Page 1 MANUALE STAZIONE DI SERVIZIO 1Q000696 NRG 50...
Page 2 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 SERVIZIO NRG 50 Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.
Page 5: Index Of Topics
INDEX OF TOPICS PRE DE DELIVERY ECHNICAL TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS...
Page 6 INDEX OF TOPICS PRE DE DELIVERY...
Page 7 NRG 50 Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety fasteners - Fastening screws Safety fasteners: Rear shock absorber upper clamp Rear lower shock absorber clamp...
Page 8 NRG 50 Pre-delivery - Electric starter 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.
Page 9: Functional Inspection
NRG 50 Pre-delivery - Warm start - Starter operation - Minimum holding (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 AS TYRES MAY BURST.
Page 10 INDEX OF TOPICS ECHNICAL...
Page 11: Safety Rules
Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
Page 12: Vehicle Identification
Engine Data ENGINE SPECIFICATIONS Specification Desc./Quantity Engine Single-cylinder, 2-stroke Piaggio Hi-Per2. Engine capacity 49 cm³ Bore per stroke 40 X 39.3 mm Maximum net power 3.0 kW at 7000 rpm Maximum net torque 4.0 Nm at 6500 rpm...
Page 13: Dimensions And Mass
NRG 50 Technical Data Specification Desc./Quantity Lubrication Engine lubrication (piston, cylinder, crankshaft, main bearings) with mixer oil. Variator transmission Continuous, automatic Primary drive V-belt Secondary transmission Gear reduction unit Clutch Automatic centrifugal dry clutch Carburettor Dell'Orto PHVA 17.5 (Diffuser Ø=17.5 mm), electronically con- trolled with dedicated control unit.
Page 14: Engine Unit
NRG 50 Technical Data Specification Desc./Quantity Kerb mass 110 kg Maximum technically permissible weight at full load 295 kg Battery 12 V - 4 Ah sealed battery Capacities CAPACITY Specification Desc./Quantity Fuel tank capacity ~ 6.5 litres (including 1.5 litre reserve) Hub oil quantity 0.75 litres...
Page 15 NRG 50 Technical Data Name Torque in Nm Half-crank case joint bolts 12 - 13 Bolts holding exhaust pipe to the crankcase 22 ÷ 24 Screws holding the filter box to the crank case 4 ÷ 5 Head nuts 10 ÷ 11...
Page 16: Cylinder-Piston Fitting
NRG 50 Technical Data Name Torque in Nm Rear brake pump - Handlebar 9.0 ± 1.0 Nm Rear brake disc - Wheel rim 9.0 ± 1.0 Nm Brake calliper - Carter 22.5 ± 2.5 Nm Oil bleed screw 10.0 ± 2.0 Nm...
Page 17 NRG 50 Technical Data Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Connecting rod 11.750-0.05 clearance E = 0.25 to 0.50 thrust washer 0.5 ± 0.03 clearance E = 0.25 to 0.50 - clearance F =...
Page 18 NRG 50 Technical Data 020272Y Piston position checking tool HIMMING SYSTEM Name Measure A Thickness shimming 2.80 to 3.04 shimming 3.04 to 3.24 shimming 3.24÷3.48 DT - 18...
Page 19 INDEX OF TOPICS TOOL OOLING...
Page 20 NRG 50 Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings 001467Y009 Bell for OD 42-mm bearings 001467Y013 Calliper to extract ø 15-mm bearings 001467Y014 Calliper to extract ø...
Page 21 NRG 50 Tooling Stores code Description 001467Y017 Bell for bearings, OD 39 mm 001467Y021 Extraction pliers for ø 11 mm bearings 002465Y Calliper for circlips 004499Y001 Bell for bearing extractor 004499Y002 Bearing extractor screw 004499Y006 Ring for bearing extractor TOOL - 21...
Page 22 NRG 50 Tooling Stores code Description 004499Y007 Half-rings 006029Y Punch for fitting steering bearing on the steering tube 020004Y Punch for removing steering bearings from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment...
Page 23 NRG 50 Tooling Stores code Description 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020165Y Starting ring gear lock 020166Y Tool for fitting the pin snap rings 020167Y Pump rotor immobiliser tool TOOL - 23...
Page 24 NRG 50 Tooling Stores code Description 020168Y Punch for mounting the water seal ring on the semi-carter 020169Y Tool for removing and installing water pump shaft 020170Y Water/mixer pump control gear extractor 020209Y Hook for springs 020265Y Bearing fitting base...
Page 25 NRG 50 Tooling Stores code Description 020325Y Pliers for brake-shoe springs 020329Y Mity-Vac vacuum pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator TOOL - 25...
Page 26 NRG 50 Tooling Stores code Description 020334Y Multiple battery charger 020335Y Magnetic mounting for dial gauge 020350Y Electric installation control instrument 020357Y 32 x 35-mm Adaptor 020358Y 37 x 40 mm Adaptor 020359Y 42 x 47 mm Adaptor TOOL - 26...
Page 27 NRG 50 Tooling Stores code Description 020363Y 20-mm guide 020376Y Sleeve for adaptors 020412Y 15-mm guide 020432Y Tool for fitting the starter section spring. 020439Y 17-mm guide 020444Y Tool for installing/removing clutch on/ from driven pulley TOOL - 27...
Page 28 NRG 50 Tooling Stores code Description 020451Y starting ring gear lock 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020483Y 30-mm guide 020565Y Flywheel lock calliper spanner 020625Y Kit for sampling gas from the exhaust...
Page 29 NRG 50 Tooling Stores code Description 021018Y Punch to fit flywheel and transmission oil seals 494929Y Exhaust fumes analyser TOOL - 29...
Page 30: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 31: Maintenance Chart
Transmission Mixer oil pipes Labour time (minutes) Recommended products Piaggio Group recommends the products of its "Castrol Official Partner" for the scheduled maintenance of its vehicles. Use lubricants and liquids having specifications that are equivalent, or superior, to the recommen- ded products.
