Gilera Stalker 50 Service Manual
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Gilera Stalker 50 Service Manual

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MANUALE STAZIONE DI SERVIZIO
638540
Stalker 50

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  • Page 1 MANUALE STAZIONE DI SERVIZIO 638540 Stalker 50...
  • Page 2 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 Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.
  • 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 CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Stalker 50 Characteristics 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

    Stalker 50 Characteristics Vehicle identification Chassis prefix ZAPC40100 xxxx xxxxxxx Engine prefix C401M xxxx Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Overall length 1760 mm. Overall width 720 mm. Maximum height 810 mm. Wheelbase 1230 mm. Kerb weight 87 kg...
  • Page 9 Stalker 50 Characteristics Engine ENGINE Specification Desc./Quantity Engine type Two-stroke, single cylinder Piaggio Hi-PER2 Bore x stroke 40 X 39.3 mm Cubic capacity 49.40 cc Compression ratio 9.4 to 10.4 :1 Carburettor DELL'ORTO PHVA 17.5 RD CO adjustment 3.5% ± 0.5 Engine idle speed 1800 to 2000 r.p.m.

  • Page 10: Electrical System

    Stalker 50 Characteristics Capacities CAPACITY Specification Desc./Quantity Fuel tank Plastic, with a capacity of 6 litres (approximate value) including reserve of ~ 1.5 l. Oil mixer tank Plastic, with a capacity of ~ 1.2 l. (including a ~0.400 l reserve).

  • Page 11: Tightening Torques

    Stalker 50 Characteristics 50cc Version Dell'Orto ORTO CARBURETTOR Specification Desc./Quantity Type PHVA 17.5 RD Diffuser diameter Ø 17.5 Regulation reference number 8423 Maximum nozzle: Maximum air nozzle (on the body): Ø 1.5 Tapered pin stamped code: Pin position (notches from above):...

  • Page 12: Assembly Clearances

    Stalker 50 Characteristics ENGINE ASSEMBLY Name Torque in Nm Clutch bell nut 40 to 44 Nm Clutch lock ring nut 55 ÷ 60 nut locking driving pulley on the crankshaft 40 to 44 Nm Start-up lever screw 12 ÷ 13...
  • Page 13 Stalker 50 Characteristics Piston rings SEALING RINGS Name Description Dimensions Initials Quantity Compression ring 0.10 to 0.25 Compression ring 1st 40.2 0.10 to 0.25 oversize Compression ring 2nd 40.4 0.10 to 0.25 Oversize Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD...
  • Page 14 Stalker 50 Characteristics Slot packing system - Fit the cylinder without installing the basic gasket. - Apply a centimetre dial gauge on the special tool and zero it on the ground plane - Fit the tool to the top of the cylinder fixing it with two nuts to the studbolts and take the piston to the T.D.C.
  • Page 15 Stalker 50 Characteristics Product Description Specifications AGIP GREASE PV2 Grease for the steering bearings, pin White anhydrous-calcium based grease seats and swinging arm to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2. CHAR - 15...
  • Page 16 INDEX OF TOPICS TOOL OOLING...
  • Page 17 Stalker 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 Stalker 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 Stalker 50 Tooling Stores code Description 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020165Y Start-up crown lock 020166Y Pin lock fitting tool TOOL - 19...
  • Page 20 Stalker 50 Tooling Stores code Description 020261Y Starter spring fitting 020262Y Crankcase splitting strip 020265Y Bearing fitting base 020325Y Brake-shoe spring calliper 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing TOOL - 20...
  • Page 21 Stalker 50 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge TOOL - 21...
  • Page 22 Stalker 50 Tooling Stores code Description 020350Y Electrical system check instrument 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide 020456Y Ø 24 mm adaptor TOOL - 22...
  • Page 23 Stalker 50 Tooling Stores code Description 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner 020625Y Kit for sampling gas from the exhaust manifold TOOL - 23...
  • Page 24 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 25: Maintenance Chart

    Stalker 50 Maintenance Maintenance chart MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C. CLEAN, R:REPLACE, A:ADJUST, L:LUBRICATE Clean the SAS air filter every 2 years ** Replace every 2 years km x 1,000 SAS filter...

  • Page 26: Spark Plug

    Stalker 50 Maintenance Spark plug Place the vehicle on its central stand - Remove the cap on the central cover, loosening the fixing screws shown in the figure; - Disconnect spark plug HV wire hood; -Undo the spark plug using the socket wrench;...
  • Page 27 Stalker 50 Maintenance Check Do the following to check the correct level: 1) Stand the vehicle on the centre-stand on flat ground; 2) Remove the dipstick «A», and dry it with a clean cloth. Reinsert it, screwing it in all the way;...

