PIAGGIO NRG 50, User Manual

Page 1: ...MANUALE STAZIONE DI SERVIZIO 1Q000696 NRG 50...

Page 2: ...y 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 p...

Page 3: ...egli impianti e delle attrezzature necessarie ed per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici N B Pr...

Page 4: ......

Page 5: ...VERY PRE DE TECHNICAL DATA DT TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYST...

Page 6: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 7: ...inging arm chassis pin Engine swinging arm pin Handlebar lock nut Lower steering ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam lights low beam li...

Page 8: ...K IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GAS KEEP CLEAR OF NAKE...

Page 9: ...D INFLATION PRESSURES AS TYRES MAY BURST Functional inspection Functional Checks Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal...

Page 10: ...INDEX OF TOPICS TECHNICAL DATA DT...

Page 11: ...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...

Page 12: ...engine identification number is stamped in the rear part of the engine near the shock absorber lower support Engine Data ENGINE SPECIFICATIONS Specification Desc Quantity Engine Single cylinder 2 str...

Page 13: ...e EURO 4 Dimensions and mass VEHICLE TECHNICAL DATA Specification Desc Quantity Chassis Double cradle steel tube Front suspension Hydraulic telescopic fork Rear suspension With coaxial spring and hydr...

Page 14: ...Kilogramme kg 1 Cubic inch in 16 4 Cubic centimetres cm 1 Foot pound lb ft 1 356 Newton metre Nm 1 Miles per hour mi h 1 602 kilometres per hour Km h 1 Pound per square inch PSI 0 069 bar 1 Fahrenhei...

Page 15: ...Crankshaft pulley nut 18 20 90 Nm Driven pulley shaft nut 40 44 Nm STEERING ASSEMBLY Name Torque in Nm Upper lock nut Steering tube 37 5 2 5 Nm Lower lock nut Steering tube 9 0 1 0 Nm Handlebars Stee...

Page 16: ...tting M1 40 197 40 204 40 143 40 15 0 047 0 061 1st oversize fitting N1 40 204 40 211 40 15 40 157 0 047 0 061 1st oversize fitting O1 40 211 40 218 40 157 40 164 0 047 0 061 1st oversize fitting P1 4...

Page 17: ...25 to 0 50 clearance F 0 20 to 0 75 Lining between the shoulders 40 64 H clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Cage 11 800 0 35 B clearance F 0 20 to 0 75 Slot packing system Fit the cylin...

Page 18: ...020272Y Piston position checking tool SHIMMING SYSTEM Name Measure A Thickness shimming 2 80 to 3 04 0 4 shimming 3 04 to 3 24 0 6 shimming 3 24 3 48 0 8 Technical Data NRG 50 DT 18...

Page 19: ...INDEX OF TOPICS TOOLING TOOL...

Page 20: ...g steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearings 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract 15 mm bearings 001467Y014 Call...

Page 21: ...ll for bearings OD 39 mm 001467Y021 Extraction pliers for 11 mm bearings 002465Y Calliper for circlips 004499Y001 Bell for bearing extractor 004499Y002 Bearing extractor screw 004499Y006 Ring for bear...

Page 22: ...ing steering bearing on the steering tube 020004Y Punch for removing steering bearings from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 0...

Page 23: ...2Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020165Y Starting ring gear lock 020166Y Tool for fitting the pin snap rings 020167Y Pump rotor immobiliser...

Page 24: ...water seal ring on the semi carter 020169Y Tool for removing and installing water pump shaft 020170Y Water mixer pump control gear extractor 020209Y Hook for springs 020265Y Bearing fitting base 02027...

Page 25: ...code Description 020325Y Pliers for brake shoe springs 020329Y Mity Vac vacuum pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator NRG 50 Tooling T...

Page 26: ...20334Y Multiple battery charger 020335Y Magnetic mounting for dial gauge 020350Y Electric installation control instrument 020357Y 32 x 35 mm Adaptor 020358Y 37 x 40 mm Adaptor 020359Y 42 x 47 mm Adapt...

Page 27: ...0363Y 20 mm guide 020376Y Sleeve for adaptors 020412Y 15 mm guide 020432Y Tool for fitting the starter section spring 020439Y 17 mm guide 020444Y Tool for installing removing clutch on from driven pul...

Page 28: ...g ring gear lock 020452Y Tube for removing and refitting the driven pulley shaft 020456Y 24 mm adaptor 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner 020625Y Kit for sampling gas from the...

Page 29: ...Stores code Description 021018Y Punch to fit flywheel and transmission oil seals 494929Y Exhaust fumes analyser NRG 50 Tooling TOOL 29...

Page 30: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 31: ...I I I I I I I Hub oil I I I R I I Headlight direction adjustment A A A Brake pads I I I I I I I I I Sliding shoes CVT rollers R R R Tyre pressure and wear I I I I I I I I I Vehicle road test I I I I...

Page 32: ...sed grease Lithium based grease suitable for vari ous uses Yellow grease ISO L X BCHA 3 DIN 51 825 K3K 20 Molybdenum disulphide grease Lithium grease with molybdenum disul phide Grey black grease Calc...

Page 33: ...losing ring of the box Insert the filter box into the rubber holder Replace the spark plug access panel Spark plug Place the vehicle on its central stand Remove the central cover Disconnect the spark...

Page 34: ...stance between the electrodes using a feeler gauge If any defects are found replace the spark plug with a new component of the specified type Engage the spark plug with the due inclination and screw i...

Page 35: ...dry it with a clean rag then reinsert it screwing it tightly into place Remove the stick and check that the oil level is slightly over the second notch starting from the lower end Screw the dipstick b...

Page 36: ...drainage cap again and fill the hub with the prescribed oil Check the oil level Recommended products Transmission oil 80W 90 Lubricant for gearboxes and transmissions SAE 80W 90 API GL 4 Air filter R...

Page 37: ...ew filter element Position the filter box cover Tighten the fastening screws of the air filter box cover N B NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE P...

Page 38: ...he reference mark on the rotating plate so that it is lined up with the reference mark on the mixer body as shown in the figure MIXER PUMP PURGE Operation to be carried out in the event of removal or...

Page 39: ...Check the level of liquid with the related warning light A Top up To top up brake fluid proceed as follows Remove the handlebar covers Unscrew the U bolt fastening screws and remove them Remove the ta...

