Gilera DNA 50 Workshop Manual
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Gilera DNA 50 Workshop Manual

633507
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633507
DNA 50

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Summary of Contents for Gilera DNA 50

  • Page 1 WORKSHOP MANUAL 633507 DNA 50...

  • Page 2: Workshop Manual

    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.
  • Page 3 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    DNA 50 Characteristics This section describes the general specifications of the vehicle. 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;...

  • Page 8: Vehicle Identification

    DNA 50 Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Frame prefix ZAPC2700000001001 Engine prefix C271M Dimensions and mass DIMENSIONS AND MASS Specification Desc./Quantity Maximum width 780 mm Maximum length 1970 mm Wheel base 1350 mm Saddle height 810 mm Dry weight 99 kg.
  • Page 9 DNA 50 Characteristics Engine ENGINE Specification Desc./Quantity Motor Fluid-cooled, two-cycle, single-cylinder. Engine capacity 49 cm³ Bore x stroke 40 X 39.3 mm Compression ratio 11.3 ÷ 12.8 : 1 Supply. With high-octane, 95 N.O.R. lead-free petrol mix - oil via car- burettor, automatic mixer (with variable capacity depending on the engine speed and opening of throttle valve) petrol pump.
  • Page 10 DNA 50 Characteristics Capacities CAPACITIES Specification Desc./Quantity Fuel tank Plastic, capacity ~ 9 lt. (including reserved ~ 1.2 lt.). Oil mixer tank In plastic, of capacity ~ 1.3 lt. (including reserve ~ 0.500 lt.) Rear hub oil ~ 85 cc...
  • Page 11 DNA 50 Characteristics Secondary air To clean the sponge filters of the secondary air system, proceed as follows: Unscrew the two studs ( 2) of the aluminium lid of the secondary air box to access the polyurethane sponge contained inside the box; after cleaning...

  • Page 12: Tightening Torques

    DNA 50 Characteristics Tightening Torques STEERING ASSEMBLY Name Torque in Nm Upper steering ring nut (safety locks) 35 to 40 Nm Lower steering ring nut (safety locks) 8 to 10 Nm Handlebar fixing pin (safety locks) 45 to 50 Nm...
  • Page 13 DNA 50 Characteristics Name Torque in Nm 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 ÷...
  • Page 14 DNA 50 Characteristics Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Connecting rod 11.750-0.05 clearance E = 0.25 to 0.50 shoulder washer 0.5 ± 0.03 clearance E = 0.25 to 0.50 - clearance F =...
  • Page 15 DNA 50 Characteristics 020272Y Piston position check tool SLOT PACKING SYSTEM Name Measure A Thickness Shimming 2.80 ÷ 3.04 Shimming 3.04 ÷ 3.24 Spacing 3,24÷3,48 Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-...
  • Page 16 INDEX OF TOPICS TOOL OOLING...
  • Page 17 DNA 50 Tooling TOOLS Stores code Description 001330Y 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 Pliers to extract ø 15-mm bearings 001467Y014 Pliers to extract ø...
  • Page 18 DNA 50 Tooling Stores code Description 001467Y017 Bell for bearings, OD 39 mm 001467Y021 Extraction pliers for ø 11 mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer- ing tube 020004Y Punch for removing fifth wheels from...
  • Page 19 DNA 50 Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate TOOL - 19...
  • Page 20 DNA 50 Tooling Stores code Description 020164Y Driven pulley assembly sheath 020165Y Start-up crown lock 020166Y Pin lock fitting tool 020167Y Arrest key for impeller pump 020168Y Water seal punch mount on half-crank- case 020169Y Water pump crankshaft fitting and remov-...
  • Page 21 DNA 50 Tooling Stores code Description 020170Y Water pump/mixer command gear ex- tractor 020261Y Starter spring fitting 020262Y Crankcase splitting strip 020265Y Bearing fitting base 020325Y Brake-shoe spring calliper 020329Y MityVac vacuum-operated pump TOOL - 21...
  • Page 22 DNA 50 Tooling Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger TOOL - 22...
  • Page 23 DNA 50 Tooling Stores code Description 020335Y Magnetic support for dial gauge 020350Y Electrical system check instrument 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide TOOL - 23...
  • Page 24 DNA 50 Tooling Stores code Description 020456Y Ø 24 mm adaptor 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner TOOL - 24...
  • Page 25 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 26: Maintenance Chart