Page 32 NRG 50 Maintenance Product Description Specifications 2-stroke oil for mixer Low smoking lubricant for 2-stroke en- API TC; JASO FC; ISO-L-EGD gines with synthetic bases and additives. Anti-freeze liquid, ready to use, colour red Ethylene glycol-based antifreeze fluid ASTM D 3306 - ASTM D 4656 - ASTM D with organic inhibition additives.
Page 33: Spark Plug
NRG 50 Maintenance - Fit the new air filter - Refit the plastic closing ring of the box. - Insert the filter box into the rubber holder. - Replace the spark plug access panel. Spark plug Place the vehicle on its central stand - Remove the central cover.
Page 34 NRG 50 Maintenance - Unscrew the spark plug using a suitable wrench. -Examine the condition of the spark plug, check that the insulating material is not word and meas- ure the distance between the electrodes using a feeler gauge. If any defects are found, replace the spark plug with a new component of the specified type.
Page 35 NRG 50 Maintenance - Refit the spark plug inspection panel. Hub oil Check Do the following to check the correct level: Park the vehicle on level ground and rest it on its central stand; - Unscrew the hub oil dipstick «A», dry it with a clean rag, then reinsert it, screwing it tightly into place;...
Page 36: Air Filter
NRG 50 Maintenance - Unscrew the oil drainage plug and drain out all the oil. - Replace the copper sealing gasket with a new one. - Screw in the drainage cap again and fill the hub with the prescribed oil.
Page 37 NRG 50 Maintenance - Remove the filtering element. FITTING - Fit a new filter element. - Position the filter box cover. - Tighten the fastening screws of the air filter box cover. N.B. NEVER RUN THE ENGINE WITHOUT THE AIR FILTER.
Page 38 NRG 50 Maintenance transmissions ADJUSTING CONTROL CABLE SPLITTER - adjust set screw on the throttle control to the han- dlebar in such a way that there is no backlash on the throttle control. CARBURETTOR CABLE: - adjust the set screw on the carburettor in such a way that the sheath has no backlash.
Page 39: Braking System
NRG 50 Maintenance - Close by tightening the screw. - Start the engine and wait for the oil to come out of the pipe. - Connect the oil delivery pipe to the mixer and se- cure it with the special metal clamp.
Page 40: Headlight Adjustment
NRG 50 Maintenance BRAKE CIRCUIT FLUID IS HIGHLY CORROSIVE: DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CON- TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.
Page 41 NRG 50 Maintenance SAS filters inspection and cleaning - Unscrew and remove the screws securing the valve covers. - Move the covers down and remove the valves. - Remove the SAS box cover. - It is possible to access the filters to remove them.
Page 42 NRG 50 Maintenance - Insert the new SAS filters in the box. - Position the SAS box cover. - Move the covers down and fit the valves. - Position the valve covers. - Insert and tighten the fastening screws MAIN - 42...
Page 43: Index Of Topics
INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 44 NRG 50 Troubleshooting Engine Battery BATTERY Possible Cause Operation Battery The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically.
Page 45: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 46 NRG 50 Electrical system Components arrangement 1. Rear light assembly connector. 2. License plate light connector. 3. Rear right turn signal connector. 4. Oil level sensor. 5. Voltage regulator. 6. Automatic starter connector. 7. Starter motor connector. 8. Magnet flywheel and pick-up connector.
Page 47 NRG 50 Electrical system 19. Rear brake stop button connector. 20. Instrument panel connector. 21. Light switch connector 22. Turn indicators switch connector. 23. Horn button connector. 24. Front brake stop button connector. 25. S.I.S. valve 26. Starter button connector.
Page 48 NRG 50 Electrical system 4. mixer oil level sensor. Remove the rear right fairing to reach it. 5. Voltage regulator connector. 6. Automatic starter connector. Remove the hel- met compartment panel to access it. 7. Starter motor connector. Remove the stand to reach it.
Page 49 NRG 50 Electrical system 8. Magnet flywheel and pick-up connector 9. electronic control unit. Remove the spark plug inspection cover to gain access to it. 10. Coil. Remove the spark plug inspection cover to gain access to it. 11. Engine temperature sensor. Remove the spark plug inspection cover to gain access to it.
Page 50 NRG 50 Electrical system 12. Fuel level sensor. Remove the central chassis cover to reach it. 13. Front right turn indicator connector. Remove the shield to reach it. 14. Horn. Remove the shield to reach it. 15. Front left turn indicator connector. Remove the shield to reach it.
Page 51 NRG 50 Electrical system 16. Speed sensor connector. Remove the shield to reach it. 17. Headlight connector: Remove the radiator grill to gain access to it. 18. Ignition switch contacts. Remove the shield to reach it. 19. Rear brake stop button connector. Remove the handlebar covers to gain access to it.
Page 52 NRG 50 Electrical system 20. Instrument panel connector. Remove the han- dlebar covers to gain access to it. 21.Light switch connector Remove the handlebar covers to gain access to it. 22.Turn indicators switch connector. Remove the handlebar covers to gain access to it.
Page 53 NRG 50 Electrical system 24. Front brake stop button connector. Remove the handlebar covers to gain access to it. 25. S.I.S. valve Remove the spark plug inspection cover to gain access to it. 26. Starter button connector. Remove the handle- bar covers to gain access to it.
Page 54 NRG 50 Electrical system 28. Diagnostics connector. Located in the battery compartment. 29. Fuses. Located in the battery compartment. 30. Rear left turn signal connector. Remove the license plate support to reach it. ELE SYS - 54...
Page 55: Instrument Panel
NRG 50 Electrical system Instrument panel Key: A = Digital display B = Turn signal indicator lamp C = SET button D = MODE button E = Low fuel warning light F = Maximum coolant temperature warning light G = Low mixer oil warning light...
