4 to 10.4 :1 

Carburettor DELL'ORTO PHVA 17.5 

CO adjustment 3.5% ± 0.5 

Engine idle speed 

1800 to 2000 r.p.m. 

Air filter 

Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and 

50% unleaded petrol). 

Starting system 

electric starter/kick starter 

Lubrication 

With blend and variable oil variable according to the engine 

revolutions and the throttle valve opening by means of a pump 

controlled by the driving shaft with toothed belt. 

Fuel supply 

With vacuum operated cock, lead-free gasoline (with 95 octane 

minimum) by means of the carburettor. 

Cooling 

Forced air circulation. 

Capacities 

TRANSMISSION 

Specification 


Transmission With automatic expandable pulley variator, torque server, V- 

belt, automatic clutch, gear reduction unit. 

Electrical system 

CAPACITY 

Specification 


Petrol tank 

In plastic, with a capacity of 5.5 lit. (approximate value) including 

reserve ~ 2 lit. 

Oil mixer tank In plastic, with a capacity of 1.5 lit. (including reserve ~0.500 

lit). 

Rear hub oil 

Quantity: approx. 80 cm³ 


Specification 


Ignition type 

Capacitive discharge electronic ignition, with incorporated HV 

coil 

Ignition advance (before TDC) Fixed 17° ± 1 

Recommended spark plug 

CHAMPION RN3C 

Battery 

12V-4Ah 

Main fuse 

7.5 A 

Generator 

In alternate current with three output sections 

CHAR - 8



Frame and suspensions 

Brakes 

Specification 

Type of chassis 

Front suspension 

Front stroke 

Front suspension stroke 

Rear suspension 

FRAME AND SUSPENSIONS 


Welded tubular steel chassis with stamped sheet reinforcements. 

upside-down hydraulic telescopic fork. 

73 mm 

58 mm 

With coaxial spring and hydraulic shock absorber. Chassis to 

engine support with swinging arm. 

Specification 

Front brake 

Rear brake 

BRAKES 


Disc D=190 / 200 mm with hydraulic control, operated by right 

brake lever on the handlebars. 

Drum D=110 mm with expansion brake shoes, mechanically 

controlled by the left brake lever on the handlebars. 

Wheels and tyres 

Specification 

Front tyre 

Rear tyre 

Wheels 

WHEELS AND TYRES 


Tubeless 120/90 x -10'' 

Tubeless 120/90 x -10'' 

with 3.50x10" wheel rims in light alloy. 

Carburettor 

50cc Version 

Dell'Orto 

ORTO CARBURETTOR 

Specification 


Type 

PHVA 17.5 RD 

Diffuser diameter Ø 17.5 

Regulation reference number 8423 

Maximum nozzle: 53 

Maximum air nozzle (on the body): Ø 1.5 

Tapered pin stamped code: 

A22 

Pin position (notches from above): 1 

Diffuser: 

209 HA 

Minimum nozzle: 32 

Minimum air nozzle (on the body): 

Free 

Secondary minimum air hole Ø 2.5 

Initial minimum mix screw opening: 1 1/2 

Starter jet 50 

Starter air nozzle (on the body): Ø 1.5 

Stroke of starter pin: 

11 mm 

Gasoline inlet hole Ø 1.5 

CHAR - 9


Tightening Torques 

Name 

Upper steering ring nut (safety locks) 

Lower steering ring nut (safety locks) 

Handlebar fixing pin (safety locks) 

Name 

Swinging arm-engine pin (safety locks) 

Swinging arm-frame pin (safety locks) 

Shock absorber - frame nut (safety locks) 

Shock absorber-engine pin (safety locks) 

Rear wheel axis (safety locks) 

Bolt holding stand to the engine 

Name 

Front wheel axle nut (safety locks) 

Wheel axle clamp screw 

Lower leg screw 

Hydraulic cartridge stem nut 

Name 

Viti fissaggio coperchio pompa freno 

Brake pump support fixing screw 

Brake fluid pump - hose fitting 

Brake fluid tube - calliper fitting 

Calliper tightening screw 

Disc tightening screw (safety locks - lock with LOCTITE 

THREADLOCK MEDIUM TYPE 243) 

Oil bleed screw 

Calliper coupling screw 

STEERING ASSEMBLY 

FRAME ASSEMBLY 

FRONT SUSPENSION 

FRONT BRAKE 

Torque in Nm 

35 to 40 Nm 

8 to 10 Nm 

45 to 50 Nm 

Torque in Nm 

33 to 41 Nm 

64 to 72 Nm 

20 to 25 Nm 

33 to 41 Nm 

104 to 126 Nm 

18 to 19 Nm 

Torque in Nm 

45 to 50 Nm 

6 ÷ 7 Nm 

15 to 20 Nm 

15 to 18 Nm 

Torque in Nm 

1,5 ÷ 2 Nm 

7 to 10 Nm 

13 to 18 Nm 

20 to 25 Nm 

20 to 25 Nm 

6 ÷ 7 Nm 

7 to 10 Nm 

20 to 25 Nm 

ENGINE ASSEMBLY 

Name 

Torque in Nm 

Clutch bell nut 

40 to 44 Nm 

Clutch lock ring nut 55 ÷ 60 

nut locking driving pulley on the crankshaft 

40 to 44 Nm 

Start-up lever screw 12 ÷ 13 

Flywheel nut 

40 to 44 Nm 

Flywheel fan screws 3 to 4 

Half-crank case joint bolts 12 ÷ 13 

Bolts holding exhaust pipe to the crankcase 22 ÷ 24 

Screws holding the filter box to the crank case 4 ÷ 5 

Head nuts 10 ÷ 11 

Starter screws 12 ÷ 13 

Ignition spark plug 25 ÷ 30 

Hub oil drainage cap 3 ÷ 5 

Oil hub level dipstick 

Manual 

Rear hub cap screws 12 ÷ 13 

Transmission cover screws 12 ÷ 13 

Inlet manifold screws 8 ÷ 9 

Flywheel hood fixing screws 1 ÷ 2 

Cylinder hood fixing screws 3.5 ÷ 5 

Stator clamping screws 3 ÷ 4 

Pick-Up clamping screw 4 ÷ 5 

Mixer clamping screws 3 ÷ 4 

Screw fixing brake lever to the journal on the engine 12 ÷ 13 

CHAR - 10



Overhaul data 

Assembly clearances 

Cylinder - piston assy. 

COUPLING BETWEEN PISTON AND CYLINDER 

Name Initials Cylinder Piston Play on fitting 

Standard coupling M 40.005 - 40.012 39.943 - 39.95 0.055 - 0.069 

Standard coupling N 40.012 - 40.019 39.95 - 39.957 0.055 - 0.069 

Standard coupling O 40.019 - 40.026 39.957 - 39.964 0.055 - 0.069 

Standard coupling P 40.026 - 40.033 39.964 - 39.971 0.055 - 0.069 

coupling 1st oversize M1 40.205 - 40.212 40.143 - 40.15 0.055 - 0.069 

coupling 1st oversize N1 40.212 - 40.219 40.15 - 40.157 0.055 - 0.069 

coupling 1st oversize O1 40.219 - 40.226 40.157 - 40.164 0.055 - 0.069 

coupling 1st oversize P1 40.226 - 40.233 40.164 - 40.171 0.055 - 0.069 

Coupling 2nd oversize M2 40.405 - 40.412 40.343 - 40.35 0.055 - 0.069 

Coupling 2nd oversize N2 40.412 - 40.419 40.35 - 40.357 0.055 - 0.069 

Coupling 2nd oversize O2 40.419 - 40.426 40.357 - 40.364 0.055 - 0.069 

Coupling 2nd oversize P2 40.426 - 40.433 40.364 - 40.371 0.055 - 0.069 

Piston rings 

SEALING RINGS 

Name Description Dimensions Initials Quantity 

Compression ring 40 A 0.10 to 0.25 

Compression ring 1st 

40.2 A 0.10 to 0.25 

oversize 

Compression ring 2nd 

Oversize 

40.4 A 0.10 to 0.25 

CHAR - 11


Crankcase - crankshaft - connecting rod 

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD 

Name Description Dimensions Initials Quantity 

Connecting rod 11.750-0.05 A clearance E = 0.25 to 

0.50 

shoulder washer 0.5 ± 0.03 G clearance E = 0.25 to 

0.50 - clearance F = 

0.20 to 0.75 

Half-shaft, transmission 

side 

13.75+0.040 C clearance E = 0.25 to 


0.20 to 0.75 

Flywheel-side half-shaft 13.75+0.040 D clearance E = 0.25 to 


0.20 to 0.75 

Lining between the 

shoulders 

40.64 H clearance E = 0.25 to 


0.20 to 0.75 

Cage 11.800-0.35 B clearance F = 0.20 to 

0.75 

CHAR - 12



Slot packing system 

- Fit the cylinder without installing the basic gasket. 

- Apply a centimetre dial gauge on the special tool 

and zero it on the ground plane 

- Fit the tool to the top of the cylinder fixing it with 

two nuts to the studbolts and take the piston to the 

T.D.C. 

- The thickness of the gasket to fit will change depending 

on the value detected. For this purpose, 

there are three with different thicknesses 

Specific tooling 

020272Y Piston position check tool 

SHIMMING SYSTEM 

Name Measure A Thickness 

Shimming 2.80 ÷ 3.04 0,4 

Shimming 3.04 ÷ 3.24 0,6 

Shimming 3.25 ÷ 3.48 0,8 

Products 

RECOMMENDED PRODUCTS TABLE 

Product Description Specifications 

AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements 

of API GL3 specifications 

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased 

adhesiveness 

AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO 

FC, ISO-L-EGD 

AGIP GP 330 Grease for brake lever, gas White calcium complex soap-based 

spray grease with NLGI 2; ISO-L-XBCIB2 

AGIP GREASE SM 2 Grease for the C-ring of the tone wheel Soap-based lithium grease containing 

NLGI 2 Molybdenum disulphide; ISO-L- 

XBCHB2, DIN KF2K-20 

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid 

MONTBLANC MOLYBDENUM 

GREASE 

Grease for driven pulley shaft adjusting 

ring and movable driven pulley housing 

Grease with molybdenum disulphide 

AGIP GREASE PV2 

Grease for steering bearings, pin seats 

and swinging arm 

White anhydrous-calcium based grease 

to protect roller bearings; temperature 

range between -20 C and +120 C; with 

NLGI 2; ISO-L-XBCIB2. 