    DNA 50 Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change Coolant - change AT 1000 KM OR 4 MONTHS Action Hub oil - change Oil mixer/throttle linkage - adjustment Steering - adjustment Brake control levers - greasing...
  • Page 27 DNA 50 Maintenance AT 15000 KM AND 45000 KM Action Hub oil level - check Spark plug/electrode gap - replacement Air filter - cleaning Oil mixer/throttle linkage - adjustment Driving belt - replacement Coolant level - check Brake control levers - greasing...
  • Page 28 DNA 50 Maintenance Action Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check SAS box (sponge) (**) - cleaning Vehicle and brake test - road test (**) See the regulations of the "Secondary air system" section...

  • Page 29: Spark Plug

    DNA 50 Maintenance Spark plug -Put the vehicle on its centre stand; -Disconnect the cap of the spark plug HV lead; -Unscrew the spark plug using a pipe spanner; -Examine the conditions of the spark plug, make sure its isolation is not damaged, measure the distance between the electrodes using the specific feeler gauge.
  • Page 30 DNA 50 Maintenance Check To check the hub oil level, proceed as follows: 1. Place the scooter on its stand on a level sur- face; 2. Unscrew the dipstick «A», dry it with a clean rag and then reinsert it, screwing it tightly into place;...
  • Page 31 DNA 50 Maintenance Replacement - Remove oil filler cap «A». - Loosen oil draining cap «B» and allow for the system to drain completely. - Refit the draining cap and refill the hub with the prescribed oil. Characteristic Rear hub oil...
  • Page 32 DNA 50 Maintenance transmissions During this phase the engine must be fuelled with a 2% mixture (at least 0.5 litres if the tank is emp- ty). Remove the carburettor guard. Start the vehicle and adjust the idle using the adjusting screw A on the carburettor.

  • Page 33: Braking System

    DNA 50 Maintenance Braking system Level check Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars 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 pads.

  • Page 34: Headlight Adjustment

    DNA 50 Maintenance 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 PAR- TIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS.
  • Page 35 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 36 DNA 50 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 POOR PERFORMANCE Possible Cause Operation Defective fuel pump or damaged depression line...
  • Page 37 DNA 50 Troubleshooting Possible Cause Operation Bear in mind that many problems engines have, derive from the use of the wrong spark plug Intake joint cracked or with a bad seal Replace the intake joint and check its tightness on the crank-...
  • Page 38 DNA 50 Troubleshooting Possible Cause Operation Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and power supply Engine overheating ENGINE OVERHEATING Possible Cause Operation Lack of liquid in the cooling circuit. Restore the level and check the absence of losses from the...
  • Page 39 DNA 50 Troubleshooting Possible Cause Operation Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace Brakes overheating OVERHEATING BRAKES Possible Cause Operation Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc.
  • Page 40 DNA 50 Troubleshooting Possible Cause Operation the seats in which the ball bearings rotate: replace if they are recessed. Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring nuts.
  • Page 41 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 42 DNA 50 Electrical system 1. Electronic ignition device 2. Spark plug 3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 8. Starter motor 9. Starter relay 10. Starter button 11. Stoplight switch on rear brake 12.
  • Page 43 DNA 50 Electrical system 21. Blinker switch 22. Headlight switch 23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight 24. Headlight A. Turn signal light bulb B. Low-beam light bulb C. High-beam light bulb 25. Horn button 26. Horn 27.
  • Page 44 DNA 50 Electrical system Ignition 1. Electronic ignition device 2. Sparkplug 3. Magneto 6. Key switch ELE SYS - 44...
  • Page 45 DNA 50 Electrical system Headlights and automatic starter section 3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 15. Automatic choke 21. Blinker switch 22. Headlight switch 23. Taillight A. Turn signal light bulb B.
  • Page 46 DNA 50 Electrical system B. Dashboard light bulbs Battery recharge and starting 3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 8. Starter motor 9. Starter relay 10. Starter button 11. Stoplight switch on rear brake 12.
  • Page 47 DNA 50 Electrical system B. Dashboard light bulbs Level indicators and enable signals section 3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 14. Low-oil warning light sender 16. Thermal switch 19. Phonic wheel encoder 20.
  • Page 48 DNA 50 Electrical system Turn signal lights 3. Flywheel magneto 4. Voltage regulator 5. Main 7.5 A fuse 6. Key-switch 7. Battery 13. Turn signal switch 23. Taillight A. Turn signal light bulb B. Sidelight C. Stoplight 24. Headlight A. Turn signal light bulb B.