Page 40: ...NA NC 956 DOT4 Headlight adjustment Proceed as follows 1 Place the vehicle in running order and with the tyres inflated to the prescribed pressure on a flat surface 10 m away from a white screen situa...

Page 41: ...ion and cleaning Unscrew and remove the screws securing the valve covers Move the covers down and remove the valves Remove the SAS box cover It is possible to access the filters to remove them NRG 50...

Page 42: ...Insert the new SAS filters in the box Position the SAS box cover Move the covers down and fit the valves Position the valve covers Insert and tighten the fastening screws Maintenance NRG 50 MAIN 42...

Page 43: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 44: ...y needs to be recharged periodically The battery runs down completely in the course of 5 6 months If the battery is fitted on a motorcycle be careful not to invert the connections keep ing in mind tha...

Page 45: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 46: ...ic starter connector 7 Starter motor connector 8 Magnet flywheel and pick up connector 9 Electronic control unit 10 Coil 11 Engine temperature sensor 12 Fuel level sensor 13 Front right turn indicator...

Page 47: ...I S valve 26 Starter button connector 27 Starter relay 28 Diagnostics connector 29 Fuses 30 Rear left turn signal connector 1 Rear light assembly connector Remove the li cense plate support to reach i...

Page 48: ...e rear right fairing to reach it 5 Voltage regulator connector 6 Automatic starter connector Remove the hel met compartment panel to access it 7 Starter motor connector Remove the stand to reach it El...

Page 49: ...l unit Remove the spark plug inspection cover to gain access to it 10 Coil Remove the spark plug inspection cover to gain access to it 11 Engine temperature sensor Remove the spark plug inspection cov...

Page 50: ...chassis cover to reach it 13 Front right turn indicator connector Remove the shield to reach it 14 Horn Remove the shield to reach it 15 Front left turn indicator connector Remove the shield to reach...

Page 51: ...it 17 Headlight connector Remove the radiator grill to gain access to it 18 Ignition switch contacts Remove the shield to reach it 19 Rear brake stop button connector Remove the handlebar covers to g...

Page 52: ...n access to it 21 Light switch connector Remove the handlebar covers to gain access to it 22 Turn indicators switch connector Remove the handlebar covers to gain access to it 23 Horn button connector...

Page 53: ...to gain access to it 25 S I S valve Remove the spark plug inspection cover to gain access to it 26 Starter button connector Remove the handle bar covers to gain access to it 27 Starter relay To reach...

Page 54: ...tics connector Located in the battery compartment 29 Fuses Located in the battery compartment 30 Rear left turn signal connector Remove the license plate support to reach it Electrical system NRG 50 E...

Page 55: ...y B Turn signal indicator lamp C SET button D MODE button E Low fuel warning light F Maximum coolant temperature warning light G Low mixer oil warning light H High beam warning lights on I Rev counter...

Page 56: ...or 2 Turn indicators switch connector 3 Light switch connector 4 Rear brake stop switch connector 5 Instrument panel connector 6 Front brake stop switch connector 7 Starter button connector Electrical...

Page 57: ...indicator connector 3 Headlight connector 4 Horn 5 Speed sensor cable connector 6 Fuel level sensor connector 7 ECU control unit 8 S I S valve connector 9 Engine temperature sensor connector NRG 50 E...

Page 58: ...rn signal connector 3 License plate light connector 4 Fuse box terminal block 5 Voltage regulator 6 Mixer oil level sensor connector 7 Fuel level sensor connector 8 Coil 9 ECU 10 S I S valve connector...

Page 59: ...THOSE INDICATED IN THIS DOCU MENT CAUTION BEFORE REPLACING THE FUSE IT IS NECESSARY TO FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW DO NOT REPLACE THE FUSE WITH ANY ALTERNATIVE FORM OF CONDUCTOR...

Page 60: ...14 40 14 70V Initial charge voltage equal to 0 3 0 5 for Nominal capacity Charge time 10 12 h recommended Minimum 6 h Maximum 24 h 3 Constant current battery charge mode Charge current equal to 1 10 o...

Page 61: ...rce to break the seals The electrolyte should start to flow inside the battery Note Do not tilt the container to prevent the flow of electrolyte from pausing or stopping 4 Control the flow of electrol...

Page 62: ...le The dry charge battery MF like the completely loa ded YTX must have a zero load voltage between 12 8 13 15 V Bring the battery to full charge us ing the 020648Y battery charger a select the type of...

Page 63: ...perly activated disconnect the battery charger from the power supply and unplug the terminals from the battery 7 Battery closing Insert the airtight cover strips into the filling holes Press horizonta...

Page 64: ...indicator input signal 6 Not connected 7 High beam lights warning light command signal input 8 LH turn indicator input signal 9 Not connected 10 Not connected 11 Engine temperature signal input 12 Eng...

Page 65: ...pply input C3 LH STOP button STOP lights and engine start enable ON signal output C4 RH STOP button STOP lights and engine start enable ON signal output C5 RH STOP button Power supply input NRG 50 Ele...

Page 66: ...switch A High beam headlights ON command signal out put B Ignition key controlled power supply input C Low beam headlights ON command signal out put D Not connected C8 Starter button 1 Signal input f...

Page 67: ...ed sensor 1 Vehicle speed signal for the instrument panel 2 Ground reference from the instrument panel 3 Display C12 Headlight 1 High beam headlights activation signal input 2 Low beam headlights acti...

Page 68: ...indicator light activation signal input 2 Ground C16 Front right turn indicator 1 Turn indicator light activation signal input 2 Ground C17 Fuel level indicator 1 Fuel level signal output for the inst...

Page 69: ...control signal input 2 Ignition key controlled power supply input C20 Engine control unit 1 Ignition coil control signal output 2 Signal input from the engine speed sensor C21 Engine control unit 1 S...

Page 70: ...K Line 2 S I S valve control signal output C23 H V coil Ground C24 H V coil Signal input from the engine control unit C25 Starter 1 AC power supply input from the voltage regula tor 2 Ground Electrica...

Page 71: ...level warning light control signal out put 2 Not connected 3 Ignition key controlled power supply input 4 DC power supply input C28 Voltage regulator 1 AC power supply 2 Ground 3 Ignition key controll...

Page 72: ...supply input for fuse F02 3 Not connected 4 Not connected 5 Ignition key controlled power supply output from F01 6 Ignition key controlled power supply output from F02 7 Not connected 8 Not connected...