Page 56: Front Side
NRG 50 Electrical system Front side 1. Horn connector. 2. Turn indicators switch connector. 3. Light switch connector 4. Rear brake stop switch connector. 5. Instrument panel connector. 6. Front brake stop switch connector. 7. Starter button connector. ELE SYS - 56...
Page 57 NRG 50 Electrical system 1. Speed sensor. 2. Front turn indicator connector. 3. Headlight connector. 4. Horn. 5. Speed sensor cable connector. 6. Fuel level sensor connector. 7. ECU control unit. 8. S.I.S. valve connector. 9. Engine temperature sensor connector...
Page 58: Back Side
NRG 50 Electrical system Back side 1. Rear right turn signal connector. 2. Rear left turn signal connector. 3. License plate light connector. 4. Fuse box terminal block 5. Voltage regulator. 6. Mixer oil level sensor connector. 7. Fuel level sensor connector.
Page 59: Fuse Chart
NRG 50 Electrical system Fuses The electrical system is protected by two main fuses located near the battery: one 15A fuse «1» and one 7.5A fuse «2». To reach it, the battery compartment cover must be removed as indicated in the «Battery» section.
Page 60: Battery Installation
NRG 50 Electrical system Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit.
Page 61 NRG 50 Electrical system 1) Battery preparation Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quick- ly as possible to run the subsequent activation phases. 2) Electrolyte preparation. Remove the container of the electrolyte from the pack.
Page 62 NRG 50 Electrical system 6) Recharging the new battery With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged.
Page 63 NRG 50 Electrical system f - Check the ignition of the green LED indicated with a red arrow in figure. g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED...
Page 64 NRG 50 Electrical system Connectors CAUTION N.B. THE DIAGRAM SHOWS THE LAYOUT OF THE CONNEC- TORS VIEWED FROM THE CABLE INLET SIDE, AS INDI- CATED IN THE EXAMPLE. C1 - Instrument panel 1. Ground 2. Ignition key-controlled power supply input 3.
Page 65 NRG 50 Electrical system C2 - LH STOP button * Power supply input C3 - LH STOP button * STOP lights and engine start enable ON signal output C4 - RH STOP button * STOP lights and engine start enable ON signal...
Page 66 NRG 50 Electrical system C6 - Turn signals switch A. Left hand turn indicator lights control signal out- B. Right hand turn indicator lights control signal output C. Power supply input from the voltage regulator C7 - Light switch A. High-beam headlights ON command signal out- B.
Page 67 NRG 50 Electrical system C10 - Ignition switch 1. Ignition key-controlled power supply output 2. Battery power supply input 3. Ground 4. Engine stop C11 - Speed sensor 1. Vehicle speed signal for the instrument panel 2. Ground reference from the instrument panel 3.
Page 68 NRG 50 Electrical system C14 - Horn 1. Horn button signal input C15 - Front left turn indicator 1. Turn indicator light activation signal input 2. Ground C16 - Front right turn indicator 1. Turn indicator light activation signal input 2.
Page 69 NRG 50 Electrical system C18 - Engine temperature sensor 1. Temperature signal output for the engine control unit 2. Temperature signal output for the instrument panel 3. Ground 4. Ground C19 - S.I.S. valve 1. Valve control signal input (-) 2.
Page 70 NRG 50 Electrical system C22 - Engine control unit 1. K Line 2. S.I.S. valve control signal output (-) C23 - H.V. coil - Ground C24 - H.V. coil - Signal input (+) from the engine control unit C25 - Starter 1.
Page 71 NRG 50 Electrical system C26 - Flywheel 1A. Not connected 1B. Not connected 1C. Not connected 2A. Engine speed signal output for the engine con- trol unit 2B. Not connected 2C. Connection with voltage regulator C27 - Oil level sensor 1.
Page 72 NRG 50 Electrical system C30 - Starter relay coil 1. Signal input (+) from the start button C31 - Fuse holder 1. Battery power supply input for fuse F01 2. Ignition key-controlled power supply input for fuse F02 3. Not connected 4.
Page 73 NRG 50 Electrical system C34 - Rear right turn indicator - Ground C35 - Rear right turn indicator - Signal input (+) from the turn indicators switch C36 - Chassis ground - Chassis ground point C37 - Taillight 1. Ground 2.
Page 74 NRG 50 Electrical system C38 - Battery positive - Battery positive C39 - Diagnostics socket 1. Not connected 2. Ground 3. K Line C40 - Rear right turn indicator - Signal input (+) from the turn indicators switch C41 - Battery negative...
Page 75 NRG 50 Electrical system C42 - Rear left turn indicator - Ground ELE SYS - 75...
Page 76: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 77 NRG 50 Engine from vehicle Exhaust assy. Removal Unscrew the fastening screws of the silencer at the big end. - Unscrew the S.A.S. (secondary air system) fas- tening screws. - Undo the screws fixing the silencer to the crank- case.
Page 78 NRG 50 Engine from vehicle Position the silencer. - Tighten the fastening screws so as to support the silencer. - Tighten the screws fixing the silencer to the motor head and tighten them to the prescribed torque. - Tighten the S.A.S. screws - Tighten the silencer screws to the crankcase to the specified torque.
Page 79 NRG 50 Engine from vehicle - the upper side fairings. - the central frame cover - the lower cover. - the helmet compartment. - the rear mudguard - Disconnect the flywheel connector. - Unscrew the screws of the transmission air cool- ing cover.
Page 80 NRG 50 Engine from vehicle - Unscrew and remove the fastening screws of the brake calliper. - Detach brake calliper from the disc. - Loosen screws to remove footrest from the trans- mission crankhouse side. - Loosen the engine ground cable screw.
Page 81 NRG 50 Engine from vehicle - Unclip the terminal block by loosening the screw and disconnect the connector. - Remove the tie for securing the cable bundle. - Release the clamp and disconnect the S.I.S. valve connection tube to the carburetor.