  • Page 49: Digital Instrument Panel

    DNA 50 Electrical system B. Dashboard light bulbs Digital instrument panel INSTRUMENT UNIT CONNECTOR 1. Rpm signal 2. Fuel signal 3. Water temperature signal 4. Spare 5. Earth 6. Phonic wheel signal 7. Oil level 8. Parking lights 9. Oil check 10.
  • Page 50 DNA 50 Electrical system 1. Rpm counter 2. Fuel warning lamp 3. Oil mix warning lamp 4. Parking light lamp 5. High beam lamp 6. Turn indicator lamp 7. Temperature indicator 8. Fuel level indicator 9. Speedometer 10. Odometer 11. Digital display buttons...
  • Page 51 DNA 50 Electrical system CHECKING THE RECHARGE COIL Specification Desc./Quantity Yellow/Red cable 800±1100 ohm CHECK CONTINUITY Specification Desc./Quantity White cable-frame continuity White cable-engine continuity Ignition circuit All the control operations of the system that require the disconnection of cables (checks of the con-...
  • Page 52 DNA 50 Electrical system 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).
  • Page 53 DNA 50 Electrical system FAULT 4 Start the vehicle and make sure that when the tester is placed between the connection of the red wire and yellow one on the stator, the voltage de- livered by the generator is within the indicated value.
  • Page 54 DNA 50 Electrical system or the wiring, otherwise carry on with tests. • With the engine off, remove the regu- lator 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.
  • Page 55 DNA 50 Electrical system Fuse 7.5 A Sealed battery Putting the watertight battery into operation INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a normal tester.
  • Page 56 DNA 50 Electrical system 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 re- charges 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°...
  • Page 57 DNA 50 Electrical system The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the -negative clamp while the other two red wires marked (+) must be con- nected to the clamp marked with the +positive sign.
  • Page 58 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 59 DNA 50 Engine from vehicle Removal of the engine from the vehicle 1. Disassemble the complete muffler. 2. Disassemble the rear wheel. 3. Disassemble the carburettor casing using the four screws. 4. Disassemble the air filter using the two set screws as shown in the figure.
  • Page 60 DNA 50 Engine from vehicle ENG VE - 60...
  • Page 61 INDEX OF TOPICS NGINE...

  • Page 62: Automatic Transmission

    DNA 50 Engine questa sezione è in lavorazione Automatic transmission Transmission cover - Unscrew the 14 screws and remove the trans- mission cover using 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.
  • Page 63 DNA 50 Engine - Remove the screws shown in the figure and re- move the engine starting lever. - For the assembly, work in reverse and tighten the screws to the prescribed torque.. Locking torques (N*m) Starter lever replacement 12 to 13 Nm - Remove the seeger ring located on the exterior of the crankshaft.