CHAR - 13


TOOLING 

TOOL


Tooling 

Stores code 

001330Y 

TOOLS 

Description 

Tool for fitting steering seats 

001467Y006 

Pliers to extract 20 mm bearings 

001467Y007 

Driver for OD 54 mm bearing 

001467Y009 

Driver for OD 42-mm bearings 

001467Y013 

Calliper to extract ø 15-mm bearings 

001467Y014 

Calliper to extract ø 15-mm bearings 

TOOL - 15

Tooling Typhoon 50 

Stores code 

001467Y017 

Description 

Bell for bearings, OD 39 mm 

001467Y021 

Extraction pliers for ø 11 mm bearings 

002465Y 

Calliper for circlips 

006029Y 

Punch for fitting fifth steering bearing on 

steering tube 

020004Y 

Punch for removing steering bearings 

from headstock 

020055Y 

Wrench for steering tube ring nut 

020150Y 

Air heater mounting 

TOOL - 16


Tooling 

Stores code 

020151Y 

Description 

Air heater 

020162Y 

Flywheel extractor 

020163Y 

Crankcase splitting plate 

020164Y 

Driven pulley assembly sheath 

020165Y 

Start-up crown lock 

020166Y 

Pin lock fitting tool 

TOOL - 17


Stores code 

020261Y 

Description 

Starter spring fitting 

020262Y 

Crankcase splitting plate 

020265Y 

Bearing fitting base 

020325Y 

Pliers for brake-shoe springs 

020329Y 

Mity-Vac vacuum-operated pump 

020330Y 

Stroboscopic light to check timing 

TOOL - 18


Tooling 

Stores code 

020331Y 

Description 

Digital multimeter 

020332Y 

Digital rpm indicator 

020334Y 

Multiple battery charger 

020335Y 

Magnetic mounting for dial gauge 

TOOL - 19


Stores code 

020350Y 

Description 

Electrical system check instrument 

020357Y 

020359Y 

32x35-mm Adaptor 

42x47-mm Adaptor 

020376Y 

Adaptor handle 

020412Y 

15-mm guide 

020456Y 

Ø 24 mm adaptor 

TOOL - 20


Tooling 

Stores code 

020483Y 

Description 

30-mm guide 

020565Y 

Flywheel lock calliper spanner 

020625Y 

Kit for sampling gas from the exhaust 

manifold 

TOOL - 21


MAINTENANCE 

MAIN


Maintenance 

Maintenance chart 

Brake fluid - change 

EVERY 2 YEARS 

Action 

50' 

Hub oil - change 

Oil mixer/throttle linkage - adjustment 

Odometer gear - greasing 

Steering - adjustment 

Brake levers - greasing 

Brake fluid level - check 

Safety fasteners - check 

Electrical system and battery - check 

Tyre pressure and wear - check 

Vehicle test and brake test - Road test 

AFTER 1000 KM 

Action 

40' 

Hub oil level - check 

Spark plug/electrode gap - replacement 

Air filter - clean 



Brake pads - check condition and wear 





95' 




Idling speed (*) - adjustment 


Variable speed rollers - replacement 


Drive belt - check 





Transmission - lubrication 


Suspensions - check 


Headlight - adjustment 



(*) See instructions in the "Adjusting the idle speed" section 

AFTER 5000 KM, 25000 KM, 35000 KM, 55000 KM 

Action 

AFTER 10000 KM, 50000 KM 

Action 

65' 

AFTER 15000 KM AND 45000 KM 

MAIN - 23

Maintenance Typhoon 50 

Hub oil level - check 


Air filter - cleaning 


Drive belt - replacement 






SAS box (sponge) (**) - cleaning 


(**) See regulations in the «Secondary air system» section 

Action 

110' 





Cylinder cooling system - check/cleaning 


Drive belt - check 


Mixer belt - replacement 













(*) See section «Adjusting the idle speed» 

AFTER 20000 KM AND 40000 KM 

Action 

130' 












Flexible brake tubes - replacement 










AFTER 30000 KM 

Action 

MAIN - 24


Maintenance 

(*) See regulations in the «Adjusting the idle speed» section 


150' 





Cylinder cooling system - check/cleaning 




Mixer belt - replacement 





Flexible brake tubes - replacement 










(*) See regulations in the «Adjusting the idle speed» section 


AFTER 60000 KM 

Action 

Checking the spark advance 

-Check to be made at over 4000 rpm with stroboscopic 

gun. The advanced ignition measured must 

be 17° before the TDC. 

- This value is correct when the reference mark on 

the flywheel hood is aligned with the reference 

mark on the cooling fan and the phase shifter on 

the stroboscopic gun is set on 17°. 

N.B. 

IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS 

PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER. 

CAUTION 

BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK 

THE CORRECT KEYING OF THE FLYWHEEL ON THE 

CRANKSHAFT. 


020330Y Stroboscopic light to check timing 

MAIN - 25


Spark plug 

Place the vehicle on its central stand 

-Remove the central cover by undoing the three 

clamping screws indicated in the figure; 

- Disconnect spark plug HV wire hood; 

-Undo the spark plug using the socket wrench; 

-Examine the condition of the spark plug, check 

that the insulating material is whole and measure 

the distance between the electrodes using a thickness 

gauge. 

-Adjust the distance if necessary by bending the 

side electrode very carefully. 

In the case of defects, replace the spark plug with 

one of the specified type; 

- Engage the spark plug with the due inclination 

and screw it right down by hand, then do it up with 

the wrench at the prescribed torque; 

-Put the hood on the sparking plug as far as it will 

go; 

- Refit the central flap. 

CAUTION 

THE SPARK PLUG MUST BE REMOVED WHEN THE MO- 

TOR IS COLD. THE SPARK PLUG MUST BE REPLACED 

EVERY 5000 KM. USE OF STARTERS NOT CONFORMING 

OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERI- 

OUSLY DAMAGE THE ENGINE. 

Characteristic 

Recommended spark plug 

CHAMPION RN3C 

Electric characteristic 

Electrode gap 

0.6 to 0.7 mm. 

Locking torques (N*m) 

Spark plug 25 - 30 Nm 

Hub oil 

MAIN - 26


Maintenance 

Check 

Do the following to check the correct level: 

1) Stand the vehicle on the centre-stand on flat 

ground; 

2) Remove the dipstick «A», and dry it with a clean 

cloth. Reinsert it, screwing it in all the way; 

3) Remove the stick and check that the oil level is 

slightly over the second notch starting from the 

lower end; 

4) Screw the dipstick back in, checking that it is 

locked in place. 

Recommended products 

AGIP ROTRA 80W-90 Rear hub oil 

SAE 80W/90 Oil that exceeds the requirements of 

API GL3 specifications 

Replacement 

-Remove the oil filler cap «A». 

- Unscrew the oil drainage cap "B" and drain out 

all the oil. 

- Screw in the drainage cap again and fill the hub 

with the prescribed oil. 


Rear hub oil 

Quantity: approx. 80 cm³ 

MAIN - 27


Air filter 

-Remove the cap of the purifier, unscrewing the six 

clamping screws and removing the filter. 

Cleaning: 

-Wash with water and neutral soap. 

- Dry with a clean cloth and short blasts of compressed 

air. 

-Saturate with a 50% mixture of gasoline and oil. 

-Drip dry the filter and then squeeze it between the 

hands without wringing. 

-Let it dry and refit it again. 

CAUTION 

NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, 

THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE 

PISTON AND CYLINDER. 


AGIP FILTER OIL Oil for air filter sponge 

Mineral oil with specific additives for increased adhesiveness 

transmissions 

During this stage, the engine must be fed with a 

2% mixture (at least 0.5 litres if the tank is empty). 

Remove the casing covering the carburettor. Put 

the vehicle in gear and regulate the idling by turning 

the adjustment screw on the carburettor. Adjust 

the control cables: 

Handlebar control: remove the rubber hood and 

regulate the cable adjustment in such a way that it 

causes a minimum backlash on the throttle. 

Carburettor control: remove the rubber hood and 

regulate the cable adjustment in such a way that 

the sheath has a minimum backlash. 

Oil mixer control: remove the cap on the engine 

crankcase and regulate the adjustment in such a 

way that with the throttle released, the reference 

mark on the rotating plate is lined up with the ref- 

MAIN - 28


Maintenance 

erence mark on the mixer body as indicated in the 

figure. 

Bring the throttle a couple of times to the end of 

the stroke and check that the adjustments have 

been made properly, then tighten them all up. 

N.B. 

TO VERIFY THE CORRECT TIMING OF THE MIXER IT IS 

NECESSARY TO REMOVE THE AIR CONDUIT OF THE 

TRANSMISSION COVER. 

CAUTION 

IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN 

THE RESERVOIR BLEED THE MIXER AS FOLLOWS: RE- 

FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED 

TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE 

MIXER PIPE FROM THE CARBURETTOR AND LOOSEN 

THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE) 

UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE 

SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO 

FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY 

PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH 

THE RELEVANT METAL CLIP. 


AGIP CITY TEC 2T Mixer oil 

synthetic oil for 2-stroke engines: JASO FC, ISO- 

L-EGD 

Braking system 

Level check 

Proceed as follows: 

- Rest the vehicle on its centre stand with the handlebars 

perfectly horizontal; 

- Check the level of liquid with the related warning 

light «A». 

A certain lowering of the level is caused by wear 

on the brake pads. 

MAIN - 29


Top-up 


- Remove the rearview mirrors 

- Remove the front handlebar cover. 

- Remove the tank cap by loosening the two 

screws, remove the gasket and top up using only 

the liquid specified without exceeding the maximum 

level. 

CAUTION 

ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. 

CAUTION 

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR 

EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL 

CONTACT, WASH WITH WATER. 

CAUTION 

BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE 

SURE THAT IT DOES NOT COME INTO CONTACT WITH 

THE PAINTWORK. 

CAUTION 

THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS, 

IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. 

IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID 

EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEF- 

FICIENT. 

NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY 

USED CONTAINERS. 

UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID 

MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EV- 

ERY TWO YEARS. 

N.B. 

SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO 

THE CHANGING OF BRAKE FLUID AND THE BLEEDING 

OF AIR FROM THE CIRCUITS. 


AGIP BRAKE 4 Brake fluid 

FMVSS DOT 4 Synthetic fluid 

Headlight adjustment 


1. Place the vehicle, in riding condition, with the 

tyres correctly inflated, on a flat piece of ground at 

a distance of 10 m from a white screen situated in 

a shaded area, making sure that the scooter is 

perpendicular to the screen; 

MAIN - 30


Maintenance 

2. Turn on the headlight and check that the edge 

of the beam of light projected on the screen is not 

more than 9/10 of the height of the centre of the 

front light from the ground and is not less than 

7/10; 

3. If this is not the case, regulate the headlight by 

turning screw «A». 

N.B. 

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 - 31


TROUBLESHOOTING 

TROUBL


Troubleshooting 

This section makes it possible to find the solutions to use in troubleshooting. 

For each breakdown, a list of the possible causes and respective interventions is given. 

Engine 

Poor performance 

Possible Cause 

Defective fuel cock or vacuum hose damaged. 

Carburettor nozzles clogged or dirty 

Fuel filter on the tank outlet fitting dirty or clogged 

Excess of encrustations in the combustion chamber 

Lack of compression wear of the piston rings or cylinder 

Exhaust pipe clogged due to excessive encrustations 

Air filter blocked or dirty 

Starter inefficient (stays on) 

Clutch slipping 

Defective mobile pulley sliding 

Driving belt worn 

Roller wear; Presence of oil; Dirt 

Rear wheel spins at idle 

POOR PERFORMANCE 

Operation 

Replace the cock or the control hose. 

Dismantle, wash with solvent and dry with compressed air 

Clean the fitting filter 

Remove the encrustations 

Check the worn parts and replace them 

Replace the exhaust pipe and check the carburation and mixer 

timer 

Clean according to the procedure 

Check the mechanical sliding, continuity of the circuit, the presence 

of power and electrical wiring 

Check the centrifugal brake shoe assembly and /or clutch bell 

and replace if necessary 

Check the parts, change the faulty parts and lubricate the driven 

pulley using only Montblanc-Molibdenum Grease (dis. 

498345) grease 

Replace 

Clean the speed variator, replace the rollers if worn out 


Idling rpm too high 

Clutch fault 

Air filter housing not sealed 

REAR WHEEL 

Operation 

Check the idling speed and, if necessary, adjust the C.O. 

