Vespa Primavera 50 4t 4v Service Manual

SERVICE STATION MANUAL
1Q000134 EN
Vespa Primavera 50 4t 4valvole

SERVICE STATION
MANUAL
The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,
to make any changes to components, parts or accessories, which it considers necessary to improve the
product or which are required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of each
model should be checked at the official PIAGGIO sales network.
© Copyright 2013 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
SERVICE STATION MANUAL
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles
has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant
changes to vehicle characteristics or to specific repair operations will be communicated by updates to
this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools
are unavailable. It is therefore advisable to read the sections of this manual concerning special tools,
along with the special tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE ENG
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
Vespa Primavera 50 4t 4valvole Characteristics
Rules
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
Vehicle identification
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Chassis prefix ZAPC53100
CHAR - 7
Characteristics Vespa Primavera 50 4t 4valvole
Engine prefix C532M
Chassis number
The chassis number «A» is stamped near the fuel
tank.
To read it, proceed as follows:
- lift the saddle;
- lift the helmet compartment by removing it.
Engine number
The engine number «B» is stamped near the rear
left shock absorber lower support.
Dimensions and mass
CHAR - 8
WEIGHTS AND DIMENSIONS

Length 1860 mm
Width 735 mm
Maximum height 1,145 mm
Wheelbase 1,330 mm
Kerb weight 105 ± 5 kg
Maximum weight allowed 295 kg
Engine
ENGINE SPECIFICATIONS
Type single-cylinder, four-stroke, four valves, air-cooled
Bore 39 mm
Stroke 41.8 mm
Engine capacity 50 cm³
Max. power 3.2 kW at 8250 rpm
MAX. torque 3.8 Nm at 7,750 rpm
Compression ratio 12 ± 0.5: 1
Timing system single overhead camshaft, chain-driven, on the left-hand side,
3-arm rocking levers and adjustment with threaded set screw
Idle speed 1800 ± 100 rpm
Lubrication engine lubrication with lobe pump (in the crankcase), chain-
driven. Mesh pre-filter and centrifugal filter on the crankshaft
Fuel system Gravity feed, with unleaded petrol (with a minimum octane rat-
ing of 95) with carburettor.
Valve clearance (cold engine) intake 0.10 mm
outlet 0.15 mm
carburettor vacuum KEIHIN NCV ø 20 with electronic control of carburation
(SIS)
Cooling Forced air circulation cooling
Transmission Automatic expandable pulley variator with torque server, V-
belt, automatic centrifugal dry clutch.
Final reduction gear Gear reduction unit in oil bath.
Ignition Electronic inductive discharge ignition, with variable advance
and separate HV coil.
Starter Starter and kick starter
Spark plug NGK ER9EH-6N
Electrode gap 0.5 ÷ 0.6 mm
OIL PUMP
Type Trochoidal
Distance between the rotors Admissible limit clearance: 0.15 mm
Axial rotor clearance Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump body Admissible limit clearance: 0.20 mm
Levelness 0.1 mm
OIL FILTER
Type mesh, plastic and centrifugal filter, before the oil pump and co-
axially mounted onto the crankshaft keyed on the right crank
CHAR - 9
Transmission
TRANSMISSION
Transmission With automatic expandable pulley variator, torque server, V-
belt, automatic clutch, gear reduction unit.
Capacities
CAPACITIES
Engine oil ~ 850 cm³
Transmission oil 100 cm³
Fuel tank capacity 6.4 ± 0.1 l
Electrical system
When the advance check is carried out with a stroboscopic gun, add 10° flywheel keying to the table
below.
ELECTRICAL COMPONENTS
1 Ignition advance reference in table
2 Spark plug NGK ER9EH-N
3 Battery 12V - 6 Ah
4 Fuses 1 15A - 2 7.5A - 3 10A - 4 5A
5 Alternator single-phase alternating current
CHAR - 10
CHECKING RELAYS «A» OPERATING AS CIR-

CUIT BREAKERS
1) Check that, given regular conditions, there is no
continuity between terminals 30 and 87.
2) Apply 12V voltage to power terminals 85 and 86
of the relay.
3) With the relay powered, check that there is con-
tinuity between terminals 30 and 87.
4) If these conditions are not fulfilled, the relay is
damaged and must be replaced.
TURN INDICATOR SWITCH
IGNITION SWITCH
LIGHT SWITCH
CHAR - 11
STARTER BUTTON
HORN BUTTON
STOP BUTTON
Resistance between green cable and ground con-

nection: approx. 170 Ohm
CHAR - 12
- Primary resistance: 0.5 to 0.6 Ohm

- Resistance between primary and ground con-
nection: infinite
- Resistance between primary and HV output: 3 to
3.6 kOhm
- Shielded cap: 5000 Ohm
- Power: 120 W
- resistance between BLUE cable and GROUND
CONNECTION: 1 Ohm
Frame and suspensions
CHASSIS AND SUSPENSIONS

Type Stamped plate body with welded structural reinforcements.
Front suspension Single arm suspension with swinging arm articulated to the
steering tube. Hydraulic double-acting shock absorber and co-
axial spring
Front suspension stroke 70 mm
Trail (suspension rebounded/compressed) 71/68 mm
Rear suspension Single hydraulic double-acting shock absorber, helical coaxial
spring. Chassis to engine support with swinging arm.
Rear suspension travel: 83.5 mm
Brakes
BRAKES
Front brake Ø 200-mm disc brake with hydraulic control activated by han-
dlebar right-side lever.
Rear drum Ø 140-mm drum brake with mechanical control activated by
handlebar left-side lever.
Wheels and tyres
WHEELS AND TYRES

Wheel rim type Light alloy.
Front wheel rim 11'' x 2.50
CHAR - 13
Rear wheel rim 11'' x 2.75
Front tyre Tubeless, 110/70 - 11'' 45L
Rear tyre Tubeless, 120/70 - 11'' 56L
Front tyre pressure 1.6 bar
Rear tyre pressure 1.8 bar
Carburettor
50cc Version
Kehin
KEIHIN CARBURETTOR
Type: NCV 20
Throttle valve diameter: Ø 20.5
Diffuser diameter Ø 18.5
Body stamping: AR3B
Maximum nozzle: 72
Maximum air nozzle (on the body): Ø2
Tapered pin stamped code: NNRA
Throttle valve spring: 70 ÷ 117 gr
Minimum nozzle: 35
Minimum air nozzle (on the body): Ø 1.8
Initial minimum mix screw opening: 1 3/4
Starter nozzle: 42
Starter air nozzle (on the body): Ø 1.5
Stroke of starter pin: 10.24 mm
Tightening Torques
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 30 to 40
Lower steering ring nut 8 to 10
Handlebar locking 50 to 55 Nm
FRAME ASSEMBLY
Name Torque in Nm
Engine-swinging arm bolt 33 to 41
Frame-swinging arm bolt 44 to 52
Shock absorber - chassis nut 20 - 25
Shock absorber nut-engine 33 to 41
Rear wheel nut 104 to 126
Screws fixing the odometer reel plate 4 to 6
FRONT SUSPENSION
Name Torque in Nm
Shock absorber upper nut 20 to 30
Front wheel axle nut 75 to 90
Shock absorber upper bracket bolts 20 - 25
Wheel rim screws 20 - 25
Shock absorber lower bolts (°) 20 to 27
(°) Lock these two bolts once the central upper nut of the shock absorber has been tightened.
N.B.
CHAR - 14
FOR SAFETY FASTENERS, SEE THE «PRE-DELIVERY» CHAPTER.
FRONT BRAKE
Name Torque in Nm
Brake fluid pump-hose joint 8 - 12
Brake fluid pipe-calliper fitting 20 to 25
Screw tightening calliper to support 20 to 25
Brake disc screw 5 to 6.5
Oil bleed valve (on the calliper) 10 - 12
Handlebar pump 7 - 10
ENGINE ASSEMBLY
Name Torque in Nm
Ignition spark plug: 10 to 15 Nm
Floating head cover screws 6 to 7
Head-cylinder stud bolt nuts 6 to 7 + 90° + 90° *
Screws fixing head and cylinder to crankcase 8 - 10
Chain tensioner pad screw 5 to 7 Nm
Timing chain tensioner central screw 5-6
Camshaft pulley screw 12 - 14
Rocking lever axle and camshaft bearing screw 3 to 4 Nm
Rocking levers adjusting nuts: 7 to 9 Nm
Engine oil pre-filter cover: 25 - 28 Nm
Engine oil drainage cap 25 - 28
Flywheel nut 40 to 44 N.m
Stator screws 3 to 4
Pick-up screws 3-4
Oil pump bulkhead screw 4-5
Timing chain/oil pump compartment cover screws 4 to 5
Oil decantation labyrinth sheet screws 7 to 8
Oil pump sprocket gear screw 8 - 10
Screws fixing oil pump to the crankcase 5-6
Oil sump screws 8 - 10 Nm
Inlet manifold screw 7-9
Carburettor/manifold clamp screw 1.2 to 1.5
Screws fixing cables to starter motor 1.5 - 2.5
Starter motor screws 11 - 13
Transmission cover screws 11 ÷ 13
Start-up lever screw 11 to 13
Crankcase cooling cover screw 2 to 2.5
Clutch assembly nut 55 to 60
Crankshaft pulley nut 18 to 20 + 90° Nm
Driven pulley shaft nut 40 to 44 Nm
Hub oil drainage screw 3 - 5 Nm
Rear hub cap screws 11 to 13
Crankcase half union screw 8 - 10
* When assembling the new stud bolts, nut tightening involves 3 turns of 90° each after the first locking
at 6 to 7 Nm, consequently: 6 to 7 Nm + 90° + 90° + 90° at criss-crossed sequences.
Overhaul data
Assembly clearances
CHAR - 15
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND CYLINDER

Name Initials Cylinder Piston Play on fitting
Cylinder A 38.993 to 39.000 38.954 to 38.961 0.032 to 0.046
Cylinder B 39.000 to 39.007 38.961 to 38.968 0.032 to 0.046
Piston C 39.007 to 39.014 38.968 to 38.975 0.032 to 0.046
Piston D 39.014 to 39.021 38.975 to 38.982 0.032 to 0.046
Cylinder 1st oversize A1 39.193 to 39.200 39.154 to 39.161 0.032 to 0.046
Cylinder 1st oversize B1 39.200 to 39.207 39.161 to 39.168 0.032 to 0.046
Piston 1st oversize C1 39.207 to 39.214 39.168 to 39.175 0.032 to 0.046
Piston 1st oversize D1 39.214 to 39.221 39.175 to 39.182 0.032 to 0.046
Cylinder 2nd oversize A2 39.393 to 39.400 39.354 to 39.361 0.032 to 0.046
Cylinder 2nd oversize B2 39.400 to 39.407 39.361 to 39.368 0.032 to 0.046
Piston 2nd oversize C2 39.407 to 39.414 39.368 to 39.375 0.032 to 0.046
Piston 2nd oversize D2 39.414 to 39.421 39.375 to 39.382 0.032 to 0.046
Cylinder 3rd oversize A3 39.593 to 39.600 39.554 to 39.561 0.032 to 0.046
Cylinder 3rd oversize B3 39.600 to 39.607 39.561 to 39.568 0.032 to 0.046
Piston 3rd oversize C3 39.607 to 39.614 39.568 to 39.575 0.032 to 0.046
Piston 3rd oversize D3 39.614 to 39.621 39.575 to 39.582 0.032 to 0.046
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
- Measure the outer diameter of the gudgeon pin.
Characteristic
Pin outside diameter
13 +0 -0.004 mm
Minimum admissible diameter gudgeon pin
12.990 mm
CHAR - 16
- Measure the diameter of the bearings on the pis-

ton.
Characteristic
Pin seat diameter
13 +0.005 + 0.010 mm
- Calculate the piston pin coupling clearance.

N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT
MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance
0.005 to 0.014 mm
- Carefully clean the seal housings.

