PIAGGIO Liberty 50 Catalyzed Workshop Manual
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PIAGGIO Liberty 50 Catalyzed Workshop Manual

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WORKSHOP MANUAL
633112
Liberty 50 Catalyzed

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  • Page 1 WORKSHOP MANUAL 633112 Liberty 50 Catalyzed...

  • Page 2: Workshop Manual

    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 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 Catalyzed 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

    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

    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.

  • Page 8: Vehicle Identification

    Wheel base 1.330 mm Saddle height 775 mm Engine ENGINE Specification Desc./Quantity Engine type Two-stroke, single cylinder Piaggio Hi-PER2 Bore x stroke 40 X 39.3 mm Cubic capacity 49.40 cc Compression ratio 10,3 :1 Carburettor DELL'ORTO PHVA 17.5 CO adjustment 3.5% ±...

  • Page 9: Frame And Suspension

    Liberty 50 Catalyzed Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V- belt, automatic clutch, gear reduction unit. Capacities CAPACITY Specification Desc./Quantity Rear hub oil Quantity : ~ 85 cc Mixer oil 1.2 litres Fuel tank capacity...

  • Page 10: Wheels And Tyres

    Liberty 50 Catalyzed 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...
  • Page 11 Liberty 50 Catalyzed Characteristics 50cc Version Dell'Orto DELLORTO CARBURETTOR Specification Desc./Quantity Type PHVA 17.5 RD Diffuser diameter Ø 17.5 Regulation reference number 8423 Maximum nozzle: Maximum air nozzle (on the body): Ø 1.5 Tapered pin stamped code: Pin position (notches from above):...

  • Page 12: Piston Rings

    Liberty 50 Catalyzed Characteristics Piston rings SEALING RING Name Description Dimensions Initials Quantity Compression ring 0.10 to 0.25 Compression ring 1st 40.2 0.10 to 0.25 oversize Compression ring 2nd 40.4 0.10 to 0.25 Oversize Crankcase - crankshaft - connecting rod...
  • Page 13 Liberty 50 Catalyzed Characteristics Slot packing system - Fit the cylinder without installing the basic gasket. - Apply a centimetre dial gauge on the special tool and zero it on the ground plane - Fit the tool to the top of the cylinder fixing it with two nuts to the studbolts and take the piston to the T.D.C.
  • Page 14 INDEX OF TOPICS TOOL OOLING...
  • Page 15 Liberty 50 Catalyzed Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y009 Driver for OD 42-mm bearings 001467Y013 Calliper to extract ø 15-mm bearings 001467Y014 Calliper to extract ø...
  • Page 16 Liberty 50 Catalyzed Tooling Stores code Description 001467Y017 Bell for bearings, OD 39 mm 001467Y021 Extraction pliers for ø 11 mm bearings 002465Y Calliper for circlips 006029Y Punch for fitting fifth steering bearing on steering tube 020004Y Punch for removing steering bearings...
  • Page 17 Liberty 50 Catalyzed Tooling Stores code Description 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020165Y Start-up crown lock 020166Y Pin lock fitting tool TOOL - 17...
  • Page 18 Liberty 50 Catalyzed Tooling Stores code Description 020261Y Starter spring fitting 020262Y Crankcase splitting plate 020265Y Bearing fitting base 020325Y Pliers for brake-shoe springs 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing TOOL - 18...
  • Page 19 Liberty 50 Catalyzed Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 19...
  • Page 20 Liberty 50 Catalyzed Tooling Stores code Description 020335Y Magnetic mounting for dial gauge 020350Y Electrical system check instrument 020357Y 32x35-mm Adaptor 020359Y 42x47-mm Adaptor 020376Y Adaptor handle 020412Y 15-mm guide TOOL - 20...
  • Page 21 Liberty 50 Catalyzed Tooling Stores code Description 020456Y Ø 24 mm adaptor 020483Y 30-mm guide 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser TOOL - 21...