  • Page 28: Air Filter

    Stalker 50 Maintenance Air filter - Remove the left side panel. - Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter. Cleaning: - Wash with water and neutral soap. - Dry with a clean cloth and short blasts of com- pressed air.
  • Page 29 Stalker 50 Maintenance During this stage, the engine must be fed with a 2% mixture (at least 0.5 litres if the tank is empty). - Remove the left side panel. - Remove the front handlebar cover. - Put the scooter in gear and adjust the idle speed by turning the set screw on the carburettor.

  • Page 30: Braking System

    Stalker 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 31: Headlight Adjustment

    Stalker 50 Maintenance AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Headlight adjustment Proceed as follows: 1. Place the vehicle in riding condition and with the tyres correctly inflated on a flat piece of ground at a distance of 10 m from a white screen situated in a shaded area, making sure that the scooter is perpendicular to the screen;...
  • Page 32 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 33: Rear Wheel Spins At Idle

    Stalker 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 cock or vacuum hose damaged.
  • Page 34 Stalker 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 35 Stalker 50 Troubleshooting Possible Cause Operation Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and power supply SAS malfunctions SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF- FLER Possible Cause Operation Secondary air reed blocking...
  • Page 36 Stalker 50 Troubleshooting Brakes overheating BRAKES OVERHEATING Possible Cause Operation Defective piston sliding Check calliper and replace any damaged part. Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the wheel correctly fitted or the concentricity of the rear drum.

  • Page 37: Noisy Suspension

    Stalker 50 Troubleshooting Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.
  • Page 38 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 39 Stalker 50 Electrical system LEGEND: 1. Electronic ignition device 2. Spark plug 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 8. Starter motor 9. Starter remote control 10. Starter button 11. STOP button on rear brake 12.
  • Page 40 Stalker 50 Electrical system 20. Front headlight assembly A. Tail light B. High beam/low beam lamp 21. Right turn front indicator lamp 22. Light switch 23. Instrument panel A. Flashing warning light B. Instrument panel lamp and lights warning light C.
  • Page 41 Stalker 50 Electrical system Starter remote control In order to access the starter remote control it is necessary to remove the left side panel. Conceptual diagrams Ignition LEGEND: 1. Electronic ignition device 2. Spark plug 3. Magneto flywheel 6. Key switch...
  • Page 42 Stalker 50 Electrical system Headlights and automatic starter section LEGEND: 3. Magneto flywheel 4. Voltage regulator 16. Tail light/stop light lamp 20. Front headlight assembly A. Tail light B. High beam/low beam lamp 22. Light switch 23. Instrument panel A. Flashing warning light B.
  • Page 43 Stalker 50 Electrical system Battery recharge and starting LEGEND: 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 8. Starter motor 9. Starter remote control 10. Starter button 11. STOP button on rear brake 12. STOP button on front brake 16.
  • Page 44 Stalker 50 Electrical system Level indicators and enable signals section LEGEND: 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 23. Instrument panel A. Flashing warning light B. Instrument panel lamp and lights warning light C.
  • Page 45 Stalker 50 Electrical system Turn signal lights LEGEND: 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 13. Horn button 14. Horn 15. Left turn rear indicator lamp 17. Turn indicator switch 18. Right turn rear indicator lamp 19.
  • Page 46 Stalker 50 Electrical system E. Mixer oil warning light F. High-beam warning light Instruments and warning lights control board LEGEND: A= Speedometer B= Odometer C= Headlight warning light D= Turn indicator warning light; E= Digital clock F= Clock setting buttons...
  • Page 47 Stalker 50 Electrical system 2. Without removing the stator, carry out the following checks: After visually checking the electrical wiring, perform measurements on the loading reel, the pickup (see chart) and the continuity using the appropriate tester. If checks on the loading reel, pickup and continuity show abnormalities, replace the stator; otherwise replace the central unit.
  • Page 48 Stalker 50 Electrical system Ignition circuit All the control operations of the system that require the disconnection of cables (checks of the con- nections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irreparably dam- aged.
  • Page 49 Stalker 50 Electrical system Measures FAULT 1 Replace the regulator because it is certainly inef- ficient. FAULT 2 Check the efficiency of the bulbs. With the vehicle in gear, check the battery voltage on the yellow-black cable of the light switch. If...
  • Page 50 Stalker 50 Electrical system FAULT 4 Put the vehicle in gear and check when the tester for the detection of alternate voltages put between the blue cable connection and the yellow cable connection on the stator, the voltage distributed by the generator is within the values indicated.
  • Page 51 Stalker 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 52 Stalker 50 Electrical system OF ELECTRIC WIRE) OR A FUSE FOR A HIGH- ER AMPERAGE THAN THE INDICATED ONE. Electric characteristic Fuse 7.5 A Sealed battery Using the sealed battery for the first time INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a normal tester.
  • Page 53 Stalker 50 Electrical system ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF REACH OF CHILDREN Use of dry-cell batteries : 1. Having removed the short, closed tube and removed the caps, put into the elements sulphuric acid of the type for specific weight 1.26 accumulators corresponding to 30°...
  • Page 54 Stalker 50 Electrical system When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged.
  • Page 55 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 56 Stalker 50 Engine from vehicle Removal of the engine from the vehicle 1) Disconnect the battery 2) Remove the full muffler. 3) Remove the rear wheel. 4) Remove the rear brake mechanical transmis- sion. 5) Disconnect the electrical system connector from the magneto flywheel, from the starter and from the automatic starter.
  • Page 57 Stalker 50 Engine from vehicle ENG VE - 57...
  • Page 58 INDEX OF TOPICS NGINE...