- Measure the coupling clearance between the
sealing rings and the piston grooves using suitable
sensors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.
Fitting clearance
Top piston ring - standard coupling clearance
0.03 to 0.065 mm Top piston ring - maximum clear-
ance allowed after use 0.07 mm Middle piston
ring - standard coupling clearance 0.02 to 0.055
mm Middle piston ring - maximum clearance al-
lowed after use 0.06 mm oil scraper ring - stand-
ard coupling clearance 0.04 to 0.16 mm oil scraper
ring - maximum clearance allowed after use
0.17 mm
- Using a bore meter, measure the inner cylinder

diameter at three different points according to the
directions shown in the figure.
- Check that the coupling surface with the head is
not worn or misshapen.
CHAR - 17
- Pistons and cylinders are classified into catego-

ries based on their diameter. The coupling is car-
ried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out:
0.001 in 0.05 mm
Piston rings
- Alternately insert the three sealing rings into the

cylinder, in the area where it retains its original di-
ameter. Using the piston, insert the rings perpen-
dicularly to the cylinder axis.
- Measure the opening, see figure, of the sealing
rings using a thickness gauge.
- If any measurements are greater than specified,
replace the piston rings.
N.B.
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE
THAT THE CLEARANCE BETWEEN THE PISTON RINGS
AND THE PISTON RING GROOVES, AND BETWEEN THE
PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY
CASE, NEW PISTON RINGS USED IN COMBINATION WITH
A USED CYLINDER MAY HAVE DIFFERENT BEDDING
CONDITIONS THAN THE STANDARD.
SEALING RINGS
Name Description Dimensions Initials Quantity
1st Compression ring 39 x 1 A 0.08 to 0.20
CHAR - 18

2nd Compression ring 39 x 1 A 0.05 to 0.20
Oil scraper ring 39 x 2 A 0.20 to 0.70
1st Compression ring 39.2 x 1 A 0.08 to 0.20
1st Oversize
2nd Compression ring 39.2 x 1 A 0.05 to 0.20
1st Oversize
Oil scraper ring 1st 39.2 x 2 A 0.20 to 0.70
Oversize
2nd Oversize
2nd Oversize
Oil scraper ring 2nd 39.4 x 2 A 0.20 to 0.70
Oversize
3rd Oversize
3rd Oversize
Oil scraper ring 3rd 39.6 x 2 A 0.20 to 0.70
Oversize
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE

Half-shaft, transmission 14 +0 -0.005 A
side
Flywheel-side half shaft 16 +0 -0.005 B
Connecting rod 14.8 +0.05 -0 C
Spacer tool 45.00 / Fits and clearan- E
ces D = 0.15 to 0.30
Characteristic
Clearance between crankshaft and connecting rod
A = 0.15 to 0.30 mm
CHAR - 19
Measure the bearings along X and Y axes
Characteristic
Crankshaft bearing, transmission side
20 -0.012 -0.025 mm
Crankshaft bearing, flywheel side
17 +0.007 0 mm
- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded
tangs are in good working order.
- In case of failures, replace the crankshaft.
Specific tooling
020074Y Support base for checking crankshaft alignment
CHAR - 20
To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated
in figure.
N.B.
IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC-
TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-
SERTING A WOODEN WEDGE BETWEEN THE HALF
SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-
DED. IF EVEN AFTER THIS OPERATION THE VALUES ARE
NOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.
Characteristic
Off-line maximum admitted - A
0.15 mm
Off-line maximum admitted - B
0.02 mm
Off-line maximum admitted - C
0.02 mm
Off-line maximum admitted - D
0.10 mm
- Using a bore gauge, measure the connecting rod

small end diameter.
N.B.
IF THE CONNECTING ROD SMALL END DIAMETER EX-
CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANK-
SHAFT AS DESCRIBED IN THE CRANKCASE AND
CRANKSHAFT CHAPTER.
Characteristic
Rod small end diameter
13 +0.015 + 0.025 mm
Max. diameter admitted: check the small end
13.030 mm
Calculate the coupling clearance between pin and rod small end
Characteristic
Pin - connecting rod clearance
0.015 - 0.029 mm
Cylinder Head
Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of
the springs and the valves so as not to change the original position during refitting
CHAR - 21
- Using a trued bar check that the cylinder head

surface is not worn or distorted.
- Check that the camshaft and rocking lever pin
bearings show no signs of wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
- It is advisable to replace the head if any failure is
found.
Characteristic
0.1 mm
- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Measure the camshaft bearing seats and rocking

lever support pins with a bore meter
HEAD CHECK
Standard diameter (mm) A Ø 32.015 to 32.025
Standard diameter (mm) B Ø 16.0 to 16.018
Standard diameter (mm) C Ø 11.0 to 11.018
CHAR - 22
Measure the unloaded spring length.
• Standard length: 31.3 mm

• Limit allowed after use: 29.3
- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the
impression on the valve seat "V".
Characteristic
Standard value:
1 - 1.3 mm
Limit allowed:
1.6 mm
- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damage, replace the head.
STANDARD VALVE LENGTH

Inlet: standard length 74.9 mm
Outlet: standard length 74.35 mm
CHAR - 23
- Measure the diameter of the valve stems in the

three positions indicated in the diagram.
STANDARD DIAMETER
Intake 3.970 to 3.985 mm
Exhaust 3.960 to 3.975 mm
MINIMUM DIAMETER PERMITTED

Intake 3.958 mm
Exhaust 3.945 mm
- Calculate the clearance between the valve and the valve guide.
- Check the concentricity of the valve head by

placing a dial gauge at right angles to the valve
head and rotating it on the «V» shaped support.
Characteristic
Limit allowed:
0.03 mm
- Check the deviation of the valve stem by resting

it on a «V» shaped abutment and measuring the
extent of the deformation with a dial gauge.
Characteristic
Limit values admitted:
0.1 mm
CHAR - 24
Measure the valve guides
VALVE GUIDE DIAMETER

Valve guide Standard diameter: 4 + 0.012 mm
Valve guide Maximum admissible diameter: 4 + 0.022 mm
- After measuring the valve guide diameter and the

valve stem diameter, check clearance between
guide and stem.
INTAKE
Standard clearance 0.015 to 0.042 mm
Admissible limit 0.06 mm
EXHAUST
Standard clearance 0.025 - 0.052 mm
- If no anomalies are found during the above checks, you can use the same valves. To obtain better
sealing performance, grind the valve seats. Grind the valves gently with a fine-grained lapping com-
pound. During the grinding, keep the cylinder head with the valve axes in a horizontal position. This will
prevent the lapping compound residues from penetrating between the valve stem and the guide (see
figure).
CAUTION
TO AVOID SCORING THE MATING SURFACE, DO NOT ROTATE THE VALVE WHEN NO LAPPING
COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A
SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
CHAR - 25
- Inspect the camshaft for signs of abnormal wear

on the cams.
Characteristic
Standard diameter - Bearing A:
Ø 12 +0.002 +0.010
mm Standard diameter - Bearing B:
Ø 16-0.015 -0.023 mm
Minimum diameter allowed - Bearing A:
Ø 11.98 mm
Minimum diameter allowed - Bearing B:
Ø 15.96 mm
-Using a gauge, measure the cam height.
Check the axial clearance of the camshaft
- If any of the above dimensions are outside the

specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
N.B.
A BALL BEARING IS FITTED ON BEARING «A»; CONSE-
QUENTLY, BEARING «B» IS THE MOST IMPORTANT AS IT
WORKS DIRECTLY ON THE HEAD ALUMINIUM
Characteristic
Standard height - Inlet
24.397 mm
Standard height - Outlet
23.996 mm
Fitting clearance
Maximum admissible axial clearance: 0.5 mm
- Measure the outside diameter of the rocking lever pins

- Check the rocking lever pins do not show signs of wear or scoring.
- Measure the internal diameter of each rocker.
- Check that the pad in contact with the cam is not worn.
ROCKING LEVERS AND PIN DIAMETER:

Rocking levers - Inside diameter 11.015 to 11.035 mm
Rocking levers - Pins diameter 10.977 to 10.985 mm
CHAR - 26
Slot packing system
Characteristic
Compression ratio
11.5 to 12 : 1
PISTON PROTRUSION CHECK

Name Measure A Thickness
shimming_1 1.7 to 1.95 0.25
shimming_2 1.95 to 2.2 0.35
Products
RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis- API GL-4
sions.
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116
- DOT 3/4 - ISO 4925 - CUNA NC 956
DOT 4
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per- JASO MA, MA2 - API SL - ACEA A3
formance four-stroke engines.
AGIP FILTER OIL Special product for the treatment of foam -
filters.
AGIP GREASE MU3 Yellow-brown, lithium-base, medium-fi- ISO L-X-BCHA 3 - DIN 51 825 K3K -20
bre multipurpose grease.
AGIP GP 330 Water repellent stringy calcium spray R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 -
grease. I.A.T.A. 2 - I.M.D.G. class 2 UN 1950
Page 9022 EM 25-89
CHAR - 27
INDEX OF TOPICS
TOOLING TOOL
Vespa Primavera 50 4t 4valvole Tooling
TOOLS
Stores code Description
001467Y008 Pliers to extract 17 mm ø bearings
001467Y029 Bell for bearings, O.D. 38 mm
004499Y Bearing extractor. Fitted with: 1 Bell, 2

Sleeve, 3 Screw, 6 Ring, 27 Half rings, 34
Half rings
005095Y Engine support
008119Y009 Tube to assemble shafts and axles
020004Y Punch for removing steering bearings

from headstock
TOOL - 29
Tooling Vespa Primavera 50 4t 4valvole

020055Y Wrench for steering tube ring nut
020074Y Tool to align crankshaft

020150Y Air heater mounting
020151Y Air heater
020162Y Flywheel extractor
020171Y Punch for driven pulley roller bearing
020265Y Bearing fitting base
TOOL - 30

020288Y Fork to assemble piston on cylinder
020291Y Valve fitting/ removal tool
020306Y Punch for assembling valve seal rings
020329Y Mity-Vac vacuum-operated pump
020330Y Stroboscopic light to check timing
020331Y Digital multimeter
TOOL - 31

020332Y Digital rpm indicator
020334Y Multiple battery charger
020335Y Magnetic mounting for dial gauge
020340Y Flywheel and transmission oil seals fitting

punch
020358Y 37 x 40mm Adaptor

TOOL - 32

020360Y 52 x 55-mm Adaptor
020362Y 12 mm guide
020363Y 20-mm guide
020364Y 25-mm guide
020376Y Adaptor handle
020431Y Valve oil seal extractor
TOOL - 33

020432Y Tool to fit the start-up sector spring
020439Y 17-mm guide
020444Y Pin fitting/removal tool

020448Y Tool for fitting the pin snap rings
020449Y Piston position check support
020450Y Camshaft fitting/removal tool
020451Y Driving pulley lock wrench

020452Y Tube for removing and refitting the driven
pulley shaft
TOOL - 34

020456Y Ø 24 mm adaptor
020565Y Flywheel lock calliper spanner
020683Y Valve pressing member
020922Y Diagnosis Tool
TOOL - 35
INDEX OF TOPICS
MAINTENANCE MAIN
Vespa Primavera 50 4t 4valvole Maintenance
Maintenance chart
SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R:REPLACE, A: ADJUST, L:LUBRICATE
* Replace every 2 years
Km x 1000 1 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
Safety fasteners I I I I I I
Spark plug R R R R R R R R R R
Drive belt I R I R I R I R I R
Throttle control A A A A A A
Tyre condition and I I I I I
wear
Air filter C C C C C
Oil filter (mesh) C C C C C C C C C C
Solenoid filter C C C C C C C C C C
Valve clearance I I I I I I
Electrical system I I I I I I I I I I I
and battery
Cylinder cooling I I
system
Brake levers L L L L L L
Brake fluid level (*) I I I I I I I I I I I
Hub oil level R I R I R I R I R I R
Engine oil R I R I R I R I R I R I R I R I R I R I R
Brake pads/shoes I I I I I I I I I I I
Tyre pressure I I I I I I I I I I I
Headlight A A A A A
Vehicle road test I I I I I I I I I I I
Idle speed A A A A A A
CVT rollers I R I R I R I R I R
Suspension I I I I I
Steering A A A A A A
Transmission L L L L L
Operation time 90' 10' 60' 10' 13 10' 60' 10' 18 10' 60' 10' 16 10' 60' 10' 18 10' 60' 10' 13
0' 0' 5' 0' 0'
Carburettor
The carburettor features a solenoid valve "A" that,

via an ECU, manages an extra flow of air.
It is connected to the carburettor via flexible pipes
as shown in the figure.
The valve is placed under the helmet compartment
as shown in the picture.
Pipe "B" is coupled to a filter placed inside the
body. The solenoid filter should be cleaned ac-
cording to the kilometres travelled as instructed in
the scheduled maintenance chart.
MAIN - 37
Maintenance Vespa Primavera 50 4t 4valvole
- Disassemble the carburettor in its parts, wash all

of them with solvent, dry all body grooves with
compressed air to ensure adequate cleaning.
- Check carefully that the parts are in good condi-
tion.
-The throttle valve should move freely in the
chamber. Replace valve in case of wear due to
excessive clearance.
- If there are wear marks in the chamber causing
inadequate tightness or a free valve slide (even if
it is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit.
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE
GASKETS TO AVOID PETROL LEAKS
1. Needle valve - 2. Idle adjustment screw - 3. Max jet - 4. Accelerating pump - 5. Tapered pin - 6. Jet
holder - 7. Float - 8. Reservoir - 9. Starter device - 10. Depression valve - 11. Cover - 12. Minimum jet.
Checking the spark advance
The vehicle is fitted with a variable advance elec-

tronic device. There are two timing references on
the flywheel cover in order to ensure a better pre-
cision when detecting the reference on the fan.
CAUTION
IF THE FLASH INDICATION IS UNSTABLE AND THE RPM
INDICATION DOES NOT CORRESPOND TO THE ACTUAL
SPEED VARIATION OF THE ENGINE (I.E. HALF VALUES),
PROCEED WITH INSERTION OF A RESISTANCE CABLE
FROM 10 ÷ 15 KΩ CONNECTED IN SERIES TO THE H.V.
CABLE IF READING IRREGULARITIES PERSIST WITH
MAIN - 38
THE SYSTEM SET UP THIS WAY, CHECK THE IGNITION

SYSTEM COMPONENTS.
When the advance check is carried out with a stroboscopic gun, add 10° flywheel keying to the table
below.
Spark plug
Disconnect and remove the spark plug tube.

- Examine it carefully and replace it if the insulator
is chipped or cracked.
- Measure electrode gap with a thickness gauge
and, if necessary, adjust the gap by carefully bend-
ing the outer electrode forward or away.
- Make sure the sealing washer is in good condi-
tions.
- Fit the spark plug, screw it manually and lock it
to the prescribed torque with a spark plug spanner.
Characteristic
Electrode gap
0.5 ÷ 0.6 mm
Electric characteristic
Spark plug
MAIN - 39
NGK ER9EH-6N
Locking torques (N*m)

Spark plug 8 ÷ 10
Hub oil
Check
Rest the vehicle on its centre stand on an even

surface.
- Unscrew the oil dipstick "A", dry it with a clean
cloth and reinsert it, screwing it in thoroughly.
- Pull out the dipstick and check that the oil level is
above the "middle" notch (dipstick with 3 notches).
For dipsticks with 2 notches, the oil level must re-
main in the lower half of the dipstick.
-Screw up the oil dipstick again and make sure it
is locked properly into place.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gear-
boxes and transmissions.
API GL-4
Replacement
Remove the oil filler cap/dipstick "A".