  • Page 22: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 23: Maintenance Chart

    Liberty 50 Catalyzed Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change AFTER 1000 KM Action Hub oil - change Oil mixer/throttle linkage - adjustment Odometer gear - greasing Steering - adjustment Brake levers - greasing Brake fluid level - check...
  • Page 24 Liberty 50 Catalyzed Maintenance Action Hub oil level - check Spark plug/electrode gap - replacement Air filter - cleaning Oil mixer/throttle linkage - adjustment Drive belt - replacement Brake levers - greasing Brake pads - check condition and wear Brake fluid level - check...
  • Page 25 Liberty 50 Catalyzed Maintenance (*) See regulations in the «Adjusting the idle speed» section (**) See regulations in the «Secondary air system» section 60000 K FTER 150' Action Hub oil - change Spark plug/electrode gap - replacement Air filter - clean...

  • Page 26: Checking The Spark Advance

    Liberty 50 Catalyzed Maintenance 1. Automatic starter - 2. Idle air set screw - 3. Idle speed set screw - 4. Throttle valve spring - 5. Throttle valve tapered pin - 6. Throttle valve - 7. Carburettor body - 8. Pin - 9. Min. jet - 10. Float - 11. Max. jet - 12.
  • Page 27 Liberty 50 Catalyzed Maintenance -Put the hood on the sparking plug as far as it will - Refit the central flap. CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MO- TOR IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5000 KM.

  • Page 28: Air Filter

    Liberty 50 Catalyzed Maintenance AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Replacement - Remove the oil filler cap «A». - Loosen the oil draining cap «B» and let the oil completely drain the tank.

  • Page 29: Checking The Ignition Timing

    Liberty 50 Catalyzed Maintenance Checking the ignition timing - Adjust the control cables: Mix cable: see procedure indicated in "Mixer tim- ing". Throttle cable: adjust the set screw on the carbu- rettor in such a way that the sheath has no back- lash.

  • Page 30: Level Check

    Liberty 50 Catalyzed Maintenance Level check Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal; - Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the brake pads.

  • Page 31: Headlight Adjustment

    Liberty 50 Catalyzed Maintenance Headlight adjustment Place the unloaded vehicle on flat ground 10 m away from a half-lit white wall and ensure the ve- hicle axis is perpendicular to the wall. Mark a horizontal line on the wall at 65 ÷ 70 cm from the ground.
  • Page 32 Liberty 50 Catalyzed Maintenance 4) Carefully ensure leak tightness between the ex- haust and the duct. Insert the analyser sensor in the duct. 5) Start the engine. 6) Switch on the high-beam. 7) Wait for a few moments, until the idle speed settles.

  • Page 33: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 34: Poor Performance

    Liberty 50 Catalyzed Troubleshooting This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation Fuel nozzles or cock clogged or dirty...
  • Page 35 Liberty 50 Catalyzed Troubleshooting Possible Cause Operation 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. Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill...

  • Page 36: High Fuel Consumption

    Liberty 50 Catalyzed Troubleshooting High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty. Clean according to the procedure Inefficient Starter Check: electric wiring, circuit continuity, mechanical sliding and power supply SAS malfunctions SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-...

  • Page 37: Brakes Overheating

    Liberty 50 Catalyzed Troubleshooting Brakes overheating BRAKES OVERHEATING Possible Cause Operation Defective piston sliding Check calliper and replace any damaged part. Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the wheel correctly fitted or the concentricity of the rear drum.

  • Page 38: Noisy Suspension

    Liberty 50 Catalyzed Troubleshooting Noisy suspension NOISY SUSPENSION Possible Cause Operation NOISY SUSPENSION If the front suspension is noisy, check: the efficiency of the front shock absorbers; the condition of the ball bearings and relevant lock-nuts, the limit switch rubber buffers and the movement bushings.