Check the spring/friction mass and the clutch bell 

Correctly refit the filter housing and replace it if it is damaged 

Starting difficulties 


Carburettor nozzles clogged or dirty 

Defective fuel cock or vacuum hose damaged. 

Starter inefficient 

Flat battery 

Engine flooded 

Altered fuel characteristics 

DIFFICULTY STARTING 

Operation 

Dismantle, wash with solvent and dry with compressed air 

Replace the cock or the control hose. 

Check: electric wiring, circuit continuity, mechanical sliding and 

power supply 

Check the state of the battery. If it shows signs of sulphation 

replace it and bring the new battery into service charging it for 

eight hours at a current of 1/10 of the capacity of the battery 

itself 

Start the vehicle keeping the throttle fully open alternately making 

the engine run for approx. five seconds and stopping for 

other five seconds. If however it does not start, remove the 

spark plug, the engine over with the throttle open being careful 

to keep the cap in contact with the spark plug and the spark 

plug grounded but away from its hole. Refit a dry spark plug 

and start the vehicle. 

Drain off the fuel no longer up to standard; then, refill 

TROUBL - 33

Troubleshooting Typhoon 50 


Defective spark plug or with incorrect electrode gap 

Intake joint cracked or with a bad seal 

Purifier-carburettor fitting damaged 

Operation 

Remove the encrustation, restore the plug gap or replace being 

sure to use the types of spark plug recommended at all times. 

Bear in mind that many problems engines have, derive from 

the use of the wrong spark plug 

Replace the intake joint and check its tightness on the crankcase 

and on the carburettor 

Replace 

Excessive oil consumption/Exhaust smoke 

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST 


Operation 

Excess of encrustations in the combustion chamber 

Remove the encrustations 

Engine tends to cut-off at full throttle 

ENGINE STOP FULL THROTTLE 


Operation 

Maximum nozzle dirty - lean mixture 

Wash the nozzle with solvent and dry with compressed air 

Dirty carburettor 

Wash the carburettor with solvent and dry with compressed air 

Water in the carburettor 

Empty the tank through the appropriate bleed nipple. 

Air filter dirty 

Clean or replace 

Defective floating valve 

Check the proper sliding of the float and the functioning of the 

valve 

Tank breather hole obstructed 

Restore the proper reservoir aeration 

Engine tends to cut-off at idle 


Minimum nozzle dirty 

Starter that stays open 

Reed valve does not close 

Wrong idling adjustment 

Spark plug defective or faulty 

Excessive exhaust noise 

ENGINE STOP IDLING 

Operation 

Wash the nozzle with solvent and dry with compressed air 


power supply 

Check / replace the reed pack 

Correctly adjust the engine idling and check the level of the 

C.O. 

Replace the spark plug with one with the specified degree and 

check the plug gap 

INCREASED NOISINESS 


Operation 

Secondary metal air pipe deteriorated 

Check the seal of the piping on the crankcase and on the housing, 

check the piping between the housing and the muffler. 

Good condition of the missing secondary air circuit components Check the individual components and the piping, check the 

precision of the fitting. Replace the damaged components 

TROUBL - 34



High fuel consumption 

SAS malfunctions 


Air filter blocked or dirty. 

Inefficient Starter 

HIGH FUEL CONSUMPTION 

Operation 

Clean according to the procedure 


power supply 

SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF- 

FLER 


Secondary air reed blocking 

Secondary air filter clogging 

Blockage of the secondary air fitting on the muffler 

Transmission and brakes 

Operation 

Replace 

Clean the filter and the housing 

Remove the encrustations from the joint being careful not to let 

the debris fall into the muffler 

Clutch grabbing or performing inadequately 


Tear or irregular functioning 

CLUTCH 

Operation 

Check that the masses open and return normally 

Check that there is no grease on the masses 

Check that the clutch masses' contact surface with the clutch 

bell is mainly in the middle with characteristics equivalent on 

the three masses 

Check that the clutch bell is not scored or worn abnormally 

Never operate the engine without the clutch bell 

Insufficient braking 


Poor braking 

Air bubbles inside the hydraulic braking system 

Fluid leakage in hydraulic braking system 

The brake fluid has lost its properties 

Defective sliding of the cables in their sheathes 

Brake noise 

BRAKING SYSTEM MALFUNCTION 

Operation 

The rear (drum type) brake is adjusted by regulating the special 

adjustment (on the wheel) bearing in mind that, with the control 

levers in the rest position, the wheels must turn freely. 

The braking action should begin when the brake levers are 

pressed by about a third. 

Check the brake pad wear. 

If it is not possible to remove any problems by simply adjusting 

the transmissions, check the brake pads and front brake disc, 

the brake shoes and the rear drum. If you encounter excessive 

wear or scoring, make the necessary replacements. 

Carefully bleed the hydraulic braking system, (there must be 

no flexible movement of the brake lever). 

Elastic fittings, piston seals or brake pump breakdown, replace 

Replace the front brake fluid and top up to the correct level in 

the pump 

Lubricate or substitute 

Check the wear of the brake pads and/or shoes 

TROUBL - 35

Troubleshooting Typhoon 50 

Brakes overheating 



Defective piston sliding 

Brake disc or drum deformed 

BRAKES OVERHEATING 

Operation 

Check calliper and replace any damaged part. 

Using a dial gauge, check the planarity of the disk with the 

wheel correctly fitted or the concentricity of the rear drum. 

Battery 


Battery 

BATTERY 

Operation 

The battery is the electrical device in the system that requires 

the most frequent inspections and thorough maintenance. If the 

vehicle is not used for some time (1 month or more) the battery 

needs to be recharged periodically. The battery runs down 

completely in the course of 5 to 6 months. If the battery is fitted 

on a motorcycle, be careful not to invert the connections, keeping 

in mind that the black ground wire is connected to the 

negative terminal while the red wire is connected to the terminal 

marked+. Follow the instructions in the ELECTRICAL SYSTEM 

chapter for the recharging of the batteries. 

Steering and suspensions 

Rear wheel 


Faulty suspension 

Tyres deflated or damaged 

Loosen the anchorage points of the front and/or rear suspension 

unit. 

Heavy steering 

POOR ROAD HOLDING 

Operation 

Check that the rear shock absorber and/or the front fork is/are 

in good working order. Replace or overhaul the front fork and/ 

or replace the rear shock absorbers in case of malfunction 

Check the correct pressure of the tyres and the condition of the 

tread. Inflate to the correct pressure or replace. 

Check the tightness between the frame, swinging arm and engine 

and the fixing of the wheels to the hub and/or the axle. 

Check the correct tightening of the steering ring nut. 


Torque not conforming 

STEERING HARDENING 

Operation 

Check the tightening of the top and bottom ring nuts. 

If irregularities continue in turning the steering even after making 

the above adjustments, check the seats in which the ball 

bearings rotate: replace if they are recessed. 

TROUBL - 36



Excessive steering play 


EXCESSIVE STEERING CLEARANCE 

Noisy suspension 

EXCESSIVE STEERING CLEARANCE 

Operation 

Check the tightening of the top and bottom ring nuts. 

If irregularities continue in turning the steering even after making 

the above adjustments, check the seats in which the ball 

bearings rotate: replace if they are recessed. 


Components of the front suspension damaged. 

Components of the rear suspension damaged. 

Suspension oil leakage 

NOISY SUSPENSION 

Operation 

Check the quiet operation in the compression or release phases 

of the fork and if necessary overhaul it. Check that there is 

no noise or seizing during the wheel rotation; if there is, change 

the wheel bearing. 

Check the absence of noise in the compression or release of 

the suspension, if necessary check the proper tightness to the 

swinging arm unit and the absence of rust or replace the entire 

shock absorber. Check that there is no noise or seizing during 

the wheel rotation; if there is noise or seizing overhaul the final 

reduction assembly. 

OIL LEAKAGE FROM SUSPENSION 


Operation 

Shock absorbers malfunctioning 

Replace the complete shock absorption unit 

Hydraulic cartridge in the fork damaged. 

Replace the hydraulic cartridge 

TROUBL - 37



ELE SYS



Key 

Key: typhoon 50 my 2006 

1. Electronic ignition device 

2. Spark plug 

3. Magneto flywheel 

4. Voltage regulator 

5. Main fuse 

6. Key switch 

7. Battery 

8. Starter 

9. Remote control ignition 

10. Ignition switch 

11. Rear brake STOP button 

12. Front brake STOP button 

13. Horn button 

14. Horn 

15. Left rear turn indicator lamp 

16. Tail light/stop light lamp 

17. Turn indicator switch 

18. Right rear turn indicator lamp 

ELE SYS - 39

Electrical system Typhoon 50 

19. Left front turn indicator lamp 

20. Front optical unit 

A. Tail light 

B. High beam/low beam lamp 

21. Right front turn indicator lamp 

22. Light switch 

23. Fuel level transmitter 

24. Instruments unit 

A. Instrument lighting lamp and lights warning light 

B. Left-hand flashing light. 

C. Right-hand flashing light. 

D. High-beam warning light 

E. Mixer oil warning light 

F. Fuel level indicator 

G. Rev counter 

H. Low fuel warning light 

25. Automatic starter 

26. Oil warning light control 

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 

Conceptual diagrams 

ELE SYS - 40



Ignition 

Key 

1. Electronic ignition device 

2. Spark plug 


6. Key switch 

ELE SYS - 41


Headlights and automatic starter section 

Key 



16. Tail light /stop light lamp 

20. Front optical unit 

A. Tail light 

B. High beam/low beam lamp 

22. Light switch 










25. Automatic starter 

ELE SYS - 42



Battery recharge and starting 

Key 



5. Main fuse 

6. Key switch 

7. Battery 

8. Starter 

9. Remote control ignition 

10. Ignition switch 

11. Rear brake STOP button 

12. Front brake STOP button 

16. Tail light/stop light lamp 

26. Oil control warning light 

ELE SYS - 43


Level indicators and enable signals section 

Key 



5. Main fuse 

6. Key switch 

7. Battery 

23. Fuel level transmitter 










26. Oil warning light control 

ELE SYS - 44



Turn signal lights 

Key 



5. Main fuse 

6. Key switch 

7. Battery 

13. Horn button 

14. Horn 

15. Left rear turn indicator lamp 

18. Right rear turn indicator lamp 

19. Left front turn indicator lamp 

21. Right front turn indicator lamp 







ELE SYS - 45





Instruments and warning lights control board 

A= High beam warning light; 

B= Mixer oil reserve warning light; 

C= Turn indicator warning light; 

D= Low fuel warning light; 

E= Headlight warning lights; 

F= Rev counter; 

M= Odometer 

N= Speedometer; 

P= Coolant temperature indicator (not available on 

this model); 

S= Fuel level indicator; 

Checks and inspections 

Checks to be made in the case of ignition irregularities and/or no spark on the spark plug 

1. Check the condition of the spark plug (clean it with a metal brush, remove the encrustations, blast 

it with compressed air and, if necessary, replace it). 

2. Without removing the stator, carry out the following checks: 

After visually checking the electrical wiring, perform measurements on the loading reel, the pickup (see 

chart) and the continuity using the appropriate tester. 

If checks on the loading reel, pickup and continuity show abnormalities, replace the stator; otherwise 

replace the central unit. Remember that disconnections due to replacement of the central unit must be 

done with the engine off. 