- Unscrew the oil drainage plug "B" shown in the
figure and drain out all the oil.
- Screw the drainage plug back and fill up the hub
with the required oil (about 100 cm³)
MAIN - 40
Air filter
Once the left side fairing has been removed, take

out the air cleaner cap by unscrewing the 4 fixing
screws and the 2 knobs (they can be reached by
tipping the saddle and removing the helmet com-
partment); afterwards, remove the filtering ele-
ment.
Cleaning:
- Wash with water and car shampoo;
- Dry with a clean cloth and short blasts of com-
pressed air; do not wring;
- Immerse it in a mixture of 50% oil and 50 % petrol.
- Allow the filtering element to drip dry and then
press it in your hands but without squeezing.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR FILTER.
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE
PISTON AND CYLINDER.
Engine oil
Replacement
Loosen the oil filler plug.

- Unscrew the drainage plug from the mesh filter
on the flywheel side, and let the oil drain off.
- Screw in the drainage cap again and fill with the
recommended oil.
eni i-Ride PG 5W-40 Synthetic based lubricant
for high-performance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
Characteristic
Engine oil
~ 850 cm³
MAIN - 41
Check
Park the vehicle on a level surface and rest it on

its stand (cold engine).
- Check that the oil level is between the MAX and
MIN marks on the dipstick.
- The MAX level reference indicates ~ 850 cm³ in
the engine.
- If the oil level is close to the MIN mark, top-up by
adding oil but do not exceed the MAX level.
Engine oil filter
- Change oil when the engine is hot.

- Place a container under the oil sump and remove
the oil drainage cap.
- After draining the oil, clean the mesh filter with a
specific solvent and then blow it with compressed
air.
- The filter can be reached after removing cap
"A" (see figure).
- After this operation, refit the filter and screw the
oil cap at the prescribed torque using a new O-
Ring
- Refill the engine with oil through the oil filling hole
located in the oil sump.
- Engine oil capacity: ~ 850 cc.
- Lock the cap manually.
N.B.
Run the engine for a couple of minutes and check the oil level
when the engine is cold. The level should always be below the
MAX mark
N.B.
MAIN - 42
For the first top-up or when servicing, add 850 cm³ of engine
oil; for any other case, add 650 cm³ and top-up, if required.

Engine oil pre-filter cover 25 - 28 Nm
Checking the ignition timing
- Turn the flywheel clockwise until its 2nd notch

coincides with the Pick-up reference mark as
shown in the figure.
Make sure that the reference point on the camshaft
command crown is aligned with the reference point
on the head as shown in the second figure.
If the reference is opposite the indicator on the
head, turn the crankshaft once more as the piston
must be at the TDC of the bursting phase.
N.B.
TIME THE TIMING SYSTEM UNIT AS DESCRIBED IN CHAP-
TER 6 IF IT IS NOT IN PHASE
Checking the valve clearance
- Remove the spark plug access cover, undo the

4 fixing screws indicated in the figure and remove
the tappet cover.
- To check valve clearance, centre the reference
marks of the timing system point as described
above.
- Use a thickness gauge to check valve clearance
- If the valve clearance values, inlet and outlet re-
spectively, differ from those indicated below, re-
MAIN - 43
place the calibrated pads in order to restore the

correct valve clearance.
Characteristic
Inlet (with cold engine)
0.10 mm
Outlet (with cold engine)
0.15 mm
Headlight adjustment
Proceed as follows:
1. Position the vehicle in running order and with
the tyres inflated to the prescribed pressure, onto
a flat surface 10 m away from a half-lit white
screen; ensure that the longitudinal axis of the ve-
hicle is perpendicular to the screen;
2. Turn on the headlight and check that the boun-
dary of the light beam projected onto the screen is
not higher than 9/10 or lower than 7/10 of the dis-
tance between the centre of the headlight and the
ground;
3. Otherwise, adjust the right headlight with screw
«A».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
MAIN - 44
CO check
The check may be necessary in the event of irreg-

ularities in the engine performances, or when ad-
justing the engine idle speed.
- The test must be carried out only after having
carefully cleaned all carburettor components with
the air filter clean and the spark plug in good con-
ditions.
1) Warm up the engine by riding the vehicle for
about 5-10 minutes, as this is the time required for
the choke device to disengage.
2) Shut down the engine only for the time required
to carry out operations 3) and 4).
3) Remove the RH side fairing and the SAS box
cover by loosening the 3 screws shown in the fig-
ure. Interpose a plastic sheet between the secon-
dary air one-way valve and its housing on the
cover. Ensure the valve gasket seals properly. Re-
fit the SAS box cover.
4) Fit the special tool for the collection of exhaust
gases as shown in the picture. Pay attention in en-
suring the seal between the exhaust pipe and the
collection tube. Insert the gas analyser and the ex-
haust tube.
5) Insert the multimetre thermometer inside the
sump, through the oil filler hole.
6) Start up the engine and, before adjusting the
idle speed, ensure the oil temperature is between
70 and 80 °C.
7) Wait for a few minutes to let the temperature
stabilise.
8) Without ever activating the throttle and
through the idle screw, bring the engine speed to
1,950 ± 50 rpm.
9) Adjust the flow screw so to obtain a "CO" read-
ing of 3.2 % ± 0.5 %.
MAIN - 45
10) Slowly twist the throttle handgrip, bringing the

engine up to a speed of 4,000 rpm and then re-
lease it; check the idle speed is the same as be-
fore, otherwise repeat the operations starting from
point (3).
Specific tooling
494929Y Exhaust fumes analyser
SAS filters inspection and cleaning
Undo the two screws «A» of the side fairing and

remove the fairing. Undo the three screws «B» and
remove the housing cover of the secondary air
system. Detach the housing cover and remove the
filtering element «C» made of sponge. Wash the
sponge with water and neutral soap, then dry with
a clean cloth and short blasts of compressed air.
While cleaning the filter, check the condition of the
reed valve «D», and fit it back in place on the
housing.
Before closing the cover of the SAS housing,
check the good condition of the sealing O-ring; re-
place it if damaged or deformed.
N.B.
The reed valve can be inserted in only one direction on the
SAS housing
MAIN - 46
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Troubleshooting Vespa Primavera 50 4t 4valvole
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Air filter obstructed or dirty. Dismantle the sponge, wash with water and shampoo, then
soak it in a mixture of 50% petrol and 50% Selenia Air Filter Oil,
then allow to drip dry. Wring out water manually without
squeezing and reassemble.
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Dirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol and wash the
tank, if necessary. Replace the cock as a last resource.
Clutch slipping Check the clutch system and/or the bell and replace if neces-
sary
Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-
aged parts and lubricate the driven pulley moveable guide with
Montblanc Molybdenum Grease
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Oil level exceeds maximum Check for causes and fill to reach the correct level
Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts (see 50 four
stroke Engines manual)
Silencer obstructed Replace
Fuel filter on vacuum operated cock blocked Clean the cock filter
Wrong valve adjustment Adjust the valve clearance properly
Valve seat distorted Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings
Rear wheel spins at idle
REAR WHEEL
Idling rpm too high Check the idling speed and, if necessary, adjust the C.O.
Clutch fault Check the spring/friction mass and the clutch housing
Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged
Purifier-carburettor fitting damaged Replace
Starting difficulties
START-UP PROBLEMS
Defective spark plug or with incorrect electrode gap Check and if necessary replace the spark plug and the elec-
trode gap
Flat battery Check the state of the battery. If it shows signs of sulphating
replace it and bring the new battery into service charging it for
eight hours at a current of 1/10 of the capacity of the battery
itself
Engine flooded Start the vehicle keeping the throttle fully open alternately mak-
ing the engine run for approx. five seconds and stopping for
other five seconds. If however it does not start, remove the
spark plug, the engine over with the throttle open being careful
to keep the cap in contact with the spark plug and the spark
plug grounded but away from its hole. Refit a dry spark plug
and start the vehicle.
Vacuum operated cock failure Check that fuel is adequately supplied through the pipe by ap-
plying a vacuum to the vacuum pipe
TROUBL - 48
Vespa Primavera 50 4t 4valvole Troubleshooting

Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace
if necessary.
Wrong ignition advance Check flywheel keying on the crankshaft, replace control unit if
necessary
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance
Rpm too low at start-up or engine and start-up system dam- Check the starter motor and the system.
aged
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE

Maximum jet clogged Remove the carburettor, wash with solvent and dry with com-
pressed air
Water or condensation in the carburettor chamber Remove the chamber, wash with solvent and dry with com-
pressed air or empty the tank through the appropriate bleed
screw
Incorrect ignition advance Use a stroboscopic light to check ignition advance and the fly-
wheel correct keying
Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then
soak in a mixture of 50% petrol and 50% of specific oil (Selenia
Air Filter Oil), then squeeze lightly without wringing, let it drip
dry and refit.
Incorrect float level Restore the correct level in the chamber (the float must be par-
allel to the upper cover contact plane, that is the throttle valve
membrane cover)
Fuel supply pipes choked or clogged Restore the adequate fuel supply
Tank breather hole obstructed Restore the proper reservoir aeration
Level in chamber too low Restore the correct level in the chamber (the float must be par-
membrane cover)
Engine tends to cut-off at idle
ENGINE STOP IDLING

Air calibrated holes in carburettor blocked Dismantle, wash with solvent and dry with compressed air
Defective floating valve Check the proper sliding of the float and the functioning of the
valve
Level in chamber too high Restore the correct level in the chamber (the float must be par-
membrane cover)
The starter remains on Check that the small piston slides smoothly and check the au-
tomatic starter power supply; replace it if required
dry and refit.
Wrong idling adjustment Correctly adjust the engine idling and check the level of the
C.O.
Spark plug defective or faulty Replace the spark plug with one with the specified degree and
check the plug gap
Pressure too low at the end of compression Check the thermal group seals and replace worn components
Incorrect timing Time the system and check the timing system components
TROUBL - 49
High fuel consumption
EXCESSIVE FUEL CONSUMPTION

dry and refit.
The starter remains on Check that the starter runs correctly and it is properly powered
Loose nozzles Check the maximum and minimum nozzles are adequately
fixed in their fittings
Incorrect float level Check and restore the correct fuel level in the chamber
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Faulty clutch Check that there is no grease on the masses. Check that the
clutch mass faying surface with the bell is mainly in the centre
with equivalent characteristics on the three masses. Check that
the clutch housing is not scored or worn in an anomalous way
Insufficient braking
INEFFICIENT BRAKING
Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk or
drum wear conditions.
Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be
no flexible movement of the brake lever).
Brake disc or drum deformed Use a dial gauge to check the levelness of the disk with the
wheel correctly fitted and the concentricity of the rear drum;
check the brake disc screws are locked
Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump breakdown, replace
Excessive clearance in the rear brake control cable Adjust backlash with the appropriate adjuster on the shoe con-
trol lever
The brake fluid has lost its properties Replace the front brake fluid and top up to the correct level in
the pump
Return spring broken Replace spring.
Shoe control bolt not lubricated Lubricate with Z2 grease.
Brakes overheating
BRAKE OVERHEAT
Defective plunger sliding Check calliper and replace any damaged part.
Brake disc or drum deformed Use a dial gauge to check the levelness of the disk with the
wheel correctly fitted and the concentricity of the rear drum;
check the brake disc screws are locked
TROUBL - 50
Vespa Primavera 50 4t 4valvole Troubleshooting
Electrical system
Battery
BATTERY
The battery is the electrical device in the system that requires The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. the most frequent inspections and thorough maintenance. If the
vehicle is not used for some time (1 month or more) the battery
needs to be recharged periodically. The battery runs down
completely in the course of 5 to 6 months. If the battery is fitted
on a motorcycle, be careful not to invert the connections, keep-
ing in mind that the black earth wire is connected to the negative
terminal while the red wire is connected to the terminal marked
+.
Turn signal lights malfunction
ELECTRICAL SYSTEM MALFUNCTION

Turn indicators do not turn on Check turn indicators device and/or wiring as described in the
«Electrical system» chapter.
Steering and suspensions
Heavy steering
STEERING HARDENING
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Excessive steering play
EXCESSIVE STEERING CLEARANCE

Excessive steering clearance Check the tightening of the top ring nut. If irregularities continue
in turning the steering even after making the above adjust-
ments, check the seats in which the ball bearings rotate: re-
place if they are recessed.
Noisy suspension
NOISY SUSPENSION
NOISY SUSPENSION If the front suspension is noisy, check: that the front shock ab-
sorber works properly and the ball bearings are good condition.
TROUBL - 51

In conclusion, check the tightening torque of the wheel hub, the
brake calliper, the shock absorber disk in the attachment to the
hub and the steering tube.
Check that the swinging arm connecting the engine to the
chassis and the rear shock absorber work properly
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION

Oil leakage from suspension Replace the damper.
TROUBL - 52
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system Vespa Primavera 50 4t 4valvole
KEY
1. Battery
2. Starter relay contact
3. Starter motor
4. Voltage regulator
5. Magneto flywheel
6. Fuse No. 1
7. Fuse no. 4
8. Ignition switch
9. Fuses No. 2-3
10. Speed sensor
11. Instrument panel
12. MODE button
13. Turn indicator control
14. Pre-installation for anti-theft device
15. Turn indicator switch
16. Left turn indicator bulbs
17. Turn indicators warning lights
18. Right turn indicator bulbs
19. Stop light
ELE SYS - 54
Vespa Primavera 50 4t 4valvole Electrical system
20. Stop buttons