  • Page 39: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 40 Liberty 50 Catalyzed Electrical system Legend: 1. Front LHS turn signal light; 2 light bulbs for each turn signal light 2. 2 amber light bulbs for turn signal light 3. Horn 4. Horn button 5. Turn signal switch 6. Headlight switch 7.
  • Page 41 Liberty 50 Catalyzed Electrical system 15. LHS turn signal warning light 16. Low oil warning light 17. Odometer level gauges with warning lights, 7 light bulbs 18. 2 light bulbs for headlamp 19. Stop switch on front brake 20. Starter button 21.
  • Page 42 Liberty 50 Catalyzed Electrical system Ar = Orange GrBl = Yellow-Blue RsBl = Pink-Blue BlV = Blue-Green BRs = White-Pink Conceptual diagrams Ignition IGNITION Specification Desc./Quantity Electronic control unit Magneto flywheel Pick - up Key switch Spark plug ELE SYS - 42...
  • Page 43 Liberty 50 Catalyzed Electrical system Headlights and automatic starter section LIGHTS Specification Desc./Quantity Voltage regulator Magneto flywheel Light switch Rear light bulb 12V - 5W Headlight bulb 12V-35/35W High-beam warning light 12V - 1.2W N°3 instrument lighting bulbs 12V - 1.2W...
  • Page 44 Liberty 50 Catalyzed Electrical system Battery recharge and starting BATTERY RECHARGE AND STARTING SECTION Specification Desc./Quantity Magneto flywheel Voltage regulator Automatic starter Main fuse 7,5A Brake light filament 12V - 21W Front and rear brake light button Start up button...
  • Page 45 Liberty 50 Catalyzed Electrical system Level indicators and enable signals section START PERMISSIVE BUTTONS AND LEVEL INDICATORS Specification Desc./Quantity Magneto flywheel Voltage regulator Key switch Main fuse 7,5A Brake light filament 12V - 21W Front and rear brake light button...

  • Page 46: Turn Signal Lights

    Liberty 50 Catalyzed Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity Battery 12V - 4Ah Main fuse 7,5A Key switch Magneto flywheel Voltage regulator Horn button Horn Indicators switch Two (2) turn signal warning light bulbs 12V - 2W...
  • Page 47 Liberty 50 Catalyzed 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 48: Ignition Circuit

    Liberty 50 Catalyzed Electrical system - Left-hand rotation view from pinion side. - Connected to the engine by pinion and crown wheel on crankshaft, transmission side. - Push-button control. - Battery used for the test:12V-3,6Ah. N.B. THESE VALUES MUST BE MEASURED WITH A CHARGED BATTERY AND AFTER THE STARTER HAS BEEN ROTATING FOR 30"...
  • Page 49 Liberty 50 Catalyzed Electrical system 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).
  • Page 50 Liberty 50 Catalyzed Electrical system 3)BATTERY FAILS TO CHARGE A fault on the direct current section of the regulator can result in the following problems, depending on the type of fault: a) Blowing of the protecting fuse due to an overvoltage condition (regulator shorted) pre- venting the battery from being recharged.
  • Page 51 Liberty 50 Catalyzed Electrical system rent is 1.5 - 2A with lights off. By increasing the engine revs number, the recharge voltage and cur- rent progressively increase, at speeds higher than 4000 revs/min. the recharge current should be about 4.5A; by turning on the lights, the stoplight and using the horn, the current values may be ≥5A...
  • Page 52 Liberty 50 Catalyzed Electrical system tests have a positive result, replace the regulator because it is certainly not functioning properly. Specific tooling 020331Y Digital multimeter Sealed battery INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
  • Page 53 Liberty 50 Catalyzed Electrical system - Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about 15 minutes and seek immediate medical attention.
  • Page 54 Liberty 50 Catalyzed Electrical system After charging the battery, check each element electrolyte level and density. If the scooter 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.

  • Page 55: Instrument Panel

    Liberty 50 Catalyzed Electrical system Dashboard 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...

  • Page 56: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 57 Liberty 50 Catalyzed 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 58 Liberty 50 Catalyzed Engine from vehicle - Disconnect the hoses (petrol-oil-vacuum-operated cock control). WARNING Handle fuel with care. CAUTION When installing the battery, first attach the positive cable and then the negative cable. WARNING Wear safety goggles when using hitting tools.
  • Page 59 INDEX OF TOPICS NGINE...

  • Page 60: Automatic Transmission

    Liberty 50 Catalyzed Engine Automatic transmission Transmission cover - Loosen the 15 screws and remove the transmis- sion cover with the aid of a mallet. N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.