020331Y Digital multimeter 

CHECK ON THE PICK UP 

Specification 


1 Red and white cable 90±140 ohm 

ELE SYS - 46



RECHARGE COIL CHECK UP 

Specification 


1 Yellow and blue cable 800±1100 ohm 

CHECK CONTINUITY 

Specification 


1 White cable-frame continuity 

2 White cable-engine continuity 

Ignition circuit 

All the control operations of the system that require 

the disconnection of cables (checks of the connections 

and the devices making up the ignition 

circuit) must be done with the engine off: if this is 

not done, the controls might be irretrievably damaged. 

ELE SYS - 47


Stator check 

- Using a tester, check the resistance between the 

stator wiring. 

N.B. 

VALUES ARE STATED AT AMBIENT TEMPERATURE. A 

CHECK WITH THE STATOR AT OPERATING TEMPERA- 

TURE LEADS TO VALUES HIGHER THAN THOSE STATED. 


Stator : Grey ÷ Ground 

~ 1 ohm 

Stator : White ÷ Ground 

~ 1 ohm 

Stator : Green - Ground 

~ 1Kohm 

Stator : Blue ÷ Yellow 

~ 1 ohm 

Pick-Up: Red - ground 

~ 170 Ω (Pick-Up) 

Voltage regulator check 

The malfunctioning of the voltage regulator might cause the following problems depending on the type 

of fault: 

1. The lighting system bulbs burn out. 

2. The lighting system bulbs stop working. 

3. The battery overcharges (the main fuse blows). 

4. Non-recharging of the battery. 

5. Non functioning of the turn indicators. 

Measures 

FAULT 1 

Replace the regulator because it is certainly inefficient. 

FAULT 2 

Check the efficiency of the bulbs. 

With the vehicle in gear, check the battery voltage 

on the yellow-black cable of the light switch. If 

there is no voltage check the presence of voltage 

between the yellow-black cable on the regulator 

and ground. If there is voltage here, the fault needs 

ELE SYS - 48



to be sought in the wiring from the regulator to the 

light switch or the correct supply of voltage to the 

stator is to be checked: without disconnecting the 

regulator connector and with the vehicle in gear, 

using the tester for alternate voltage readings 

check that the voltage supplied between the connection 

of the grey-blue cable (pin 2) and the black 

cable (pin 6) is within the values indicated. If faults 

are detected, replace the stator. 

If no faults are detected in the controls carried out, 

replace the regulator. 

If functioning is still not correct even when the regulator 

is replaced, check the connections of the 

electrical system. 




Voltage distributed at 3000 rpms 

25 to 30V 

FAULT 3 

After checking that there are no short circuits in the system towards the earth, replace the regulator 

because it is certainly inefficient and replace it with a protective fuse. 

Following the replacement, measure the current and the recharging voltage on the battery end. 

FAULT 4 

Put the vehicle in gear and check when the tester 

for the detection of alternate voltages put between 

the blue cable connection and the yellow cable 

connection on the stator, the voltage distributed by 

the generator is within the values indicated. In the 

case of malfunction, check the continuity of the 

stator or continue with the tests. 

Insert an ammeter between the stator (blue cable) 

and the battery and check, with the tester, that the 

current is properly distributed at 3000 rpm and the 

battery is kept between 12 and 13V as indicated. 

If the values detected are lower than those speci- 

ELE SYS - 49


fied, replace the regulator; otherwise replace the 

battery. 

N.B. 

BEFORE CARRYING OUT THE CHECKS ON THE REGU- 

LATOR AND RELATIVE SYSTEM, IT IS ALWAYS GOOD 

PRACTICE TO CHECK THAT THERE IS CONTINUITY BE- 

TWEEN THE BLACK CABLE AND THE GROUND. 

N.B. 

TO KEEP THE BATTERY BETWEEN 12 AND 13V, CAUSING 

CURRENT ABSORPTION BY THE SYSTEM, A 12V - 35W 

BULB CONNECTED BETWEEN THE + BATTERY AND 

GROUND CAN BE USED. 




Distributed current 

1.5 to 2A 

Voltage distributed at 3000 rpms 

25 to 30V 

FAULT 5 

If the turn indicators do not work, do the following: 

• Without removing the connector from 

the voltage regulator, move the keycontrolled 

switch to ON and verify the 

presence of intermittent voltage between 

contact 7 and the ground. If 

there is voltage, the failure must be attributed 

to the flashing indicator switch 

or the wiring, otherwise carry on with 

tests. 

• With the engine off, remove the regulator 

connector, and insert the ends of 

the tester between contact 5 and the 

ground. 

• Move the key controlled switch to ON 

and check there is battery voltage. If no 

voltage is detected, check the wiring 

and the contacts on the key switch and 

on the battery. 

ELE SYS - 50



• Repeat the same procedure with the 

ends of the tester inserted between 

contact 5 (+) and 6 (-) and check the 

presence of the battery voltage with the 

key switch at on. If this does not happen, 

check the regulator's ground cable. 

• If these last two tests have a positive result replace the regulator because it is certainly not 

functioning properly. 



Fuses 

The electrical system is protected by a fuse connected 

on the left-hand side of the helmet compartment 

next to the battery. To get at it, it is 

necessary to remove the battery cover and the 

transparent protection B over the fuse block. The 

ignition system, headlight and the rear tail light are 

not fuse-protected. 

CAUTION 

BEFORE REPLACING THE BLOWN FUSE, SEARCH AND 

ELIMINATE THE BREAKDOWN THAT HAS LED TO THE 

BLOW OUT. 

NEVER TRY TO REPLACE A FUSE USING DIFFERENT MA- 

TERIAL (FOR EXAMPLE A PIECE OF ELECTRIC WIRE) OR 

A FUSE FOR A HIGHER AMPERAGE THAN THE INDICA- 

TED ONE. 


Fuse 

7.5 A 

Sealed battery 

Using the sealed battery for the first time 

INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 

1) Voltage check 

Before installing the battery on the vehicle, check the open circuit voltage with a standard tester. 

- If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge. 

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 

ELE SYS - 51


2) Constant voltage battery charge mode 

-Constant voltage equal to 14.40÷14.70V 

-Initial charge voltage equal to 0.3÷0.5 for nominal capacity 

-Duration of the charge: 10 to 12 h recommended 

Minimum 6 h 

Maximum 24 h 

3) Constant current battery charge mode 

-Charge current equal to 1/10 of the nominal capacity of the battery 

-Duration of the charge: 5 h 

WARNING 

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF 

RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. 

GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CON- 

TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF. 

Dry-charge battery 

WARNING 

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON- 

TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF 

COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP- 

PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. 

IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE 

QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. 

SEEK IMMEDIATE MEDICAL ATTENTION. 

THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR 

CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. 

ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. 

KEEP OUT OF REACH OF CHILDREN 

Use of dry-cell batteries : 

1. Having removed the short, closed tube and removed the caps, put into the elements sulphuric 

acid of the type for specific weight 1.26 accumulators corresponding to 30° Bé at a temperature 

of no less than 15°, until you reach the upper level. 

2. Leave to stand for at least 2 hours; afterwards top-up to the level with sulphuric acid. 

3. Within twenty four hours, recharge with the special (single or multiple) battery charger that recharges 

at an intensity the same as approximately 1/10 the rated capacity of the said battery. At 

the end of the charge, make sure that the density of the acid is around 1.27, corresponding to 31° 

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 performed, install the battery in the vehicle ensuring that 

it is wired up properly.. 

WARNING 

- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE 

THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE- 

SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO 

ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY. 

ELE SYS - 52




020333Y Single battery charger 

020334Y Multiple battery charger 

1 Hold the vertical tube 

2 Look at the level 

3 The float must be freed 

Battery maintenance 

The battery is an electrical device which requires careful monitoring and diligent maintenance. The 

maintenance rules are: 

1) Check the level of the electrolyte 

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled 

water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical 

system: the battery works overcharged and is subject to quick wear. 

2)Load status check 

After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). 

When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific 

weight of 1.26 to 1.28 at a temperature of no lower than 15° C. 

A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore 

be recharged. 

If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge 

the battery. 

The battery runs down completely in the course of three months. If it is necessary to refit the battery in 

the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked 

(-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected 

to the clamp marked with the +positive sign. 

3) Recharging the battery 

Remove the battery from the vehicle removing the negative clamp first. 

The normal bench charging must be carried out with the specific (single or multiple) battery charger, 

placing the battery charger selector on the type of battery to be recharged. The connections to the power 

supply must be made by connecting to the corresponding poles (+ with+ and -with -). 

4) Battery cleaning 

The battery should always be kept clean, especially on its top side, and the terminals should be coated 

with Vaseline. 

ELE SYS - 53


WARNING 

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS 

AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING. 

CAUTION 

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. 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 

CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE 

CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST 

USED SHORTENS THE LIFE OF THE BATTERY. 


020334Y Multiple battery charger 

020333Y Single battery charger 

ELE SYS - 54


ENGINE FROM VEHICLE 

ENG VE

Engine from vehicle Typhoon 50 

Removal of the engine from the vehicle 

1) Disconnect the battery 

2) Remove the full muffler. 

3) Remove the rear wheel. 

4) Remove the rear brake mechanical transmission. 

5) Disconnect the electrical system connector from 

the magneto flywheel, from the starter and from 

the automatic starter. 

6) Disconnect the accelerator and mixer control 

transmissions. 

7) Disconnect the mixer oil, fuel pipes and vacuum 

pump control on the carburettor. 

8) Disconnect the high-voltage cable from the 

spark plug. 

9) Remove the bolt fixing the rear shock absorber 

from the engine. 

10) Undo the nut on the right-hand side then remove 

the engine-swinging arm fixing pin from the 

left-hand side. 


Engine-swinging arm bolt 33 to 41 Shock absorber-engine 

pin 33 to 41 Nm Rear wheel axle 

nut 104 to 126 

ENG VE - 56



ENG

Engine Typhoon 50 

Automatic transmission 

Transmission cover 

- Loosen the 15 screws and remove the transmission 

cover with the aid of a mallet. 

N.B. 

THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT 

FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY 

AND THE BEARING HOUSED ON THE CRANKCASE. 

Kickstart 

- Remove the screws shown in the figure and remove 

the engine starting lever. 

- For the assembly, work in reverse and tighten the 

screws to the prescribed torque.. 


Starter lever replacement 12 to 13 Nm 

- Upon refitting, apply the recommended grease to 

the bushing, to the spring and along the toothed 

sector. 

- Use the special tool for the charging of the spring, 

as shown in the figure. 

- Refit the seeger ring after checking that it is in 

good condition. 


020261Y Starter spring fitting 


AGIP GREASE MU3 Grease for odometer 

transmission gear case 

Soap-based lithium grease with NLGI 3; ISO-L- 

XBCHA3, DIN K3K-20 

ENG - 58


Engine 

- Remove the seeger ring located on the exterior 

of the crankshaft. 

- Dismantle the dog gear from its seat, slackening 

the tension that the toothed sector applies to it by 

means of the spring; to do this, it is necessary to 

rotate the toothed sector slightly (see the figure). 

CAUTION 

WHILE REMOVING THE TOOTHED SECTOR, BE VERY 

CAREFUL OF THE SPRING TENSION: IT COULD CONSTI- 

TUTE A HAZARD FOR THE OPERATOR. 

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 PAINTED 

SURFACE. 



