PIAGGIO Liberty 50 4tempi 2008 Workshop Manual
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PIAGGIO Liberty 50 4tempi 2008 Workshop Manual

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WORKSHOP MANUAL
633104
Liberty 50 4tempi

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Summary of Contents for PIAGGIO Liberty 50 4tempi 2008

  • Page 1 WORKSHOP MANUAL 633104 Liberty 50 4tempi...
  • Page 2 Not all versions/models shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 WORKSHOP MANUAL Liberty 50 4tempi This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. The non original or non-compliant spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle.

  • Page 8: Vehicle Identification

    1.330 mm Saddle height 775 mm Engine ENGINE Specification Desc./Quantity Engine type Single cylinder 4-stroke Piaggio Hi-PER4 Bore x stroke 39 X 41.8 mm Engine capacity 49.93 cm³ Compression ratio 11.5 :1 Timing system single overhead camshaft, driven by a chain to the left side.
  • Page 9 Liberty 50 4tempi Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V- belt, automatic clutch, gear reduction unit. Capacities CAPACITIES Specification Desc./Quantity Rear hub oil Quantity: approx. 85 cc Engine oil Capacity: approx. 850 cm³ Fuel tank capacity 6 litres (of which 1 l is reserve) Electrical system...

  • Page 10: Wheels And Tyres

    Liberty 50 4tempi Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front tyre Tubeless 90/80-16" Front wheel rim Die-cast aluminium alloy, 2.15 x16" Rear tyre Tubeless 110/80-14" Rear wheel rim Die-cast aluminium alloy, 2.75 x14" Front tyre pressure 2 bar Rear tyre pressure 2.2 bar Rear tyre pressure (rider and luggage)

  • Page 11: Tightening Torques

    Liberty 50 4tempi Characteristics Kehin KEHIN CARBURETTOR Specification Desc./Quantity Type CVK 18 Throttle valve diameter: Ø 18,5 Choke diameter Ø 17 Stamping on body 17ND Maximum nozzle: Maximum air nozzle (on the body): Ø1.1 Tapered pin stamping NACA Gas valve spring 70 ÷...
  • Page 12 Liberty 50 4tempi Characteristics STEERING ASSEMBLY Name Torque in Nm Steering upper ring nut 35 to 40 Steering lower ring nut 12 ÷ 14 handlebar fixing screw 45 ÷ 55 FRAME ASSEMBLY Name Torque in Nm Engine-swinging arm bolt 33 ÷ 41 Frame-swinging arm bolt 64 ÷...
  • Page 13 Liberty 50 4tempi Characteristics COUPLING BETWEEN PISTON AND CYLINDER Name Initials Cylinder Piston Play on fitting Cylinder (with asso/right 38.993 to 39.000 38.954 to 38.961 0.032 to 0.046 way piston) Cylinder (with shiram 38.993 to 39.000 38.949 to 38.956 0.037 to 0.051 piston) Cylinder (with asso/right 39.000 to 39.007...
  • Page 14 Liberty 50 4tempi Characteristics Name Description Dimensions Initials Quantity Oil scraper ring 2nd 39.4 x 2 0.20 to 0.70 Oversize 1st Compression ring 39.6 x 1 0.08 to 0.20 3rd Oversize 2nd Compression ring 39.6 x 1 0.05 to 0.20 3rd Oversize Oil scraper ring 3rd 39.6 x 2...
  • Page 15 Liberty 50 4tempi Characteristics PISTON PROTRUSION CHECK Name Measure A Thickness shimming_1 0.05 to 0.25 0.35 shimming_2 0.25 to 0.40 0.25 Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis- API GL-4 sions.
  • Page 16 INDEX OF TOPICS TOOL OOLING...
  • Page 17 Liberty 50 4tempi Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y008 Pliers to extract 17 mm ø bearings 001467Y009 Bell for OD 42-mm bearings 004499Y Camshaft bearing extractor 005095Y Engine support 008119Y009 Tube to assemble shafts and axles TOOL - 17...
  • Page 18 Liberty 50 4tempi Tooling Stores code Description 020004Y Punch for removing steering bearings from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater mounting 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for Ø 17 mm roller bearing TOOL - 18...
  • Page 19 Liberty 50 4tempi Tooling Stores code Description 020265Y Bearing fitting base 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 TOOL - 19...
  • Page 20 Liberty 50 4tempi Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 20...
  • Page 21 Liberty 50 4tempi Tooling Stores code Description 020335Y Magnetic mounting for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40-mm Adaptor 020359Y 42x47-mm Adaptor 020360Y 52x55-mm Adaptor 020362Y 12 mm guide TOOL - 21...
  • Page 22 Liberty 50 4tempi Tooling Stores code Description 020363Y 20-mm guide 020364Y 25-mm guide 020376Y Adaptor handle 020431Y Valve oil seal extractor 020432Y Tool to fit the start-up sector spring 020439Y 17-mm guide TOOL - 22...
  • Page 23 Liberty 50 4tempi Tooling Stores code Description 020448Y Pin lock fitting tool 020449Y Piston position check support 020450Y Camshaft fitting/removal tool 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner TOOL - 23...
  • Page 24 Liberty 50 4tempi Tooling Stores code Description 494929Y Exhaust fumes analyser TOOL - 24...
  • Page 25 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 26: Maintenance Chart

    Liberty 50 4tempi 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 Safety locks Spark plug Drive belt Throttle control Tyre condition and wear...