  • Page 61: Removing The Driven Pulley Shaft Bearing

    Liberty 50 Catalyzed Engine - Upon refitting, apply the recommended grease to the bushing, to the spring and along the toothed sector. - Use the special tool for the charging of the spring, as shown in the figure. - Refit the seeger ring after checking that it is in good condition.

  • Page 62: Removing The Driven Pulley

    Liberty 50 Catalyzed Engine Removing the driven pulley - Lock the clutch bell housing with the specific tool. - Remove the nut, the clutch bell housing and the whole of the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.
  • Page 63 Liberty 50 Catalyzed Engine - Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw thereby undoing the driven pulley unit - Separate the components. Specific tooling 020444Y Tool for fitting/ removing the driven...
  • Page 64 Liberty 50 Catalyzed Engine - Remove the three guide pins and the mobile half pulley. Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION...
  • Page 65 Liberty 50 Catalyzed Engine Stationary driven half-pulley/Standard diame- Ø 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diam- eter admitted after use Ø 33.96 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings.
  • Page 66 Liberty 50 Catalyzed Engine Refitting the driven half-pulley bearing - Fit a new ball bearing with the specific tool. - Fit the ball bearing retention snap ring. - Fit the new roller bearing with the wording visible from the outside.

  • Page 67: Refitting The Driven Pulley

    Liberty 50 Catalyzed Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE...

  • Page 68: Removing The Driving Pulley

    Liberty 50 Catalyzed 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 69 Liberty 50 Catalyzed Engine 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.
  • Page 70 Liberty 50 Catalyzed Engine ORDER TO AVOID WRONG TIGHTENING AND CONSE- QUENTLY DAMAGING THE CRANKSHAFT KNURLING. Specific tooling 020451Y Starting ring gear lock Locking torques (N*m) Crankshaft pulley nut 18 to 20 + 90° Nm End gear Removing the hub cover...
  • Page 71 Liberty 50 Catalyzed 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...
  • Page 72 Liberty 50 Catalyzed Engine - Remove the bearing off the driven pulley shaft using the specific tool and a press N.B. USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALL- ER INTERNAL DIAMETER Specific tooling 020452Y Tube for removing and refitting the...
  • Page 73 Liberty 50 Catalyzed Engine Refitting the driven pulley shaft bearing - Slightly heat the hub cover and then fit the bear- ing with the specific drift. - Fit the circlip with the concave or radial part facing the bearing. N.B.
  • Page 74 Liberty 50 Catalyzed 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...

  • Page 75: Flywheel Cover

    Liberty 50 Catalyzed Engine Gasket Locking torques (N*m) hub cap screws 24 - 26 Flywheel cover Cooling hood - Remove the four fixings shown in the figure. - Remove the fan cover - Remove the oil piping retention band from the...

  • Page 76: Removing The Stator

    Liberty 50 Catalyzed Engine Removing the stator - Remove the three stator fixings shown in the photo - Remove the two pick-up fixings shown in the photo - Remove the stator with the wiring Refitting the stator - Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
  • Page 77 Liberty 50 Catalyzed Engine Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS - Extract the flywheel with the extractor.

  • Page 78: Removing The Intake Manifold

    Liberty 50 Catalyzed Engine 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. Locking torques (N*m) Flywheel nut 40 to 44 N.m Refitting the starter motor - Fit a new O-ring on the starter and lubricate it.

  • Page 79: Inspecting The Small End

    Liberty 50 Catalyzed Engine Removing the cylinder - piston assy. Remove the cylinder very carefully Remove the snap rings and remove the pin CAUTION AFTER EACH REMOVAL OPERATION REPLACE THE PIN RETENTION SNAP RINGS Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer.

  • Page 80: Inspecting The Piston

    Liberty 50 Catalyzed Engine Inspecting the wrist pin - Check the wrist pin external diameter using a mi- crometer Characteristic Wrist pin: standard diameter 12 +0.005 +0.001 mm Inspecting the piston - Measure the bearings on the piston using a bore meter - Calculate the piston-pin coupling clearance.