21. Starter button
22. Starter relay coil
23. Headlight relay
24. Light switch
25. High beam warning light
26. Headlight
27. Horn button
28. Horn
29. Fuel gauge
30. Low fuel warning light
31. Fuel level transmitter
32. Rear daylight running light bulb
33. PTC
34. Automatic starter
35. NTC engine temperature sensor
36. Electronic ignition device
37. H.V. coil
38. Engine speed sensor
39. S.I.S. Valve
40. Diagnostics socket
Colours of the electrical cables:

B = White, Bl = Blue, G = Yellow, Mr = Brown, N = Black, Gr = Grey,
Rs = Pink, R = Red, Vi = Purple, V = Green
Conceptual diagrams
ELE SYS - 55
Ignition
KEY
1. Battery
6. Fuse No. 1
8. Ignition switch
9. Fuse No. 3
37. H.V. coil
38. Engine speed sensor
ELE SYS - 56
Headlights and automatic starter section
KEY
1. Battery
5. Magneto flywheel
6. Fuse No. 1
8. Ignition switch
9. Fuses No. 2-3
23. Headlight relay
24. Light switch
25. High beam warning light
26. Headlight
32. Rear daylight running light bulb
33. PTC
34. Automatic starter
ELE SYS - 57
Battery recharge and starting
KEY
1. Battery
3. Starter motor
5. Magneto flywheel
6. Fuse No. 1
8. Ignition switch
9. Fuse no. 2
19. Stop light
20. Stop buttons
21. Starter button
22. Starter relay coil
ELE SYS - 58
Level indicators and enable signals section
KEY
1. Battery
6. Fuse No. 1
7. Fuse no. 4
8. Ignition switch
9. Fuse no. 2
10. Speed sensor
12. MODE button
29. Fuel gauge
30. Low fuel warning light
31. Fuel level transmitter
35. NTC engine temperature sensor
39. S.I.S. Valve
ELE SYS - 59
Turn signal lights
KEY
1. Battery
6. Fuse No. 1
7. Fuse no. 4
8. Ignition switch
9. Fuse no. 2
13. Turn indicator control
14. Pre-installation for anti-theft device
16. Left turn indicator bulbs
17. Turn indicators warning lights
18. Right turn indicator bulbs
27. Horn button
28. Horn
ELE SYS - 60
Checks and inspections
In case the cause of ignition failure or malfunction

cannot be easily identified at sight, first of all re-
place the control unit by another one in operating
conditions.
Remember that the engine must be off to discon-
nect and replace the control unit.
If after replacement the vehicle starts properly, the
control unit is failing and must be replaced.
If the failure persists, check the alternator and the

stator components as follows:
After visually checking the electrical connections,
use a specific tester to measurement the stator
winding and the pickup (see table).
If any failure is found after checking the loading coil
and the pick-up, replace the stator and the dam-
aged parts.
Disconnect the connector on the flywheel cover
and measure the resistance between either con-
tact and the earthing.
Specific tooling
STATOR WINDING CHECK

1 Blue cable and ground ~1Ω
PICK-UP CHECK
1 Green cable and ground ~ 170 Ω
Ignition circuit
All the control operations of the system that require the disconnection of cables (checks of the connec-
tions and the devices making up the ignition circuit) must be done with the engine off: if this is not done,
the controls might be irretrievably damaged.
ELE SYS - 61
No spark plug
Once the lack of power to the spark plug has been

detected and the LED indicates it can be ignited,
follow this procedure:
- Check the Pick-Up.
Disconnect the electronic starter connector and
check continuity between terminal No. 3 (Green)
and terminal No. 4 (Black).
The check includes the Pick-Up and its power line.
If a break in the circuit is found, check again the
flywheel and the engine earth connectors. If non-
conforming values are measured, replace the
Pick-Up; otherwise, repair the cable harness.
Pick - up resistance
approx. 170 Ohm
- HV primary coil check

Disconnect the electronic starter connector and
check continuity between terminal No. 3 (purple)
and terminal No. 1 (black) (see figure).
If non-conforming values are measured, check
again the HV coil primary directly on the positive
and negative terminals.
If the values are correct, repair the cable harness
or reset the connections; otherwise, replace the
HV coil
HV coil primary resistance
0.5 ÷ 0.6 Ohm
- HV coil secondary check

Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable
terminal and the HV coil negative terminal (see figure).
If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis,
check the peak voltage with the multimeter adaptor.
HV coil secondary resistance
3000 ÷ 3600 Ohm
ELE SYS - 62
- Pick-Up
Disconnect the ECU connector and connect the
positive terminal to connector No. 3 (green) and
the negative terminal to connector No. 4 (black).
Use the start-up system to run the engine and
measure the voltage produced by the Pick-Up.
Replace Pick-Up if non-conforming values are
measured.
N.B.
THE MULTIMETER MUST BE SELECTED TO DETECT
CONTINUOUS VOLTAGE.
Pick-Up voltage value
Pick-Up voltage value: > 2 Volt
- H.V. coil
With the electronic starter and the HV coil connec-
ted to the system, measure the voltage of the coil
primary during the start-up test with the voltage
peak adaptor and by connecting the positive ter-
minal to the ground lead and the negative terminal
to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS
BLACK.
High voltage coil voltage value
High voltage coil voltage value: > 100 Volt
ELE SYS - 63
Stator check
- With a tester, check the resistance between muf-

flers green-ground and blue-ground.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERA-
TURE LEADS TO VALUES HIGHER THAN THOSE STATED.
Green cable and ground
~ 170 Ω
Blue cable and ground
~1Ω
Voltage regulator check
A malfunction in the voltage regulator might cause the following problems depending on the type of
fault:
1) Bulbs burned out (regulator in short circuit).

2) Malfunction of the lighting system and the electric starter (regulator interrupted).
3) Battery not recharging.

4) Turn indicators not working.
The regulator is earthed through the electrical system, so the regulator body does not earth the circuits
inside the regulator.
There must be insulation between each regulator terminal and the regulator body (use the tester to
check electric resistance).
2) LIGHTS AND STARTER NOT WORKING

Gain access to the voltage regulator by removing
the plastic cover on the legshield; start the engine
and keep running it at idle speed.
Connect the tester positive probe to terminal No.
1 (yellow cable) and the negative probe to terminal
No. 2 (black cable); check if there is voltage.
If there is voltage, check that the light remote con-
trol and its excitation line, coming from the elec-
tronic starter (sky blue PIN 7 - purple PIN 3) work
properly. Check the cable harness from the light
switch to the remote control and whether the
switch works properly .
ELE SYS - 64
If no voltage is detected, try connecting the nega-

tive probe directly to earth; if voltage is detected
with this operation, check the earth wiring of the
regulator; otherwise, replace the regulator be-
cause it is failing.
As a last check, the voltage supplied by the stator
can be measured:
- Disconnect the regulator connector and place a
tester to detect alternating voltage between the
Blue cable (4) and the ground connection (see fig-
ure).
- Voltage supplied at 2000 rpm must be about 25
÷ 35V.
If no value is obtained even with this test, replace
the regulator because it is obviously failing.
N.B.
TO MEASURE THE ABOVE VOLTAGE USE AN ANALOGUE
TESTER THAT CAN MEASURE ALTERNATING VOLTAG-
ES AND KEEP THE ENGINE AT IDLE TO HAVE AN ALTER-
NATING VOLTAGE OF A FREQUENCY AS CLOSE AS
POSSIBLE TO 50HZ SO AS TO DETECT THE EFFICIENT
VOLTAGE VALUE SUPPLIED BY THE REGULATOR
(ABOUT 12V).
Recharge system voltage check
3) BATTERY NOT RECHARGING

A failure in the direct current section of the voltage
regulator may cause the following problems de-
pending on the type of fault:
a) Protection fuse blows due to overvoltage
(regulator in short circuit) and consequently
the battery fails to recharge.
b) Battery fails to recharge (regulator interrup-
ted).
Measures
a) Protection fuse blows (regulator in short circuit).
Check that the cable harness going from the pro-
tection fuse to the key switch is not damaged,
which may cause a short circuit to ground (thus
preventing damaging the regulator).
ELE SYS - 65
Afterwards measure the resistance between con-

tact 3 (Orange) and contact 2 (Black) of the voltage
regulator (with connector disconnected)
If the value measured is far from that indicated,
replace the regulator because it is in short circuit.
b) Battery fails to recharge (regulator interrupted).
To check if there is any failure in the voltage reg-
ulator recharge section, first connect 2 testers to
the battery (one to detect voltage and the other to
detect current) as indicated in the second figure
and follow the procedure below:
Start the engine (temporarily connect the red cable
to the battery positive terminal in order to avoid
damaging the device that measures current).
Check that there is a 13V voltage minimum (bat-
tery charged) and a recharge current of 1.5 ÷ 2A
with the lighting system but the starter disabled. To
disable the lighting system, remove the light re-
mote control.
As the engine rpm increases, so do the current and
the recharge voltage; with rpm over 4000 there
must be a recharge current of about 4.5A; enabling
both the lighting system and the starter, the stop
light and if the horn is powered, current values ≥
5A and a voltage value of 14 ÷ 14.5V ( regulator
threshold voltage) can be found.
If values other than those above are detected,
replace the regulator; contrariwise, check the
cable harness and the connections.
Voltage regulator resistance
~ 8 MΩ
ELE SYS - 66
Turn signals system check
1. Battery
2. Fuse No. 1
3. Ignition switch
4. Fuse no. 2
5. Turn indicator device
7. Turn indicators
ELE SYS - 67
Dashboard
A = Speedometer
B = Turn indicator warning light
C = Fuel reserve warning light
D = Digital display
E = Low engine oil pressure warning light
F = High-beam warning light
G = Fuel gauge with petrol symbol

H = Total and partial odometer
I = Clock
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
ELE SYS - 68
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-
quired, before storing the vehicle and afterwards every six months.
INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 to 14.70V
- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h
Dry-charge battery
Where provided
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CON-
TACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES
AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
ELE SYS - 69
Commissioning dry-charged batteries:

1) - Remove the short closed tube and the plugs,
then pour sulphuric acid into the cells using the
type specified for batteries with a specific gravity
of 1.26, corresponding to 30 Bé at a minimum tem-
perature of 15°C. until the upper level is reached.
2) - Leave to rest for at least 2 hours; then, restore
the level with sulphuric acid.
3) - Within the following 24 hours, recharge using
the specific battery charger (single) or (multiple) at
a density of about 1/10 of the battery nominal ca-
pacity until fully charged; check that the acid den-
sity is about 27, corresponding to 31 Be, and that
these values are stabilised.
4) - Once the charge is over, level the acid (by
adding distilled water). Close and clean carefully.
5) Once the above operations have been per-
formed, install the battery on the vehicle ensuring
that it is wired up properly.
1 Hold the vertical tube
2 Look at the level
3 The float must be freed
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VE-
HICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE
(WITH CLOSED END) NEAR THE + POSITIVE TERMINAL
WITH THE CORRESPONDING LONG TUBE (WITH OPEN
END), THAT YOU FIND FITTED TO THE VEHICLE, TO EN-
SURE THAT THE GASES THAT FORM CAN ESCAPE
PROPERLY.
Specific tooling
020333Y Single battery charger
Battery maintenance
The battery is an electrical device which requires careful monitoring and careful maintenance. The
maintenance rules are:
1) Check the level of the electrolyte
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level. If water topping is required too often, check the vehicle electrical system:
the battery works overcharged and is subject to quick wear.
2)Load status check
ELE SYS - 70
After topping-up the electrolyte level, check its density using an appropriate densitometer (see figure).
When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific
weight of 1.26 to 1.28 at a temperature of no lower than 15° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
If the vehicle is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
The battery runs down completely in the course of three months. If it is necessary to refit the battery in
the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked
(-) must be connected to the -negative clamp while the other two red wires marked (+) must be con-
nected to the clamp marked with the +positive sign.
3) Recharging the battery
Remove the battery from the vehicle removing the negative clamp first.
Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),
setting the battery charger selector to the type of battery to be recharged. Connections to the power
supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).
4) Cleaning the battery
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. THE
USE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE
WHOLE VEHICLE OR EVEN CAUSE A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.
LACK OF PROPER CHARGING OF THE BATTERY BEFORE FIRST USE AT LOW ELECTROLYTE
LEVEL, CAN LEAD TO PREMATURE BATTERY LIFE.
Specific tooling
020333Y Single battery charger
Battery installation
Where provided
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)

WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CON-
TACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES
AND SEEK IMMEDIATE MEDICAL ATTENTION.
ELE SYS - 71
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE

QUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quick-
ly as possible to run the subsequent activation
phases.
2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulphu-
ric acid.
3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
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 electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.
Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container
two or three times. Do not remove the container from the battery.
5) Take out the container.
ELE SYS - 72
Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte
remains in the container. Now, gently pull the container out from the battery, only do this when the
container is completely empty, and proceed immediately to the next point.
6) Battery closing.
Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure
that the strip is levelled with the top part of the battery.
Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Place the battery down for 1 to 2 hours prior to the charging from the battery.
7) Recharging the new battery

With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeop-
ardising its useful life on vehicle.
The dry charge battery MF like the completely loa-
ded YTX, must have a no-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 battery with the red switch on
the left of the panel battery charger panel
b - select NEW on the yellow timer
c - connect the clamps of the battery charger to the
battery poles (black clamp to negative pole (-) and
red clamp to positive pole (+)).
ELE SYS - 73
d - Press the red button, as shown in figure.
e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-
ure.
f - Check the ignition of the green LED indicated

with a red arrow in figure.
g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED
has taken place
ELE SYS - 74
h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less
than 12.8 V, proceed with a new recharge of the
battery starting from point c of the recharge pro-
cedure of the new battery, otherwise go to point i
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,
disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
Connectors
ELECTRONIC IGNITION DEVICE