  • Page 27: Checking The Spark Advance

    Liberty 50 4tempi Maintenance Carburettor - 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.

  • Page 28: Spark Plug

    Liberty 50 4tempi Maintenance REVOLUTION LIMITER Specification Desc./Quantity 1 spark on 7 8200 Rpm 1 spark on 3 8300 Rpm all sparks are suppressed 8500 Rpm Spark plug The central electrode of the above spark plug is treated with silicone oil that acts as an antioxidant agent.
  • Page 29 Liberty 50 4tempi Maintenance Disconnect the cap and remove the spark plug. - Inspect the plug and if the insulator is chipped or damaged, renew it. - Measure the spark plug gap with a feeler gauge. If necessary adjust the gap by bending the outer electrode.
  • Page 30 Liberty 50 4tempi Maintenance 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) Air filter...

  • Page 31: Engine Oil

    Liberty 50 4tempi Maintenance Engine oil -The oil decanting system is a labyrinth type so it does not require servicing. N.B. IN THE EVENT OF LONG ROUTES OR LACK OF SERVIC- ING, ADEQUATELY CLEAN THE LABYRINTH BY REMOV- ING THE FOUR SCREWS AND SHEET METAL COVER. Replacement Loosen the oil filler plug.

  • Page 32: Engine Oil Filter

    Liberty 50 4tempi Maintenance 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.

  • Page 33: Checking The Valve Clearance

    Liberty 50 4tempi Maintenance N.B. TIME THE TIMING SYSTEM UNIT AS DESCRIBED IN CHAP- TER 6 IF IT IS NOT IN PHASE Checking the valve clearance - To check the play in the valves collimate the dis- tribution timing point references as described above.
  • Page 34 Liberty 50 4tempi Maintenance light dipped beam and position it so that the boun- dary between the brightly illuminated area and the surrounding area is no higher than the line you have drawn. To access the adjustment screw remove the cover on the legshield rear fairing at the height of the bag clip.
  • Page 35 Liberty 50 4tempi Maintenance 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 ±...
  • Page 36 Liberty 50 4tempi Maintenance 13 ÷ 15 bar ~ 630 rpm (starting speed). Locking torques (N*m) Ignition spark plug 10 to 15 Nm MAIN - 36...
  • Page 37 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 38: Rear Wheel Spins At Idle

    Liberty 50 4tempi Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; vacuum operated cock failure Remove, wash with solvent and dry with compressed air or re- place Excess of scales in the combustion chamber...