  • Page 81: Removing The Piston

    Liberty 50 Catalyzed Engine Inspecting the cylinder - Check that the cylinder does not show seizures. Otherwise, replace it or adjust it respecting the al- lowable increases - Measure the internal diameter of the cylinder with a bore meter, according to the directions given in...
  • Page 82 Liberty 50 Catalyzed Engine - Use new wrist pin snap rings. - Use new cylinder base gasket. - Before refitting carefully clean all the surfaces. - Use oil to be mixed during the fitting of the piston and the cylinder.

  • Page 83: Crankcase - Crankshaft

    Liberty 50 Catalyzed Engine Inspecting the timing system components CAUTION CHECK THE CORRECT REED UNIT SEAL; NO LIGHT MUST PASS BETWEEN THE SUPPORT AND LAMELLA. Crankcase - crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners. Install the special strip on the half crankcase on...

  • Page 84: Removing The Crankshaft

    Liberty 50 Catalyzed Engine Removing the crankshaft - Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length. - Remove the crankshaft from the transmission side half crankcase Specific tooling...
  • Page 85 Liberty 50 Catalyzed Engine Refitting the crankshaft bearings Heat the bearings in an oil bath at around 150°C and fit them on the crankshaft, if necessary using a section of tube that acts on the bearing's inner track Specific tooling...
  • Page 86 Liberty 50 Catalyzed Engine - Firmly insert the crankshaft until the bearing rea- ches the end-of-stroke stop - Let the temperature of the half crankcase settle at the temperature of the crankshaft. - Again install the special crankcase separation plate NOT installing the crankshaft protection - During the assembly phase keep the central thrust screw loose.

  • Page 87: Crankshaft Oil Seals

    Liberty 50 Catalyzed Engine - Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement - Insert at least three clamping screws and tighten up rapidly - Insert the other 5 screws and tighten them to the specified torque.
  • Page 88 Liberty 50 Catalyzed Engine Refitting - Install a new flywheel-side oil seal only with the special tool's punch The flywheel-side oil seal is recognised by its smaller diameter N.B. THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE WITH THE FITTED WRENCH...

  • Page 89: Fuel Supply

    Liberty 50 Catalyzed Engine Remove the tube passage seal from the crank- case shown in the figure Refitting To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure...
  • Page 90 Liberty 50 Catalyzed Engine OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB- TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT- LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUC- TION PULSATION AND THEREBY GUARANTEE A CON- STANT TAP FLOW RATE.

  • Page 91: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 92: Front Wheel Hub Overhaul

    Liberty 50 Catalyzed 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 93: Front Fork

    Liberty 50 Catalyzed Suspensions Front fork 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.
  • Page 94 Liberty 50 Catalyzed Suspensions - 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. Steering collar Steering lock ring nut Removal Lower and upper races from frame To remove the bearing seats from the chassis, use the appropriate tool as shown in the figure.

  • Page 95: Removing The Rear Wheel

    Liberty 50 Catalyzed Suspensions Removing the rear wheel - Use a screwdriver as a lever between the drum and the cover. -Straighten the split pin and remove the cap. -Remove the wheel acting on the central fixing point. WARNING -ALWAYS USE NEW SPLIT PINS FOR REFITTING.

  • Page 96: Centre-Stand

    Liberty 50 Catalyzed Suspensions Centre-stand Expelling stand pivot pin from bracket - Remove the stand support bracket from the en- gine. - Drill a 5 mm hole in the bracket so that the pin «P» can come out. Assembly and staking of stand pivot pin to bracket - Caulk the end of the pin «P»...
  • Page 97 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 98: Rear Brake Calliper

    Liberty 50 Catalyzed 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 99 Liberty 50 Catalyzed Braking system Screw tightening calliper to support 20 to 25 Calliper to tube connection 8 ÷ 12 Nm Front brake calliper Removal - Detach the oil brake hose from calliper, pouring the fluid inside a container. - Remove the mountings indicated in the figure.

  • Page 100: Front Brake Disc

    Liberty 50 Catalyzed Braking system - Secure the tube connection to the caliper with the required torque. - 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.

  • Page 101: Disc Inspection

    Liberty 50 Catalyzed 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, fit a new disc and re- peat the check.