  • Page 59: Automatic Transmission

    Stalker 50 Engine Automatic transmission Transmission cover - Loosen the 15 screws and remove the transmis- sion cover with the aid of a mallet. N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.
  • Page 60 Stalker 50 Engine - Remove the seeger ring located on the exterior of the crankshaft. - Dismantle the dog gear from its seat, slackening the tension that the toothed sector applies to it by means of the spring; to do this, it is necessary to rotate the toothed sector slightly (see the figure).

  • Page 61: Removing The Driven Pulley

    Stalker 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 62 Stalker 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 63 Stalker 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 64 Stalker 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 65 Stalker 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 66: Refitting The Driven Pulley

    Stalker 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 67: Removing The Driving Pulley

    Stalker 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 68 Stalker 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 69 Stalker 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 70 Stalker 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 71 Stalker 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 72 Stalker 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 73 Stalker 50 Engine Cooling hood - Remove the four fixings shown in the figure. - Remove the fan cover - Remove the oil piping retention band from the hood - Remove the 2 screws shown in the figure Cooling fan - Remove the cooling fan by acting on the three fixings indicated in the figure.

  • Page 74: Removing The Stator

    Stalker 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 carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
  • Page 75 Stalker 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 76 Stalker 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 77: Removing The Cylinder Head

    Stalker 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 78: Inspecting The Small End

    Stalker 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 79 Stalker 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 80: Removing The Piston

    Stalker 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 81 Stalker 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 - 81...
  • Page 82 Stalker 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 83 Stalker 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 84 Stalker 50 Engine Refitting the crankshaft - Position the transmission side half crankcase on two wooden supports - Using a thermal gun, heat the bearing seat to about 120° - Firmly insert the crankshaft until the bearing rea- ches the end-of-stroke stop - Let the temperature of the half crankcase settle at the temperature of the crankshaft.
  • Page 85 Stalker 50 Engine 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 86: Oil Pump

    Stalker 50 Engine Lubrication Crankshaft oil seals Refitting - Install a new flywheel-side oil seal only with the special tool's punch The flywheel-side oil seal is recognised by its smaller diameter N.B. THE USE OF THE SPECIFIC TOOL IS NOT...

  • Page 87: Fuel Supply

    Stalker 50 Engine 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 shown in the figure...
  • Page 88 Stalker 50 Engine OF THE TUBE.. IN THIS CASE, THE TENDENCY IS TO OB- TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT- LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUC- TION PULSATION AND THEREBY GUARANTEE A CON- STANT TAP FLOW RATE.
  • Page 89 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 90: Removing The Front Wheel

    Stalker 50 Suspensions Front suspension This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Support the vehicle in such a way that the front wheel is raised. - Using two 18 mm hexagonal wrenches remove the front wheel axle.