Page 73: ...ear right turn indicator Signal input from the turn indicators switch C36 Chassis ground Chassis ground point C37 Taillight 1 Ground 2 STOP lights activation signal input 3 AC power supply 4 DC power...

Page 74: ...attery positive C39 Diagnostics socket 1 Not connected 2 Ground 3 K Line C40 Rear right turn indicator Signal input from the turn indicators switch C41 Battery negative Battery negative Electrical sys...

Page 75: ...C42 Rear left turn indicator Ground NRG 50 Electrical system ELE SYS 75...

Page 76: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 77: ...ws of the silencer at the big end Unscrew the S A S secondary air system fas tening screws Undo the screws fixing the silencer to the crank case Support the silencer and remove it FITTING THE COMPLETE...

Page 78: ...ncer to the motor head and tighten them to the prescribed torque Tighten the S A S screws Tighten the silencer screws to the crankcase to the specified torque Removal of the engine from the vehicle To...

Page 79: ...nt the rear mudguard Disconnect the flywheel connector Unscrew the screws of the transmission air cool ing cover Unscrew the screw of each of the brake cable retaining flaps Unscrew and remove the fas...

Page 80: ...e fastening screws of the brake calliper Detach brake calliper from the disc Loosen screws to remove footrest from the trans mission crankhouse side Loosen the engine ground cable screw Engine from ve...

Page 81: ...e screw and disconnect the connector Remove the tie for securing the cable bundle Release the clamp and disconnect the S I S valve connection tube to the carburetor Disconnect the engine temperature s...

Page 82: ...plug cap Unscrew the throttle control cable screw Unscrew the retaining clamp screw of the throttle control Remove the rubber cap and disconnect the mixer cable on the transmission side Engine from ve...

Page 83: ...pull the cable outwards Disconnect the fuel pipe by cutting the clamp Disconnect the vacuum tube from the sleeve by releasing the clamp Loosen the fuel pipe check valve and the vacuum pipe screw NRG 5...

Page 84: ...y for the pipe and the tank side fitting Remove the coolant pipe clamp and make sure to collect the liquid with a special container Open the coolant delivery pipe clamp on the en gine head side Cut ca...

Page 85: ...Remove the sheath and disconnect the connec tor Secure the vehicle suitably Unscrew the shock absorber fixing nut Unscrew the fixing nut of the engine support pin NRG 50 Engine from vehicle ENG VE 85...

Page 86: ...eel side You can now remove the engine from the frame Installing engine in vehicle Bring the whole engine into position by placing it near the frame Fit the engine support pin on the flywheel side Eng...

Page 87: ...engine support pin nut to the prescri bed torque Tighten the shock absorber nut to the specified torque Connect to the connector Reposition the sheath and tighten a new clamp NRG 50 Engine from vehic...

Page 88: ...fit a new clamp and tighten it with a suitable pliers Remove the caps previously placed over the oil pipe while the pipe facing up and close to the oil tank connection then quickly join the pipe to th...

Page 89: ...t Insert the fuel pipe insert a new clamp and tight en it with suitable pliers Insert the vacuum pipe to the sleeve and close the clamp Position the non return fuel pipe and vacuum tube and tighten th...

Page 90: ...le cable into position and tighten the screw Position the throttle cable retaining clamp and tighten the screw Connect the spark plug cap Connect the engine temperature connector Engine from vehicle N...

Page 91: ...mp Connect the connector and reposition the termi nal block by tightening the screw Position the engine ground cable and tighten it to the specified torque Fit a new clamp to tie the cables to the fra...

Page 92: ...ion crankcase side and tighten the screws Position the brake calliper Fit the brake calliper screws and tighten them to the specified torque Position the brake cable retaining clamps and tighten the s...

Page 93: ...ighten the screws of the transmission air cooling cover Connect the flywheel side connector Fill the coolant tank with the specified amount Reinstall anything previously removed the rear mudguard the...

Page 94: ...the upper side fairings the complete silencer Engine from vehicle NRG 50 ENG VE 94...

Page 95: ...INDEX OF TOPICS ENGINE ENG...

Page 96: ...rankcase 12 5 0 5 Nm Crankshaft pulley nut 18 20 90 Nm Driven pulley shaft nut 40 44 Nm Automatic transmission Transmission cover REMOVAL Unscrew and remove the transmission cover s fas tening screws...

Page 97: ...crankcase Tighten the anti tamper screws making sure they are positioned correctly Tighten the transmission cover fastening screws Kickstart REMOVAL To remove the kick starter transmission first remo...

Page 98: ...Select the engagement gear Unscrew the crank bolt and remove it Remove the Seeger ring Remove the washer Engine NRG 50 ENG 98...

Page 99: ...to gentle tap from the outside turn the transmission cover over and remove the toothed sector from its seat Remove the spring FITTING Position the spring in its seat using the specific tool Specific t...

Page 100: ...ng the starter section spring Recommended products Grease Jota 3 FS Mineral oil and lithium soap based grease Green ISO6743 9 DIN 51502 Using a specific product thoroughly lubricate all contact surfac...

Page 101: ...all indicated points have been lubricated 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 shaf...

Page 102: ...n pulley Lock the clutch housing with the specific tool Remove the nut the clutch housing and the whole of the driven pulley assembly N B THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED S...

Page 103: ...e components Specific tooling 020444Y Tool for installing removing clutch on from driven pulley Inspecting the clutch Check the thickness of the clutch mass friction material The masses must exhibit n...

Page 104: ...THE HOLDING EDGE OF THE EXTRACTION PLI ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEAL RING Specific tooling 001467Y029 Bell for 38 mm outside diameter bearings Remove the ball bearing reten...

Page 105: ...half pulley bushing Characteristic Mobile driven half pulley Maximum diameter admissible 34 08 mm Check the belt contact surfaces Insert the new oil seal and O rings on the mobile half pulley Fitting...

Page 106: ...Specific tooling 020376Y Sleeve for adaptors 020456Y 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for 17 mm roller bearing Inspecting the clutch spring Check that the contrast spring of the driven...

Page 107: ...Nut locking clutch unit on pulley 55 60 Nm Refitting the driven pulley Refit the driven pulley assembly the clutch bell and the nut using the specific tool Specific tooling 020565Y Flywheel lock calli...