  • Page 102: Recommended Products

    Liberty 50 Catalyzed Braking system Front -Once the bleed valve is closed, fill the system with brake liquid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in...
  • Page 103 Liberty 50 Catalyzed Braking system AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid 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 104 Liberty 50 Catalyzed Braking system 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. Refitting Before fitting, the parts must be perfectly clean and free of traces of oil, diesel fuel, grease, etc..
  • Page 105 INDEX OF TOPICS CHAS HASSIS...
  • Page 106 Liberty 50 Catalyzed 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 107: Rear Rack

    Liberty 50 Catalyzed 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 - 107...
  • Page 108 Liberty 50 Catalyzed 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.
  • Page 109 Liberty 50 Catalyzed 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 110 Liberty 50 Catalyzed 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 111 Liberty 50 Catalyzed 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 112 Liberty 50 Catalyzed Chassis Knee-guard • Remove the 4 external screws of the shield back plate and the 3 screws inside the front box. • Using the bag hook, pull the shield back plate backwards until it slides off the fitting with the leg- shield.
  • Page 113 Liberty 50 Catalyzed 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 114: Rear Mudguard

    Liberty 50 Catalyzed 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 115 Liberty 50 Catalyzed Chassis Please take note that, starting from chassis serial number ZAPM3840000005931, a washer drawing 709047 has been added in order to guarantee the rear mudguard correct fixing Helmet bay • Remove the helmet compartment central cover. • Remove the battery and the fuse box.

  • Page 116: Front Mudguard

    Liberty 50 Catalyzed 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 117 Liberty 50 Catalyzed Chassis 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 118: Index Of Topics

    INDEX OF TOPICS PRE DE DELIVERY...
  • Page 119 Liberty 50 Catalyzed 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...
  • Page 120 Liberty 50 Catalyzed 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.

  • Page 121: Static Test

    Liberty 50 Catalyzed Pre-delivery Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 122 INDEX OF TOPICS TIME...
  • Page 123 Liberty 50 Catalyzed Time This section is devoted to the time necessary to carry out repairs. The description and code for each operation is in- dicated. Engine ENGINE Code Action Duration 001001 engine from frame - removal and re- fitting...
  • Page 124 Liberty 50 Catalyzed Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement TIME - 124...
  • Page 125 Liberty 50 Catalyzed Time Crankshaft RANKSHAFT Code Action Duration 001118 Main bearings - Replacement 001100 Clutch-side oil seal - Replacement 001099 Flywheel-side oil seal - Replacement 001117 Crankshaft - Replacement TIME - 125...

  • Page 126: Cylinder Assy

    Liberty 50 Catalyzed Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001107 Cylinder / piston - Inspection / clean- TIME - 126...

  • Page 127: Cylinder Head Assy

    Liberty 50 Catalyzed Time Cylinder head assy. HEAD Code Action Duration 001097 Cooling hood - Replacement 001093 Spark plug - Replacement 001126 Head - Replacement 001013 Intake manifold - Replacement 001178 Disc pack - Replacement TIME - 127...

  • Page 128: Driven Pulley

    Liberty 50 Catalyzed Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001012 Driven pulley - overhaul 001110 Driven pulley- Replacement 001022 Clutch - Replacement 001155 Clutch bell - Replacement TIME - 128...

  • Page 129: Oil Pump

    Liberty 50 Catalyzed Time Oil pump OIL PUMP Code Action Duration 001028 Mix movement gear socket - Re- placement 001019 Mixer belt - replacement 001018 Mixer - Replacement TIME - 129...

  • Page 130: Driving Pulley

    Liberty 50 Catalyzed Time Driving pulley DRIVING PULLEY Code Action Duration 001066 Driving pulley - Removal and refitting 001086 Driving half-pulley - replace 001011 Driving belt - Replacement 001177 CVT rollers / sliders - Replacement TIME - 130...

  • Page 131: Transmission Cover

    Liberty 50 Catalyzed Time Transmission cover TRANSMISSION COVER Code Action Duration 001087 Flywheel cover - Replacement 001135 Transmission cover bearing - Re- placement 001096 Transmission crankcase cover - Re- placement TIME - 131...