Removing the driven pulley 

- Lock the clutch bell housing with the specific tool. 

- Remove the nut, the clutch bell housing and the 

whole of the driven pulley assembly. 

N.B. 

THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING 

PULLEY MOUNTED. 


020565Y Flywheel lock calliper spanner 

Inspecting the clutch drum 

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

- Measure the inner diameter of the clutch bell. 


Clutch bell diameter/standard value 

Ø 107+0.2 +0 mm 

Clutch bell diameter/max. value allowed after 

use 

Ø 107.5 mm 

Eccentricity measured /max. 

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 put the central screw under stress. 

CAUTION 

THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW 

IS TIGHTENED UP TOO FAR. 



Engine 

- Using a 34 mm socket wrench remove the clutch 

locking nut. 

- Loosen the central screw thereby undoing the 

driven pulley unit 

- Separate the components. 


020444Y Tool for fitting/ removing the driven 

pulley clutch 

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. 


Check minimum thickness 

1 mm 

Pin retaining collar 

- Remove the collar with the aid of 2 screwdrivers. 



- Remove the three guide pins and the mobile half 

pulley. 

Removing the driven half-pulley bearing 

- Remove the roller bearing with the special extractor 

inserted from the bottom of the fixed halfpulley. 

CAUTION 

POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- 

ERS BETWEEN THE END OF THE BEARING AND THE 

BUILT IN SEALING RING. 


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 


020376Y Adaptor handle 

020363Y 20-mm guide 

Inspecting the driven fixed half-pulley 

- Check that there are no signs of wear on the work 

surface of the belt. If there are, replace the halfpulley.. 

- Make sure the bearings do not show signs of unusual 

wear. 

- Measure the external diameter of the pulley bushing. 




Engine 

Stationary driven half-pulley/Standard diameter 

Ø 33.965 to 33.985 mm 

Stationary driven half-pulley / Minimum diameter 

admitted after use 

Ø 33.96 mm 

Inspecting the driven sliding half-pulley 

- Remove the 2 inner sealing rings and the two O- 

rings. 

- Measure the inside diameter of the mobile halfpulley 

bushing. 


Mobile driven half-pulley/ Maximum diameter 

allowed 

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 Grease for the C-ring of 

the tone wheel 

Soap-based lithium grease containing NLGI 2 Molybdenum 

disulphide; ISO-L-XBCHB2, DIN 

KF2K-20 

- Make sure the pins and collar are not worn, reassemble the pins and collar. 

- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This 

operation must be done through one of the holes inside the bushing until grease comes out of the 

opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring. 


AGIP GREASE SM 2 Grease for the C-ring of the tone wheel 

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 



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. 



020456Y Ø 24 mm adaptor 

020362Y 12 mm guide 

020171Y Punch for Ø 17 mm roller case 

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 


Standard length 

118 mm 

Minimum length allowed after use 

113 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 bar. 



Engine 

- Reassemble the nut securing the clutch and tighten 

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 


Nut locking clutch unit on pulley 55 to 60 Nm 

Refitting the driven pulley 

-Refit the driven pulley assembly, the clutch bell 

and the nut, using the specific tool. 




Driven pulley shaft nut 40 to 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. 


Transmission belt/Minimum width 

17.5 mm 



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. 


020451Y Starting ring gear lock 

Mixer gears and belt 

- Remove gear and belt. 

CAUTION 

PAY PARTICULAR ATTENTION TO NOT TOUCHING OR 

BENDING THE BELT BECAUSE THIS COULD BREAK SUD- 

DENLY DURING OPERATION. 

CAUTION 

ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET 

INTO THE INNER BUSHING OF THE MIXER CONTROL 

GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON 

THE CRANKCASE PIN. 

N.B. 

REPLACE THE BELT EVERY 20000 KM. 

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. 



Engine 

4) Check the integrity of the sliding shoes of the 

contact plate. 

- Check that the internal bushing shown in the figure 

is not abnormally worn and measure inside 

diameter «A». 

- Measure outside diameter «B» of the pulley sliding 

bushing shown in the figure. 

CAUTION 

DO NOT LUBRICATE OR CLEAN THE BUSHING. 


Driving pulley / Maximum diameter: 

20.12 mm 

Driving pulley/ Standard diameter: 

20.021 mm 

Driving pulley bushing/ Diameter maximum: 

XXX mm 

Driving pulley bushing/ Standard diameter: 

20 -0.020/-0.041mm 

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 container 

assembly with bushing, limiting washer, stationary 

half-pulley, cooling fan belt with drive, 

washer and nut). 

- With the specific tool, tighten the lock nut to 20 

Nm and then perform a final 90° locking in order to 

prevent the rotation of the driving pulley. 

N.B. 

REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT 

CAUTION 

UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT- 

MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN 



ORDER TO AVOID WRONG TIGHTENING AND CONSE- 

QUENTLY DAMAGING THE CRANKSHAFT KNURLING. 


020451Y Starting ring gear lock 


Crankshaft pulley nut 18 to 20 + 90° Nm 

End gear 

Removing the hub cover 

• Remove the transmission cover 

• Remove the clutch assembly 

• Discharge the rear hub oil. 

• Remove the 5 screws indicated in the figure. 

• Remove the hub cover with driven pulley shaft. 

See also 

Refitting the clutch 

Removing the wheel axle 

- Remove the intermediate gear and the complete 

gear wheel axle. 

- When removing the intermediate gear pay attention 

to the various shim adjustments. 



Engine 

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. 




020358Y 37x40-mm Adaptor 

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. 


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. 






Inspecting the hub shaft 

- Check that the three shafts exhibit no wear or 

deformation on the toothed surfaces, at the bearing 

housings and at the oil guards. 

- In case of anomalies, replace the damaged components. 

- Check that the fitting surface is not dented or distorted. 

- If faults are found, replace the hub cover. 

Inspecting the hub cover 

- Check that the fitting surface is not dented or distorted. 

- If faults are found, replace the hub cover. 

Refitting the driven pulley shaft bearing 

- Support the inner track of the bearing from the 

outside of the hub cover with the specific tool positioned 

under the press and insert the driven pulley 

axle. 

- Refit the oil seal flush with the cover. 




• 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. 


020151Y Air heater 






Engine 

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. 






Refitting the ub cover 

- Refit the whole wheel axle. 

- Refit the intermediate gear paying attention to the 

two shim thicknesses. 

- Apply LOCTITE 510 for surfaces to the hub covers 

and refit the same with driven pulley shaft. 

- Refit the 5 screws and tighten them to the specified 

torque. 

N.B. 

CLEAN THE CONTACT SURFACES OF THE HUB COVER 

AND THE HALF CRANKCASE OF RESIDUE FROM PREVI- 

OUS GASKETS BEFORE APPLYING A NEW ONE. 


Locking torque: 11 to 13 Nm 

Flywheel cover 



Cooling hood 

- Remove the four fixings shown in the figure. 

- Remove the fan cover 

- Remove the oil piping retention band from the 

hood 

- Remove the 2 screws shown in the figure 

Cooling fan 

- Remove the cooling fan by acting on the three 

fixings indicated in the figure. 



Engine 

Removing the stator 

- Remove the three stator fixings shown in the 

photo 

- Remove the two pick-up fixings shown in the 

photo 

- Remove the stator with the wiring 

Refitting the stator 

- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to 

the specified torque. 

N.B. 

THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE 

CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM- 

BLY. 


Pick-up screws 3 to 4 Stator screws 3 to 4 

Flywheel and starting 

Removing the starter motor 

• Remove the center stand by unscrewing 

the four clamping screws (two per 

side) of the engine block 

• R 

emove the two clamps shown in the figure 



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. 



020162Y Flywheel extractor 

Inspecting the flywheel components 

- Check the condition of the flywheel and any distortions 

that might cause rubbing on the stator and 

on the Pick-Up. 



Engine 

Refitting the flywheel magneto 

- Fit the flywheel being careful to insert the key 

properly. 

- Lock the flywheel nut at the prescribed torque 

- Check the Pick-Up air gap. 

- The air gap may not be modified in the fitting of 

the Pick-Up. 

- Other values derive from deformations visible on 

the Pick-Up support. 

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. 


Flywheel nut 40 to 44 N.m 

Refitting the starter motor 

- Fit a new O-ring on the starter and lubricate it. 

- Fit the starter motor on the crankcase and lock 

the 2 screws to the prescribed torque. 

N.B. 

REFIT THE REMAINING PARTS AS DESCRIBED IN THE 

CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL 

AND TRANSMISSION CHAPTERS. 


Starter screws 11 to 13 

Cylinder assy. and timing system 

Removing the intake manifold 

Use an anti-tampering TORX spanner to remove 

the two clamping screws of the intake manifold 



Removing the cylinder head 

Remove the 4 screws shown in the figure 

Removing the cylinder - piston assy. 

Remove the cylinder very carefully 

Remove the snap rings and remove the pin 

CAUTION 

AFTER EACH REMOVAL OPERATION REPLACE THE PIN 

RETENTION SNAP RINGS 



Engine 

Inspecting the small end 

- Measure the internal diameter of the small end 

using an internal micrometer. 

N.B. 

IF THE DIAMETER OF THE CONNECTING ROD SMALL 

END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, 

SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE 

THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE 

AND CRANKSHAFT" CHAPTER". 


Rod small end: standard diameter 

17 +0.011-0.001 

Rod small end: maximum allowable diameter 

17,060 mm 

Inspecting the wrist pin 

- Check the wrist pin external diameter using a micrometer 


Wrist pin: standard diameter 

12 +0.005 +0.001 mm 

Inspecting the piston 

- Measure the bearings on the piston using a bore 

meter 

- Calculate the piston-pin coupling clearance. 


Wrist pin housing: standard diameter 

12 +0.007 +0.012 

Wrist pin housing: standard clearance 

0.002 ÷ 0.011 mm 



- Measure the outer diameter of the piston, perpendicular 

to the pin axis. 

- Take the measurement in the position shown in 

the figure 

To classify the cylinder-piston fitting, check the appropriate 

table 

See also 


Inspecting the cylinder 

- Check that the cylinder does not show seizures. 

Otherwise, replace it or adjust it respecting the allowable 

increases 

- Measure the internal diameter of the cylinder with 

a bore meter, according to the directions given in 

the figure 

- Check that the fitting surface with the head is not 

dented or distorted. 

To classify the cylinder-piston fitting, check the appropriate 

table 

See also 


Inspecting the piston rings 

- Alternatively insert the two sealing rings in the 

cylinder 

Using the piston, insert the seals perpendicularly 

to the cylinder axis. 

- Measure the opening of the sealing rings using a 

thickness gauge as shown in the photograph 

- If the values are higher than the values prescribed 

in the chart, substitute the rings 



Engine 

Removing the piston 

- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool. 

-Push detail 2 into detail 1 until the stop and extract detail 2. 

- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3 

all the way in. 

N.B. 

REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM 

THE REMOVAL OPERATIONS 


020166Y Pin lock fitting tool 


Locking head nuts: 10 to 11 N·m 

- Use new wrist pin snap rings. 

- Use new cylinder base gasket. 

- Before refitting carefully clean all the surfaces. 

- Use oil to be mixed during the fitting of the piston 

and the cylinder. 

CAUTION 

POSITION THE ARROW PRINTED ON THE PISTON 

CROWN TOWARDS THE EXHAUST OPENING. 

THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON 

THE PISTON WITH THE SPECIFIC TOOL 


AGIP CITY TEC 2T Oil 

Recommended oil 



Inspecting the timing system components 

CAUTION 

CHECK THE CORRECT REED UNIT SEAL; NO LIGHT 

MUST PASS BETWEEN THE SUPPORT AND LAMELLA. 

Crankcase - crankshaft 

Splitting the crankcase halves 

Remove the eight crankcase union fasteners. 



Engine 

Install the special strip on the half crankcase on 

the flywheel side and separate the half crankcase 

on the flywheel side from the transmission side 


020163Y Crankcase splitting plate 

Removing the crankshaft 

- Install the specific tool on the half crankcase on 

the transmission side using four M6 screws of an 

adequate length. 

- Remove the crankshaft from the transmission 

side half crankcase 



Removing the crankshaft bearings 

The bearings can stay on either the half crankcase 

or the crankshaft indifferently 

- Using the special tool, remove any bearings that 

have been left on the crankshaft 

N.B. 

The half rings must be inserted on the bearings with a few mallet 

blows. 


004499Y001 Bearing extractor bell 

004499Y006 Bearing extractor ring 

004499Y002 Bearing extractor screw 

004499Y007 Half rings 



- Using the specific tool remove any bearings left 

on the half crankcase 


001467Y007 Driver for OD 54 mm bearing 

001467Y006 Pliers to extract 20 mm bearings 

Refitting the crankshaft bearings 

Heat the bearings in an oil bath at around 150°C 

and fit them on the crankshaft, if necessary using 

a section of tube that acts on the bearing's inner 

track 


020265Y Bearing fitting base 

Inspecting the crankshaft alignment 

With the specific tool shown check that the eccentricity 

of the surfaces of diam. «A»-«B»-« C» are 

within 0.03 mm. (reading limit on the dial gauge); 

in addition, check the eccentricity of diam. «D», for 

which a maximum reading of 0.02 mm is permitted. 

In the case where eccentricity is not much above 

prescribed levels, straighten the shaft by acting 

on the counterweights with a shim or tighten them 

in a clamp (with an aluminium bushing) as required.. 


020335Y Magnetic mounting for dial gauge 

020074Y Support base for checking crankshaft 

alignment 



Engine 

Refitting the crankshaft 

- Position the transmission side half crankcase on 

two wooden supports 

- Using a thermal gun, heat the bearing seat to 

about 120° 

- Firmly insert the crankshaft until the bearing reaches 

the end-of-stroke stop 

- Let the temperature of the half crankcase settle 

at the temperature of the crankshaft. 

- Again install the special crankcase separation 

plate NOT installing the crankshaft protection 

- During the assembly phase keep the central 

thrust screw loose. 

- Take the four clamping screws to the end of the 

stroke and loosen them again with the same angle 

(e.g. 90°) 

- When the temperature has settled, preload the 

thrust screw of the tool manually until the ball bearing 

clearance is cancelled out. 





Refitting the crankcase halves 

- Prepare the coupling surface with LOCTITE 510 

applying a thin layer of it after degreasing the surface 

using a suitable solvent (e.g. trichloroethylene) 

- Heat the flywheel-side half crankcase with a thermal 

gun. 


Loctite 510 Liquid sealant 

Gasket 

- Keeping the half crankcase on the transmission 

side, insert the flywheel side half crankcase with a 

clean precise movement 

- Insert at least three clamping screws and tighten 

up rapidly 

- Insert the other 5 screws and tighten them to the 

specified torque. 


crankcase coupling screws 11 - 13 

- Move the crankcase separation plate in a position 

back from the one indicated in the figure 

- Install the special magnetic support with dial 

gauge at the end of the crankshaft 

- Check the axial clearance of the crankcase 

If this is not within the maximum limit allowed, repeat 

the crankcase coupling procedure 




Axial clearance with warm crankcase 

0.10 ÷ 0.12 mm 

Axial clearance with cold crankcase 

0.06 to 0.08 mm 

Limit value with cold crankcase 

0.02 ÷ 0.03 mm 



Engine 

Lubrication 

Crankshaft oil seals 

Refitting 

- Install a new flywheel-side oil seal only with the 

special tool's punch 

The flywheel-side oil seal is recognised by its 

smaller diameter 

N.B. 

THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE 

WITH THE FITTED WRENCH 


020340Y Flywheel and transmission oil seals 

fitting punch 

- Install a new transmission side oil seal using the 

special tool with adapter ring. 

The transmission-side oil seal is recognised by the 

larger diameter 


020340Y Flywheel and transmission oil seals 

fitting punch 

Oil pump 

Removal 

- Remove the 2 screws shown in the figure 



Remove the tube passage seal from the crankcase 

shown in the figure 

Refitting 

To refit, perform the steps in the reverse direction 

to disassembly 

Remember to drain after refitting using the screw 

shown in the figure 

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. 

- By means of the MITYVAC pump apply 0.1 bar 

of suction to the tap. 

- Make sure that the suction is kept stable and that 

and that there are no fuel leaks. 

- Reconnect the vacuum pipe to the manifold. 

- 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 



Engine 

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. 


020329Y Mity-Vac vacuum-operated pump 


Minimum flow rate 

20 cc 

- Completely empty the fuel tank. 

- Remove the petrol delivery pipe and the lowpressure 

pipe. 

- Loosen the clip and remove the cock. 

- Clean the tank and the filter of the cock with a 

specific solvent. 

- Refit the cock making sure that there is an 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. 



SUSPENSIONS 

SUSP


Suspensions 


This section is dedicated to operations that can be carried out on the suspensions. 

Front 

Removing the front wheel 

- Support the vehicle in such a way that the front 

wheel is raised. 

- Using two 18 mm hexagonal wrenches remove 

the front wheel axle. 

Refitting the front wheel 

- When refitting, pay attention in repositioning the 

odometer drive correctly. 


Wheel fixing nut 40 to 50 N.m 

Handlebar 

SUSP - 89

Suspensions Typhoon 50 

Removal 

- Remove the front handlebar cover. 

- Remove the rear handlebar cover. 

- After removing the transmissions and disconnecting 

the electrical terminals, remove the bolt 

«A» and the handlebar 

- Check all components and replace faulty parts. 

N.B. 

IF THE HANDLEBAR IS BEING REMOVED TO REMOVE 

THE STEERING, TILT THE HANDLEBAR FORWARD TO 

AVOIDING DAMAGING THE TRANSMISSIONS. 

Refitting 

When refitting, tighten to the prescribed torque and 

apply the recommended grease to the threaded 

cone. 


AGIP GREASE PV2 Grease for control levers 

on the engine 

White anhydrous-calcium based grease to protect 

roller bearings; temperature range between -20 ° 

C and +120 °C; NLGI 2; ISO-L-XBCIB2 


Locking torque: 65 to 70 N•m 

Front fork 

Removal 

- Remove the front brake calliper. 

- Remove the odometer cable from the reduction 

gear box. 

- Remove the front mudguard. 

- Remove the handlebar. 

After removing the steering ring-nut using the special 

tool, lean the vehicle on one side and extract 

the steering tube. 


020055Y Wrench for steering tube ring nut 

SUSP - 90


Suspensions 

See also 

Handlebar 

Front 

brake calliper 

Overhaul 

Stem removal 

- Remove the dust guard (1) using a screwdriver 

to prise it out. 

- Remove the seeger (2) and remove the power 

pipe. 

N.B. 

GREASE THE SPRINGS AND THE BUSHINGS BEFORE 

REFITTING, WITH A SMALL QUANTITY OF GREASE 

(AROUND 3 GR.) 


AGIP GREASE MU3 Grease for odometer 

transmission gear case 

Soap-based lithium grease with NLGI 3; ISO-L- 

XBCHA3, DIN K3K-20 

Removing damper 

- Remove screw 1 fixing the screw to the stem and 

remove the stanchion heating it if necessary with 

the specified heater, then remove sealing ring 2 

and seeger 3. 

- Using nut 4, remove the spring stem and bushing. 

The damper is an integral part of the stem and 

cannot therefore be overhauled, so if you need to 

work on the damper (loss of fork oil), carry out the 

operations mentioned above and replace the 

shock absorber-stem unit. 

When refitting, tighten to the prescribed torque and 

apply the recommended grease to the threadlock 

nut. 


020150Y Air heater mounting 



SUSP - 91


Loctite 243 Medium strength threadlock 

Medium Loctite 243 threadlock 


Stud-stanchion fixing screw 20 to 25 N•m Nut 

tightening torque 20 to 25 N•m 

Replacing sealing ring 

- Remove the wheel axle. 

- Remove the screw (4). 

- Remove the stanchion (3). 

- Remove the dust guard (1). 

- Insert the new sealing ring after lubricating the 

inside parts of the ring and paying attention not to 

damage it. 

- Insert the stanchion appIying the recommended 

product to the clean surface. 

- Lock the screw (4). 


Loctite 243 Medium strength threadlock 

Medium Loctite 243 threadlock 

Refitting 

Lubricate the seats and the balls with the grease 

recommended. 

- Lock at the prescribed torque and turn the key 

anticlockwise by 90° to 100°. 




AGIP GREASE PV2 Grease for control levers 

on the engine 

White anhydrous-calcium based grease to protect 

roller bearings; temperature range between -20 ° 

C and +120 °C; NLGI 2; ISO-L-XBCIB2 


Locking torque: 50 to 60 Nm 

SUSP - 92


Suspensions 

Steering column 

Removal 

Removal of the upper and lower frame seat 

- Only remove the seats if it is strictly necessary. 

- Using the special tool remove the upper fifth 

wheel seat by putting the special tool into the lower 

part of the headstock as indicated in the figure. 

- By inserting the punch into the top of the tube, 

remove the lower fifth wheel seat from the headstock. 


020004Y Punch for removing steering bearings 


Refitting 

Refitting the lower and upper seat on the frame 

- Using the special tool, refit the upper and lower 

bearing seats on the headstock. 


001330Y Tool for fitting steering seats 

Steering bearing 

Removal 

Removing steering lock nut 

SUSP - 93


- Remove the handlebar. 

- Remove the bearing of steering ring nut using the 

specific tool. 



See also 

Handlebar 

Overhauling the fifth wheel seat on the fork 

Check the condition of the fifth wheel and the fifth 

wheel seat on the fork (steering tube). Replace if 

there are faults. 

- Support the fork properly. 

- Using the special tool, remove the fifth wheel seat 

on the steering tube as shown in the photograph 

by applying small mallet blows. 


020004Y Punch for removing steering bearings 


Always use a new fifth wheel seat on refitting. 

- Using the special tool, refit the fifth wheel seat 

with the aid of a few mallet blows and bring it as 

far as the stop shown in the photo. 


006029Y Punch for fitting fifth steering bearing 

on steering tube 

Refitting 

Refitting steering lock ring nut 

- After locking the first ring nut in place, lock the 

second ring nut using a specific tool. 


SUSP - 94


Suspensions 



Locking torque: 30 to 40 Nm 

Rear 

Removing the rear wheel 

- Use a screwdriver as a lever between the drum 

and the cover. 

-Straighten the split pin and remove the cap. 

-Remove the wheel acting on the central fixing 

point. 

WARNING 

-ALWAYS USE NEW SPLIT PINS FOR REFITTING. 

Removal 

To replace the shock absorber you just need to 

remove the battery access flap to get and remove 

the shock absorber/ frame anchorage nut. Then 

remove the shock absorber/engine anchorage 

nut. 