Page 82 NRG 50 Engine from vehicle - Disconnect the spark plug cap. - Unscrew the throttle control cable screw - Unscrew the retaining clamp screw of the throttle control. - Remove the rubber cap and disconnect the mixer cable on the transmission side...
Page 83 NRG 50 Engine from vehicle - Loosen the adjustment nut and pull the cable outwards - Disconnect the fuel pipe by cutting the clamp. - Disconnect the vacuum tube from the sleeve by releasing the clamp. - Loosen the fuel pipe check valve and the vacuum pipe screw.
Page 84 NRG 50 Engine from vehicle - Disconnect the oil pipe from the tank, making sure you have suitable caps ready for the pipe and the tank side fitting. - Remove the coolant pipe clamp and make sure to collect the liquid with a special container.
Page 85 NRG 50 Engine from vehicle - Remove the sheath and disconnect the connec- tor. - Secure the vehicle suitably. - Unscrew the shock absorber fixing nut. - Unscrew the fixing nut of the engine support pin. ENG VE - 85...
Page 86 NRG 50 Engine from vehicle - Slide the pin out from the flywheel side. - You can now remove the engine from the frame. Installing engine in vehicle Bring the whole engine into position by placing it near the frame.
Page 87 NRG 50 Engine from vehicle - Tighten the engine support pin nut to the prescri- bed torque. Tighten the shock absorber nut to the specified torque. - Connect to the connector. - Reposition the sheath and tighten a new clamp.
Page 88 NRG 50 Engine from vehicle - Connect the coolant outlet pipe on the engine head side, fit a new clamp and tighten it with a suitable pliers. - Connect the coolant inlet pipe, fit a new clamp and tighten it with a suitable pliers.
Page 89 NRG 50 Engine from vehicle - Tighten the nut and adjust the mixer cable set. - Insert the fuel pipe, insert a new clamp and tight- en it with suitable pliers. Insert the vacuum pipe to the sleeve and close the...
Page 90 NRG 50 Engine from vehicle - Move the throttle cable into position and tighten the screw. - Position the throttle cable retaining clamp and tighten the screw. - Connect the spark plug cap. - Connect the engine temperature connector. ENG VE - 90...
Page 91 NRG 50 Engine from vehicle - Connect the air pipe and close the clamp. - Connect the connector and reposition the termi- nal block by tightening the screw. - Position the engine ground cable and tighten it to the specified torque.
Page 92 NRG 50 Engine from vehicle - Reposition the footrest on the transmission crankcase side and tighten the screws. - Position the brake calliper. Fit the brake calliper screws and tighten them to the specified torque. Position the brake cable retaining clamps and...
Page 93 NRG 50 Engine from vehicle Position the fender support side plate and fasten it to the crankcase by tightening the screws - Tighten the screws of the transmission air cooling cover. - Connect the flywheel side connector. Fill the coolant tank with the specified amount...
Page 94 NRG 50 Engine from vehicle - the upper side fairings. - the complete silencer. ENG VE - 94...
Page 95: Index Of Topics
INDEX OF TOPICS NGINE...
Page 96: Automatic Transmission
NRG 50 Engine ENGINE Name Torque in Nm Engine - Swinging arm 42.5 ± 2.5 Nm Muffler - Engine big end 11.0 ± 1.5 Nm Muffler - Crankcase 23.0 ± 1.0 Nm Engine ground -Chassis 8.0 ± 1.0 Nm Shock absorber - Carter 42.5 ±...
Page 97 NRG 50 Engine FITTING Flank the transmission cover to the crankcase. Tighten the anti-tamper screws, making sure they are positioned correctly. - Tighten the transmission cover fastening screws. Kickstart REMOVAL To remove the kick starter transmission, first remove: - transmission cover...
Page 98 NRG 50 Engine Select the engagement gear - Unscrew the crank bolt and remove it. - Remove the Seeger ring. - Remove the washer. ENG - 98...
Page 99 NRG 50 Engine - Gently tap the axis of the toothed section with a mallet. - After using a mallet to gentle tap from the outside, turn the transmission cover over and remove the toothed sector from its seat. - Remove the spring.
Page 100 NRG 50 Engine - Using the specific tool, pre-load the spring with a half turn and insert the toothed sector into its seat- ing, after having spread a thin layer of the specific product on all contact surfaces. Specific tooling 020432Y Tool for fitting the starter section spring.
Page 101 NRG 50 Engine - Fit the seeger ring. - Reposition the starting lever in its seat and tight- en the screw. Before remounting the transmission cover on the carter, make sure that all indicated points have been lubricated. Removing the driven pulley shaft bearing...
Page 102 NRG 50 Engine Refitting the driven pulley shaft bearing -Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside. N.B. WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.
Page 103: Removing The Clutch
NRG 50 Engine Removing the clutch - Equip the tool with long pins screwed into position «A» from the outside, insert the entire driven pulley in the tool and put the central screw under stress. CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW IS TIGHTENED UP TOO FAR.
Page 104 NRG 50 Engine Pin retaining collar - Remove the collar with the aid of 2 screwdrivers. - 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.
Page 105 NRG 50 Engine Inspecting the driven fixed half-pulley - Check that there are no signs of wear on the work surface of the belt. If there are, replace the half- pulley.. - Make sure the bearings do not show signs of un- usual wear.
Page 106 NRG 50 Engine Molybdenum disulphide grease Lithium grease with molybdenum disulphide Grey black grease. 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 107 NRG 50 Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE...
Page 108: Removing The Driving Pulley
NRG 50 Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley. - Remove the belt 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 109 NRG 50 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 110 NRG 50 Engine - Fit the specific tool to stop the starter crown. - Tighten the nut to the prescribed torque, then carry out a final 90° locking. N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT. CAUTION...