Page 108: ...AK 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 REPL...

Page 109: ...iving pulley Standard diameter 20 021 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...

Page 110: ...RONG TIGHTENING AND CONSE QUENTLY DAMAGING THE CRANKSHAFT KNURLING Specific tooling 020451Y starting ring gear lock Locking torques N m Crankshaft pulley nut 18 20 90 Nm End gear Removing the hub cove...

Page 111: ...ate gear and wheel axle Take care to recover the intermediate gear shim if it is in the position shown in the picture Removing the wheel axle Remove the hub cap first and carefully position the interm...

Page 112: ...Extract the wheel axle from the hub cap Extract the intermediate gear Place both the axle and the gear on the bench Removing the wheel axle bearings Remove the oil seal Engine NRG 50 ENG 112...

Page 113: ...r Remove the bearing by pushing from the outside wheel side towards the inside of the gear com partment Specific tooling 020363Y 20 mm guide 020376Y Sleeve for adaptors 020358Y 37 x 40 mm Adaptor Remo...

Page 114: ...using a suitable cable spacer so that the pressure of the press takes place as shown in the figure Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Once this is done ch...

Page 115: ...020439Y 17 mm guide 020358Y 37 x 40 mm Adaptor Inspecting the hub shaft Check that the driven pulley shaft the intermediate gear and the wheel axle do not show signs of wear or deformation If anomali...

Page 116: ...20151Y Air heater Position the bearing on the specific tool being careful to face the shielded part of the bearing to wards the oil seal Specific tooling 020376Y Sleeve for adaptors 020439Y 17 mm guid...

Page 117: ...Y Tube for removing and refitting the driven pulley shaft Before fitting the seeger ring make sure it is con vex side facing the bearing Fit the seeger ring Fit the new oil seal on the outer side of t...

Page 118: ...c tooling 020151Y Air heater Fit the new bearing inside the crankcase using the specific tool Specific tooling 020363Y 20 mm guide 020376Y Sleeve for adaptors 020359Y 42 x 47 mm Adaptor For main bear...

Page 119: ...diate gear and the wheel axle check for wear Place the intermediate gear into the hub cap Place the wheel axle into the hub cap Before refitting the hub cap onto the crankcase check the position of th...

Page 120: ...g surface of the hub cap Recommended products Loctite 510 Medium strength paste sealant Pink Position the shim on the driven pulley shaft cor rectly Position the hub cap flush with the intermediate ge...

Page 121: ...products Transmission oil 80W 90 Lubricant for gear boxes and transmissions SAE 80W 90 API GL 4 Flywheel cover Removing the stator Unscrew and remove the Pick Up fastening screws Unscrew and remove t...

Page 122: ...Refitting the stator Fit the Stator with the pick up onto the crankshaft Tighten the stator s fastening screws Tighten the pick up screws Flywheel and starting Engine NRG 50 ENG 122...

Page 123: ...the centre stand by unscrewing the fas tening screws Unscrew and remove the starter motor fastening screws Remove the starter motor Removing the flywheel magneto Unscrew the screws used to fasten the...

Page 124: ...and unscrew the fixing nut Specific tooling 020565Y Flywheel lock calliper spanner Remove the nut making sure to reuse the nut during fitting since it is knurled Apply the specific tool and remove th...

Page 125: ...at might cause rubbing on the stator and on the Pick Up Refitting the flywheel magneto Position the flywheel and refit the knurled nut re moved during removal Using the specific tool lock the flywheel...

Page 126: ...the flywheel cover fastening screws Refitting the starter motor Fit a new O ring on the starter and lubricate it Insert the starter motor in its seat Insert and tighten the fastening screws Cylinder a...

Page 127: ...retor Using a suitable wrench remove the fastening screws of the intake manifold Remove the intake manifold Removing the cylinder head Remove the spark plug Remove the engine temperature sensor Unscre...

Page 128: ...e head fixing nuts Remove the cylinder head Removing the cylinder piston assy Remove the cylinder head Remove the cylinder taking care to support the piston Remove the cylinder base gasket Engine NRG...

Page 129: ...l micrometer N B IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ADMISSIBLE SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRA...

Page 130: ...ston using a bore meter Calculate the piston pin coupling clearance Characteristic Wrist pin housing standard diameter 12 0 007 0 012 Wrist pin housing standard clearance 0 002 0 011 mm Measure the ou...

Page 131: ...ap propriate table 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...

Page 132: ...l for mixer Low smoking lubricant for 2 stroke engines with synthetic bases and additives API TC JASO FC ISO L EGD Fit part 3 onto part 1 Position the group on the piston Push part 3 right into place...

Page 133: ...ecific tool and set it to zero on a horizontal plane Specific tooling 020272Y Piston position checking tool Assemble the tool on top of the cylinder by fixing it with two nuts to the stud bolts and br...

Page 134: ...Refitting the piston rings Lubricate the sealing rings and fit them to the piston Refitting the cylinder Fit the previously selected new cylinder base gas ket Fit the cylinder Engine NRG 50 ENG 134...

Page 135: ...correct sealing of the reed unit no light must pass between the support and the reed unit Refitting the head and timing system components Position the head Fit the head fixing nuts Tighten head fixin...

Page 136: ...e temperature sensor Fit and tighten the spark plug Refitting the intake manifold Fit the intake manifold Use a suitable wrench to tighten the fastening screws of the intake manifold Crankcase cranksh...

Page 137: ...nifold Unscrew and remove the crankcase fastening screws Fit the crankcase on the flywheel side of the crankshaft Install the specific tool on the flywheel side crank case half Specific tooling 020163...

Page 138: ...e the flywheel side crankcase half Fit the guard on the transmission side of the crankshaft Specific tooling 020163Y Crankcase splitting plate Install the tool on the transmission side crankcase half...

Page 139: ...shaft using a hammer with resin heads Specific tooling 004499Y001 Bell for bearing extractor 004499Y002 Bearing extractor screw 004499Y006 Ring for bearing extractor 004499Y007 Half rings Fit the tool...

Page 140: ...heel side half crankcase Refitting the crankshaft bearings Support the main bearings and put them in a heatable container filled with cold oil Heat the container with oil using a heat gun Bring the oi...

Page 141: ...ity of D for which a maximum reading of 0 02 mm is per mitted If the eccentricity is not much higher than what is required straighten the shaft pushing a wedge between the counterweights or tightening...