  • Page 91: Front Fork

    Stalker 50 Suspensions Removal - Remove the front handlebar cover. - Remove the rear handlebar cover. - After removing the transmissions and discon- necting the electrical terminals, remove the bolt «A» and the handlebar - Check all components and replace faulty parts.
  • Page 92 Stalker 50 Suspensions See also Front brake calliper Handlebar Overhaul Stem removal - Remove the dust guard (1) using a screwdriver to prise it out. - Remove the seeger (2) and remove the power pipe. N.B. GREASE THE SPRINGS AND THE BUSHINGS BEFORE REFITTING, WITH A SMALL QUANTITY OF GREASE (AROUND 3 GR.)
  • Page 93 Stalker 50 Suspensions Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Stud-stanchion fixing screw 20 to 25 N•m tightening torque 20 to 25 N•m Replacing sealing ring - Remove the wheel axle. - Remove the screw (4).

  • Page 94: Steering Column

    Stalker 50 Suspensions Steering column Removal Removal of the upper and lower frame seat - Only remove the seats if it is strictly necessary. - Using the special tool remove the upper fifth wheel seat by putting the special tool into the lower part of the headstock as indicated in the figure.
  • Page 95 Stalker 50 Suspensions Check the condition of the fifth wheel and the fifth wheel seat on the fork (steering tube). Replace if there are faults. - Support the fork properly. - Using the special tool, remove the fifth wheel seat on the steering tube as shown in the photograph by applying small mallet blows.

  • Page 96: Removing The Rear Wheel

    Stalker 50 Suspensions 020055Y Wrench for steering tube ring nut Locking torques (N*m) Locking torque: 30 to 40 Nm Rear Removing the rear wheel - Use a screwdriver as a lever between the drum and the cover. -Straighten the split pin and remove the cap.
  • Page 97 Stalker 50 Suspensions Locking torques (N*m) Shock absorber/frame nut torque 20 to 25 Nm Shock absorber/engine pin torque 33 to 41 N·m Centre-stand Expulsion of stand fastening pin to the bracket - Remove the stand support bracket from the en- gine.
  • Page 98 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 99 Stalker 50 Braking system Front brake calliper Removal • Check that the brake piping, gasket and fitting are in good condition. If you see any oil on the brake calliper and/on the components of the system, it is necessary to replace them.
  • Page 100 Stalker 50 Braking system • Insert the sealing rings and the pistons in the calliper body • Check the state of the floating body seats and grease them. • Refit the pads • - Position the calliper on the disc and lock to the mounting by tightening the bolts.

  • Page 101: Front Brake Disc

    Stalker 50 Braking system Front brake disc Removal Proceed as follows: - Remove the front wheel - Undo the three disc clamping screws. Refitting -When refitting, position the disc correctly making sure that it rotates in the right direction. Locking torques (N*m)

  • Page 102: Front Brake Pads

    Stalker 50 Braking system If the value measured is greater, re- place the disc and repeat the check. • If the problem persists, check and re- place the wheel hub if necessary. Specific tooling 020335Y Magnetic support for dial gauge...
  • Page 103 Stalker 50 Braking system Refitting Follow the steps in the opposite order from the re- moval, making sure the retention spring is inserted properly. Fill BRAK SYS - 103...
  • Page 104 Stalker 50 Braking system Front -Once the bleed valve is closed, fill the system with brake liquid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in...

  • Page 105: Rear Drum Brake

    Stalker 50 Braking system CAREFULLY DRY THE CALLIPER AND DE- GREASE THE DISC SHOULD THERE BE OIL ON IT. Specific tooling 020329Y MityVac vacuum-operated pump Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Locking torques (N*m) Oil bleed screw 8÷12...
  • Page 106 Stalker 50 Braking system After removing the muffler and the rear wheel do the following: 1. Remove the shoe spring with the special tool 2. Remove the shoe with the aid of a lever 3. Refit the new shoes giving a few taps with the mallet 4.
  • Page 107 INDEX OF TOPICS CHAS HASSIS...

  • Page 108: Instrument Panel

    Stalker 50 Chassis Rear handlebar cover • Remove the front handlebar cover. • - Remove the four screws indicated in the figure. • Disconnect the connections to the switches. For installation, reverse the removal sequence. Instrument panel - Remove the three screws indicated in the figure.
  • Page 109 Stalker 50 Chassis Headlight assy. • - Remove the front shield. • Turn the two screws indicated in the figure to remove the headlight assem- bly. During assembly, pay attention to the correct con- nection of the cables to the lamp support.
  • Page 110 Stalker 50 Chassis Legshield - Remove the shield back plate - Remove the four screws from the front wheel housing. - Remove the three screws from the front shield. - Pull the shield from its seat and disconnect the turn indicators and front headlight connectors.
  • Page 111 Stalker 50 Chassis Knee-guard - Remove the central chassis cover. - Remove the footrest. - Remove the eight screws shown in the figure (four on each side). - Remove the luggage rack hook by turning the two screws. - Pull the shield back plate down.
  • Page 112 Stalker 50 Chassis Footrest • Remove the central chassis cover. • Remove the 6 screws indicated in the figure and remove the footrest by pri- sing at the fittings. Side fairings • Remove the rear spoiler by loosening the 4 retaining screws.