Connector A
1. H.V. coil control (Black):
2. Ignition switch contacts to ground (Blue)
3. H.V. coil positive (Violet)
Connector B
1. Key positive (Orange-Black)
2. Starter power (White-Black)
3. Pick-Up Signal (Green)
4. Ground lead (Black)
5. Solenoid valve (Brown)
6. NTC temperature sensor (Yellow-Pink)
7. Light relay (Sky blue)
8. Diagnostics socket (Red-Black)
INSTRUMENT PANEL
1. Not connected
2. MODE button (Green)
3. Left turn indicator warning light (Pink)
4. Right turn indicator warning light (White-Blue)
5. High beam warning light (Purple)
6. Not connected
7. Not connected
8. Speed sensor negative (Black-Green)
9. Not connected
10. Not connected
ELE SYS - 75
11. Not connected

12. Fuel level indicator (White - Green)
13. Not connected
14. Speed sensor signal (Sky blue)
15. Not connected
16. Not connected
18. Not connected
19. Live power supply and instrument panel light-
ing (White)
20. Battery-powered (Grey-Red)
MAGNETO FLYWHEEL
A1. Not connected
B1. Not connected
C1. Not connected
A2. Pick-up (Green)
B2. Not connected
C2. Stator (Blue)
VOLTAGE REGULATOR
1. Lighting system power (alternating) (Yellow)
3. Battery positive (Orange)
4. From flywheel (alternating) (Blue)
5. Not connected
PRE-INSTALLATION FOR ANTI-THEFT DE-

VICE
2. Left indicator (White - Blue)
3. Right indicator (Pink)
4. Battery-powered (Grey-Red)
5. Key powered (White)
6. Not connected
7. Not connected
8. Not connected
ELE SYS - 76
SPEED SENSOR
1. Signal (Sky blue)
2. Negative from instrument panel (Black-Green)
FUEL LEVEL TRANSMITTER

1. Instrument panel (White-Green)
DIAGNOSTICS SOCKET
1. Not connected
3. Electronic ignition device (Red-Black)
H.V. COIL
1. Positive from electronic ignition device (Purple)
2. Negative from electronic ignition device (Black)
ELE SYS - 77
P.T.C.
1. Live (White)
2. Electronic ignition device (White-Black)
AUTOMATIC STARTER
2. Power supply from voltage regulator (Yellow-
Black)
S.I.S. VALVE
1. Electronic ignition device (Brown)
2. Live (White)
ELE SYS - 78
INDEX OF TOPICS
ENGINE ENG
Engine Vespa Primavera 50 4t 4valvole
Automatic transmission
Transmission cover
- Remove the 12 fixing screws.

- Remove the oil filling cap and then slide out the
cover.
If this operation is carried out directly on the vehi-
cle, it is necessary to remove the transmission
cooling coupling and the air filter housing retain-
ers.
N.B.
USE A MALLET ON THE APPROPRIATE COUPLINGS TO
REMOVE THE COVER.
Kickstart
-To remove the start up pinion push the starter

lever to facilitate extracting the pinion.
-Remove the kick-start screw and lever.
-Remove the Seeger ring and the washer indica-
ted in the figure.
-Pull out the toothed sector.
WARNING
THE SECTOR KEEPS THE SPRING SET, BE CAREFUL SO
AS NOT TO CAUSE ANY ACCIDENTS
Air duct
- To remove the intake throat on the transmission

cover, just remove the three fixing screws indica-
ted in the figure.
ENG - 80
Vespa Primavera 50 4t 4valvole Engine
Removing the driven pulley shaft bearing
- Slightly heat the crankshaft from the inside side

to avoid damaging the coated surface and use the
driven pulley shaft or a pin of the same diameter
to remove the bearing.
N.B.
IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-
AMETER EXTRACTOR CAN BE USED.
Refitting the driven pulley shaft bearing
Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.
N.B.
WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.
CAUTION
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE COVER
PAINTED SURFACE.
Removing the driven pulley
- Lock the clutch housing with the specific tool.

- Remove the nut, the clutch housing and the
whole of the driven pulley assembly.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Specific tooling
ENG - 81
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.
Characteristic
clutch housing diameter/standard value
Ø 107+0.2 +0 mm
clutch housing diameter/max. value allowed
after use
Ø 107.5 mm
Eccentricity measured /max.
0.20 mm
Removing the clutch
- Equip the tool with long pins screwed into position

«A» from the outside, insert the entire driven pulley
in the tool and have the central screw make con-
tact.
CAUTION
THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW
IS TIGHTENED UP TOO FAR.
- Using a 34 mm socket wrench remove the clutch

locking nut.
- Loosen the central screw by undoing spring of
the driven pulley unit
- Separate the components.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
ENG - 82
Inspecting the clutch
- Check the thickness of the clutch mass friction

material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
- Remove the three guide pins and the mobile half

pulley.
ENG - 83
Removing the driven half-pulley bearing
- Remove the roller bearing with the special ex-

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

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

surface of the belt. If there are, replace the half-
pulley..
- Make sure the bearings do not show signs of un-
usual wear.
- Measure the outside diameter of the pulley bush-
ing.
Characteristic
Stationary driven half-pulley/Standard diame-
ter
Ø 33.965 to 33.985 mm
Stationary driven half-pulley / Minimum diam-
eter admitted after use
Ø 33.96 mm
ENG - 84
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two O-

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

- Insert the new oil seal and O-rings on the mobile
half-pulley.
- Fitting the half-pulley on the bushing.
AGIP GREASE SM 2 Gray black smooth-tex-
tured lithium grease, containing molybdenum
disulphide.
-
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This
operation must be done through one of the holes inside the bushing until grease comes out of the
opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum di-
sulphide.
-
Refitting the driven half-pulley bearing
- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.
- Fit the new roller bearing with the wording visible
from the outside.
CAUTION
PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT
DAMAGE TO THE THREADED END WHILE THE BEARINGS
ARE BEING FITTED.
Specific tooling
ENG - 85
020456Y Ø 24 mm adaptor
020362Y 12 mm guide
020171Y Punch for Ø 17 mm roller bearing
Inspecting the clutch spring
- Check that the contrast spring of the driven pulley

does not show signs of deformation
- Measure the free length of the spring
Characteristic
Standard length
118 mm
Minimum length allowed after use
XXXX
- Check the thickness of the clutch mass friction

material.
-The masses must not show traces of lubricants;
otherwise, check the driven pulley unit.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-
ENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN
CAUSE THE CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS SO AS TO
PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Minimum thickness permitted:
1 mm
Refitting the clutch
- Preassemble the driven pulley group with spring,

sheath and clutch.
- Position the spring with the sheath
- Insert the components in the tool and preload the
spring being careful not to damage the plastic
sheath and the end of the threaded shank.
ENG - 86
- Reassemble the nut securing the clutch and tight-

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

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

Driven pulley shaft nut 40 to 44 Nm
Drive-belt
- Make sure the drive belt is not damaged and does

not have cracks in the toothed grooves.
- Check the width of the belt.
Characteristic
Transmission belt/Minimum width
17.5 mm
ENG - 87
Removing the driving pulley
- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer,
then remove the drive and the plastic fan.
- Remove the stationary half-pulley.
- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the
rollers and contrast plate fitted loosely on it do not come off.
Specific tooling
020451Y Starting ring gear lock
Inspecting the rollers case
1) Check that the bushing and the sliding rings of

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

ure is not abnormally worn and measure inside
diameter «A».
- Measure outside diameter «B» of the pulley slid-
ing bushing shown in the figure.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHING.
Characteristic
Driving pulley / Maximum diameter:
ENG - 88
20.12 mm
Driving pulley/ Standard diameter:
20.021 mm
Driving pulley bushing/ Diameter maximum:
XXX mm
Driving pulley bushing/ Standard diameter:
20 -0.020/-0.041mm
Refitting the driving pulley
- Manually move the movable driven half-pulley

away by pulling it towards the clutch unit and insert
the belt observing the direction of rotation of the
first fitting.
N.B.
IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO
THAT THE WORDS CAN BE READ IN CASE IT DOES NOT
SHOW A FITTING SIDE.
- Refit the components of the assembly (roller

housing assembly with bushing, limiting washer,
stationary half-pulley, cooling fan belt with drive,
washer and nut).
- With the specific tool, tighten the lock nut to 20
Nm and then perform a final 90° locking in order to
prevent the rotation of the driving pulley.
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
CAUTION
UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-
MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN
ORDER TO AVOID WRONG TIGHTENING AND CONSE-
QUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling
020451Y Starting ring gear lock

Crankshaft pulley nut 18 to 20 + 90° Nm
ENG - 89
Refitting the transmission cover
- Check the following for wear: toothed section,

toothed section shaft, cover seat bushing, pinion
shaft and its seating in the crankcase and the re-
turn spring.
- Remove the damaged components.
- Grease the spring.
- Remove the toothed sector and load the spring
with an appropriate tool.
- Refit the washer, the Seeger and the Kick-start
lever.
AGIP GREASE MU3 Yellow-brown, lithium-
base, medium-fibre multipurpose grease.
ISO L-X-BCHA 3 - DIN 51 825 K3K -20
- Insert the pinion in its seating by pushing the starter lever.

- Fit the intake throat and tighten the 3 screws.
-Make sure the oil sump presents centring dowels

and sealing gaskets.
- Replace the cover tightening the 12 screws to the
prescribed torque.
-Refit the oil filling cap.

Transmission cover screws 11 - 13 Nm
End gear
ENG - 90
Removing the hub cover
• Remove the transmission cover

• Remove the clutch assembly
• Discharge the rear hub oil.
• Remove the 5 screws indicated in the figure.
• Remove the hub cover with driven pulley shaft.
See also
Refitting the clutch
Removing the wheel axle
- Remove the intermediate gear and the complete

gear wheel axle.
- When removing the intermediate gear pay atten-
tion to the various shim adjustments.
Removing the wheel axle bearings
- Remove the oil seal and the Seeger ring.

- Remove the bearing by pushing from the outside
towards the inside of the gear compartment, using
the appropriate punch.
Specific tooling
020363Y 20-mm guide
ENG - 91
Removing the driven pulley shaft bearing
- Remove the Seeger ring inside the cover.

- Remove the oil seal from the outside.
- Remove the centring dowels and position the
cover on a plane.
- Position the special tool on the internal track of
the bearing and remove said bearing with the aid
of a press.
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
- Position the special tube on the internal raceway
of the bearing and from the shaft toothed side as
indicated in the figure. Expel the driven pulley shaft
with the aid of a press.
Specific tooling
driven pulley shaft
Inspecting the hub shaft
- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and
the oil seal housings.
- If faults are found, replace the damaged compo-
nents.
- Check capacity (A) of the transmission gear
(wear, deformations, etc.)
- Check the pulley shaft seating: Superficial wear
(B) may indicate irregularities in the crankcase
seats or in the pulley shaft capacities
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.
ENG - 92
Refitting the driven pulley shaft bearing
- Support the inner track of the bearing from the

outside of the hub cover with the specific tool posi-
tioned under the press and insert the driven pulley
axle.
- Refit the oil seal flush with the cover.
Specific tooling
driven pulley shaft
• Heat the hub cover and insert the bearing with

the specific punch.
• Fit the snap ring with the concave or radial part
on the bearing side.
N.B.
FIT THE BALL BEARING WITH THE SHIELD FACING THE
OIL SEAL.
Specific tooling
020151Y Air heater
020439Y 17-mm guide
Refitting the wheel axle bearing
- Heat the half crankcase on the transmission side

using a thermal gun.
- After lubricating its outer strip, insert the bearing
with the special adapter with the aid of a hammer.
- Refit the Seeger ring and the oil seal using the 42
x 47 mm adapter and the handle.
Specific tooling
020151Y Air heater
020363Y 20-mm guide
ENG - 93
Refitting the ub cover
- Refit the whole wheel axle.

- Refit the intermediate gear paying attention to the
two shim washers.
- Apply LOCTITE 510 for surfaces to the hub cov-
ers and refit the same with driven pulley shaft.
- Refit the 5 screws and tighten them to the speci-
fied torque.
N.B.
CLEAN THE CONTACT SURFACES OF THE HUB COVER
AND THE HALF CRANKCASE OF RESIDUE FROM PREVI-
OUS GASKETS BEFORE APPLYING A NEW ONE.

Locking torque: 11 to 13 Nm
Flywheel cover
Cooling hood
- Remove the manifold and the carburettor undo-

ing the 2 fixing screws on the head
- Remove the fastening clamp of the secondary air
pipe and disconnect it
- Remove the 4 front coupling screws (1 of them is
a knob) and the side fixing screw at the crankcase
base.
- Remove the 4 side screws
- Extract the 3 covers - Remove the cover sealing
gaskets on the head
- For refitting, repeat the removal steps but in re-
verse order
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL
CONNECTOR.
N.B.
WHEN REFITTING THE COVER, TAKE CARE NOT TO DAM-
AGE THE STATOR WIRING.
ENG - 94
Cooling fan
- Remove the cooling fan by undoing the 3 screws

fixing it to the rotor
- When refitting the fan, pay attention that the
screw holes in the fan and the rotor coincide, then
tighten screws at the specified torque.
Removing the stator
- Remove the 2 Pick-Up screws and the 2 stator

fixing screws indicated in the figure.
- Remove the stator and its wiring.
ENG - 95
Refitting the stator
- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.
N.B.
THE PICK-UP CABLE MUST BE POSITIONED ADHERING
TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH
A WAY AS TO AVOID BEING CRUSHED BY THE FAN COV-
ER ASSEMBLY.