Page 142: ...crew 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...

Page 143: ...ise movement Insert at least three fastening screws and tighten up rapidly Fit and tighten the other screws applying the recommended torque Move the crankcase separation plate into a re tracted positi...

Page 144: ...0 06 to 0 08 mm Limit value with cold crankcase 0 02 0 03 mm Remove the crankcase coupling plate Using the specific tool refit the oil seals on the crankshaft Lubrication Crankshaft oil seals Refittin...

Page 145: ...l tool with adapter ring Specific tooling 021018Y Punch to fit flywheel and transmis sion oil seals Oil pump Removal Remove the fastening screws of the oil pump Remove the oil pump and the pipe gasket...

Page 146: ...vacuum generated in the intake manifold Therefore the tank has an outlet at the lowest point which sends fuel to the pump and then to the carburetor To make sure this is working properly proceed as fo...

Page 147: ...then switch it off Check that the amount of fuel is not lower than that prescribed Characteristic Fuel supplied 100cc X 10 Removing the carburettor Remove the carburetor Remove the boot of the automa...

Page 148: ...move the automatic starter device Unscrew and remove the gas valve cover fas tening screw Remove the gas valve cover and gas valve spring Remove the gas valve and the conical needle Engine NRG 50 ENG...

Page 149: ...Unscrew and remove the fastening screws of the pan Remove the pan Remove the float pin Remove the float and the petrol needle NRG 50 Engine ENG 149...

Page 150: ...remove the gas valve adjustment screw with its spring Unscrew and remove the main jet Unscrew and remove the idling jet Unscrew and remove the minimum air adjustment screw with its spring Engine NRG...

Page 151: ...n the minimum air adjustment screw complete and its spring until it is completely closed Fit and tighten the idling jet Fit and tighten the main jet Insert and tighten the gas valve adjustment screw c...

Page 152: ...Position the float and the petrol needle Fit the float pin Position the pan Insert and tighten the pan fastening screws Engine NRG 50 ENG 152...

Page 153: ...Fit the gas valve and the conical needle Position the gas valve spring Insert and tighten the gas valve cover fastening screw Fit the automatic starter device NRG 50 Engine ENG 153...

Page 154: ...screws of the auto matic starter Position the boot of the automatic starter Inspecting the automatic choke device Remove the automatic choke device from the carburetor Check that the automatic choke p...

Page 155: ...he device is intact and is not deformed or cracked Measure the piston protrusion and check the cor responding value Characteristic Automatic stroke of starter pin 11 07 0 2 mm Temperature 22 C Refit t...

Page 156: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 157: ...N Name Torque in Nm Shock absorber Chassis 22 5 2 5 Nm Rear wheel Wheel axle 130 13 Nm Stand screws torque 18 5 19 N m STEERING ASSEMBLY Name Torque in Nm Upper lock nut Steering tube 37 5 2 5 Nm Lowe...

Page 158: ...acer Remove the front wheel Using wooden supports sustain the wheel to be able to work on a level surface Using the specific gripper and tool remove the wheel bearing on the side of the odometer socke...

Page 159: ...rwise replace it With a specific heat gun heat the seat of the bearing on the brake calliper side Using the specific tool reinstall the bearing on the brake disc side Insert the spacer bushing on the...

Page 160: ...e spacer gently tap to adjust the wheel axle cover Refitting the front wheel Fit the wheel Sustain the wheel so as to be able to insert the axle Tighten the wheel axle nut to the specified torque Susp...

Page 161: ...e washers Check the distance between the speed sensor and shim with washers according to the obtained val ue If the x distance is below 3 65 mm shim with 4 washers If the x distance is comprised betwe...

Page 162: ...to the specified torque Handlebar Removal To remove the handlebar first remove the rear view mirrors the brake pumps the handlebar covers Unscrew and remove the screw fastening the handlebars Unscrew...

Page 163: ...Remove the handgrip Remove the handlebar Refitting Fit the handlebar in its position Tighten to the specified torque the handlebar fixing screw NRG 50 Suspensions SUSP 163...

Page 164: ...clamps to fasten the throttle con trol cable and the electrical connections to the handlebar Front fork Removal To remove the front fork first remove the front mudguard the front wheel the brake call...

Page 165: ...ing operations are used to remove the fork leg Carry out the same operations to remove the second fork leg Loosen the upper screw fastening the fork to the plate Unscrew the threaded plug carefully ho...

Page 166: ...Extract the short spring Unscrew the screws fastening the fork leg to the plate Extract the fork leg Overhaul To perform the overhaul first remove the fork leg Suspensions NRG 50 SUSP 166...

Page 167: ...Drain the oil from the fork collecting it in a proper manner Remove the cap Extract the second spring Extract the dust cover NRG 50 Suspensions SUSP 167...

Page 168: ...t the retainer ring Extract the stem Apply the specific tool on the fork leg Specific tooling 020487Y Fork oil seal extractor Screw the nut of the previously applied specific tool Suspensions NRG 50 S...

Page 169: ...seal and of the spring and to replace them if necessary After checking the components start refitting Insert the muffler together with the related com ponents in the stem Fit the muffler until it pro...

Page 170: ...tightening Using a specific tool insert the oil seal in its seat Specific tooling 020376Y Sleeve for adaptors 020359Y 42 x 47 mm Adaptor For main bear ings and wheel axle Insert the retainer ring Inse...

Page 171: ...rt the screw while firmly keeping the previ ously applied wrench Tighten the calliper mounting bracket fixing screw Insert the dust cover Refitting Insert the stem in the plate NRG 50 Suspensions SUSP...

Page 172: ...Screw the lower screw of the plate without yet tightening it Insert the spring Insert the cap Insert the short spring Suspensions NRG 50 SUSP 172...

Page 173: ...to the prescribed torque Tighten the plate fixing screws at the specified torque observing the following tightening order 1 lower screw 2 upper screw 3 lower screw Tighten the lower screw Reinstall e...

Page 174: ...ve the front wheel the brake calliper the handlebar Unscrew the upper ring nut using the specific tool Specific tooling 020055Y Wrench for steering tube ring nut Extract the upper ring nut Extract the...

Page 175: ...the lower ring nut while sustaining the fork so that is does not come out Specific tooling 020055Y Wrench for steering tube ring nut Extract the lower ring nut Extract the upper ball cage Remove the...