  • Page 39: Engine Tends To Cut Out At Full Throttle

    Liberty 50 4tempi Troubleshooting Possible Cause Operation Automatic starter failure Check: mechanical movement, electric connection and fuel supply, replace if required. Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.
  • Page 40 Liberty 50 4tempi Troubleshooting Possible Cause Operation Incorrect idle adjustment Adjust using the rpm indicator Pressure too low at the end of compression Check the thermal group seals and replace worn components Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components The starter remains on Check: electric wiring, circuit not interrupted, mechanical movement and power supply;...
  • Page 41 Liberty 50 4tempi Troubleshooting Insufficient braking NSUFFICIENT BRAKING Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits;...
  • Page 42 Liberty 50 4tempi Troubleshooting Rear wheel REAR WHEEL ROTATES WITH ENGINE AT IDLE Possible Cause Operation Idling rpm too high Adjust the engine idle speed and the CO%, if necessary. Clutch fault Check the springs / clutch masses Controls STEERING CONTROLS AND SUSPENSIONS Possible Cause Operation Torque not conforming...
  • Page 43 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 44 Liberty 50 4tempi Electrical system Legend: 1. Left front turn indicator 2 bulbs 2. 2 amber bulbs for indicators 3. Horn button 4. Turn signal selector. 5. High/low beam selector 6. Rear brake stop button 7. Bulb 8. Bulb for front position light 9.
  • Page 45 Liberty 50 4tempi Electrical system 13. Main beam indicator light 14. Speedometer with indicators and level indicator instrument with 7 bulbs and 2 bulbs 15. Horn 16. Headlight 17. Front brake stop button 18. Start button 19. Keyswitch 20. Front right indicator 21.
  • Page 46 Liberty 50 4tempi Electrical system Ignition IGNITION Specification Desc./Quantity Magneto flywheel Pick - up Key switch contacts Electronic ignition device Fuse 10 A Voltage regulator Battery 12V-9Ah Headlights and automatic starter section LIGHTS Specification Desc./Quantity Magneto flywheel Voltage regulator ELE SYS - 46...
  • Page 47 Liberty 50 4tempi Electrical system Specification Desc./Quantity Light switch Headlight bulb 12V-35/35W High-beam warning light 12V - 1.2W Rear light bulb 12V - 5W Headlight warning light 12V - 1.2W Front position light filament 12V - 5W N°3 instrument lighting bulbs 12V - 1.2W Battery recharge and starting BATTERY RECHARGE AND STARTING SECTION...
  • Page 48 Liberty 50 4tempi Electrical system Level indicators and enable signals section START PERMISSIVE BUTTONS AND LEVEL INDICATORS Specification Desc./Quantity Voltage regulator Fuel gauge Fuel level sender Low fuel warning light 12V - 1.2W Front and rear brake light button Fuse 10 A Battery 12V-9Ah...
  • Page 49 Liberty 50 4tempi Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity Indicators switch Horn button Horn Two (2) turn signal warning light bulbs 12V - 2W 4 Turn indicator bulbs 12V-10W Voltage regulator Key switch contacts Fuse 10 A Battery 12V-9Ah...
  • Page 50 Liberty 50 4tempi Electrical system higher than 130 Amp and the torque must not be lower than 0.55 N·m. N.B. THESE VALUES MUST BE MEASURED WITH A CHARGED BATTERY AND AFTER THE STARTER HAS BEEN ROTAT- ING FOR 30" UNDER CONDITIONS OF POINT 1 ELECTRIC MOTOR Specification Desc./Quantity...
  • Page 51 Liberty 50 4tempi Electrical system 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.
  • Page 52 Liberty 50 4tempi Electrical system Ignition circuit All the control operations of the system that require the disconnection of cables (checks of the con- nections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably dam- aged.
  • Page 53 Liberty 50 4tempi Electrical system 1) BULBS BURNT Replace the regulator because it is certainly inef- ficient. 2) LIGHTS AND STARTER NOT WORKING Access the voltage regulator by removing the plas- tic cover on the legshield; start the engine and keep it running at idle speed.
  • Page 54 Liberty 50 4tempi Electrical system 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.
  • Page 55 Liberty 50 4tempi Electrical system 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; when the vehicle's lights and stop light are switched on and the horn is powered, current values ≥...
  • Page 56 Liberty 50 4tempi Electrical system Specific tooling 020331Y Digital multimeter Turn signals system check 4) TURN INDICATORS NOT WORKING If the turn indicators do not work, do the following: - Disconnect the regulator connection and insert the multimeter probes between the white cable (3) and the black one (2).
  • Page 57 Liberty 50 4tempi Electrical system Sealed battery INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check up Before installing the battery on the vehicle, check the open circuit voltage with a standard tester. - If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge.
  • Page 58 Liberty 50 4tempi Electrical system 1)- Remove the short closed tube and the caps, 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 temperature of 15°C until the upper level is reached.
  • Page 59 Liberty 50 4tempi Electrical system 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.
  • Page 60 Liberty 50 4tempi Electrical system INSTRUMENT PANEL Specification Desc./Quantity Left turn indicator warning light 12V - 2W High-beam warning light 12V - 1.2W Instrument panel lighting bulbs 12V - 1.2W Headlight warning light 12V - 1.2W Low fuel warning light 12V - 1.2W Right turn indicator warning light 12V - 2W...
  • Page 61 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 62 Liberty 50 4tempi Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Undo the 2 screws fixing the silencer to the hous- ing; then remove the whole muffler paying atten- tion to the interference between its supporting bracket and the cooling cover.
  • Page 63 Liberty 50 4tempi Engine from vehicle -Remove the muffler assembly. - Remove the rear wheel. - Remove the mechanical transmission of the rear brake. -Disconnect the electric terminals. - Remove the throttle grip and mixer transmissions. - Disconnect the hoses (petrol-oil-vacuum-operated cock control). WARNING Handle fuel with care.
  • Page 64 INDEX OF TOPICS NGINE...

  • Page 65: Automatic Transmission

    Liberty 50 4tempi Engine 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.

  • Page 66: Removing The Driven Pulley

    Liberty 50 4tempi 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.

  • Page 67: Inspecting The Clutch Drum

    Liberty 50 4tempi Engine 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...
  • Page 68 Liberty 50 4tempi Engine 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.
  • Page 69 Liberty 50 4tempi Engine 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.
  • Page 70 Liberty 50 4tempi Engine 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.
  • Page 71 Liberty 50 4tempi Engine 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...

  • Page 72: Refitting The Driven Pulley

    Liberty 50 4tempi Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE NUT IN CONTACT WITH THE CLUTCH Locking torques (N*m) Nut locking clutch unit on pulley...