  • Page 132: Flywheel Magneto

    Liberty 50 Catalyzed Time Flywheel magneto FLYWHEEL - FAN Code Action Duration 001109 Cooling fan - Replacement 001173 Rotor - Replacement 001067 Stator - Fitting and Refitting 001058 Flywheel - Replacement TIME - 132...
  • Page 133 Liberty 50 Catalyzed Time Carburettor CARBURATOR Code Action Duration 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heating tubing - replace- ment 001081 Automatic choke - Replacement TIME - 133...

  • Page 134: Exhaust Pipe

    Liberty 50 Catalyzed Time Exhaust pipe SILENCER Code Action Duration 001009 Silencer - Replacement 001095 Silencer heatshield - Replacement 001136 Exhaust emissions - Adjustment 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 135: Air Cleaner

    Liberty 50 Catalyzed Time Air cleaner AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting - Re- placement 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement TIME - 135...
  • Page 136 Liberty 50 Catalyzed Time Centre-stand STAND Code Action Duration 004001 Frame - replace 004004 Stand - Replacement 001053 Stand bolt - Replacement TIME - 136...
  • Page 137 Liberty 50 Catalyzed Time Legshield spoiler MUFFLER - GLOVE COMPARTMENT Code Action Duration 004159 Plates / Stickers - Replacement 004149 Shield central cover - Replacement 004064 Front shield, front section - Removal and refitting 004015 Footrest - Disassembly and reas-...

  • Page 138: Rear Cover

    Liberty 50 Catalyzed Time Rear cover REAR COVER Code Action Duration 004174 Glove-box remote opening linkage - Replacement 004065 Knee-guard - Removal and refitting 004131 Rear rack mounting bracket - Re- placement 004082 Glove-box packing - Replacement 004081 Glove comparment door - Replace-...
  • Page 139 Liberty 50 Catalyzed Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replace- ment 004106 Undersaddle band - Replacement 004085 Fairing (1) - Replacement TIME - 139...

  • Page 140: Underseat Compartment

    Liberty 50 Catalyzed Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004136 License plate holder support - Re- placement 005048 number plate holder - Replacement TIME - 140...
  • Page 141 Liberty 50 Catalyzed Time Fuel tank FUEL TANK Code Action Duration 004168 Fuel tank cap - Replacement 005010 Fuel tank float - Replacement 004109 Fuel tank breather - Replacement 004005 Fuel tank - Replacement 004007 Mixture cock - Replacement 004112...

  • Page 142: Oil Reservoir

    Liberty 50 Catalyzed Time Tank oil OIL RESERVOIR Code Action Duration 005018 Oil reservoir float - Replacement 004017 Oil reservoir - Replacement 004095 Oil reservoir cock - Replacement 004091 Oil reservoir hose - Replacement TIME - 142...

  • Page 143: Rear Shock Absorber

    Liberty 50 Catalyzed Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting TIME - 143...
  • Page 144 Liberty 50 Catalyzed Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003051 Complete fork - Replacement 003002 Steering bearing - Replacement 003073 Steering clearance - Adjustment TIME - 144...

  • Page 145: Handlebar Covers

    Liberty 50 Catalyzed Time Handlebar covers ODOMETER - HANDLEBAR COVERS Code Action Duration 004019 Rear handlebar covers - Replace- ment 004018 Handlebar front section - Replace- ment 005078 Odometer glass - Replacement 005076 Clock / Cell - Replacement 005014 Odometer - Replacement...
  • Page 146 Liberty 50 Catalyzed Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 004066 Driving mirror - Replacement 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 003001 Handlebar - Replacement 005017 Stop switch - Replacement 002024 Front brake pump - Removal and Re-...

  • Page 147: Swinging Arm

    Liberty 50 Catalyzed Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-chassis connection swinging arm - Replacement TIME - 147...
  • Page 148 Liberty 50 Catalyzed Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004008 Luggage rack - Replacement 004062 Luggage rack cover - Replacement TIME - 148...

  • Page 149: Turn Signal Lights

    Liberty 50 Catalyzed Time Turn signal lights REAR RED LAMP Code Action Duration 005002 Front headlamp - Replacement 005012 Front turning indicators - Replace- ment 005067 Front turn indicator bulb - Replace- ment 005008 Front headlamp bulbs - replace TIME - 149...
  • Page 150 Liberty 50 Catalyzed Time LAMP CLUSTER Code Action Duration 005022 Rear turn signal light- Replacement 005068 Rear turning indicator bulb - Re- placement 005005 Taillight - change 005066 Rear light bulbs - Replacement 005028 Rear light assembly glass - Replace-...