Pick-up screws 3 ÷ 4 Stator screws 3 - 4
Flywheel and starting
Removing the starter motor
- Undo the screw on the power positive contact

and disconnect the cable
- Undo the 2 screws fixing the starter motor to the
crankcase and recover the power wiring.
ENG - 96
Removing the flywheel magneto
- Lock the rotation of the flywheel using the calliper

spanner.
- Remove the nut.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
- Extract the flywheel with the extractor.
Specific tooling
020162Y Flywheel extractor
Inspecting the flywheel components
- Check that the flywheel internal magnets are in

good conditions.
- Check that the flywheel splines exhibit no loos-
ening.
- Check there are no deformations that may cause
rubbing on the stator and the Pick-Up.
- Check that the stator winding, its ferromagnetic
support and the pick-up are in good conditions.
ENG - 97
Starter gear rim
- Check the toothing is level and in good conditions
Intermediate gear
- Check that the keying toothing on the crown and

the starter motor are in good conditions.
- Check that the Bendix opens and returns ade-
quately.
Refitting the flywheel magneto
- Refit the stator and the pick-up being careful to

pass the wiring through the appropriate crankcase
couplings.
- Refit the flywheel to the crankshaft being careful
to respect the keying, then lock rotation with the
specific tool and tighten the nut to the prescribed
torque.
N.B.
A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO
A VARIATION IN THE IGNITION ADVANCE SUCH AS TO
CAUSE PINGING, KNOCKING ETC.
Specific tooling

Flywheel nut 52 - 58
ENG - 98
Refitting the starter motor
- Install the starter motor in its seating in the crank-

case.
- Tighten the screw on the head side but do not
lock it, screw the second screw inserting the earth
cable (black), then tighten the 2 screws at the pre-
scribed torque.
- Tighten the locking screw of the positive cable
(red) on the side contact.
N.B.
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.

Starter screws 11 - 13
Cylinder assy. and timing system
Removing the rocker-arms cover
- Remove the cooling covers

- Remove the 4 retainers of the tappet cover
- Remove the cover and the O-ring
- Remove the 3 screws and then remove the Blow-
by cover
- Clean the nozzle labyrinth and the membrane
(replace it, if necessary), then remove the cover
unit.
ENG - 99
Removing the timing system drive
- Temporarily loosen the tensioner central screw

and remove it together with the spring.
- Unscrew the 2 retainers indicated in the figure
and remove the chain tightener support being
careful to recover the sealing gasket.
N.B.
SHOULD THE GASKET NOT BE IN GOOD CONDITIONS,
REPLACE IT AFTER CAREFULLY CLEANING THE FAYING
SURFACE IN ORDER TO AVOID ENGINE OIL LEAKS
- Remove the driving pulley

- Remove the oil pump chain
- Remove the tappet cover
- Remove the central screw and the belleville
washer indicated in the figure and lock the cam-
shaft crown with the specific tool.
N.B.
TO FACILITATE REMOVING THE HEAD COMPONENTS,
SET THE CRANKSHAFT TO THE TIMING POINT (TDC OF
THE COMPRESSION END).
Specific tooling
- Remove the camshaft control pulley and the washer below.
- Remove the pinion of the crankshaft timing control
- To remove the chain lower guiding pad, remove the head by pulling it upwards
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE DIRECTION OF RO-
TATION IS MAINTAINED.
See also
Removing the rocker-arms cover
Removal
ENG - 100
Removing the cam shaft
- Remove the limit screw of the rocking lever pins

shown in the figure.
- Remove the Seeger ring retaining the camshaft
bearing.
- Remove pins and rocking levers.
- Remove the calibrated pads
N.B.
MARK THE ASSEMBLY POSITION OF THE ROCKING LEV-
ERS IN ORDER TO AVOID MISPLACING THE INTAKE AND
DISCHARGE ENDS.
- Remove the entire camshaft with bearing using

the specific tool shown in the figure.
- Take out the camshaft bearing with the aid of the
specific tool, being careful to mount a screw on the
camshaft in order to protect its thread.
N.B.
IF A BEARING SEPARATES FROM THE CAMSHAFT, IT IS
ESSENTIAL TO FIT A NEW BEAR.
Specific tooling
004499Y Camshaft bearing extractor
004499Y001 Bearing extractor bell
004499Y002 Bearing extractor screw
004499Y006 Bearing extractor ring
004499Y027 Bearing extractor part
ENG - 101
Removing the cylinder head
- Remove the cooling covers, the timing control,

the camshaft and the rocking levers.
- Remove the spark plug.
- Remove the 2 side fixings shown in the figure.
- Loosen the 4 head-cylinder fastening nuts in two
or three stages and in criss-cross fashion.
- Remove the head, the two alignment dowels and
the gasket.
N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, PINS AND ROCKING LEVERS WITHOUT RE-
MOVING THE DRIVING PULLEY UNIT. REMEMBER TO
HOLD THE TIMING CHAIN WITH A PIECE OF METAL CA-
BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE-
FITTING.
Removing the valves
- Using the specific tool fitted with the part shown

in the figure, remove cotters, caps and valve
springs.
- Remove the oil seals with the appropriate tool.
Specific tooling
020431Y Valve oil seal extractor
020382Y Valve cotters equipped with part 012
removal tool
ENG - 102
Removing the cylinder - piston assy.
- Remove the cylinder paying attention to the 2

cylinder centring dowels in the housing.
- Remove the cylinder base gasket.
To avoid damaging the piston, keep it fixed while
removing the cylinder.
- Remove the two stop rings, the wrist pin and the
piston.
- Remove the 3 piston rings from the piston.
N.B.
BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR-
ING REMOVAL.
Inspecting the small end
- Measure the internal diameter of the connecting

rod small end using an internal micrometer.
N.B.
IF THE DIAMETER OF THE CONNECTING ROD SMALL
END EXCEEDS THE MAXIMUM DIAMETER ADMISSIBLE,
SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE
THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE
AND CRANKSHAFT" CHAPTER".
Characteristic
Max. diameter admitted: check the small end
13.030 mm
Standard diameter: check the small end
13 +0.025+0.015mm
ENG - 103
Inspecting the wrist pin
- Measure the outer diameter of the gudgeon pin.
Characteristic
Standard diameter: gudgeon pin
13 -0 -0.004mm
Minimum admissible diameter gudgeon pin
12.990 mm
Inspecting the piston
- Measure the diameter of the bearings on the pis-

ton.
Characteristic
Pin seat diameter
13 +0.005 + 0.010 mm
- Carefully clean the seal housings.

- Measure the coupling clearance between the
sealing rings and the piston grooves using suitable
sensors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.
Fitting clearance
Top piston ring - standard coupling clearance
0.03 to 0.065 mm Top piston ring - maximum clear-
ance allowed after use 0.07 mm Middle piston
ring - standard coupling clearance 0.02 to 0.055
mm Middle piston ring - maximum clearance al-
lowed after use 0.06 mm oil scraper ring - stand-
ard coupling clearance 0.04 to 0.16 mm oil scraper
ring - maximum clearance allowed after use
0.17 mm
ENG - 104
Inspecting the cylinder
- Using a bore meter, measure the inner cylinder

diameter at three different points according to the
directions shown in the figure.
- Check that the coupling surface with the head is
not worn or misshapen.
- Pistons and cylinders are classified into catego-
ries based on their diameter. The coupling is car-
ried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
0.001 in 0.05 mm
Inspecting the piston rings
- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di-
ameter. Using the piston, insert the rings perpendicularly to the cylinder axis.
- Measure the opening, see figure, of the sealing rings using a thickness gauge.
- If any measurements are greater than specified, replace the piston rings.
N.B.
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN
THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE
CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH
A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
ENG - 105
SEALING RINGS
1st Compression ring 39 x 1 A 0.08 to 0.20
2nd Compression ring 39 x 1 A 0.05 to 0.20
Oil scraper ring 39 x 2 A 0.20 to 0.70
1st Oversize
1st Oversize
Oil scraper ring 1st 39.2 x 2 A 0.20 to 0.70
Oversize
2nd Oversize
2nd Oversize
Oil scraper ring 2nd 39.4 x 2 A 0.20 to 0.70
Oversize
3rd Oversize
3rd Oversize
Oil scraper ring 3rd 39.6 x 2 A 0.20 to 0.70
Oversize
Removing the piston
- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-
wards the exhaust.
- Fit the pin retainer ring onto the appropriate tool.
Specific tooling
020448Y Tool for fitting the pin snap rings
ENG - 106
- With the opening in the position indicated on the

tool, set the lock ring into position in the tool with
the punch.
- Rest the tool on the piston paying attention that
the 90°chamfered side faces upwards as indicated
in the figure.
- Fit the gudgeon pin stop using the plug.
CAUTION
USING A HAMMER TO POSITION THE RINGS CAN DAM-
AGE THE LOCKING HOUSING.
Refitting the piston rings
- Fit the oil scraper ring starting from the spring,

taking care that the spring ends do not superim-
pose. Fit the two piston rings so that their gaps and
that of the oil scraper ring are never aligned.
- Fit the 2nd sealing ring with the identifying letter
«T» facing towards the piston crown.
- Fit the 1st sealing ring with the reference letter
«T» facing towards the piston crown.
- Misalign the lining openings at 120° as shown in
the figure.
- Lubricate the components with engine oil.
N.B.
IN ORDER TO OBTAIN A GOOD BEDDING, THE 2 SEALING
PISTON RINGS ARE MADE OF CONE SHAPED CONTACT
SECTION TO THE CYLINDER. AS A RESULT IT IS IMPOR-
TANT TO RESPECT THE FITTING INSTRUCTION TO AS-
SEMBLY THE RINGS WITH THE "T" MARK FACING
UPWARDS.
ENG - 107
Refitting the cylinder
- Insert the cylinder base gasket.

- Fit the cylinder as shown in the figure.
- The piston can be kept out of the housing plane
using the appropriate tool.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
OUT THE LUBRICATION DUCT AND OIL THE CYLINDER
BARREL.
Specific tooling
020288Y Fork to assemble piston on cylinder
If the four cylinder stud bolts should be replaced in this kind of engine, it is necessary to tighten the
head nuts strictly following the procedure below.
The procedure is different from that indicated in the vehicle manuals:
Head tightening nut (only to replace stud bolts) 6÷7 N*m + 135° + 90°
The 45° rotation reduction of the key is necessary to avoid stud bolt stretching.
Inspecting the cylinder head
- Using a trued bar check that the cylinder head

surface is not worn or distorted.
- Check that the camshaft and rocking lever pin
bearings show no signs of wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
- It is advisable to replace the head if any failure is
found.
Characteristic
0.1 mm
ENG - 108
Measure the camshaft bearing seats and rocking

lever support pins with a bore meter
HEAD CHECK
Standard diameter (mm) A Ø 32.015 to 32.025
Standard diameter (mm) B Ø 16.0 to 16.018
Standard diameter (mm) C Ø 11.0 to 11.018
Inspecting the timing system components
- Check that the guide slider and the tensioner

slider are not worn out.
- Ensure that the camshaft drive pulley, the chain
assembly and the sprocket wheel are not worn.
- If sings of wear are found, replace the parts. if the
chain, pinion or pulley are worn, replace the whole
assembly.
- Remove the central screw and the tensioner

spring. Check that the one-way mechanism is not
worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
unit.
ENG - 109
Inspecting the valve sealings
- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the
impression on the valve seat "V".
Characteristic
Standard value:
1 - 1.3 mm
Limit allowed:
1.6 mm
- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damage, replace the head.
- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Inspecting the valves
STANDARD VALVE LENGTH

Inlet: standard length 74.9 mm
Outlet: standard length 74.35 mm
ENG - 110
- Measure the diameter of the valve stems in the

three positions indicated in the diagram.
STANDARD DIAMETER
Intake 3.970 to 3.985 mm
Exhaust 3.960 to 3.975 mm
MINIMUM DIAMETER PERMITTED

Intake 3.958 mm
Exhaust 3.945 mm
- Calculate the clearance between the valve and the valve guide.
- Check the concentricity of the valve head by

placing a dial gauge at right angles to the valve
head and rotating it on the «V» shaped support.
Characteristic
Limit allowed:
0.03 mm
- Check the deviation of the valve stem by resting

it on a «V» shaped abutment and measuring the
extent of the deformation with a dial gauge.
Characteristic
Limit values admitted:
0.1 mm
ENG - 111
Inspecting the valve stem guide clearance
Measure the valve guides
VALVE GUIDE DIAMETER

Valve guide Standard diameter: 4 + 0.012 mm
Valve guide Maximum admissible diameter: 4 + 0.022 mm
- After measuring the valve guide diameter and the

valve stem diameter, check clearance between
guide and stem.
INTAKE
Standard clearance 0.015 to 0.042 mm
EXHAUST
Standard clearance 0.025 - 0.052 mm
ENG - 112
Refitting the valves
- Lubricate the valve guides with graphite grease.

- Place the lower caps of the valve spring on the
head.
- Use the punch to fit the 4 sealing rings one at a
time.
- Fit the valves, the springs and the upper caps.