Refitting 

When refitting, tighten the shock absorber/frame anchorage nut and the shock absorber/engine pin at 

the prescribed torque. 

SUSP - 95



Shock absorber/chassis nut torque 20 to 25 Nm Shock absorber/engine pin torque 33 to 41 N·m 

Centre-stand 

Expulsion of stand fastening pin to the bracket 

- Remove the stand support bracket from the engine. 

- Drill a 5 mm hole in the bracket so that the pin 

«P» can come out. 

Fitting and caulking the stand pin to the bracket 

- Caulk the end of the pin «P» between the two 

punches shown in the figure. 

- After caulking it must be possible for the stand to 

turn freely. 

N.B. 

UPON REFITTING USE NEW O-RING AND PIN, GREASE 

THE SPRING ATTACHMENTS AND THE PIN. 

Replace complete stand 

- Work on the screws shown in the figure. 

- When refitting, secure to the prescribed torque. 


Stand screw torque 18.5 to 19 Nm 

SUSP - 96


BRAKING SYSTEM 

BRAK SYS

Braking system Typhoon 50 

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/on 

the components of the system, it is 

necessary to replace them. 

• - Disconnect the oil line from the calliper, 

collecting the oil in a container. 

• - Remove the two clamps highlighted 

in the diagram. 

Overhaul 

CAUTION 

• Disconnect the oil line from the calliper 

and collect the brake fluid in a suitable 

container. 

• Remove the brake calliper from the 

fork. 

• Exerting leverage on the floating body, 

remove the external brake pad, then 

the internal one, and lastly the retention 

spring. 

• Remove the piston and make sure that 

there is no scoring or erosion. If there 

is, replace the pincer. 

ALL THE INTERNAL COMPONENTS MUST BE REPLACED 

EVERY TIME THE CALLIPER IS SERVICED. 

BRAK SYS - 98



• Insert the sealing rings and the pistons 

in the calliper body 

• Check the state of the floating body 

seats and grease them. 

• Refit the pads 

• - Position the calliper on the disc and 

lock to the mounting by tightening the 

bolts. 

• Lock the piping fitting on the calliper at 

the prescribed torque and bleed the air 

from the system. 

Before fitting, the parts must be perfectly clean and 

free of traces of oil, diesel fuel, grease, etc.. 

They should be washed thoroughly in denatured 

alcohol before proceeding. 

The sealing rings must be immersed in the operating 

liquid; the use of the PRF1 protection is 

tolerated. 

CAUTION 

RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL 

FOR LONGER THAN 20 SECONDS. 

AFTER WASHING, THE PIECES MUST BE DRIED WITH A 

BLAST OF COMPRESSED AIR AND A CLEAN CLOTH. 


Calliper coupling screw 20 to 25 Nm Oil bleed 

screw 7 to 10 Nm 

Refitting 

• Refit the pincer on the support and 

tighten the screws at the prescribed 

torque. 

• Refit the tube complete with fitting with 

new copper gaskets. 

• Bleed the air from the system. 


Brake fluid tube calliper 20 ÷ 25 Fastening 

screws calliper to the crankcase 20 - 25 Oil bleed 

screw 7 to 10 Nm 

BRAK SYS - 99


Front brake disc 

Removal 


- Remove the front wheel 

- Undo the three disc clamping screws. 

Refitting 

-When refitting, position the disc correctly making sure that it rotates in the right direction. 


Disc tightening screw 8 - 12 

Disc Inspection 

• Use the micrometer to check the thickness 

of the disc as shown in the photograph 


Standard thickness: 

4 +02-01mm 

• Using the appropriate tool, measure 

how much the disc protrudes when the 

wheel is fitted properly. The protrusion, 

measured near the external edge of 

the disc, must be less than 0.1 mm. 

• If a value is measured other than the 

specified value, remove the front wheel 

(Front/Rear Suspension chapter) and 

check the protrusion of the disc. Maximum 

permissible out of true is 0.1 mm. 

BRAK SYS - 100



If the value measured is greater, replace 

the disc and repeat the check. 

• If the problem persists, check and replace 

the wheel hub if necessary. 



Front brake pads 

Removal 

• Remove the brake calliper from the 

fork. 

• Exert leverage on the floating body and 

remove the outer pad. 

• Then remove the internal pad by exerting 

pressure on the retention spring. 

The pads must be replaced if the friction material 

lining is less than 1.5 mm 

BRAK SYS - 101


Refitting 

Follow the steps in the opposite order from the removal, 

making sure the retention spring is inserted 

properly. 

Fill 

BRAK SYS - 102



Front 

-Once the bleed valve is closed, fill the system with 

brake liquid to the maximum level. 

-Undo the bleed screw. 

-Apply the tube of the special tool to the bleed 

screws. 

When bleeding it is necessary to fill the oil tank in 

continuation while working with a MITYVAC pump 

on the bleed screws until no more air comes out of 

the system. 

The operation is finished when just oil comes out 

of the bleed screws. 

-Do up the bleed screw. 

-When the operation is over, tighten up the oil 

bleed screw to the prescribed torque. 

N.B. 

IF AIR CONTINUES TO COME OUT DURING PURGING, 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. 


020329Y Mity-Vac vacuum-operated pump 


BRAK SYS - 103


AGIP BRAKE 4 Brake fluid 

FMVSS DOT 4 Synthetic fluid 


Oil bleed screw 8 - 12 

Front brake pump 

-After removing the front and rear handlebar covers, act on the two stand fixing points (see the figure). 

- Disconnect the tube, collecting the brake oil in a container. 

- On refitting, perform the operation in reverse. 

- Tighten the hydraulic line to the prescribed torque 

and bleed the system. 


Brake fluid pump - hose fitting 20 ÷ 25 Nm 

Rear drum brake 

Drum brake adjustment 

Regulate the point where the rear drum brake intervenes, 

using the adjustment indicated in the 

figure. 

With the brake lever at rest, the wheel must turn 

freely. 

Drum brake removal 

After removing the muffler and the rear wheel do 

the following: 

1. Remove the shoe spring with the special tool 

2. Remove the shoe with the aid of a lever 

3. Refit the new shoes giving a few taps with 

the mallet 

4. Fasten the spring using the special tool. 

BRAK SYS - 104


CHASSIS 

CHAS

Chassis Typhoon 50 

Rear handlebar cover 

• Rimuovere la copertura manubrio anteriore. 

• Rimuovere le tre viti indicate in figura. 

• Rimuovere la connessione al cavo tachimetro. 

• Disconnettere i connettori degli interruttori 

e del quadro strumenti. 

Per il montaggio seguire i passi in sequenza inversa. 

Front handlebar cover 

• Rimuovere gli specchietti. 

• Rimuovere le due viti indicate in figura. 

• Facendo leva verso l'alto e agendo sugli 

incastri laterali, distaccare la copertura 

anteriore da quella posteriore. 

• Disconnettere i cablaggi degli indicatori 

di direzione. 

Per il montaggio seguire i passi in sequenza inversa 

facendo attenzione al corretto inserimento 

degli incastri. 

Headlight assy. 

• Rimuovere le due viti indicate in figura. 

• Spingere il gruppo ottico attraverso il 

foro per la regolazione dell'altezza del 

fascio luminoso come mostrato in figura. 

• Rimuovere la connessione elettrica. 

CHAS - 106


Chassis 

Frame central cover 

• Remove the 3 fixing screws located 

under the saddle as shown in the figure. 

• Remove the cover by pulling it off the 

lower fittings. 

For installation, reverse the removal sequence. 

Legshield 

• Rimuovere il gruppo ottico anteriore. 

• Rimuovere le 7 viti indicate in figura. 

• Rimuovere le 2 viti nel vano ruota anteriore. 

• Sfilare dagli incastri inferiori lo scudo 

anteriore. 



degli incastri inferiori dello scudo. 

Knee-guard 

• Rimuovere le 2 viti di fissaggio del 

gruppo ottico anteriore. 


• Sfilare dagli incastri inferiori il controscudo 

anteriore. 



degli incastri inferiori. 

CHAS - 107


Taillight assy. 

Per la sostituzione della lampada è sufficiente rimuovere 

le due viti indicate in figura, quindi sfilare 

il cristallo del fanalino. 

Per lo smontaggio del gruppo ottico copmpleto è 

necessario: 

• Rimuovere le due placche centrali sopra 

e sotto il fanalino agendo sulle 4 viti 

di fissaggio. 

• Rimuovere le fiancate laterali. 

• Rimuovere il gruppo ottico completo 

agendo sulle due viti di fissaggio. 

Footrest 

• Rimuovere la copertura centrale telaio. 

• Rimuovere il controscudo. 

• Rimuovere le 4 viti indicate in figura e 

facendo leva sugli incastri rimuovere la 

pedana. 

CHAS - 108


Chassis 

Side fairings 

• Rimuovere lo spoiler posteriore. 

• Rimuovere le due placche centrali sopra 

e sotto il fanalino agendo sulle 4 viti 

di fissaggio. 

• Rimuovere la copertura centrale telaio. 

• Rimuovere le 8 viti di fissaggio (4 per 

lato) indicate in figura. 

CHAS - 109


• Rimuovere la connessione elettrica 

degli indicatori di direzione. 

Per il montaggio seguire i passi in sequenza inversa. 

Rear mudguard 



• Rimuovere la connessione elettrica del 

gruppo ottico posteriore, quindi sfilare 

il parafango. 

CHAS - 110


Chassis 

Helmet bay 

• Rimuovere la sella. 

• Rimuovere la copertura centrale. 


• Rimuovere la batteria e sfilare dalla relativa 

sede il portafusibile. 

• Rimuovere tappo serbatoio carburante, 

tappo serbatoio olio e relativa 

gomma di tenuta. 

• Rimuovere le tre viti e sfilare il vano 

portacasco. 


Fuel tank 


• Rimuovere il vano portacasco. 

• Rimuovere il parafango posteriore. 

• Disconnettere il tubo del carburante e 

il tubo di depressione per la valvola 

carburante. 

• Disconnettere il cablaggio elettrico 

dell'indicatore di livello del carburante 

CHAS - 111


• Rimuovere le tre viti indicate in figura e 

sfilare da sotto il telaio il serbatoio 

Mixture oil tank 

• Rimuovere la fiancata laterale destra. 

• Disconnettere il tubo olio facendo attenzione 

a raccogliere l'olio residuo nel 

serbatoio con un apposito recipiente. 

• Disconnettere il cablaggio elettrico al 

sensore livello olio. 

• Rimuovere le 2 viti di fissaggio del serbatoio 

olio. 


CHAS - 112


PRE-DELIVERY 

PRE DE

Pre-delivery Typhoon 50 

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: 

- Main switch 

- Headlamps: high beam, low beam, position and parking lights and the respective warning lights 

- Adjusting the headlights according to the regulations currently in force 

- Rear light, parking light, stop light 

- Front and rear stop light switches 

- Turn indicators and their warning lights 

- Instrument panel lights 

- Instrument panel: fuel and temperature indicator 

- Instrument panel warning lights 

- Horn 

- Starter 

PRE DE - 114


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 - 115

Pre-delivery Typhoon 50 

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 - 116


TIME 

TIME

Time Typhoon 50 

This section is devoted to the time necessary to 

carry out repairs. 

The description and code for each operation is indicated. 