  • Page 73: Removing The Driving Pulley

    Liberty 50 4tempi Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley. - Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.
  • Page 74 Liberty 50 4tempi Engine 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.
  • Page 75 Liberty 50 4tempi Engine 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.
  • Page 76 Liberty 50 4tempi Engine Removing the hub cover - Drain the rear hub oil - Remove driven pulley - Remove the rear brake shoes - Remove the 5 screws fixing the cover to the crankcase - Remove the cover with the wheel axle and pull it - Remove the intermediate gear with the appropri- ate shim washers Removing the wheel axle bearings...
  • Page 77 Liberty 50 4tempi Engine Removing the driven pulley shaft bearing - Remove the seeger ring - Heat the engine crankcase but do not direct the hot air towards the bearing - Extract the driven pulley shaft together with the bearing with a few mallet blows - Remove the bearing off the driven pulley shaft using the specific tool and a press N.B.
  • Page 78 Liberty 50 4tempi Engine 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...
  • Page 79 Liberty 50 4tempi Engine 020363Y 20-mm guide 020359Y 42x47-mm Adaptor Refitting the hub bearings - Remove the wheel axle on the cover and pay at- tention not to damage the sealing lip of the oil seal - Apply a thin layer of grease on the two shim washers of the intermediate gear and fit one on the cap so that it does not interfere with the wheel axle gear when placing the transmission shaft...
  • Page 80 Liberty 50 4tempi Engine Gasket Locking torques (N*m) hub cap screws 24 - 26 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...

  • Page 81: Removing The Stator

    Liberty 50 4tempi Engine 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.
  • Page 82 Liberty 50 4tempi Engine 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. Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner.
  • Page 83 Liberty 50 4tempi Engine 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.
  • Page 84 Liberty 50 4tempi Engine 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.
  • Page 85 Liberty 50 4tempi Engine 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 4 screws and then remove the Blow- by cover - Clean the nozzle labyrinth and the membrane (replace it, if necessary), then remove the cover unit.
  • Page 86 Liberty 50 4tempi Engine - 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.

  • Page 87: Removing The Cylinder Head

    Liberty 50 4tempi Engine 020450Y Camshaft fitting/removal tool 004499Y Camshaft bearing extractor 004499Y001 Bearing extractor bell 004499Y002 Bearing extractor screw 004499Y006 Bearing extractor ring 004499Y027 Bearing extractor part - Pull out the rocking lever bolt operating on the flywheel hole and remove the rocking levers at the same time.

  • Page 88: Removing The Valves

    Liberty 50 4tempi Engine Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the caps and the spring between the valves. - Remove the oil seals with the appropriate tool. - Remove the lower spring supports.

  • Page 89: Inspecting The Small End

    Liberty 50 4tempi Engine 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 ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT"...
  • Page 90 Liberty 50 4tempi Engine - Measure the coupling clearance between the sealing rings and the piston grooves using a thickness gauge, as shown in the figure. - If the clearances detected exceed the limits specified in the table, the piston and the piston rings should be replaced.
  • Page 91 Liberty 50 4tempi Engine - The pistons are oversized due to cylinder rectifi- cation and are subdivided into two categories 1st and 2nd with 0.2-0.4mm oversize. They are also classified into 4 categories A-A, B-B, C-C, D-D. Inspecting the piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter.

  • Page 92: Removing The Piston

    Liberty 50 4tempi Engine 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 Pin lock fitting tool - With the opening in the position indicated on the tool, set the lock ring into position in the tool with...
  • Page 93 Liberty 50 4tempi Engine Characteristic Standard compression ratio C.R. 11.5 ÷ 12 ÷ 1 CYLINDER BASE GASKET THICKNESS Specification Desc./Quantity Cylinder height 56.45 ± 0.05 Head gasket thickness (fibre) 0.95 ± 0.06 Value measured 0.9 ± 0.05 Base gasket thickness Value measured 1 ±...
  • Page 94 Liberty 50 4tempi Engine ENG - 94...
  • Page 95 Liberty 50 4tempi Engine 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»...

  • Page 96: Inspecting The Cylinder Head

    Liberty 50 4tempi Engine NATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD. SEALING RINGS Name Descripti Dimensio Initials Quantity Top piston 0.08 ÷ 0.35 mm ring 0.20 mm Middle pis- 0.05 ÷ 0.30 mm ton ring 0.20 mm oil scraper 0.20 ÷...
  • Page 97 Liberty 50 4tempi Engine 0.05 mm HEAD CHECK Specification Desc./Quantity 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.
  • Page 98 Liberty 50 4tempi Engine Inspecting the valve sealings - Insert the valves into the cylinder head. - Test the 2 valves alternatively. - 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.
  • Page 99 Liberty 50 4tempi Engine Wear limits: Max. 1.6 mm Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between valve and valve guide. Characteristic Minimum diameter allowed: Intake 4.970 mm Minimum admissible diameter drainage 4.960 mm...
  • Page 100 Liberty 50 4tempi Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with graphite grease. - Place the lower caps of the valve spring on the head.
  • Page 101 Liberty 50 4tempi Engine Ø 11.98 mm Minimum diameter allowed - Bearing B: Ø 15.96 mm - 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.
  • Page 102 Liberty 50 4tempi Engine 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.
  • Page 103 Liberty 50 4tempi Engine - 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.
  • Page 104 Liberty 50 4tempi Engine - 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.
  • Page 105 Liberty 50 4tempi Engine 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. Locking torques (N*m) Timing chain tensioner screws 8 ÷...
  • Page 106 Liberty 50 4tempi Engine 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.
  • Page 107 Liberty 50 4tempi Engine - 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.
  • Page 108 Liberty 50 4tempi Engine - 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.
  • Page 109 Liberty 50 4tempi Engine 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. - Fit the gasket recommended for surfaces on the half casing on the transmission side after greasing the two faying surfaces carefully.
  • Page 110 Liberty 50 4tempi Engine Removal - 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.
  • Page 111 Liberty 50 4tempi Engine 020376Y Adaptor handle 020358Y 37x40-mm Adaptor Locking torques (N*m) Timing chain/oil pump compartment cover screws 4 to 5 Nm Oil pump 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-...
  • Page 112 Liberty 50 4tempi Engine 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.
  • Page 113 Liberty 50 4tempi Engine 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.