  • Page 64: Removing The Clutch

    DNA 50 Engine 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 DRIVE PULLEY MOUNTED.
  • Page 65 DNA 50 Engine - Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw thereby undoing the driven pulley unit - Separate the components. Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch...
  • Page 66 DNA 50 Engine - Remove the three guide pins and the mobile half pulley. Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
  • Page 67 DNA 50 Engine Stationary driven half-pulley/Standard diame- Ø 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diam- eter admitted after use Ø 33.96 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings.
  • Page 68 DNA 50 Engine 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...
  • Page 69 DNA 50 Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE...
  • Page 70 DNA 50 Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley. - Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.
  • Page 71 DNA 50 Engine 4) Check the integrity of the sliding blocks of the contact plate. - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inside diameter «A». - Measure outside diameter «B» of the pulley slid- ing bushing shown in the figure.
  • Page 72 DNA 50 Engine ORDER TO AVOID WRONG TIGHTENING AND CONSE- QUENTLY DAMAGING THE CRANKSHAFT KNURLING. Specific tooling 020451Y Starting ring gear lock Locking torques (N*m) Crankshaft pulley nut 18 to 20 + 90° Nm End gear Removing the hub cover •...
  • Page 73 DNA 50 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. Specific tooling 020363Y 20 mm guide...
  • Page 74 DNA 50 Engine Inspecting the hub shaft - Check that the three shafts exhibit no wear or deformation on the toothed surfaces, at the bear- ing housings and at the oil guards. - In case of anomalies, replace the damaged com- ponents.
  • Page 75 DNA 50 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.
  • Page 76 DNA 50 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 proceeding in the inverse direction, tightening the studs to the pre- scribed torque.
  • Page 77 DNA 50 Engine • Keeping the flywheel connector rubber clamp on the coolant inlet hose, refit the flywheel cover paying attention in inserting the strap in the groove. • Tighten the 4 studs, noting that the two longer golden screws are inserted in...
  • Page 78 DNA 50 Engine 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.
  • Page 79 DNA 50 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.

  • Page 80: Removing The Cylinder Head

    DNA 50 Engine 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...
  • Page 81 DNA 50 Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANK-...
  • Page 82 DNA 50 Engine - Measure the outer diameter of the piston, per- pendicular to the pin axis. - Take the measurement in the position shown in the figure To classify the cylinder-piston fitting, check the ap- propriate table See also Cylinder - piston assy.

  • Page 83: Removing The Piston

    DNA 50 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.
  • Page 84 DNA 50 Engine 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. ENG - 84...
  • Page 85 DNA 50 Engine Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side Specific tooling 020163Y Crankcase splitting plate Removing the crankshaft - Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length.
  • Page 86 DNA 50 Engine - Using the specific tool remove any bearings left on the half crankcase Specific tooling 001467Y007 Driver for OD 54 mm bearing 001467Y006 Pliers to extract 20 mm bearings Refitting the crankshaft bearings Heat the bearings in an oil bath at around 150°C...
  • Page 87 DNA 50 Engine in a clamp (with an aluminium bushing) as re- quired.. Specific tooling 020335Y Magnetic support for dial gauge 020074Y Support base for checking crankshaft alignment Refitting the crankshaft - Position the transmission side half crankcase on two wooden supports - Using a thermal gun, heat the bearing seat to about 120°...
  • Page 88 DNA 50 Engine 020163Y Crankcase splitting plate Refitting the crankcase halves - Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the sur- face using a suitable solvent (e.g. trichloroethy- lene) - Heat the flywheel-side half crankcase with a ther- mal gun.
  • Page 89 DNA 50 Engine 020335Y Magnetic support for dial gauge Characteristic Axial clearance with warm crankcase 0.10 ÷ 0.12 mm Axial clearance with cold crankcase 0.06 to 0.08 mm Limit value with cold crankcase 0.02 ÷ 0.03 mm Lubrication Crankshaft oil seals...
  • Page 90 DNA 50 Engine Removal - Remove the 2 screws shown in the figure Remove the tube passage seal from the crank- case shown in the figure Refitting To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw...
  • Page 91 DNA 50 Engine Fuel supply The vehicle comes with a membrane pump con- trolled by the depression that is generated in the intake manifold. Therefore, the tank has an intake in the lowest point that sends the fuel to the pump and from here to the carburettor.
  • Page 92 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 93: Removing The Front Wheel

    DNA 50 Suspensions Sospensioni anteriore This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Loosen the wheel axle set screws A - Unscrew and extract the wheel axle B...

  • Page 94: Front Fork

    DNA 50 Suspensions Removal - Remove the drives and disconnect the electrical terminals. - Remove the bracket using the four screws. Front fork Removal Pump unit disassembly - Disassemble the front brake calliper using the two screws. - Remove the front wheel.
  • Page 95 DNA 50 Suspensions Disassembling the complete fork - Remove the front wheel. - Remove the front brake calliper. Take out the brake hose and the speedometer lead from the support bracket anchored on the lower plate. - Remove the handlebar support bracket and bring the handlebar forward without disconnecting the drives.