Page 111 NRG 50 Engine - Gently use a mallet to tap the axle on the wheel side. - Position the hub cap flush with the intermediate gear and wheel axle - Take care to recover the intermediate gear shim if it is in the position shown in the picture.
Page 112 NRG 50 Engine - Extract the wheel axle from the hub cap. - Extract the intermediate gear. Place both the axle and the gear on the bench Removing the wheel axle bearings Remove the oil seal. ENG - 112...
Page 113 NRG 50 Engine - Remove the Seeger ring. - Use a heat gun to heat around the bearing. Specific tooling 020151Y Air heater - Remove the bearing by pushing from the outside (wheel side) towards the inside of the gear com- partment.
Page 114 NRG 50 Engine - Remove the Seeger ring. - Position the hub support and driven pulley shaft on the specific tool and drive out the shaft using a suitable cable spacer, so that the pressure of the press takes place as shown in the figure.
Page 115 NRG 50 Engine - Use a heat gun to heat around the bearing seat- ing, position the specific tool and drive out the bearing. Specific tooling 020151Y Air heater 020376Y Sleeve for adaptors 020439Y 17-mm guide 020358Y 37 x 40 mm Adaptor...
Page 116 NRG 50 Engine Refitting the driven pulley shaft bearing Place the hub cap on the bench and heat the bear- ing seat locally using the heat gun. Specific tooling 020151Y Air heater - Position the bearing on the specific tool, being careful to face the shielded part of the bearing to- wards the oil seal.
Page 117 NRG 50 Engine - Place the hub cap on the specific tool and drive the shaft onto the previously mounted bearing from above using the press. Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft - Before fitting the seeger ring, make sure it is con- vex side facing the bearing.
Page 118 NRG 50 Engine Refitting the wheel axle bearing Use a heat gun to heat around the bearing. Specific tooling 020151Y Air heater - Fit the new bearing inside the crankcase using the specific tool. Specific tooling 020363Y 20-mm guide 020376Y Sleeve for adaptors...
Page 119 NRG 50 Engine FITTING WHEEL AXLE Before positioning both the intermediate gear and the wheel axle, check for wear. - Place the intermediate gear into the hub cap. - Place the wheel axle into the hub cap. - Before refitting the hub cap onto the crankcase, check the position of the shim on the intermediate shaft.
Page 120 NRG 50 Engine Refitting the ub cover Remove any traces of the old product. Then, apply the sealant to the entire perimeter of the crank- case, along the mating surface of the hub cap. Recommended products Loctite 510 Medium-strength paste sealant.
Page 121: Flywheel Cover
NRG 50 Engine - Tighten the oil drain screw again and refill with the prescribed quantity and type of oil. Recommended products Transmission oil 80W-90 Lubricant for gear- boxes and transmissions. SAE 80W-90 API GL-4 Flywheel cover Removing the stator - Unscrew and remove the Pick-Up fastening screws.
Page 122 NRG 50 Engine Refitting the stator Fit the Stator with the pick-up onto the crankshaft. Tighten the stator's fastening screws. - Tighten the pick-up screws. Flywheel and starting ENG - 122...
Page 123: Removing The Starter Motor
NRG 50 Engine Removing the starter motor Remove the centre stand by unscrewing the fas- tening screws. - Unscrew and remove the starter motor fastening screws. - Remove the starter motor. Removing the flywheel magneto Unscrew the screws used to fasten the top-box lid.
Page 124 NRG 50 Engine - Remove the flywheel cover. - Using the specific tool, lock the flywheel rotation and unscrew the fixing nut. Specific tooling 020565Y Flywheel lock calliper spanner - Remove the nut, making sure to reuse the nut during fitting since it is knurled..
Page 125 NRG 50 Engine - Remove the flywheel. Inspecting the flywheel components - Check the condition of the flywheel and any distortions that might cause rubbing on the stator and on the Pick-Up. Refitting the flywheel magneto - Position the flywheel and refit the knurled nut re- moved during removal.
Page 126 NRG 50 Engine - Move the flywheel cover into place. - Tighten the flywheel cover fastening screws. Refitting the starter motor - Fit a new O-ring on the starter and lubricate it. - Insert the starter motor in its seat.
Page 127: Removing The Intake Manifold
NRG 50 Engine Removing the intake manifold - Remove the carburetor. - Using a suitable wrench, remove the fastening screws of the intake manifold. - Remove the intake manifold. Removing the cylinder head - Remove the spark plug. - Remove the engine temperature sensor.
Page 128 NRG 50 Engine - Remove the head fixing nuts. - Remove the cylinder head. Removing the cylinder - piston assy. - Remove the cylinder head. - Remove the cylinder, taking care to support the piston. - Remove the cylinder base gasket.
Page 129 NRG 50 Engine - Remove the snap rings. - Remove the pin. - Remove the roller cage. 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...
Page 130 NRG 50 Engine 17.060 mm 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 131: Removing The Piston
NRG 50 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 132 NRG 50 Engine - Lubricate the snap ring, the inside of the piston and the internal surface of detail 1 of the tool using the specific product. - Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.
Page 133 NRG 50 Engine - Using the specific tool, fit the second snap ring in the free slot on the piston. Specific tooling 020166Y Tool for fitting the pin snap rings Choosing the gasket - Fit the cylinder without fitting the base gasket.
Page 134 NRG 50 Engine Refitting the piston rings - Lubricate the sealing rings and fit them to the piston. Refitting the cylinder Fit the previously selected new cylinder base gas- ket. - Fit the cylinder. ENG - 134...
Page 135 NRG 50 Engine Inspecting the timing system components - Check the correct sealing of the reed unit; no light must pass between the support and the reed unit. Refitting the head and timing system components - Position the head - Fit the head fixing nuts.
Page 136: Crankcase - Crankshaft
NRG 50 Engine - Fit and tighten the engine temperature sensor. - Fit and tighten the spark plug. Refitting the intake manifold - Fit the intake manifold. - Use a suitable wrench to tighten the fastening screws of the intake manifold.