  • Page 113: Rear Mudguard

    Stalker 50 Chassis Rear mudguard • Remove the side panels • Remove the 3 screws indicated in the figure. • Disconnect the electrical connection of the tail light assembly and then pull off the mudguard. During assembly, position the connectors in the correct housings.

  • Page 114: Fuel Tank

    Stalker 50 Chassis Helmet bay • Remove the saddle. • Remove the central cover. • Remove the side panels • Remove the battery and pull out the fu- seholder from its seat. • Remove the fuel tank cap and the oil tank cap.
  • Page 115 Stalker 50 Chassis Mixture oil tank • Remove the left side panel. • Disconnect the oil hose, paying atten- tion to collect the oil remaining in the tank in a suitable container. • Disconnect the electric cable harness from the oil level sensor.
  • Page 116 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 117 Stalker 50 Pre-delivery For the NAKED model, the rear turn indicators should not be mounted on the vehicle when it is taken to the dealer's. To fit the turn indicators, pro- ceed as follows: Take the turn indicators out of the package...
  • Page 118 Stalker 50 Pre-delivery Place the turn indicator unit into its fitting and lock it using the specific screw as indicated in the pho- tograph Refit the glass of the rear light unit. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics...
  • Page 119 Stalker 50 Pre-delivery Rear shock absorber upper fixing Rear shock absorber lower fixing Front wheel axle nut Wheel hub nut Frame - swinging arm bolt * Swinging arm bolt - Engine Engine arm pin - Frame arm Handlebar lock nut...
  • Page 120 Stalker 50 Pre-delivery BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO EN- SURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES.
  • Page 121 Stalker 50 Pre-delivery - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Throttle travel check Others - Check documentation - Check the frame and engine numbers - Tool kit - License plate fitting...
  • Page 122 INDEX OF TOPICS TIME...
  • Page 123 Stalker 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 - 123...
  • Page 124 Stalker 50 Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement TIME - 124...
  • Page 125 Stalker 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 - 125...
  • Page 126 Stalker 50 Time Cylinder assy. YLINDER PISTON Code Action Duration 001002 Cylinder piston - Replacement 001107 Cylinder / piston - Inspection / clean- TIME - 126...
  • Page 127 Stalker 50 Time Cylinder head assy. YLINDER HEAD ASSEMBLY Code Action Duration 001013 Intake manifold - Replacement 001093 Spark plug - Replacement 001126 Head - Replacement 001097 Cooling hood - Replacement 001178 Disc pack - Replacement 001087 Flywheel cover - Replacement...

  • Page 128: Driven Pulley

    Stalker 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 - 128...
  • Page 129 Stalker 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 - 129...
  • Page 130 Stalker 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 - 130...
  • Page 131 Stalker 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 132 Stalker 50 Time Transmission cover RANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement 004179 Stand buffer - Replacement TIME - 132...

  • Page 133: Starter Motor

    Stalker 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 134: Flywheel Magneto

    Stalker 50 Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001058 Flywheel - Replacement 001067 Stator - Replacement 001173 Rotor - Replacement 001109 Cooling fan - Replacement TIME - 134...
  • Page 135 Stalker 50 Time Brake shoes RAKE SHOES Code Action Duration 002002 Rear brake shoe(s) - Replacement TIME - 135...
  • Page 136 Stalker 50 Time Carburettor ARBURETTOR INSPECTION Code Action Duration 001081 Automatic choke - Replacement 001008 Carburettor - Inspection TIME - 136...
  • Page 137 Stalker 50 Time ARBURETTOR Code Action Duration 001063 Carburettor - Replacement 003058 Carburettor - Adjustment 004177 Heating hood - Replacement Exhaust pipe UFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment...