  • Page 114: Fuel Supply

    Liberty 50 4tempi Engine 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.

  • Page 115: Removing The Carburettor

    Liberty 50 4tempi Engine 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.
  • Page 116 Liberty 50 4tempi Engine - 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.
  • Page 117 Liberty 50 4tempi Engine -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. -Remove the minimum nozzle. ENG - 117...
  • Page 118 Liberty 50 4tempi Engine - 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.
  • Page 119 Liberty 50 4tempi Engine - 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.
  • Page 120 Liberty 50 4tempi Engine - 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.
  • Page 121 Liberty 50 4tempi Engine - 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...
  • Page 122 Liberty 50 4tempi Engine - 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.
  • Page 123 Liberty 50 4tempi Engine - 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- Characteristic Battery...
  • Page 124 Liberty 50 4tempi Engine - 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.
  • Page 125 Liberty 50 4tempi Engine - 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.
  • Page 126 Liberty 50 4tempi Engine loss of engine blows as the mixture is too lean (low CO), ignition failure or, incorrect timing or a clogged or unsealed exhaust valve. If it is difficult to adjust CO values, check accurately: - That the automatic starter is efficient. - That the tapered pin-housing is efficient - Tank level adjustments ENG - 126...
  • Page 127 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 128 Liberty 50 4tempi Suspensions Front suspension This section is dedicated to operations that can be carried out on the suspensions. Front Front wheel hub overhaul Ball bearings to hub - Fit the spacer - Fit the ball bearings and bushes and position the seal rings.

  • Page 129: Front Fork

    Liberty 50 4tempi Suspensions Front fork Removal Overhaul O-ring renewal and rod disassembly - Remove the wheel axle. - Remove the lower screw (1). - Discharge the oil in the suspension. - Remove the stem. - Replace the sealing rings (3-4) with new ones. - Insert the new sealing rings only after lubricating their grooves.
  • Page 130 Liberty 50 4tempi Suspensions Steering lock ring nut Steering bearing upper race - Lubricate race and balls with Z2 grease. - Tighten to the specified torque and then rotate the tool through 80° - 90° in an anticlockwise di- rection. Removal Upper bearing washer and race After removing the upper seating, tilt the vehicle to...

  • Page 131: Removing The Rear Wheel

    Liberty 50 4tempi Suspensions Removing the rear wheel - Use a screwdriver as a lever between the drum and the cover. -Straighten the cotter pin and remove the cap. -Remove the wheel acting on the central fixing point. WARNING -ALWAYS USE NEW SPLIT PINS FOR REFITTING. Refitting the rear wheel -Refit the parts in the reverse order as for removal, lock the wheel nut to the specified torque.
  • Page 132 Liberty 50 4tempi Suspensions Centre-stand Assembly and staking of stand pivot pin to bracket - Caulk the end of the pin «P» between the two punches shown in the figure. - After caulking it must be possible for the stand to turn freely.
  • Page 133 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 134 Liberty 50 4tempi Braking system Once the silencer and the wheel have been re- moved, follow these steps: 1.Remove the shoe spring using the specific span- ner. 2. Remove the shoe with the aid of a lever. 3. Refit the new shoes giving a few taps with the mallet.
  • Page 135 Liberty 50 4tempi Braking system Front brake calliper Removal - Detach the oil brake hose from calliper, pouring the fluid inside a container. - Remove the mountings indicated in the figure. - When refitting, tighten the nuts to the prescribed torque.

  • Page 136: Front Brake Disc

    Liberty 50 4tempi Braking system - Before reassembly, the parts must be perfectly clean and bear no traces of oil, diesel fuel, grease, etc.. They must therefore be washed thor- oughly in denatured alcohol before proceeding. Immerse the seals in brake fluid; the use of pro- tective agent PRF1 is tolerated.

  • Page 137: Front Brake Pads

    Liberty 50 4tempi Braking system Disc Inspection - Remove the wheel and check for unevenness of the disc. Maximum permissible out of true is 0.1 mm. If the value measured is greater, replace the disc and repeat the check. - If the problem persists, check and replace the wheel rim if necessary.

  • Page 138: Recommended Products

    Liberty 50 4tempi Braking system Front -Once the bleed valve is closed, fill the system with brake liquid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system.
  • Page 139 Liberty 50 4tempi Braking system AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4 Locking torques (N*m) Oil bleed screw 8 - 12 Front brake pump -After removing the front and rear handlebar covers, act on the two stand fixing points (see the figure).
  • Page 140 Liberty 50 4tempi Braking system RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS. AFTER WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH. THE SEALING RINGS MUST BE IMMERSED IN THE OPER- ATING LIQUID.
  • Page 141 INDEX OF TOPICS CHAS HASSIS...
  • Page 142 Liberty 50 4tempi Chassis BODYWORK Taking apart approached cover motor Remove the 2 implantations. Seat - Unscrew the 2 fixing screws and remove the sad- Saddle After checking the typeapproval specifications, it was concluded that the strap on the saddle is redun- dant.