Engine 


Code Action Duration 

1 001001 Engine to chassis - Replacement 

TIME - 118


Time 

Crankcase 

CRANKCASE 


1 001133 Engine crankcase - Replacement 

TIME - 119


Crankshaft 

CRANKSHAFT 


1 001117 Crankshaft - Replacement 

2 001118 Main bearings - Replacement 

3 001099 Flywheel-side oil seal - Replacement 

4 001100 Clutch-side oil seal - Replacement 

TIME - 120


Time 

Cylinder assy. 

CYLINDER / PISTON 


1 001002 Cylinder / Piston - Replacement 

2 001107 Cylinder / piston - Inspection / cleaning 

TIME - 121


Cylinder head assy. 

CYLINDER HEAD ASSEMBLY 


1 001013 Intake manifold - Replacement 

2 001093 Spark plug - Replacement 

3 001126 Head - Replacement 

4 001097 Cooling hood - Replacement 

5 001178 Disc pack - Replacement 

6 001087 Flywheel cover - Replacement 

TIME - 122


Time 

Driven pulley 

DRIVEN PULLEY 


1 001110 Driven pulley- Replacement 

2 001022 Clutch - Replacement 

3 001155 Clutch bell - Replacement 

4 001012 Driven pulley - overhaul 

TIME - 123


Oil pump 

OIL MIX PUMP 


1 001018 Mixer - Replacement 

2 001019 Mixer belt - replacement 

3 001028 Mix movement gear socket - Replacement 

TIME - 124


Time 

Final gear assy. 

FINAL REDUCTION GEAR 


1 001010 Geared reduction unit - Service 

2 001156 Gear reduction unit cover - Replacement 

3 003065 Gear box oil - Replacement 

4 004125 Rear wheel axle - Replacement 

TIME - 125


Driving pulley 

DRIVING PULLEY 


1 001011 Driving belt - Replacement 

2 001066 driving pulley - Replacement 

3 001017 Start-up pinion - Replacement 

4 001086 Driving half-pulley - replace 

5 001177 CVT rollers / sliders - Replacement 

TIME - 126


Time 

Transmission cover 

TRANSMISSION COVER 


1 001096 Transmission crankcase cover - Replacement 

2 001131 Transmission air intake - Replacement 

3 001135 Transmission cover bearing - Replacement 

4 004179 Stand bumper - Replacement 

TIME - 127


Starter motor 

STARTER MOTOR AND KICK STARTER 


1 001020 Starter motor - Replacement 

2 001021 Kick starter - Inspection 

3 001084 Starter lever - Replacement 

4 008008 Starter spring pack - Replacement 

5 005045 Starter motor cable assembly - Replacement 

TIME - 128


Time 

Flywheel magneto 

MAGNETO FLYWHEEL 


1 001058 Flywheel - Replacement 

2 001067 Stator - Replacement 

3 001173 Rotor - Replacement 

4 001109 Cooling fan - Replacement 

TIME - 129


Brake shoes 

BRAKE SHOES 


1 002002 Rear brake shoe(s) - Replacement 

TIME - 130


Time 

Carburettor 

CARBURETTOR INSPECTION 


1 001081 Automatic choke - Replacement 

2 001008 Carburettor - Inspection 

TIME - 131


CARBURETTOR 


1 001063 Carburettor - Replacement 

2 003058 Carburettor - Adjustment 

3 004177 Heating hood - Replacement 

Exhaust pipe 

MUFFLER 


1 001009 Silencer - Replacement 

2 001095 Silencer heatshield - Replacement 

3 001136 Exhaust emissions - Adjustment 

TIME - 132


Time 

Air cleaner 

AIR FILTER 


1 001014 Air filter - Replacement / cleaning 

2 001015 Air filter box - Replacement 

3 004122 Air cleaner carburettor fitting - Replacement 

TIME - 133


Frame 

CHASSIS 


1 001053 Stand pin - Replacement 

2 004004 Stand - Replacement 

3 004001 Chassis - Replacement 

4 004015 Footrest - Replacement 

5 004171 Stand support plate - Replacement 

6 004143 Footrest support - Replacement 

TIME - 134


Time 

Legshield spoiler 

FRONT SHIELD 


1 004064 Legshield - Replacement 

2 004065 Front shield rear section - Replacement 

3 004178 Footrest - Replacement 

4 004053 Spoiler - Replacement 

TIME - 135


Side fairings 

CHASSIS REAR COVER 


1 004011 Central chassis cover - Replacement 

2 004085 Fairing (1) - Replacement 

3 004012 Rear side panels (2) - Replacement 

4 004096 Lock series - Replacement 

TIME - 136


Time 

Underseat compartment 

HELMET COMPARTMENT 


1 004016 Helmet compartment - Replacement 

2 005046 Battery cover - change 

TIME - 137


Plate holder 

LICENSE PLATE 


1 004136 License plate holder mounting - Replacement 

2 004056 Upper rear light cover - Replacement 

3 005048 number plate holder - Replacement 

TIME - 138


Time 

Mudguard 

REAR MUDGUARD 


1 004009 Rear mudguard - Replacement 

Fuel tank 

TIME - 139


FUEL TANK 


1 004005 Fuel tank - Replacement 

2 005010 Tank float - Replacement 

3 004072 Fuel filter - Replacement 

4 004139 Fuel no return valve - Replacement 

5 004112 Cock / carburettor hose - Replacement 

6 004109 Fuel tank breather - change 

Tank oil 

OIL TANK 


1 004017 Oil reservoir - Replacement 

2 005018 Oil reservoir float - Replacement 

3 004095 Oil reservoir cock - Replacement 

4 004091 Oil reservoir hose - Replacement 

TIME - 140


Time 

Rear shock-absorber 

REAR SHOCK ABSORBER 


1 003007 Rear shock absorbers - Replacement 

TIME - 141


Steering column bearings 

STEERING BEARING 


1 003002 Steering bearing - Replacement 

2 003073 Steering clearance - Adjustment 

3 004119 Steering Bearing / upper steering fifth 

wheel - Replacement 

TIME - 142


Time 

Handlebar components 

HANDLEBAR COMPONENTS 


1 002071 Left hand grip - Replacement 

2 002037 Brake or clutch lever - Replacement 

3 005017 Stop switch - Replacement 

TIME - 143


HANDLEBAR COMPONENTS 


1 004066 Driving mirror - Replacement 

2 003001 Handlebar - Replacement 

3 005017 Stop switch - Replacement 

4 002037 Brake or clutch lever - Replacement 

5 002059 Right hand grip - Replacement 

TIME - 144


Time 

Swing-arm 

SWINGING ARM 


1 001072 Engine / frame swinging arm fitting - 

Replacement 

TIME - 145


Seat 

SADDLE 


1 004003 Saddle - Replacement 

TIME - 146


Time 

Instrument panel 

INSTRUMENT PANEL AND HANDLEBAR COVER 


1 005014 Odometer - Replacement 

2 004018 Handlebar front section - Replacement 

3 004019 Handlebar rear section - Replacement 

4 005078 Odometer glass - Replacement 

5 005076 Clock / Cell - Replacement 

TIME - 147


Turn signal lights 

FRONT HEADLAMP 


1 005067 Front turn indicator bulb - Replacement 

2 005008 Headlight bulbs - Replacement 

3 005002 Front headlamp - Replacement 

4 005091 Turn indicator glass - Replacement 

5 005012 Front turn indicator - Replacement 

TIME - 148


Time 

REAR LIGHT 


1 005022 Rear turning indicators - Replacement 

2 005068 Rear turning indicator bulb - Replacement 

3 005091 Turn indicator glass - Replacement 

4 005028 Rear light assembly glass - Replacement 

5 005066 Rear light bulbs - Replacement 

6 005005 Taillight - change 

TIME - 149


Front wheel 

FRONT WHEEL 


1 002041 Front brake disc - Replacement 

2 003040 Front wheel bearings - Replacement 

3 003037 Front wheel rim - Replacement 

4 003047 Front tyre - Replacement 

5 004123 Front wheel - Replacement 

6 003038 Front wheel axle - Replacement 

7 002011 Odometer movement sensor - Replacement 

Grease tone wheel or drive 

Please take note that the code has been introduced: 

900001 - Tone wheel / drive greasing - 15'. 

Never mistake the codes 002011 (movement sensor 

replacement) and 005089 (tone wheel replacement) 

in the event of noise of the indicated 

components. The grease recommended is TUTE- 

LA MRM 2 (soap-based lithium grease with Molybdenum 

disulphide). 

In the following points we indicate with an arrow 

the area to be greased (1 - Drive, 2 - Tone wheel) 

TIME - 150


Time 

Rear wheel 

REAR WHEEL 


1 001071 Rear wheel rim - Replacement 

2 001016 Rear wheel - Replacement 

3 004126 Rear wheel tyre - Replacement 

TIME - 151


Electric devices 

BATTERY 


1 005007 Battery - change 

2 005024 Battery fuse - Replacement 

3 005025 Fuse holder - Replacement 

4 005011 Starter relay - Replacement 

TIME - 152


Time 



1 001023 Control unit - Replacement 

2 001094 Spark plug cap - Replacement 

3 005001 Electrical system - Replacement 

4 005009 Voltage regulator - Replacement 

TIME - 153


Electronic controls 

ELECTRIC CONTROLS 


1 005041 Starter button - Replacement 

2 005040 Horn button - Replacement 

3 005016 Key switch - Replacement 

4 004096 Lock series - Replacement 

5 004010 Antitheft lock - replace 

6 005003 Horn - Replacement 

7 005006 Light or turning indicator switch - Replacement 

8 005039 Lights switch - Replacement 

9 005077 Emergency stop switch - Replacement 

TIME - 154


Time 

Transmissions 

SPLITTER 


1 002012 Splitter - Replacement 

2 002058 Mix / splitter transmission complete - 

Replacement 

3 002057 Carburettor / splitter transmission 

complete - Replacement 

4 002054 Throttle or splitter transmission complete 

- Replacement 

TIME - 155


REAR BRAKE TRANSMISSION AND ODOMETER 


1 002051 Odometer transmission assembly - 

Replacement 

2 002053 Rear brake transmission complete - 

Replacement 

TIME - 156


Time 


FORK 


1 003010 Front suspension - Service 

2 003051 Complete fork - Replacement 

3 003048 Fork oil seal - Replacement 

4 003041 Fork stanchion - Replacement 

TIME - 157



FRONT BRAKE 


1 002103 Brake fluid reservoir - Replacement 

2 002052 Front brake transmission - Replacement 

3 002025 Brake piping - Replacement 

4 002021 Front brake piping - Replacement 

5 002039 Front brake calliper - Replacement 

6 002024 Front brake pump - replace 

TIME - 158

A 

Air filter: 28 

B 

Battery: 36, 43, 51, 52 

Brake: 91, 98, 100, 101, 104, 130 

C 

Carburettor: 9, 131 

Checks: 46 

E 

Electric: 152 

Engine stop: 

F 

Fuel: 35, 86, 111, 139 

Fuses: 51 

H 

Headlight: 30, 106 

Hub oil: 26 

I 

Identification: 7 

Instrument panel: 147 

M 

Maintenance: 6, 23 

O 

Odometer: 

R 

Recommended products: 

S 

Saddle: 

Spark plug: 26 

Suspension: 37, 157 

T 

Tank: 111, 112, 139, 140 

Transmission: 8, 35, 58, 127 

Tyres: 9

V 

Vehicle: 7, 56

Piaggio-Typhoon-50-EN _Service Manual

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?