  • Page 96: Removing The Rear Wheel

    DNA 50 Suspensions Refitting For the assembly proceed in the opposite order of the disassembly making sure to lubricate the seats and bearing with recommended grease. Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings;...
  • Page 97 DNA 50 Suspensions Refitting When refitting, tighten the shock absorber/frame anchorage nut and the shock absorber/engine pin at the prescribed torque. Locking torques (N*m) Shock absorber/frame nut torque 20 to 25 Nm Shock absorber/engine pin torque 33 to 41 N·m...
  • Page 98 DNA 50 Suspensions - Work on the screws shown in the figure. - When refitting, secure to the prescribed torque. Locking torques (N*m) Stand screw torque 18.5 to 19 Nm SUSP - 98...
  • Page 99 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 100 DNA 50 Braking system questa sezione è in lavorazione 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.
  • Page 101 DNA 50 Braking system 1) insert the pistons (6) and the sealing rings (7) in the body; 2) place the guide rubbers (8) and refit the fixed plate (4); 3) assemble the reaction plate (3) tightening the screws (2), insert the brake pad check spring (9) and then the pads, fixing them with the corre- sponding screws (1);...
  • Page 102 DNA 50 Braking system 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. Locking torques (N*m)

  • Page 103: Front Brake Pads

    DNA 50 Braking system 3.5 mm • Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm. •...
  • Page 104 DNA 50 Braking system - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. N.B. IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT- TING, GENTLY EXPAND THE PADS.
  • Page 105 DNA 50 Braking system - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SUR- ROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS.
  • Page 106 DNA 50 Braking system Rear brake pump - combined - Drain the brake fluid from the circuit using the bleed screw located on the calliper and operating the brake lever until more fluid comes out. - Remove the handlebar pump using the two stand set screws indicated in the figure.
  • Page 107 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 108 DNA 50 Cooling system System bleed 1. Fill the circuit through the expansion tank to the maximum level. 2. Fasten the rubber line to the drain fitting on the head and thread it into the expansion tank mouth.. 3. Loosen the fitting and restore the tank level.
  • Page 109 DNA 50 Cooling system - Use a new oil seal to refit - Position the new oil seal on the special tool with the main lip facing the bearings as shown in the picture - Lubricate the oil seal and push it home using the...
  • Page 110 DNA 50 Cooling system Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 - Remove the pick-up/coolant inlet hose clamp - Remove the transmission cover - Remove the mixer - Setup the special as shown in the picture N.B.
  • Page 111 DNA 50 Cooling system - With the aid of the special tool, loosen the impel- ler shaft turning the spanner clockwise (left-hand- ed thread) - As the thread is fully disengaged, extract the shaft with the aid of pliers. Specific tooling...
  • Page 112 DNA 50 Cooling system 3) Replace the thermostat if not working properly. CAUTION TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI- THER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER. Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check: Opening start temperature 60±2°C...
  • Page 113 INDEX OF TOPICS CHAS HASSIS...
  • Page 114 DNA 50 Chassis Headlight assy. - Remove the 9 screws shown in the figure. - Remove the rubber caps and disconnect the con- nectors from the bulbs. - Remove the headlamp unit set screws and pull the unit out from the top.
  • Page 115 DNA 50 Chassis Side fairings Rear side panels - Remove the saddle. - Remove the passenger footrest. - Remove the screws indicated in the photo and then the side panels. Front side panels: Remove the screws shown in the photo and then disconnect the joint between the side panels and the lower central cover.
  • Page 116 DNA 50 Chassis Lower central covering: - Remove the front side frames and the helmet compartment. - Remove the connectors A, rear brake hose B from the left brake pump, the accelerator control lead C, then pull it all out from the slot in the lower central cover.
  • Page 117 DNA 50 Chassis Helmet bay - Remove the saddle and the left rear side panel. - Open the helmet compartment, remove the ex- pansion cap and the gas tank cover, then screw the cap back on. - Remove the two screws inside the helmet com- partment indicated in the photo.
  • Page 118 DNA 50 Chassis Fuel tank - Remove the helmet compartment. - Remove the from side frames and the lower central covering. - Remove the lower radiator support using the two screws and the pump guard indicated in the photo. Disconnect the three hoses A towards the engine unit, then remove the fuel pump using the two screws B indicated in the photo.
  • Page 119 DNA 50 Chassis Remove the four fuel tank set screws shown in the photo, then pull the tank out from the front. When reassembling make sure to secure the split- ter block support with the left front set screws of the tank.
  • Page 120 DNA 50 Chassis Expansion tank - Remove the helmet compartment. - Remove the tow support screws shown in the figure - Disconnect the two hoses collecting the coolant in a container Mixture oil tank - Remove the saddle, remove the battery cover, disconnect the mix oil level connector and unscrew the screw shown in the photo.
  • Page 121 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 122 DNA 50 Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing...