- Using the appropriate tool, compress the springs
and insert the cotters in their seats.
Inspecting the cam shaft
- Inspect the camshaft for signs of abnormal wear

on the cams.
Characteristic
Standard diameter - Bearing A:
Ø 12 +0.002 +0.010
mm Standard diameter - Bearing B:
Ø 16-0.015 -0.023 mm
Minimum diameter allowed - Bearing A:
Ø 11.98 mm
Minimum diameter allowed - Bearing B:
Ø 15.96 mm
-Using a gauge, measure the cam height.
Check the axial clearance of the camshaft
ENG - 113
- If any of the above dimensions are outside the

specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
N.B.
A BALL BEARING IS FITTED ON BEARING «A»; CONSE-
QUENTLY, BEARING «B» IS THE MOST IMPORTANT AS IT
WORKS DIRECTLY ON THE HEAD ALUMINIUM
Characteristic
Standard height - Inlet
24.397 mm
Standard height - Outlet
23.996 mm
Fitting clearance
Maximum admissible axial clearance: 0.5 mm
- Measure the outside diameter of the rocking lever pins

- Check the rocking lever pins do not show signs of wear or scoring.
- Measure the internal diameter of each rocker.
- Check that the pad in contact with the cam is not worn.
ROCKING LEVERS AND PIN DIAMETER:

Rocking levers - Inside diameter 11.015 to 11.035 mm
Rocking levers - Pins diameter 10.977 to 10.985 mm
Refitting the head and timing system components

- Fix the head on a workbench.
- Screw the tool to fit the camshaft fully down on the bearing's inner track.
- Fit the camshaft fully into its seating together with the bearing with the aid of a mallet.
- Remove the tool.
- Fit the head gasket after cleaning the faying surface carefully.
ENG - 114
- Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque.
Specific tooling
- Fit pins, inlet rocking lever and discharge rocking

lever.
- Lubricate the 2 rocking levers through the holes.
N.B.
IF A BEARING SEPARATES FROM THE CAMSHAFT, IT IS
ESSENTIAL TO FIT A NEW BEARING.
- Screw up the limit screw of the rocking lever pins

and tighten it to the prescribed torque.
- Reposition the Seeger ring retaining the cam-
shaft

Rocking lever shafts screw 3 ÷ 4
- Finish the head tightening following the proce-

dure below: screw the four head nuts to an initial
torque at two crossed passes. Afterwards tighten
the nuts with 2 turns of 90° each to be done at two
crossed passes.
-Finish the tightening of the head to the crankcase
with the 2 side screws.
N.B.
SHOULD THE CRANKCASE OR THE CYLINDER STUD
BOLTS BE REPLACED, IT IS NECESSARY TO CARRY OUT
AN INITIAL TIGHTENING PLUS OTHER 3 TURNS OF 90°
EACH AT 3 CROSSED PASSES

Head-cylinder stud bolt nuts: 6 to 7 +135° +90° Nm
first fitting, upon refitting tighten again at 6 to 7 90° +90°
Nm Head cover screws 8 to 10 Nm
ENG - 115
Refitting the timing chain
- Insert the timing chain pads in their correspond-

ing seatings, the screw and the spacer as indica-
ted in the figure.
- Tighten to the prescribed torque and check the
tensioner pad moves adequately.
- Insert the timing pinion in driving shaft with the
chamfered side facing the insertion (towards the
main bearing).
- Loop the timing chain around the sprocket on the
crankshaft.

Chain tensioner pad screw 5 to 7 Nm
- Refit the spacer on the camshaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- With this operation, insert the chain on the cam-
shaft control pulley and make the reference notch
coincide with the point on the head.
- Fit the pulley onto the camshaft.
- Fit the belleville washer so that the outer rim
touches the pulley.
- Bring the screw closer but without reaching its
final locking point.
- Push the tensioner pad lightly so as to check the

correct timing.
- Use the specific tool to lock the camshaft crown
gear and tighten the screw.
- Adjust valve clearance.
- Replace the O-ring on the tappet cover.
- Fit the tappet cover and lock it with the 4 fixing
screws indicated in the figure.
Specific tooling
ENG - 116
Camshaft pulley screw 12 - 14 Head cover

screw 8 to 10 Nm
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed
torque.
- Insert the spring with the central screw and tighten it to the prescribed torque.
- Fit the spark plug.
Characteristic
Electrode gap
0.5 ÷ 0.6 mm
Spark plug
NGK ER9EH-6N

Timing chain tensioner central screw 5 - 6 Timing chain tensioner screw 8 to 10 Nm Ignition
spark plug 10 - 15 Nm
Refitting the rocker-arms cover
- Carry out the removal procedure but in reverse

order and tighten the four fixing screws to the
specified torque.
N.B.
FIT A NEW O-RING ON THE TAPPET COVER.
Refitting the intake manifold
-Fit the cover sealing gaskets on the head.

-Fit the 2 covers.
- Fit the inlet manifold and do up the 2 screws to
the specified torque.
-Fit the carburettor on the inlet manifold and lock
the clamp.
-Fit the secondary air pipe and fix it with the ap-
propriate clamp.
N.B.
ENG - 117
FIT THE CARBURETTOR THROUGH THE SUPPLEMENT

ON THE MANIFOLD.

Inlet manifold screw 7 to 9 Nm
Crankcase - crankshaft
- First remove the following units:

Driving pulley Driven pulley
Final reduction greasing
Oil pump Flywheel with stator
Cylinder-piston-head unit
Starter motor with cables.
See also
Removal
Removing the driven pulley
Removing the cylinder - piston assy.
Removing the starter motor
Removing the stator
Splitting the crankcase halves
- Remove the ten crankshaft coupling screws.

-Separate the crankcase halves keeping the half
casing driving shaft engaged on the transmission
side.
- Remove the crankshaft.
CAUTION
IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC-
CIDENTALLY FALL.
- Remove the oil guard on the flywheel side.

CAUTION
THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT. DO NOT WASH WITH SOL-
VENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT. A CENTRIFUGAL
OIL FILTER'S LIFE IS THE SAME AS THE ENGINE'S AND IS MAINTENANCE FREE.
ENG - 118
- Check the axial clearance on the connecting rod.
Fitting clearance
Standard connecting rod axial clearance 0.15 to
0.30 mm Max.
connecting rod clearance 0.5 mm
- Check the correct radial clearance of the con-

necting rod by holding the driving shaft with your
hands and, with a dial gauge fitted to the rod small
end, measuring the clearance, move the connect-
ing rod vertically as shown in the figure.
Fitting clearance
Connecting rod radial - standard clearance
0.006 to 0.018 mm Connecting rod max. - radial
clearance 0.25 mm
- Check that the half shaft surfaces are not scored
and with the aid of a gauge check the driving shaft
width as indicated in the figure.
Characteristic
Standard measure
45 mm
Removing the crankshaft bearings
- Remove the flywheel bearing fitted on the driving

shaft using the specific tool.
Specific tooling
004499Y Camshaft bearing extractor
004499Y001 Bearing extractor bell
004499Y002 Bearing extractor screw
004499Y006 Bearing extractor ring
004499Y034 Bearing extractor part
ENG - 119
Refitting the crankshaft bearings
- Support the crankcase on a surface and place it

with the driving shaft axle in a vertical position.
- Warm the crankcase at ~ 120° C with a thermal
gun (and support).
- Fit the punch with guide and adaptor, place the
bearing on the punch using grease (to keep it from
falling).
-Insert the bearing in the crankcase; if needed, use
a mallet but do so with extreme care so as not to
damage the engine crankcase limit stop.
Specific tooling
020364Y 25-mm guide
020360Y 52 x 55-mm Adaptor
- Heat a new main bearing in an oil bath at 120°.

- Place the driving shaft on the support base and
insert the bearing with the aid of an adequate piece
of tube if necessary.
N.B.
USE A NEW BEARING WHEN REFITTING
WARNING
THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL
AXLE SHAFT. DO NOT WASH WITH SOLVENTS OR BLOW
COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT.
Specific tooling
020265Y Bearing fitting base
008119Y009 Tube to assemble shafts and
axles
ENG - 120
Inspecting the crankshaft alignment
To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated
in figure.
N.B.
IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC-
TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-
SERTING A WOODEN WEDGE BETWEEN THE HALF
SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-
DED. IF EVEN AFTER THIS OPERATION THE VALUES ARE
NOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.
Characteristic
Off-line maximum admitted - A
0.15 mm
Off-line maximum admitted - B
0.02 mm
Off-line maximum admitted - C
0.02 mm
Off-line maximum admitted - D
0.10 mm
- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded
tangs are in good working order.
- In case of failures, replace the crankshaft.
Specific tooling
020074Y Support base for checking crankshaft alignment
Refitting the crankcase halves
-Be careful to place the two centring dowels pref-

erably on the flywheel side half casing.
-Insert the crankshaft on the half casing on the
transmission side.
ENG - 121
- Fit the gasket recommended for surfaces on the

half casing on the transmission side after greasing
the two faying surfaces carefully.
-Insert the flywheel half casing.
- Fit the 10 screws and tighten them to the pre-
scribed torque.
N.B.
WHEN FITTING THE HALF CASING AND THE CRANK-
SHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREA-
DED TANGS.
Loctite 510 Liquid sealant
Gasket

Half casing joint bolts: 8 - 10 Nm
- Fit a new O-Ring on the mesh oil filter and on the
filling cap; lubricate the rings.
- Insert the filter on the engine and lock the cap to
the prescribed torque.

Engine oil pre-filter cover: 25 - 28 Nm
Lubrication
Crankshaft oil seals
Removal
- Extract the flywheel oil seal from the crankcase

being careful not to damage or score the crank-
case.
ENG - 122
- Check that the chain contrast pad is not worn.

-Otherwise, replace the pad or fit it inverted to
make it work on the other side.
- Any operation on the chain cover oil seal should
be carried out placing the cover on the workbench
on the covering plate side of the oil pump chain.
-Remove the oil seal with a tube section of 30 mm
in diameter (Ø 32 mm Max).
Refitting
- Apply engine oil on the oil seal and it seating on

the crankcase.
- From the outside and using the specific punch,
place the oil seal fully down until it reaches the
bottom of the seating in the crankcase.
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSE-
QUENCE IN INADEQUATE OIL SEAL.
- Fit a new oil seal on the outer rim with the help of
the specific tools below.
- Fit a new O-ring and lubricate it with grease.
- Install the cover on the engine crankcase, insert
the three screws and place the cover in its position.
- Tighten the 3 screws to the prescribed torque.
Specific tooling

Timing chain/oil pump compartment cover
screws 4 to 5 Nm
Oil pump
ENG - 123
Removal
- Remove the chain compartment cover undoing

the 3 fixing screws indicated in the figure.
- Take out the cover using the appropriate fusion
couplings on the cover with a pair of pliers
- Undo the 2 clamping screws in the figure and re-

move the cover over the pump control crown gear.
- Block the rotation of the oil pump control gear with
a screwdriver inserted through one of its pump
holes.
- Remove the central screw and the belleville

washer
- Remove the chain with the crown gear.
- Remove the crankshaft control pinion.
- Remove the oil pump by undoing the 2 screws
indicated in the figure.
- Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.

- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with a
degreasing solvent and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible Replace the
clip.
ENG - 124
- Measure distance between rotors (inner rotor/

outer rotor) with a thickness gauge in the position
shown in the picture.
Characteristic
Admissible maximum clearance 1
0.15 mm
Measure the distance between the outer rotor and

the pump body (see figure).
Characteristic
0.20 mm
- Check the axial clearance of the rotors using a

trued bar as reference as shown in the figure.
N.B.
MAKE SURE THE TRUED BAR IS POSITIONED PROPERLY
ON THE TWO POINTS ON THE PUMP BODY.
Characteristic
0.09 mm
Refitting
- Check there are no signs of wear on the oil pump

shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the assembly.
- Fit the cover on the pump being careful to align
the holes (2 on the cover and 2 on the pump body)
fixing the oil pump on the crankcase.
- Fit the oil pump on the crankcase by tightening
the two screws to the prescribed torque.
ENG - 125
- Fit the pulley on the pump, the central screw to

the specified torque and the belleville washer.
- Check that there is no seizing and/or friction dur-
ing the pulley rotation.
N.B.
FIT THE CUP WASHER SO THAT ITS OUTER (CURVED)
RIM TOUCHES THE PULLEY.

Central screw 12 to 14 Nm Cover screws 0.7 to 0.9
Nm Oil pump screws 5 - 6
Removing the oil sump
- Remove the oil filling cap, the transmission cover,

the complete driving pulley assembly with belt and
pinion.
- Unscrew the oil drainage plug «A» shown in the
figure and drain out all the oil from the sump.
- Remove the 6 screws indicated in the figure.
Refitting the oil sump
- Clean and grease the faying surfaces.

- Apply LOCTITE 510 on the sump surface and
tighten the 6 fixing screws to the specified torque.
- Refit the driving pulley assembly, the belt, the
pinion and the transmission cover.
WHEN TESTING THE LUBRICATION SYSTEM, REFER TO
THE "CRANKCASE AND CRANKSHAFT" CHAPTER, RE-
GARDING LUBRICATION OF THE CRANKSHAFT AND
CONNECTING ROD

Oil sump screws 8 - 10 Nm
ENG - 126
Fuel supply
- Disconnect the fuel supply and the suction taking

pipe from the carburettor.
- Check that there are no fuel leaks between the
two tubes.
- Close the fuel outlet pipe.
- By means of the MITYVAC pump apply 0.1 bar
of suction to the tap.
- Make sure that the suction is kept stable and that
and that there are no fuel leaks.
- Reconnect the vacuum pipe to the manifold.
- Position the fuel pipe with the outlet at the point
of the tap.
- Turn the engine by using the starter motor for five
seconds with the carburettor at minimum.
- Take up the fuel by means of a graded burette.
N.B.
THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-
RECT NUMBER OF REVS OR BY THE WRONG POSITION
OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB-
TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-
LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY
REDUCED FOR THE PURPOSE OF ENHANCING THE SUC-
TION PULSATION AND THEREBY GUARANTEE A CON-
STANT TAP FLOW RATE.
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Characteristic
Minimum flow rate
20 cc
- Completely empty the fuel tank.