  • Page 138: Air Cleaner

    Stalker 50 Time Air cleaner IR FILTER Code Action Duration 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement 004122 Air cleaner carburettor fitting - Re- placement TIME - 138...
  • Page 139 Stalker 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 - 139...
  • Page 140 Stalker 50 Time Legshield spoiler RONT SHIELD Code Action Duration 004064 Front shield - Replacement 004065 Front shield rear section - Replace- ment 004178 Footrest - Replacement 004053 Spoiler - Replacement TIME - 140...
  • Page 141 Stalker 50 Time Side fairings EAR COVERS Code Action Duration xxxx Rear spoiler - Replacement 004085 Fairing (1) - Replacement 004012 Rear side panels (2) - Replacement xxxxx Lower cover side panel - Replace- ment TIME - 141...
  • Page 142 Stalker 50 Time Underseat compartment ENTRAL FRAME COVER Code Action Duration 004011 Central chassis cover - Replacement TIME - 142...
  • Page 143 Stalker 50 Time ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 005046 Battery cover - Replacement Mudguard EAR MUDGUARD Code Action Duration 004009 Rear mudguard - Replacement TIME - 143...
  • Page 144 Stalker 50 Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004072 Fuel filter - Replacement 004112 Cock / carburettor hose - Replace- ment TIME - 144...
  • Page 145 Stalker 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 - 145...
  • Page 146 Stalker 50 Time Rear shock-absorber EAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorbers - Replace- ment TIME - 146...
  • Page 147 Stalker 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 - 147...
  • Page 148 Stalker 50 Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 002071 Left hand grip - Replacement 002037 Brake or clutch lever - Replacement 005017 Stop switch - Replacement TIME - 148...
  • Page 149 Stalker 50 Time ANDLEBAR COMPONENTS Code Action Duration 004066 Driving mirror - Replacement 003001 Handlebar - Replacement 005017 Stop switch - Replacement 002037 Brake or clutch lever - Replacement 002059 Right hand grip - Replacement TIME - 149...
  • Page 150 Stalker 50 Time Swing-arm WINGING ARM Code Action Duration 001072 Engine / frame swinging arm fitting - Replacement TIME - 150...
  • Page 151 Stalker 50 Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement TIME - 151...
  • Page 152 Stalker 50 Time Instrument panel NSTRUMENT PANEL 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 005076 Clock / Cell - Replacement...

  • Page 153: Turn Signal Lights

    Stalker 50 Time Turn signal lights RONT HEADLAMP Code Action Duration 005067 Front turn indicator bulb - Replace- ment 005008 Front headlamp bulbs - Replacement 005002 Front headlamp - Replacement 005091 Turn indicator glass - Replacement 005012 Front turn indicator - Replacement...
  • Page 154 Stalker 50 Time EAR LIGHTS Code Action Duration 005022 Rear turn indicators - Replacement 005068 Rear turn indicator bulb - Replace- ment 005091 Turn indicator glass - Replacement 005028 Rear light assembly glass - Replace- ment 005066 Rear light bulbs - Replacement...

  • Page 155: Front Wheel

    Stalker 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 156 Stalker 50 Time Rear wheel EAR WHEEL Code Action Duration 001071 Rear wheel rim - Replacement 001016 Rear wheel - Replacement 004126 Rear wheel tyre - Replacement TIME - 156...
  • Page 157 Stalker 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 xxxxxx Turn indicator assembly - Replace- ment xxxxxxx Diode - Replacement...
  • Page 158 Stalker 50 Time LECTRICAL SYSTEM Code Action Duration 001023 Control unit - Replacement 001094 Spark plug cap - Replacement 005001 Electrical system - Replacement 005009 Voltage regulator - Replacement TIME - 158...
  • Page 159 Stalker 50 Time Electronic controls LECTRIC CONTROLS 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 160 Stalker 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 - 160...
  • Page 161 Stalker 50 Time EAR BRAKE TRANSMISSION AND ODOMETER Code Action Duration 002051 Odometer transmission assembly - Replacement 002053 Rear brake transmission complete - Replacement TIME - 161...
  • Page 162 Stalker 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 - 162...
  • Page 163 Stalker 50 Time Braking system RONT BRAKE Code Action Duration 002103 Brake fluid reservoir - Replacement 002052 Front brake transmission - Replace- ment 002025 Brake piping - Replacement 002021 Front brake piping - Replacement 002039 Front brake calliper - Replacement...
  • Page 164 Air filter: 28 Battery: 36, 43, 52 Brake: 92, 99, 101, 102, 105, 135 Carburettor: 10, 136 Engine stop: Fuel: 34, 87, 114, 144 Fuses: 51 Headlight: 31, 109 Hub oil: 26 Identification: 8 Instrument panel: 108, 152 Maintenance: 7, 25 Odometer: Saddle: Spark plug: 26...

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