  • Page 123: Road Test

    DNA 50 Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
  • Page 124 DNA 50 Pre-delivery 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.
  • Page 125 INDEX OF TOPICS TIME...
  • Page 126 DNA 50 Time This section is devoted to the time necessary to carry out repairs. The description and code for each operation is in- dicated. Engine ENGINE Code Action Duration 001001 Engine to chassis - Replacement TIME - 126...
  • Page 127 DNA 50 Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement TIME - 127...
  • Page 128 DNA 50 Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001118 Main bearings - Replacement 001099 Oil seal, flywheel side - Replacement 001100 Oil seal, clutch side - Replacement TIME - 128...
  • Page 129 DNA 50 Time Cylinder assy. YLINDER PISTON Code Action Duration 001002 Cylinder piston - Replacement 001107 Cylinder / piston - Inspection / clean- TIME - 129...
  • Page 130 DNA 50 Time Cylinder head assy. EAD ASSEMBLY Code Action Duration 001013 Intake manifold - Replacement 001056 Head gasket - change 001057 Thermostat - Replacement 001093 Spark plug - Replacement 001126 Head - Replacement 007010 Bleed valve - Replacement 001178...
  • Page 131 DNA 50 Time Driven pulley RIVEN PULLEY Code Action Duration 001110 Driven pulley - Replacement 001022 Clutch - Replacement 001155 Clutch bell housing - Replacement 001012 Driven pulley - Service TIME - 131...
  • Page 132 DNA 50 Time Oil pump IL MIX PUMP Code Action Duration 001018 Mixer - Replacement 001019 Mixer belt - replacement 001028 Mix movement gear socket - Re- placement TIME - 132...
  • Page 133 DNA 50 Time Final gear assy. INAL REDUCTION GEAR Code Action Duration 001010 Geared reduction unit - Service 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 004125 Rear wheel axle - Replacement TIME - 133...
  • Page 134 DNA 50 Time Driving pulley RIVING PULLEY Code Action Duration 001011 Driving belt - Replacement 001066 driving pulley - Replacement 001017 Starter sprocket wheel - Replace- ment 001086 Driving half-pulley - replace 001177 Variator rollers / shoes - Replace- ment...
  • Page 135 DNA 50 Time Transmission cover RANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - Re- placement 001131 Transmission air intake - Replace- ment 001132 Transmission air inlet pipe - Replace- ment 001135 Transmission cover bearing - Re- placement 004179...

  • Page 136: Water Pump

    DNA 50 Time Water pump ATER PUMP Code Action Duration 001113 Water pump - Replacement 001062 Water pump command shaft - Re- placement 007019 Connection water pump pipe / return pipe - Replacement TIME - 136...

  • Page 137: Starter Motor

    DNA 50 Time Starter motor TARTER MOTOR AND KICK STARTER Code Action Duration 001020 Starter motor - Replacement 001021 Kick starter - Inspection 001084 Starter lever - Replacement 008008 Starter spring pack - Replacement 005045 Starter motor cable harness - Re-...