- Remove the petrol delivery pipe and the low-
pressure pipe.
- Loosen the clip and remove the cock.
- Clean the tank and the filter of the cock with a
specific solvent.
- Refit the cock making sure that there is an O-
Ring.
- Turn the cock to the direction it had before it was
removed and block the clip.
ENG - 127
N.B.
THE FILTER CAN BE UNSCREWED FROM THE COCK TO
FACILITATE CLEANING.
Removing the carburettor
- To detach the carburettor from the engine, re-

move the two clamps anchoring the carburettor to
the inlet manifold and the air intake coupling to the
filter.
- Remove the fuel supply pipe.
- Disconnect the starter connection.
- Detach the accelerator cable with the sheath that
connects the plate and the support.
- Remove the carburettor.
- Remove the protection, the bracket and the start-

er undoing the screw shown in the figure.
CAUTION
THE CARBURETTOR FEATURES AN ANTI-VIBRATION
RUBBER BUFFER FITTED ON THE LOWER SUPPLEMENT
OF THE ACCELERATING PUMP BODY. UPON REFITTING
THE CARBURETTOR ON THE ENGINE, MAKE SURE THIS
BUFFER IS PRESENT SO THAT THE PETROL IN THE TANK
DOES NOT EMULSIFY.
- Remove the 2 fixing screws indicated in the fig-

ure, the vacuum chamber cover and the spring.
- Remove the vacuum valve together with the di-
aphragm; the pin, the spring and its plastic guide.
WARNING
DURING THE REMOVAL OF THE COVER TAKE SPECIAL
CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
- Remove the 3 fixing screws and the chamber with

the gasket.
ENG - 128
- Remove the chamber components following the

procedure below.
- Undo the 2 screws fixing the intake pump dia-
phragm cover.
- Remove the cover being careful with the spring

below, then remove the spring, take out the rubber
protection and the diaphragm together with the
pipe O-Ring.
-Remove the accelerating pump jet together with

the ball spring.
- Remove the screw indicated in the figure fixing

the float pin.
- Remove the float and the plunger.
-Remove the maximum nozzle.

-Remove diffuser.
ENG - 129
-Remove the minimum nozzle.
- Remove the sprayer tilting the carburettor body.

N.B.
THIS OPERATION IS NECESSARY TO AVOID LOSING
SPRAYER PARTS WHEN CLEANING THE CARBURETTOR
BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO
NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM-
AGE IT.
- Remove the idle flow screw with the O-ring and

the spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS:
FUEL SUPPLY PIPE, PIN SEATING, STARTER NOZZLE, THROTTLE VALVE CONTROL VALVE
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS
ARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT.
ENG - 130
Refitting the carburettor
- Before refitting, wash the carburettor body accu-

rately with a degreasing solvent and compressed
air.
- Pay special attention to the fuel supply pipe and
the plunger seat.
- For the minimum circuit, make sure the following

points are properly cleaned: air gauging, exhaust
section controlled by flow screw, progression
holes near the throttle valve.
- For the starter circuit, blow the connection pipe

properly with the jet. This is necessary because
the nozzle support hides other inaccessible inter-
nal calibrations.
- Blow the intake nozzle properly.
The acceleration nozzle outlet is extremely small
and is oriented to the throttle valve.
- Check that the carburettor body has the closing ball for the idle circuit pipe.
- Check that the coupling surfaces, the chamber and the diaphragm are not dented.
-Check that the depression valve housing pipe is not scratched.
- Check that the throttle valve and the shaft do not show abnormal wear.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
ENG - 131
- Wash and blow the minimum nozzle properly and

reassemble it.
- Accurately wash and blow the components of the

maximum circuit, the sprayer, the diffuser and the
nozzle.
- Introduce the sprayer in the carburettor body with
the bigger cylindrical part directed to the diffuser.
- Fit the diffuser.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs

of wear on the sealing surfaces of the shock ab-
sorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing
or on the contact plate with the rod and that there
are no fuel infiltrations.
- Replace it in case of failures.
- Fit the float together with the pin and rod in its
position and lock it with its screw.
N.B.
INTRODUCE THE RETURN SPRING ON THE FLOAT
PLATE ADEQUATELY
- Insert the ball in the corresponding accelerating

pump.
- Fit the spring.
- Fit the accelerating pump nozzle.
WARNING
WHEN REFITTING, PAY SPECIAL ATTENTION TO THE
COMPONENTS AS THEY ARE SMALL.
ENG - 132
- Check the diaphragm is in good conditions and

remove the remaining components of the acceler-
ating pump following these steps:
- Insert the O-Ring in the pipe.
- Insert the diaphragm together with the pin and its
spring.
N.B.
REPLACE THE DIAPHRAGM IF THERE ARE SIGNS OF UN-
DULATIONS, CRACKS OR HARDENING.
- Fit the accelerating pump diaphragm cover and

tighten the 2 fixing screws making sure the spring
below is correctly positioned.
- Fit the rubber bellows protecting the pin in the
upper part of the accelerating pump.
Level check
- Tilt the carburettor so that the needle valve at the

fuel supply is closed and the float weight does not
affect it.
- Check that the diaphragm closing line and the
float central line are parallel as shown in the figure.
- Blow air in to the tank and then assembly it and

its gasket on the carburettor body with the 3 fixing
screws.
N.B.
-ALWAYS USE NEW RINGS AND GASKETS FOR REFIT-
TING.
WARNING
THE SCREW IN THE TANK BOTTOM IS A BLEEDING ONE
AND CONSEQUENTLY IT ONLY REQUIRES CLEANING.
ENG - 133
- Insert the diaphragm into the throttle valve.

- Insert the tapered pin together with the plastic
support and the contrast spring into the throttle
valve.
N.B.
PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH
FACING THE INNER SIDE OF THE MEMBRANE TO BE
ABLE TO FIT THE LOWER END OF THE THROTTLE VALVE
SPRING.
- Fit the vacuum chamber cover with the 2 fixing

screws paying special attention to the spring.
Inspecting the automatic choke device
- Check that the automatic starter piston is not de-

formed or rusty.
- Check that the piston slides freely in its seating.
- Check that the piston sealing O-Ring is not de-
formed.
- The starter must be more or less functional de-
pending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the am-
bient temperature.
Characteristic
Protrusion value
11.5 mm
ambient temperature
24° C
ENG - 134
- The starter should disconnect progressively by

means of electric heating.
- Check the starter resistance when adjusted to the
ambient temperature.
Characteristic
ambient temperature
24° C
Automatic starter resistance
20 Ω ± 5 %
- Use battery to power the automatic starter and

check that piston protrudes as much as possible.
- The correct warm up time depends on the ambi-
ent temperature.
- If protrusion, resistance or timing values are dif-
ferent from the ones prescribed, replace the start-
er.
Characteristic
Battery
12V - -9 Ah
max. protrusion
15 mm
max. time
15 min
- Fit the starter, the support bracket and the pro-

tection with the screw indicated in the figure.
ENG - 135
- Insert rubber pipes for chamber ventilation.

- Insert the O-Ring, the washer, the spring and the
idle flow screw in their seats.
- Refit the carburettor on the engine and connect

again the accelerator cable with the sheath and the
support plate and the electrical connection of the
starter.
- Reconnect the fuel supply pipe and tighten the 2
clamping screw fixing the carburettor to the inlet
manifold and the air inlet coupling to the filter.
Adjusting the idle
- The engine does not require frequent idle speed adjustments, but it is essential to strictly follow certain
rules when adjusting the idle speed.
- Before adjusting the carburettor make sure to respect requirements on lubrication, valve clearance,
and complying timing; spark plug should be in optimum conditions, air filter clean and sealed, and the
exhaust system tight.
- Connect the tester thermometer to the sump, us-

ing a cover with oil expressly prepared for probes.
- Start the engine and before adjusting the idle
speed, make sure that the oil temperature is be-
tween 70÷80 °C.
Specific tooling
ENG - 136
- Using the rpm indicator in the analyser or a sep-

arate one, adjust the idle screw.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS RE-
MARKABLE POWER. READINGS MAY NOT BE ACCU-
RATE IF INADEQUATE RPM INDICATORS ARE USED.
Specific tooling
Characteristic
Engine idle speed
1700 - 1900
ENG - 137
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Vespa Primavera 50 4t 4valvole Pre-delivery
Aesthetic inspection
- Paintwork
- Fitting plastics parts
- Damage
- Dirt
Tightening torques inspection
Lock check
- All tightening torques
- External screw of covers
SAFETY FASTENERS
Name Torque in Nm
Handlebar locking 40 to 50
Lower steering ring nut 8 to 10
Upper steering ring nut 30 to 40
Front wheel axle nut 75 to 90
Rear wheel nut 137 to 152
Rear shock absorber nut-engine 33 to 41 N·m
Shock absorber - chassis nut 20 - 25
Engine-swinging arm bolt 33 to 41
Frame-swinging arm bolt 44 to 52
Electrical system
- Check voltage at pre-delivery; it should be 12.6V minimum; otherwise, recharge the battery following
the specifications indicated on the battery itself.
Check the following devices:
- Key switch
- Low beam light, high beam light, light warning lights, position light
- Headlight adjustment
- Rear light
- Stop light (front and rear brake, if required)
- Turn indicators and relevant warning lights
- Speedometer and instrument panel lighting
- Horn
- Starter button
CAUTION
IN ORDER TO ENSURE MAXIMUM PERFORMANCE CHARGE THE BATTERY BEFORE USE ON-
LY IF VOLTAGE DROPS BELOW 12.7 V. FAILURE TO CHARGE THE BATTERY ADEQUATELY
BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE.
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE LEAD.
PRE DE - 139
Pre-delivery Vespa Primavera 50 4t 4valvole
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
WARNING
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN. BATTERY ELECTROLYTE IS TOXIC AND IT MAY
CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR
EYES, SKIN AND CLOTHING. NEVER TRY TO FORCE OR DAMAGE THE OUTER CASING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
Levels check
- Brake oil level

- Hub oil level
- Engine oil level
Road test
- Cold start.
- Speedometer activation check.
- Throttle control operation.
- Riding stability.
- Front and rear brake efficiency.
- Front and rear wheel shock absorber efficiency.
- Abnormal noise.
- Hot engine restart.
- Fluid leak (after test drive).
Functional inspection
- Brake lever travel.

- Throttle control adjustment and free travel.
- Uniform turning of the steering.
Others
- Tyre pressure
- Correct operation of all locks
- Mirrors and accessories fitting
- Tools supplied, user's manual, warranty certificate and customer services documents
CAUTION
PRE DE - 140
Vespa Primavera 50 4t 4valvole Pre-delivery
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
WARNING
HANDLE FUEL WITH CARE.
PRE DE - 141
A
Air filter: 41
B
Battery: 51, 58, 68, 69, 71
Brake:
C
Carburettor: 14, 37, 128, 131
Checks: 61
E
Engine oil: 41
Engine stop:
F
Fuel: 50, 127
H
Headlight: 44
Hub oil: 40
I
Identification: 7
M
Maintenance: 7, 37
O
Oil filter: 42
R
Recommended products:
S
Spark plug: 39, 62
Start-up:
Suspension: 51, 52
T
Transmission: 10, 50, 80, 90
Tyres: 13
V
Vehicle: 7

Vespa Primavera 50 4t 4v Service Manual

Uploaded by

Copyright:

Available Formats

Vespa Primavera 50 4t 4v Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Vespa Primavera 50 4t 4v Service Manual

Uploaded by

Copyright:

Available Formats

SERVICE STATION MANUAL

Vespa Primavera 50 4t 4valvole

Vespa Primavera 50 4t 4valvole

ELECTRICAL SYSTEM ELE SYS

Dimensions and mass

WEIGHTS AND DIMENSIONS

CHECKING RELAYS «A» OPERATING AS CIR-

TURN INDICATOR SWITCH

Resistance between green cable and ground con-

- Primary resistance: 0.5 to 0.6 Ohm

Frame and suspensions

CHASSIS AND SUSPENSIONS

Wheels and tyres

WHEELS AND TYRES

FOR SAFETY FASTENERS, SEE THE «PRE-DELIVERY» CHAPTER.

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDER

- Measure the diameter of the bearings on the pis-

- Calculate the piston pin coupling clearance.

- Carefully clean the seal housings.

- Using a bore meter, measure the inner cylinder

- Pistons and cylinders are classified into catego-

- Alternately insert the three sealing rings into the

Name Description Dimensions Initials Quantity

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE

Measure the bearings along X and Y axes

To install the crankshaft on the support and to

- Using a bore gauge, measure the connecting rod

- Using a trued bar check that the cylinder head

- Insert the valves into the cylinder head.

Measure the camshaft bearing seats and rocking

Measure the unloaded spring length.

• Standard length: 31.3 mm

- Clean the valve seats of any carbon residues.

STANDARD VALVE LENGTH

- Measure the diameter of the valve stems in the

MINIMUM DIAMETER PERMITTED

- Check the concentricity of the valve head by

- Check the deviation of the valve stem by resting

Measure the valve guides

VALVE GUIDE DIAMETER

- After measuring the valve guide diameter and the

- Inspect the camshaft for signs of abnormal wear

-Using a gauge, measure the cam height.

Check the axial clearance of the camshaft

- If any of the above dimensions are outside the

- Measure the outside diameter of the rocking lever pins

ROCKING LEVERS AND PIN DIAMETER:

Slot packing system

PISTON PROTRUSION CHECK

RECOMMENDED PRODUCTS TABLE

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

004499Y Bearing extractor. Fitted with: 1 Bell, 2

005095Y Engine support

008119Y009 Tube to assemble shafts and axles

020004Y Punch for removing steering bearings

Stores code Description

020074Y Tool to align crankshaft

020151Y Air heater