Page 176: ...ic tool remove the upper plate of the lower steering bearing from the headstock Specific tooling 020004Y Punch for removing steering bearings from headstock Using the specific tool remove the lower pl...

Page 177: ...bearing Specific tooling 001330Y Tool for fitting steering seats Using the specific tool install the lower plate of the lower steering bearing seat on the steering tube Specific tooling 006029Y Punch...

Page 178: ...mended products Calcium based grease Calcium grease Smooth textured appearance Ivory coloured Specification TL 9150 066 symbol NATO G 460 Insert the lower ring nut Using the specific tool tighten the...

Page 179: ...sert the upper ring nut Using the specific tool tighten the upper ring nut applying the recommended torque Specific tooling 020055Y Wrench for steering tube ring nut Refit anything previously removed...

Page 180: ...wheel To remove the rear wheel you must first remove the complete silencer Remove the screw cap Undo the fastening nut of the wheel while holding the rear brake lever firmly Remove the nut Suspension...

Page 181: ...screws of the brake calliper Unclip the brake calliper and remove the wheel Refitting the rear wheel Position the rear wheel Put the brake calliper and tighten the relative screws to the specified to...

Page 182: ...Put the nut in its position Tighten the nut to the specified torque Reinstall the screw cap Reinstall anything that was previously removed the complete muffler Swing arm Suspensions NRG 50 SUSP 182...

Page 183: ...first remove the side covers of the footpeg spoilers Disconnect the flywheel connector Unscrew the screw of each of the brake cable retaining flaps Loosen the fuel pipe check valve and the vacuum pipe...

Page 184: ...ew the fixing nut of the engine support pin Extract the pin from the engine right side Move the engine slightly back Unscrew the nut fastening the swinging arm pin to the chassis Suspensions NRG 50 SU...

Page 185: ...Extract the pin from the engine left side Remove the swinging arm Refitting Fit the swinging arm Connect the flywheel side connector NRG 50 Suspensions SUSP 185...

Page 186: ...e pin from the engine left side Tighten the nut fastening the swinging arm pin to the chassis Bring the engine close Insert the engine support pin from the right side of the vehicle Suspensions NRG 50...

Page 187: ...osition the non return fuel pipe and vacuum tube and tighten the screws Position the two brake cable retaining clamps and tighten the relative screws Reinstall the previously removed side covers of th...

Page 188: ...e fairings the lower covers the helmet compartment Unscrew the nut fastening the shock absorber to the chassis Unscrew the nut fastening the shock absorber to the carter Extract the shock absorber Now...

Page 189: ...ighten to the specified torque the nut fastening the shock absorber to the carter Centre stand Complete stand replacement Operate on the screws highlighted in the figure When refitting secure to the p...

Page 190: ...ust rotate freely N B UPON REFITTING USING NEW O RINGS AND PINS GREASE THE SPRING COUPLINGS AND THE PIN Removal of the pin fastening the stand to the bracket Remove the bracket supporting the engine s...

Page 191: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 192: ...E Name Torque in Nm Hydraulic hose Rear brake pump 15 0 3 0 Nm Rear brake pump Handlebar 9 0 1 0 Nm Rear brake disc Wheel rim 9 0 1 0 Nm Brake calliper Carter 22 5 2 5 Nm Oil bleed screw 10 0 2 0 Nm R...

Page 193: ...e of the rear brake calliper Unscrew and remove the screws fastening the brake calliper to the carter Detach the brake calliper from the wheel disc Unscrew and remove the coupling screw of the rear br...

Page 194: ...crew of the rear brake pipe Position the brake calliper Tighten to the specified torque the screws fas tening the brake calliper to the carter Tighten to the specified torque the screw of the hydrauli...

Page 195: ...usly removed mudguard Refill and bleed the rear brake system Front brake calliper Removal To remove the front brake calliper first drain the brake fluid from the circuit of the front braking sys tem F...

Page 196: ...he brake calliper to the fork Detach the brake calliper from the wheel disc Unscrew and remove the coupling screw of the front brake pipe Refitting Insert and screw the coupling screw of the front bra...

Page 197: ...per to the fork Tighten to the specified torque the screw of the hydraulic hose Refill the circuit with the specific brake fluid and with the vehicle at a standstill carry out the stroke of the brake...

Page 198: ...rst the following must be removed the rear wheel Put the wheel with the brake disc on the bench Unscrew the screws fastening the disc Remove the rear brake disc Refitting Put the brake disc in its pos...

Page 199: ...ng Check the thickness of the disc in multiple areas and check that it lies within the permitted wear lim its Characteristic New brake disc thickness 4 0 mm Minimum permissible thickness of the brake...

Page 200: ...remove the front brake disc first the following must be removed the front wheel Put the wheel with the brake disc on the bench Unscrew the screws fastening the disc Remove the front brake disc Braking...

Page 201: ...wheel Disc Inspection Carefully clean the surface of the braking race and make sure there is no abnormal scoring Check the thickness of the disc in multiple areas and check that it lies within the per...

Page 202: ...replace the brake disc Characteristic Maximum axial deviation 0 1 mm Front brake pads Removal To replace the front brake pads first remove the brake calliper unscrewing the fork fastening screws Unscr...

Page 203: ...s Characteristic Friction material minimum permissible thick ness 1 5 mm Also check that the wear of the friction material is uniform and make sure it does not exceed the indicated tolerance Otherwise...

Page 204: ...tighten to the speci fied torque the screws fastening the brake calliper to the fork Rear brake pads Removal To release the brake calliper to replace the brake pads first remove the rear mudguard Uns...

Page 205: ...Unscrew the screws fixing the brake calliper to the carter Detach the calliper from the disc Remove the cotter pin Extract the pin NRG 50 Braking system BRAK SYS 205...

Page 206: ...e pads Characteristic Friction material minimum permissible thick ness 1 5 mm Also check that the wear of the friction material is uniform and make sure it does not exceed the indicated tolerance Othe...

Page 207: ...Refitting Insert the new brake pads in their seat Fit the retainer plate of the pads Insert the pin Insert the cotter pin NRG 50 Braking system BRAK SYS 207...

Page 208: ...spurgo necessario rifornire con stantemente il serbatoio olio e contemporanea mente agire con la pompetta Mityvac sullo spurgo fino a quando non fuoriesce pi aria dall impianto L operazione va termina...