  • Page 143: Rear Rack

    Liberty 50 4tempi Chassis See also Knee-guard Rear rack • Operating from the rear and using a screwdriver, remove the plastic cap of the central screw cover. • Remove the central and the 2 side screws. CHAS - 143...
  • Page 144 Liberty 50 4tempi Chassis Driving mirrors • With the set screw fully tightened, screw the mir- ror stem on the handlebar until it stops. • Loosen the mirror and set it in the desired position. • Loos- en the set screw until the stem is locked. Locking torques (N*m) Mirror set screw 24 to 26...
  • Page 145 Liberty 50 4tempi Chassis Instrument panel • Remove the rear handlebar cover • Unscrew the 4 fixing screws and remove the in- strument panel N.B. THE WARNING LIGHT BULBS HAVE A BAYONET JOINT ON THE BULB HOLDER; THE LATTER CAN BE REMOVED BY ROTATING IT 30°...
  • Page 146 Liberty 50 4tempi Chassis Headlight assy. • Remove the front handlebar cover. • Unscrew the 4 fixing screws and remove the headlight assembly. N.B. N.B. TO REPLACE THE HIGH/LOWBEAM HEADLIGHT BULB, REMOVE THE RUBBER COVER AND TURN THE SUPPORTING PLATE BY 30° ANTICLOCKWISE. TO RE- PLACE THE SIDE LIGHT BULB, JUST SLIDE IT OFF THE RUBBER BULB HOLDER.
  • Page 147 Liberty 50 4tempi Chassis Legshield • Remove the shield back plate • Remove the footrest. • Remove the front fork. • Remove the front badge using a blade and op- erating carefully from the right side. • Undo the screw underneath and slide the cover upwards.
  • Page 148 Liberty 50 4tempi Chassis Knee-guard • Remove the 4 external screws of the leg shield back plate and the 3 screws inside the front box. • Using the bag hook, pull the leg shield back plate backwards until it slides off the fitting with the leg- shield.
  • Page 149 Liberty 50 4tempi Chassis Taillight assy. • To remove the taillight and position light or the 2 turn signals, just unscrew the screws located on the related light covers and disconnect the electri- cal connections. N.B. REMOVAL OF THE REAR LIGHT BULBS IS ONLY POSSI- BLE BY REMOVING THE LIGHT COVERS ROTATING THEM 30°...

  • Page 150: Rear Mudguard

    Liberty 50 4tempi Chassis License plate holder • Remove the saddle compartment cover • Unscrew the 2 screws securing it to the frame, then remove the license plate housing See also Frame central cover Air filter • Unscrew the 7 cover screws and remove the cover to reach the filter sponge.
  • Page 151 Liberty 50 4tempi Chassis Helmet bay • Remove the helmet compartment central cover. • Remove the battery and the fuse box. • Remove the fuel tank cap and the start-up remote control switch. • Unscrew the rear fixing screw and lift the helmet compartment.
  • Page 152 Liberty 50 4tempi Chassis Fuel tank • Remove the helmet compartment central cover. • Undo the front and rear screws on the chassis right side. • Disconnect the breather pipe and remove the float. See also Frame central cover Front mudguard •...
  • Page 153 Liberty 50 4tempi Chassis See also Removal Top-case Front Disassembling the inner shield fairing (glove box assy.) - Remove the two screws from inside the glove box. - Remove the two screws at the lower part of the inner shield fairing - Remove the two screws located behind the front grille.
  • Page 154 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 155 Liberty 50 4tempi Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety fasteners - Fixing screws Safety fasteners: Rear shock absorber upper fixing Rear shock absorber lower fixing Front wheel axle nut Wheel hub nut Swinging arm - chassis pin...
  • Page 156 Liberty 50 4tempi Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
  • Page 157 Liberty 50 4tempi Pre-delivery - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. Functional inspection Functional Checks: Braking system (hydraulic)
  • Page 158 INDEX OF TOPICS TIME...
  • Page 159 Liberty 50 4tempi Time TRANSMISSIONS Code Action Duration 002053 Rear brake transmission complete - Replacement 003060 Rear brake transmission - Adjust- ment 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement This section is dedicated to the time necessary to carry out repairs.
  • Page 160 Liberty 50 4tempi Time Engine ENGINE Code Action Duration 001001 Engine from chassis - Removal and refit. 001127 Engine - Complete service 003064 Engine oil - change 003057 Engine fixing - Nuts tightening 4 TIME - 160...
  • Page 161 Liberty 50 4tempi Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement Crankshaft TIME - 161...
  • Page 162 Liberty 50 4tempi Time DRIVING SHAFT Code Action Duration 001117 Crankshaft - Replacement 001101 Engine - Overhaul 001099 Oil seal flywheel side - Replacement 001100 Clutch-side oil seal - Replacement 001118 Main bearings - Replacement Cylinder assy. CYLINDER - PISTON Code Action Duration...
  • Page 163 Liberty 50 4tempi Time Cylinder head assy. HEAD Code Action Duration 001056 Head gasket - change 001045 Valves - Replacement 001126 Head - Replacement Rocker arms support assy. CAMSHAFT SUPPORT Code Action Duration 003056 Head/cylinder - Nuts tightening 001049 Valve clearance - Adjustment 001148 Valve rocking...