Page 137 NRG 50 Engine Splitting the crankcase halves - remove the transmission. - Remove the stator. - remove the heat unit and the intake manifold. - Unscrew and remove the crankcase fastening screws. - Fit the crankcase on the flywheel side of the crankshaft.
Page 138: Removing The Crankshaft
NRG 50 Engine - Remove the flywheel side crankcase half. Removing the crankshaft - Remove the flywheel side crankcase half. - Fit the guard on the transmission side of the crankshaft. Specific tooling 020163Y Crankcase splitting plate Install the tool on the transmission side crankcase half.
Page 139 NRG 50 Engine Removing the crankshaft bearings The bearings can stay on either the crankcase half or the crankshaft. - Using the special tool, remove any bearings that have been left on the crankshaft - Fit the half-rings between the bearing and the crankshaft using a hammer with resin heads.
Page 140 NRG 50 Engine - Using a specific tool, remove any bearings left in the flywheel side half-crankcase. Refitting the crankshaft bearings - Support the main bearings and put them in a heatable container filled with cold oil. - Heat the container with oil using a heat gun.
Page 141 NRG 50 Engine - Position the crankshaft on the specific tool, sup- port it on the connecting rod side and fit the bear- ings Specific tooling 020265Y Bearing fitting base Inspecting the crankshaft alignment With the specific equipment shown, check that the eccentricities of the surfaces of Ø...
Page 142 NRG 50 Engine - Firmly fit the crankshaft until the bearing reaches the end-of-stroke stop - Let the temperature of the crankcase half settle at the temperature of the crankshaft. - Install the special crankcase separation plate again without installing the crankshaft crankcase - During the assembly phase keep the central thrust screw loose.
Page 143 NRG 50 Engine - Heat the flywheel-side crankcase half with a ther- mal gun. - Keeping the crankcase half on the transmission side, fit the flywheel side crankcase half with a clean precise movement - Insert at least three fastening screws and tighten...
Page 144 NRG 50 Engine - Check the axial clearance of the crankshaft, if the values found are not within the limit value, repeat the carter mating procedure. Characteristic Axial clearance with warm crankcase 0.10 ÷ 0.12 mm Axial clearance with cold crankcase 0.06 to 0.08 mm...
Page 145: Oil Pump
NRG 50 Engine - Install a new transmission side oil seal using the special tool with adapter ring. Specific tooling 021018Y Punch to fit flywheel and transmis- sion oil seals Oil pump Removal - Remove the fastening screws of the oil pump.
Page 146: Fuel Supply
NRG 50 Engine Refitting - Fit the oil pump on the drive shaft. - Fit the pipe gasket, inserting it into the crankcase. - Insert the screws of the pump into the crank- house and tighten them. Fuel supply The vehicle has a membrane pump controlled by the vacuum generated in the intake manifold.
Page 147: Removing The Carburettor
NRG 50 Engine - Start the engine without touching the accelerator and keep it at idling speed. - Count 10 seconds from when the engine starts, then switch it off. - Check that the amount of fuel is not lower than that prescribed.
Page 148 NRG 50 Engine - Remove the automatic starter device. - Unscrew and remove the gas valve cover fas- tening screw. - Remove the gas valve cover and gas valve spring. - Remove the gas valve and the conical needle. ENG - 148...
Page 149 NRG 50 Engine - Unscrew and remove the fastening screws of the pan. - Remove the pan. - Remove the float pin. Remove the float and the petrol needle. ENG - 149...
Page 150 NRG 50 Engine Unscrew and remove the gas valve adjustment screw with its spring. Unscrew and remove the main jet. Unscrew and remove the idling jet. Unscrew and remove the minimum air adjustment screw with its spring. ENG - 150...
Page 151 NRG 50 Engine Refitting the carburettor - Thoroughly clean all components. - Insert and tighten the minimum air adjustment screw complete and its spring until it is completely closed. - Fit and tighten the idling jet. - Fit and tighten the main jet.
Page 152 NRG 50 Engine - Position the float and the petrol needle. - Fit the float pin. - Position the pan - Insert and tighten the pan fastening screws. ENG - 152...
Page 153 NRG 50 Engine - Fit the gas valve and the conical needle. - Position the gas valve spring - Insert and tighten the gas valve cover fastening screw. - Fit the automatic starter device. ENG - 153...
Page 154 NRG 50 Engine - Fit the fixing plate. - Fit and tighten the fastening screws of the auto- matic starter. - Position the boot of the automatic starter. Inspecting the automatic choke device - Remove the automatic choke device from the carburetor.
Page 155 NRG 50 Engine - Check that the piston flows in its seat. - Check that the O-ring of the device is intact and is not deformed or cracked. - Measure the piston protrusion and check the cor- responding value. Characteristic Automatic stroke of starter pin: 11.07 ±...
Page 156: Index Of Topics
INDEX OF TOPICS SUSP USPENSIONS...
Page 157: Front Suspension
NRG 50 Suspensions Front suspension FRONT SUSPENSION Name Torque in Nm Speed sensor - Bracket 8.5 ± 2.0 Nm Fork fastening screws - Plate 29.5 ± 4.5 Nm Stem cap - Stem 45 ± 10 Nm Calliper mounting bracket screw - Muffler unit 30 ±...
Page 158 NRG 50 Suspensions - Extract the wheel axle while sustaining the wheel. - Extract the wheel. Front wheel hub overhaul REMOVAL Using a mallet, gently tap to remove the cover and the spacer. - Remove the front wheel - Using wooden supports, sustain the wheel to be...
Page 159 NRG 50 Suspensions - Remove the internal spacer - Using a specific sleeve, an adaptor and guide, with a few mallet taps, eject the bearing and the spacing bushing from the brake disc side, inserting the sleeve from the odometer socket side, as in-...