Page 209: ...S FLUID 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 BLEE...

Page 210: ...hydraulic hose of the front braking system Unscrew and remove the screws of the U bolt fastening the front brake pump to the handlebar Unscrew and remove the coupling screw of the front brake pipe In...

Page 211: ...ke pipe in the pump Fit the front brake pump and tighten to the speci fied torque the screws of the U bolt Tighten to the specified torque the screw coupling the hydraulic hose to the front brake pump...

Page 212: ...lever and if necessary bleed the in stallation Rear brake pump combined Removal To remove the rear brake pump first drain the brake fluid from the circuit of the rear braking sys tem Disconnect the el...

Page 213: ...emove the pump and disconnect the coupling of the rear brake pipe In this way the brake pump can be removed Refitting Insert the coupling of the rear brake pipe in the brake pump Fit the rear brake pu...

Page 214: ...Tighten to the specified torque the hydraulic hose coupling to the rear brake pump Connect the electrical connections Refill and bleed the rear brake system Braking system NRG 50 BRAK SYS 214...

Page 215: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 216: ...REMOVAL To remove the radiator remove the front shield first drain the coolant Remove the metallic clamps of the radiator pipes Disconnect the pipes Remove the expansion tank Cooling system NRG 50 COO...

Page 217: ...s fastening the radiator to the upper and lower bracket Remove the radiator RADIATOR FITTING Fit the radiator Insert and tighten the screws fastening the radi ator to the upper and lower bracket NRG 5...

Page 218: ...the expansion tank Connect the pipes Using the appropriate gripper apply new clamps on the pipes Refit the front shield Fill with the coolant tank in the specified amount Cooling system NRG 50 COOL SY...

Page 219: ...Start the engine and wait until only coolant comes out from the tube then tighten the coupling on the big end Stop the engine restore to the maximum fluid level then close the expansion tank Heat the...

Page 220: ...TION NOT TO OVERLOAD THE PLASTIC IMPELLER Specific tooling 020167Y Pump rotor immobiliser tool Remove the mixer water pump drive belt with the two sprockets Remove the split ring from the shaft togeth...

Page 221: ...picture Specific tooling 020209Y Hook for springs Ensure the shaft is not abnormally worn and the bearings not noisy Otherwise replace shaft and bearings Carefully clean oil seal and bearing housings...

Page 222: ...removing and installing water pump shaft Using the air heater warm up the water pump bearing housing without directing the air flow di rectly against the oil seal Lubricate the end of the water pump...

Page 223: ...ermostat Heat up the bowl using the thermal gun Check the thermostat opening start temperature Heat up until the thermostat is completely open 3 Replace the thermostat if not working properly CAUTION...

Page 224: ...Refitting Fit the thermostat as high as possible on the big end so that the by pass section is as small as pos sible Re install anything that was previously removed Cooling system NRG 50 COOL SYS 224...

Page 225: ...INDEX OF TOPICS CHASSIS CHAS...

Page 226: ...e screws Unscrew and remove the fixing screws Extract the saddle FITTING Put the saddle keeping it open and screw the fixing screws In this way the saddle can be closed Driving mirrors REMOVAL Remove...

Page 227: ...Remove the rear view mirror FITTING Put the rear view mirror Tighten the screw fastening the rear view mirror to the handlebar Fit the screw cap NRG 50 Chassis CHAS 227...

Page 228: ...e front handlebar cover Unscrew and remove the central screw fixing the rear handlebar cover to the handlebar Unscrew and remove the side screws fixing the rear handlebar cover to the handlebar Discon...

Page 229: ...onnect the connectors Tighten the side screws fixing the rear handlebar cover to the handlebar Tighten the central screws fixing the rear han dlebar cover to the handlebar Reinstall anything previousl...

Page 230: ...ew mirrors Unscrew the front handlebar cover fastening screws and remove them Remove the front handlebar cover FITTING Bring the front handlebar cover into place Tighten the screws fixing the front ha...

Page 231: ...eed as follows Unscrew the three fastening screws of the central frame cover at the fuel tank cap holder Unscrew and remove the two screws securing the central frame cover to the footrest Open the fue...

Page 232: ...l frame cover Screw the two fastening screws of the central frame cover into the footrest Replace the fuel tank cap Screw the three fastening screws of the central frame cover to the fuel tank cap hol...

Page 233: ...the side covers of the footpeg spoilers Unscrew and remove the screws fixing the shield to the leg shield back plate Unscrew and remove the radiator cover Remove the radiator cover Unscrew and remove...

Page 234: ...crew and remove the screws fastening the shield to the leg shield back plate located under the turn indicator unit Detach the shield from the back plate while sup porting it to gain access to disconne...

Page 235: ...nt shield so that you can connect the connectors Connect the connectors Bring the shield flush with the back plate Screw the shield fixing screws to the shield back plate Reposition the radiator cover...

Page 236: ...e central frame cover the footrest the side covers of the footpeg spoilers Knee guard REMOVAL To remove the leg shield back plate first remove the central frame cover the footrest the plug of the fuel...

Page 237: ...lant tank Unscrew and remove the screws located under the previously removed footrest fastening the leg shield back plate to the chassis Remove the leg shield back plate FITTING Position the leg shiel...

Page 238: ...ld back plate to the chassis Screw the screw fastening the coolant tank to the leg shield back plate Refit the coolant tank plug Refit anything previously removed Taillight assy REMOVAL To remove the...

Page 239: ...ove the screws fastening the rear light assembly Disconnect the connector FITTING Connect the connector and bring the light assem bly close Screw the screws fastening the rear light assem bly NRG 50 C...

Page 240: ...the saddle the side fairings License plate light REMOVAL To access the licence plate light do the following unscrew the licence plate light screw Remove the complete licence plate light Unscrew the bu...

Page 241: ...ULL THE ELECTRICAL CABLES WHEN TAKING OUT THE BULB HOLDER Remove the lamp for the licence plate light and replace it FITTING Put a new light bulb in the light bulb holder Insert the light bulb holder...

Page 242: ...fixing screws Put the licence plate light fixture and screw its fixing screw Footrest REMOVAL To remove the footrest first remove the central frame cover Disconnect the fuel level indicator connector...