  • Page 164: Cylinder Head Cover

    Liberty 50 4tempi Time Cylinder head cover EAD COVER Code Action Duration 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement 001097 Cooling hood - Replacement 001089 Head cover - Replacement Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001110...
  • Page 165 Liberty 50 4tempi Time Oil pump OIL PUMP Code Action Duration 001051 Belt/Timing chain - Change 001112 Oil pump - change 001042 Oil pump - overhaul 001121 Chain cover oil seal - Replacement 001122 Oil pump chain - Replacement 001125 Chain guide pads - Replacement 001130 Oil sump - change...
  • Page 166 Liberty 50 4tempi Time Final gear assy. REDUCTION GEAR Code Action Duration 001010 Geared reduction unit - Service 004125 Rear wheel axle - Replacement TIME - 166...
  • Page 167 Liberty 50 4tempi Time Driving pulley DRIVING PULLEY Code Action Duration 001006 Driving pulley - Overhaul 001086 Driving half-pulley - Replacement 001066 Driving pulley - Removal and refitting 001011 Drive belt - Replacement TIME - 167...
  • Page 168 Liberty 50 4tempi Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - Re- placement 001132 Transmission air intake pipe - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement TIME - 168...

  • Page 169: Starter Motor

    Liberty 50 4tempi Time Starter motor STARTER MOTOR - START UP LEVER Code Action Duration 001020 Starter motor - change 001017 Starter sprocket wheel - replace 005045 Starter motor with cables unit - Re- plac. 001084 Starter lever - Replacement 008008 Starter spring pack - Replacement 001021...

  • Page 170: Flywheel Magneto

    Liberty 50 4tempi Time Flywheel magneto FLYWHEEL FAN Code Action Duration 001067 Stator - Fitting and Refitting 001058 Flywheel - Replacement 001102 Net oil filter - change / Cleaning 001109 Cooling fan - Replacement 001087 Flywheel cover - Replacement TIME - 170...
  • Page 171 Liberty 50 4tempi Time Exhaust pipe MUFFLER Code Action Duration 001092 Exhaust manifold - Replacement 001009 Silencer - Replacement 001095 Muffler guard - Replacement Silencer fixing Please take note that, starting from chassis serial number ZAPM3810000003971, the two M8 x 50 silencer fixing flaged head screws have been replaced by two M8 x 50 internal hexagonal cylindrical head screws.

  • Page 172: Air Cleaner

    Liberty 50 4tempi Time Air cleaner AIR FILTER Code Action Duration 001014 Air filter - Replacement /Cleaning 001015 Air filter box - Replacement TIME - 172...
  • Page 173 Liberty 50 4tempi Time Frame CHASSIS Code Action Duration 004004 Stand - Replacement 001053 Stand bolt - Replacement 004001 Chassis - Replacement TIME - 173...
  • Page 174 Liberty 50 4tempi Time Legshield spoiler MUFFLER - GLOVE COMPARTMENT Code Action Duration 004024 Co Steering cover - Replacement 004064 Front shield, front section - Removal and refitting 004015 Footrest - Disassembly and reas- sembly 004053 Spoiler - Replacement 006006 Steering head tube cover - Painting 006012 Front shield, front section - Painting...
  • Page 175 Liberty 50 4tempi Time Rear cover FRONT FOOTBOARD Code Action Duration 004081 Glove comparment door - Replace- ment 004065 Front shield, rear section - Replace- ment TIME - 175...
  • Page 176 Liberty 50 4tempi Time Central cover CENTRAL COVER Code Action Duration 004106 Undersaddle band - Replacement 004059 Spark plug inspection flap - Replace- ment 006035 Undersaddle band - Painting 006032 Door - Painting 004085 Fairing (1) - Replacement Mudguard TIME - 176...
  • Page 177 Liberty 50 4tempi Time REAR MUDGUARD Code Action Duration 004136 Number-plate holder support - Re- placement Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004109 Fuel tank breather - Replacement 004112 Cock-carburettor hose - Replace- ment 004007...
  • Page 178 Liberty 50 4tempi Time REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock ab- sorber - Disas- sembly and reas- sembly Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003002 Steering bearing - Replacement 003073 Steering clearance - Adjustment TIME - 178...