Page 160: Refitting The Front Wheel
NRG 50 Suspensions FITTING Using an adequate spacer, gently tap to adjust the wheel axle cover. Refitting the front wheel Fit the wheel. - Sustain the wheel so as to be able to insert the axle. - Tighten the wheel axle nut to the specified torque.
Page 161 NRG 50 Suspensions - Tighten to the specified torque the previously loosened screws of the calliper mounting bracket. After having refitted the front wheel, check the distance between the speed sensor and the brake disc. - Unscrew and remove the fixing screw of the speed sensor.
Page 162 NRG 50 Suspensions Reposition the speed sensor together with the washers (after checking the distance between the sensor and the brake disc) and tighten the sensor fixing screw to the specified torque. Handlebar Removal To remove the handlebar, first remove: - the rear view mirrors .
Page 163 NRG 50 Suspensions - Remove the handgrip. - Remove the handlebar. Refitting Fit the handlebar in its position . Tighten to the specified torque the handlebar fixing screw. SUSP - 163...
Page 164: Front Fork
NRG 50 Suspensions - Insert the handgrip. - Screw the handlebar fixing screw. - Tighten the new clamps to fasten the throttle con- trol cable and the electrical connections to the handlebar. Front fork Removal To remove the front fork, first remove: - the front mudguard.
Page 165 NRG 50 Suspensions - Detach the fork from the vehicle. - Position the fork on the work bench. - The following operations are used to remove the fork leg. Carry out the same operations to remove the second fork leg.
Page 166 NRG 50 Suspensions - Extract the short spring. - Unscrew the screws fastening the fork leg to the plate. - Extract the fork leg. Overhaul To perform the overhaul, first remove : - the fork leg. SUSP - 166...
Page 167 NRG 50 Suspensions Drain the oil from the fork, collecting it in a proper manner. - Remove the cap. - Extract the second spring. - Extract the dust cover. SUSP - 167...
Page 168 NRG 50 Suspensions - Extract the retainer ring. - Extract the stem. - Apply the specific tool on the fork leg. Specific tooling 020487Y Fork oil seal extractor - Screw the nut of the previously applied specific tool. SUSP - 168...
Page 169 NRG 50 Suspensions - Remove the oil seal. - Now it is possible to check all components, the state of the plastic seal and of the spring and to replace them if necessary. After checking the components, start refitting. - Insert the muffler together with the related com- ponents in the stem.
Page 170 NRG 50 Suspensions - Insert an adequately long wrench in the stem to meet the rotation of the muffler to allow the sub- sequent tightening. - Using a specific tool, insert the oil seal in its seat. Specific tooling 020376Y Sleeve for adaptors...
Page 171 NRG 50 Suspensions - Insert the screw while firmly keeping the previ- ously applied wrench. - Tighten the calliper mounting bracket fixing screw. - Insert the dust cover. Refitting Insert the stem in the plate. SUSP - 171...
Page 172 NRG 50 Suspensions - Screw the lower screw of the plate without yet tightening it. - Insert the spring. - Insert the cap. - Insert the short spring. SUSP - 172...
Page 173: Steering Bearing
NRG 50 Suspensions - Fill the fork with the specified oil. Insert the plug in its seat screwing and pressing it manually. In this way, the initial spring compres- sion is inhibited. - Tighten the plug to the prescribed torque.
Page 174 NRG 50 Suspensions Removal To remove the front fork, first remove: - the front wheel. - the brake calliper. - the handlebar. - Unscrew the upper ring nut, using the specific tool. Specific tooling 020055Y Wrench for steering tube ring nut - Extract the upper ring nut.
Page 175 NRG 50 Suspensions - Using the specific tool, unscrew the lower ring nut, while sustaining the fork so that is does not come out. Specific tooling 020055Y Wrench for steering tube ring nut - Extract the lower ring nut. - Extract the upper ball cage .
Page 176 NRG 50 Suspensions - Put the fork on the bench and extract the lower ball cage. - Using the proper tool, remove the steering bear- ing lower plate from steering tube. - Using the specific tool, remove the upper plate of the lower steering bearing from the headstock.
Page 177 NRG 50 Suspensions Refitting To reinstall the plates of the steering bearing on the headstock, prepare the specific tool with the specific pieces for the vehicle. Fit all pieces and lock the lower nut of the tool. Specific tooling 001330Y Tool for fitting steering seats - Tighten the upper nut of the tool until the plates reach the end on the steering bearing.
Page 178 NRG 50 Suspensions - Insert the fork and sustain it properly. - Insert the upper ball cage after having previously greased it with the specific product. Recommended products Calcium based grease Calcium grease Smooth-textured appearance; Ivory coloured Specification TL 9150 066, symbol NATO G 460 - Insert the lower ring nut.
Page 179 NRG 50 Suspensions - Insert the safety washer. - Insert the upper ring nut. - Using the specific tool, tighten the upper ring nut, applying the recommended torque. Specific tooling 020055Y Wrench for steering tube ring nut - Refit anything previously removed.
Page 180: Removing The Rear Wheel
NRG 50 Suspensions Removing the rear wheel To remove the rear wheel, you must first remove: - the complete silencer. Remove the screw cap - Undo the fastening nut of the wheel while holding the rear brake lever firmly. - Remove the nut.
Page 181: Refitting The Rear Wheel
NRG 50 Suspensions - Unscrew and remove the fastening screws of the brake calliper. Unclip the brake calliper and remove the wheel Refitting the rear wheel Position the rear wheel. - Put the brake calliper and tighten the relative screws to the specified torque.
Page 182 NRG 50 Suspensions Put the nut in its position. - Tighten the nut to the specified torque. - Reinstall the screw cap. Reinstall anything that was previously removed: - the complete muffler. Swing-arm SUSP - 182...
Page 183 NRG 50 Suspensions Removal To remove the swinging arm, first remove: - the side covers of the footpeg (spoilers). - Disconnect the flywheel connector. - Unscrew the screw of each of the brake cable retaining flaps. - Loosen the fuel pipe check valve and the vacuum pipe screw.