Page 243: ...screw fastening the footrest Unscrew and remove the lateral screws fastening both the chrome plated protections and the foot rest Remove the chrome plated protections and then the footrest Remove the...

Page 244: ...Position the footrest Fit the chrome plated protections Screw the lateral screws fastening the chrome plated protections and the footrest Screw the central screw fastening the footrest Chassis NRG 50...

Page 245: ...ector Reinstall the previously removed chassis central cover Side fairings To remove the side fairings first remove the saddle Unscrew and remove the screws fastening the taillight upper cover and the...

Page 246: ...crew and remove the screws fastening the side fairings Unscrew and remove the lateral screws fasten ing the side fairings Unscrew and remove the screws located on the taillight support fastening the s...

Page 247: ...ove the side fairings FITTING Position the side fairings Fit the taillight upper cover Screw all the screws fastening the side fairings including those of the taillight upper cover NRG 50 Chassis CHAS...

Page 248: ...he licence plate support first remove the side fairings the rear light assembly Unscrew the lateral screws fastening the licence place support Unscrew the lower screws fastening the licence place supp...

Page 249: ...he licence plate light connector and remove the licence plate support FITTING Sustain the licence plate support bringing it close to its position and connect the licence plate light connector Connect...

Page 250: ...crews fastening the licence place support Screw the lateral screws fastening the licence plate support and reinstall everything that was pre viously removed Air filter REMOVAL To remove the air filter...

Page 251: ...e screw of the throttle control retaining clamp Disconnect the fuel pipe Cut the clamp of the sleeve and release the air filter FITTING Put the air filter and connect the sleeve applying a new clamp N...

Page 252: ...throttle control Put the fuel pipe back in its position Reinstall the rear mudguard Rear mudguard REMOVAL To remove the rear mudguard proceed as follows Unscrew the screws fastening the engine cover...

Page 253: ...rew the lateral screws fastening the mud guard to the carter Unscrew the screw fastening the filter box and the mudguard to the carter Unscrew the screws fastening the mudguard to the relative support...

Page 254: ...the mudguard FITTING Position the rear mudguard Screw the screws fastening the mudguard to the relative bracket Screw the screw fastening the filter box and the mudguard to the carter Chassis NRG 50...

Page 255: ...e engine cover Screw the screws fastening the engine cover to the mudguard Helmet bay REMOVAL To remove the helmet compartment first remove the saddle the side fairings the battery Unscrew the screws...

Page 256: ...the fastening screws of the terminal box Unscrew the screw located in the battery com partment Unscrew the screw located in the helmet com partment Remove the plug of the mixer oil tank Chassis NRG 50...

Page 257: ...Now the helmet compartment can be released FITTING Put the helmet compartment Insert the plug of the mixer oil tank Screw the screw located in the helmet compart ment NRG 50 Chassis CHAS 257...

Page 258: ...ing screws of the terminal box Screw the screws fixing the helmet compartment to the chassis and reinstall everything that was previously removed spoiler REMOVAL To remove the footpeg side covers firs...

Page 259: ...ing the shield to the footpeg lateral covers Unscrew and remove the lower screws fastening the shield to the footpeg lateral covers Remove the side covers of the footpeg FITTING Position the lateral c...

Page 260: ...stening the shield to the footpeg lateral covers Re install anything that was previously removed the central frame cover the footrest Fuel tank REMOVAL To release the tank from the chassis first remov...

Page 261: ...and remove the screw of the tank plug support Cut the sleeve clamp Unscrew and remove the screw fastening the tank to the chassis Unscrew the screws fastening the tank support bracket NRG 50 Chassis...

Page 262: ...e the tank from the chassis FITTING Put the tank in its seat and fit the bracket Screw the screws fastening the tank support bracket Screw the screw fastening the tank to the chas sis Chassis NRG 50 C...

Page 263: ...ripper Screw the screws of the fuel tank plug support Reinstall anything previously removed the central frame cover the footrest the side covers of the footpeg spoilers Front mudguard REMOVAL Unscrew...

Page 264: ...ard fixing screws Expansion tank REMOVAL To remove the expansion tank first remove The front shield Empty the coolant circuit collecting the fluid in an adequate container Unscrew and remove the screw...

Page 265: ...Screw the screw fastening the coolant tank to the leg shield back plate Fill the coolant tank with the specified amount of the specific product Recommended products Anti freeze liquid ready to use co...

Page 266: ...system Mixture oil tank REMOVAL To remove the mixer oil tank first remove the upper and lower side fairings the helmet compartment Unscrew and remove the screw fastening the mixer oil tank to the cha...

Page 267: ...ipe and the tank side fitting Detach the tank FITTING Put the mixer oil tank Remove the caps previously placed over the oil pipe while the pipe facing up and close to the oil tank connection then quic...

Page 268: ...the screw fastening the mixer oil tank to the chassis Reinstall anything previously removed the upper and lower side fairings the helmet compartment Flyscreen REMOVAL Loosen and remove the screws fix...

Page 269: ...Remove the top fairing FITTING Position the top fairing Tighten the top fairing screws Radiator cover REMOVAL Unscrew the fixing screw of the radiator cover NRG 50 Chassis CHAS 269...

Page 270: ...radiator cover Battery REMOVAL To access the battery do the following set the vehicle on its centre stand make sure that the ignition switch is set to the OFF position lift the saddle and unscrew the...

Page 271: ...sconnect the battery s negative terminal clamp Unscrew the fastening screw and disconnect the battery s positive terminal clamp Remove the battery by extracting it upwards FITTING Put the new battery...

Page 272: ...fixing screw Put the battery cover back screw the relative fix ing screws and close the saddle Lower cover REMOVAL To remove the lower side fairings first remove the saddle the upper side fairings th...

Page 273: ...screw fastening the lower side fairings to the chassis Unscrew the lower screw fastening the lower side fairings to the chassis Remove the lower side fairings FITTING Fit the lower side fairings NRG...

Page 274: ...crew the lateral screw fastening the lower side fairings to the chassis Screw the central screw fastening the lower side fairings to the footpeg Reinstall anything previously removed the saddle the up...

Page 275: ...147 151 Checks 58 E Electric F Fuel 146 260 Fuses 59 H Headlight 40 Hub oil 35 I Identification 12 Instrument panel 55 M Maintenance 11 31 Mirrors 226 R Recommended products 31 S Shock absorbers 187 S...