  • Page 179: Handlebar Covers

    Liberty 50 4tempi Time Handlebar covers ODOMETER - HANDLEBAR COVERS Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 005014 Odometer - Replacement 006013 Handlebar front part - Painting 005038 Instrument panel warning light bulbs - Replacement 005078 Speedometer glass - Replacement...
  • Page 180 Liberty 50 4tempi Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002037 Brake or clutch lever - Replacement 002059 Right hand grip - Replacement 003067 Front brake fluid - Renewal 003061 Accelerator transmission - adjust 002060 Complete throttle control - Replace- ment 002047 Front brake fluid and air bleeding...
  • Page 181 Liberty 50 4tempi Time HANDLEBAR COMPONENTS Code Action Duration 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 003001 Handlebar - Removal and refitting 004066 Driving mirror - Replacement Swing-arm We inform you that, starting from frame C15000 160199, a new frame-side swinging arm pin locknut part no.
  • Page 182 Liberty 50 4tempi Time SWINGING ARM Code Action Duration 001072 Engine/frame connection swing arm - Replacement Seat SADDLE - CARRIER Code Action Duration 004003 Saddle - Replacement 004008 Carrier - Replacement 006002 Luggage rack - Painting TIME - 182...
  • Page 183 Liberty 50 4tempi Time Turn signal lights LAMP CLUSTER Code Action Duration 005008 Headlight bulbs - Replacement 005002 Front headlamp - Replacement 005012 Front turning indicators - Replace- ment 005067 Front turning indicator bulb - replace- ment 005044 Front lights cable unit - replace 004020 Headlight frame - Replacement TIME - 183...

  • Page 184: Front Wheel

    Liberty 50 4tempi Time REAR RED LAMP Code Action Duration 005005 Taillight - change 005022 Rear turning indicators - Replace- ment 005066 Rear light bulbs - Replacement 005068 Rear turning indicator bulb - Re- placement 005028 Rear optical unit glass - Replace- ment Front wheel TIME - 184...
  • Page 185 Liberty 50 4tempi Time FRONT WHEEL Code Action Duration 003068 Front wheel spindle - Removal and refitting 002041 Brake disc - Replacement 002011 Odometer drive - Replacement 004123 Front wheel - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim - Remov. and Refit. 003040 Front wheel bearings - Replacement Tone wheel or drive greasing...
  • Page 186 Liberty 50 4tempi Time Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 004126 Rear wheel tyre - Replacement 003063 Tyres pressure - Check 006018 Wheel rim - Paintwork 001071 Front wheel rim - Removal and Re- fitting TIME - 186...
  • Page 187 Liberty 50 4tempi Time Electric devices ELECTRICAL DEVICES Code Action Duration 005009 Voltage regulator - Replacement 001094 Spark plug cap - Replacement 001023 CPU - Replacement 005001 Electrical system - Removal and re- fitting TIME - 187...

  • Page 188: Electrical Devices

    Liberty 50 4tempi Time ELECTRICAL DEVICES Code Action Duration 005006 Light or turning indicator switch - Re- placement 005069 Left-hand switch - Replacement 005039 Lights switch - Replacement 005040 Horn button - Replacement 005041 Starting device push button - Re- placement 005003 Electric horn - Replacement...
  • Page 189 Liberty 50 4tempi Time ELECTRICAL DEVICES Code Action Duration 005007 Battery - change 005011 Start-up solenoid - Replacement 005024 Battery fuse - Replacement 005025 Battery fuse box - Replacement TIME - 189...

  • Page 190: Brake Callipers

    Liberty 50 4tempi Time Brake callipers FRONT BRAKE CALIPER Code Action Duration 002039 Front brake caliper - Removal and refitting 002040 Front brake caliper - Overhaul 002021 Front brake hose - Remov. and Re- fitt. 003070 Front brake pads - Wear check 002007 Front brake pads - Replacement TIME - 190...
  • Page 191 Liberty 50 4tempi Time BRAKE LEVER Code Action Duration 003071 Rear brake pads/shoes - Check for wear 002002 Rear brake pads/shoes - Wear check Front mudguard FRONT AND REAR MUDGUARD Code Action Duration 004009 Rear mudguard - Replacement 004002 Front mudguard - Replacement 006003 Paragraph - Painting Helmet bay...
  • Page 192 Liberty 50 4tempi Time HELMET CARRIER Code Action Duration 001027 Body cleaner connection - Replace- ment 004016 Helmet compartment - Disassembly and reass. 005046 Battery cover - change Front suspension To unify licensed vehicles starting with frame C28200 10346, a new frame dis. no. 576680 has been introduced instead of the old dis.
  • Page 193 Liberty 50 4tempi Time Secondary air box SECONDARY AIR HOUSING Code Action Duration 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning 001162 Secondary air housing - Replace- ment 001163 Silencer secondary air connection - Replacement 001165 Secondary air reed - Replacement...
  • Page 194 Air filter: 30, 150 Battery: 41, 47, 57 Brake: 135–137, 139, 190 Carburettor: 10, 27, 115, 118 Checks: 49 Electric: 187 Engine oil: 31 Fuel: 40, 114, 152, 177 Headlight: 33, 146 Horn: Hub oil: 29 Identification: 8 Instrument panel: 145 Maintenance: 7, 26 Mirrors: 144 Odometer:...
  • Page 195 Tank: 152, 177 Transmission: 9, 40, 65, 75, 168 Turn indicators: Tyres: 10 Vehicle: 8, 62...

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