  • Page 138: Flywheel Magneto

    DNA 50 Time Flywheel magneto FLYWHEEL MAGNETO Code Action Duration 001058 Flywheel - Replacement 001067 Stator - Replacement 001173 Rotor - Replacement 001087 Flywheel cover - Replacement TIME - 138...
  • Page 139 DNA 50 Time Brake shoes RAKE SHOES Code Action Duration 002002 Rear brake shoe(s) - Replacement TIME - 139...
  • Page 140 DNA 50 Time Carburettor ARBURETTOR Code Action Duration 001063 Carburettor - Replacement 007020 Carburettor heating tubing - replace- ment 003058 Carburettor - Adjustment TIME - 140...

  • Page 141: Exhaust Pipe

    DNA 50 Time ARBURETTOR INSPECTION Code Action Duration 001081 Automatic choke - Replacement 001008 Carburettor - Inspection Exhaust pipe TIME - 141...

  • Page 142: Air Cleaner

    DNA 50 Time UFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment Air cleaner IR FILTER Code Action Duration 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement...
  • Page 143 DNA 50 Time Frame HASSIS Code Action Duration 001053 Stand bolt - Replacement 004004 Stand - Replacement 004001 Frame - replace 004015 Footrest - Replacement 004171 Stand support plate - Replacement 004143 Footrest support - replace TIME - 143...
  • Page 144 DNA 50 Time Legshield spoiler RONT SHIELD Code Action Duration 004065 Front shield rear section - Replace- ment 004064 Front shield - Replacement 003087 Wheel housing - Replacement 004167 Grill / radiator cover - Replacement 004176 Air vent - Replacement...
  • Page 145 DNA 50 Time Side fairings ENTRAL COVER Code Action Duration 004053 Spoiler - Replacement 004178 Footrest - Replacement 004011 Central chassis cover - Replacement TIME - 145...
  • Page 146 DNA 50 Time Underseat compartment ELMET COMPARTMENT Code Action Duration 004059 Spark plug inspection flap - Replace- ment 004016 Helmet compartment - Replacement 005046 Battery cover - Replacement TIME - 146...
  • Page 147 DNA 50 Time Plate holder ICENSE PLATE HOLDER Code Action Duration 005022 Rear turn indicators - Replacement 005068 Rear turn indicator bulb - Replace- ment 005005 Taillight - Replacement 005023 Rear tail light support - Replacement 005091 Turn indicator glass - Replacement...
  • Page 148 DNA 50 Time Mudguard UDGUARDS Code Action Duration 004009 Rear mudguard - Replacement 004052 Bumper - Replacement 004002 Front mudguard - Replacement TIME - 148...
  • Page 149 DNA 50 Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004011 Central chassis cover - Replacement 004072 Fuel filter - Replacement 004110 Fuel tank hose - Replacement 004168 Fuel tank cap - Replacement...
  • Page 150 DNA 50 Time Tank oil IL TANK Code Action Duration 004017 Oil reservoir - Replacement 005018 Oil reservoir float - Replacement 004095 Oil reservoir cock - Replacement 004091 Oil reservoir hose - Replacement TIME - 150...
  • Page 151 DNA 50 Time Rear shock-absorber EAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorbers - Replace- ment TIME - 151...
  • Page 152 DNA 50 Time Steering column bearings TEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Replacement 003073 Steering clearance - Adjustment 004119 Bearing / upper steering fifth wheel - Replacement TIME - 152...
  • Page 153 DNA 50 Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 002060 Complete throttle control - Replace- ment 002059 Right hand grip - Replacement 005017 Stop switch - Replacement 003059 Counterweight - Replacement 002024 Front brake pump - replace...
  • Page 154 DNA 50 Time Swing-arm WINGING ARM Code Action Duration 001072 Engine / frame swinging arm fitting - Replacement TIME - 154...
  • Page 155 DNA 50 Time Seat Code Action Duration 004003 Saddle - Replacement 004054 Seat lock hook - Replacement 002083 Saddle opening transmission - Re- placement TIME - 155...

  • Page 156: Instrument Panel

    DNA 50 Time Instrument panel NSTRUMENT UNIT AND HANDLEBAR COVER Code Action Duration 005014 Odometer - Replacement 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 005078 Odometer glass - Replacement TIME - 156...
  • Page 157 DNA 50 Time Turn signal lights RONT LIGHT Code Action Duration 005067 Front turn indicator bulb - Replace- ment 005008 Front headlamp bulbs - Replacement 005002 Front headlamp - Replacement 005012 Front turn indicator - Replacement TIME - 157...