  • Page 151: Front Wheel

    Liberty 50 Catalyzed Time Front wheel FRONT WHEEL Code Action Duration 003038 Front wheel axle - Remov. and refitt. 002011 Odometer movement sensor - Re- placement 003040 Front wheel bearings - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim - Removal and Re-...
  • Page 152 Liberty 50 Catalyzed Time Rear wheel REAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replacement 001071 Rear wheel rim - Removal and Refit- ting 001016 Rear wheel - Replacement TIME - 152...

  • Page 153: Electric Starter

    Liberty 50 Catalyzed Time Electric start ELECTRIC STARTER Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable assembly - Re- placement 001017 Start-up pinion - Replacement 001021 Kick starter - Inspection 008008 Starter spring pack - Replacement...

  • Page 154: Electric Devices

    Liberty 50 Catalyzed Time Electric devices ELECTRICAL DEVICES Code Action Duration 005007 Battery - change 005011 Starter relay - Replacement 005052 Fuse (1) - Replacement 005054 Fuse block (1) - Replacement TIME - 154...
  • Page 155 Liberty 50 Catalyzed Time ELECTRICAL DEVICES Code Action Duration 005001 Electrical system - Replacement 005009 Voltage regulator - Replacement 001094 Spark plug cap - Replacement 001023 Control unit - Replacement 005114 Electrical system - Service TIME - 155...
  • Page 156 Liberty 50 Catalyzed Time ELECTRICAL DEVICES Code Action Duration 005039 Light switch - Replacement 005006 Light switch or turn indicators - re- place 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starting device push button - Re- placement...
  • Page 157 Liberty 50 Catalyzed Time Transmissions RANSMISSION Code Action Duration 002051 Odometer transmission assembly - Replacement 002012 Splitter - Replacement 002057 Carburettor / splitter transmission complete - Replacement 002058 Mix / splitter transmission complete - Replacement 002053 Rear brake transmission complete -...

  • Page 158: Brake Callipers

    Liberty 50 Catalyzed Time Brake callipers CALLIPER Code Action Duration 002021 Front brake hose - Remov. and Re- fitt. 002007 Front brake shoes/pads - Remov. and Refitt 002039 Front brake calliper - Removal and Refitting 002047 Front brake fluid and air bleed sys-...

  • Page 159: Front Brake Caliper

    Liberty 50 Catalyzed Time FRONT BRAKE CALIPER Code Action Duration 002002 Rear brake pads/shoes - Wear check Front mudguard TIME - 159...

  • Page 160: Rear Mudguard

    Liberty 50 Catalyzed Time REAR MUDGUARD Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement Steering column STEERING Code Action Duration 003048 Fork oil seal - Replacement 003076 Fork sheath - Replacement 003079 Fork stem - Replacement...
  • Page 161 Liberty 50 Catalyzed Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 005046 Battery cover - change TIME - 161...

  • Page 162: Rear Wheel Axle

    Liberty 50 Catalyzed Time Rear wheel axle REAR WHEEL AXLE Code Action Duration 001156 Gear reduction unit cover - Replace- ment 004125 Rear wheel axle - Replacement 001010 Geared reduction unit - Service 003065 Gear box oil - Replacement TIME - 162...
  • Page 163 Liberty 50 Catalyzed 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 -...
  • Page 164 Air filter: 28, 114 Battery: 37, 44, 52 Brake: 98–101, 103, 158 Carburettor: 10, 25, 133 Checks: 46 Electric: 153, 154 Engine stop: Fuel: 36, 89, 116, 141 Headlight: 31, 110 Horn: Hub oil: 27 Identification: 8 Instrument panel: 109 Maintenance: 7, 23 Mirrors: 108 Odometer:...
  • Page 165 Tank: 116, 141, 142 Transmission: 9, 36, 60, 131 Turn indicators: Tyres: 10 Vehicle: 8, 57...

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