  • Page 158: Front Wheel

    DNA 50 Time Front wheel RONT WHEEL Code Action Duration 002041 Front brake disc - Replacement 003040 Front wheel bearings - Replacement 003037 Front wheel rim- Replacement 003047 Front tyre - replace 004123 Front wheel - Replacement 003038 Front wheel axle - Replacement...
  • Page 159 DNA 50 Time Rear wheel EAR WHEEL Code Action Duration 001071 Rear wheel rim - Replacement 001016 Rear wheel - Replacement 002070 Rear brake disc - Replacement 004126 Rear wheel tyre - Replacement 002028 Rear wheel hub - Replacement TIME - 159...

  • Page 160: Fuel Pump

    DNA 50 Time Fuel pump UEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Pump / carburettor hose - Replace- ment 004086 Petrol pump depression tube - Re- placement TIME - 160...
  • Page 161 DNA 50 Time Electric devices ATTERY Code Action Duration 005007 Battery - Replacement 005024 Battery fuse - Replacement 005025 Fuse holder - Replacement 005011 Start-up remote control switch - Re- placement TIME - 161...
  • Page 162 DNA 50 Time LECTRICS Code Action Duration 001023 Control unit - Replacement 001094 Spark plug cap - Replacement 005001 Electrical system - Replacement 005009 Voltage regulator - Replacement 005136 Resistance - Replacement 005044 Front lights cable unit- Replacement TIME - 162...
  • Page 163 DNA 50 Time Electronic controls LECTRICAL COMMANDS Code Action Duration 005041 Starter button - Replacement 005040 Horn button - Replacement 005016 Key switch - Replacement 004096 Lock series - Replacement 004010 Antitheft lock - replace 005003 Horn - Replacement 005006...
  • Page 164 DNA 50 Time Transmissions PLITTER Code Action Duration 002012 Splitter - Replacement 002058 Mix / splitter transmission complete - Replacement 002057 Carburettor / splitter transmission complete - Replacement 002054 Throttle or splitter transmission com- plete - Replacement TIME - 164...
  • Page 165 DNA 50 Time Brake callipers BRAKE CALLIPERS Code Action Duration 002007 Front brake pads - Replacement 002021 Front brake piping - Replacement 002039 Front brake calliper - Replacement 002002 Rear brake pads - Replacement 002020 Rear brake disc piping - Replace-...
  • Page 166 DNA 50 Time Rear side fairings EAR COVERS Code Action Duration 004159 Plates / Stickers - Replacement 004056 Upper rear light cover - Replacement 004036 Lower chassis cover - Replacement 004085 Fairing (1) - Replacement 004129 Rear fairing - Replacement...
  • Page 167 DNA 50 Time Front suspension Code Action Duration 003010 Front suspension - Service 003051 Complete fork - replace 003048 Fork oil seal - Replacement 003041 Fork stanchion - Replacement TIME - 167...

  • Page 168: Cooling System

    DNA 50 Time Cooling system OOLING SYSTEM Code Action Duration 007001 Expansion tank - Replacement 007002 Water cooling radiator - Replace- ment 001052 Coolant and air bleed - Replacement 007024 Expansion tank cap - Replacement 007013 Expansion tank / radiator connecting...
  • Page 169 DNA 50 Time Secondary air box ECONDARY AIR SYSTEM Code Action Duration 001163 Muffler secondary air connection - Replacement 001165 Secondary air reed - Replacement 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning...
  • Page 170 Air filter: 31, 116 Battery: 39, 46, 55, 120 Brake: 95, 100, 102, 103, 105, 106, 139, 165 Carburettor: 11, 140 Engine stop: Fuel: 37, 91, 118, 149, 160 Fuses: 54 Headlight: 34, 114 Hub oil: 29 Identification: 8 Instrument panel: 49, 156 Maintenance: 7, 26 Shock absorbers: 96 Spark plug: 29...

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