Page 184 NRG 50 Suspensions - Unscrew the fixing nut of the engine support pin. - Extract the pin from the engine right side. - Move the engine slightly back . - Unscrew the nut fastening the swinging arm pin to the chassis.
Page 185 NRG 50 Suspensions - Extract the pin from the engine left side. - Remove the swinging arm. Refitting Fit the swinging arm. - Connect the flywheel side connector. SUSP - 185...
Page 186 NRG 50 Suspensions - Insert the pin from the engine left side. - Tighten the nut fastening the swinging arm pin to the chassis. - Bring the engine close. - Insert the engine support pin from the right side of the vehicle.
Page 187: Shock Absorbers
NRG 50 Suspensions - Tighten the engine support pin nut to the prescri- bed torque. - Position the non-return fuel pipe and vacuum tube and tighten the screws. - Position the two brake cable retaining clamps and tighten the relative screws.
Page 188 NRG 50 Suspensions Removal To remove the shock absorber, first remove: - the side fairings. - the lower covers. - the helmet compartment. Unscrew the nut fastening the shock absorber to the chassis. - Unscrew the nut fastening the shock absorber to the carter.
Page 189: Centre-Stand
NRG 50 Suspensions Refitting Position the shock absorber. - Tighten the nut fastening the shock absorber to the chassis. - Tighten to the specified torque the nut fastening the shock absorber to the carter. Centre-stand Complete stand replacement - Operate on the screws highlighted in the figure.
Page 190 NRG 50 Suspensions - Caulk the end of the "P" pin using the two punch- es indicated in the figure. - After caulking, the stand must rotate freely. N.B. UPON REFITTING, USING NEW O-RINGS AND PINS, GREASE THE SPRING COUPLINGS AND THE PIN.
Page 191: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 192: Front Brake
NRG 50 Braking system FRONT BRAKE Name Torque in Nm Hydraulic hose - Front brake calliper 22.5 ± 2.5 Nm Hydraulic hose - Front brake pump 22.5 ± 2.5 Nm Front brake disc - Wheel rim 9.0 ± 1.0 Nm Front brake pump - Handlebar 9 ±...
Page 193 NRG 50 Braking system - First loosen the screw of the hydraulic hose of the rear brake calliper. - Unscrew and remove the screws fastening the brake calliper to the carter. - Detach the brake calliper from the wheel disc.
Page 194 NRG 50 Braking system Refitting Insert and screw the coupling screw of the rear brake pipe. - Position the brake calliper. - Tighten to the specified torque the screws fas- tening the brake calliper to the carter. - Tighten to the specified torque the screw of the hydraulic hose.
Page 195: Front Brake Calliper
NRG 50 Braking system - Put the mudguard support bracket back into its place, screwing the relative screws and reinstall the previously removed mudguard. - Refill and bleed the rear brake system. Front brake calliper Removal - To remove the front brake calliper, first drain the brake fluid from the circuit of the front braking sys- tem.
Page 196 NRG 50 Braking system - Unscrew and remove the screws fastening the brake calliper to the fork. - Detach the brake calliper from the wheel disc. - Unscrew and remove the coupling screw of the front brake pipe. Refitting Insert and screw the coupling screw of the front brake pipe.
Page 197: Rear Brake Disc
NRG 50 Braking system - Position the brake calliper. - Tighten to the specified torque the screws fas- tening the brake calliper to the fork.. - Tighten to the specified torque the screw of the hydraulic hose. - Refill the circuit with the specific brake fluid and,...
Page 198 NRG 50 Braking system Removal To remove the rear brake disc, first the following must be removed: - the rear wheel. - Put the wheel with the brake disc on the bench; - Unscrew the screws fastening the disc. - Remove the rear brake disc.
Page 199: Disc Inspection
NRG 50 Braking system - Tighten to the specified torque the screws fas- tening the brake disc to the wheel rim. - Reinstall the rear wheel. Disc Inspection - Carefully clean the surface of the braking race and make sure there is no abnormal scoring.
Page 200: Front Brake Disc
NRG 50 Braking system Front brake disc Removal To remove the front brake disc, first the following must be removed: - the front wheel. - Put the wheel with the brake disc on the bench; - Unscrew the screws fastening the disc.
Page 201 NRG 50 Braking system Refitting Put the brake disc in its position. - Tighten to the specified torque the screws fas- tening the brake disc to the wheel rim. - Install the front wheel. Disc Inspection - Carefully clean the surface of the braking race and make sure there is no abnormal scoring.
Page 202: Front Brake Pads
NRG 50 Braking system 3.5 mm - Use a suitable tool to check that the axial devia- tion lies within the permissible limits. - Otherwise, replace the brake disc. Characteristic Maximum axial deviation 0.1 mm Front brake pads Removal To replace the front brake pads, first remove the brake calliper, unscrewing the fork fastening screws.
Page 203 NRG 50 Braking system - Extract the front brake pads. Check the wear state and replace them if necessary. - Check the thickness of the wear material and, if below the minimum value, replace the pads. Characteristic Friction material minimum permissible thick- ness 1.5 mm...
Page 204: Rear Brake Pads
NRG 50 Braking system - Put the retainer screws of the brake pads. - Tighten the screws. - Reposition the calliper and tighten to the speci- fied torque the screws fastening the brake calliper to the fork. Rear brake pads...
Page 205 NRG 50 Braking system - Unscrew the screws fixing the brake calliper to the carter. - Detach the calliper from the disc. - Remove the cotter pin. - Extract the pin. BRAK SYS - 205...
Page 206 NRG 50 Braking system - Remove the retainer plate of the pads. - Extract the pads. - Check the thickness of the wear material and, if below the minimum value, replace the pads. Characteristic Friction material minimum permissible thick- ness 1.5 mm...
Page 207 NRG 50 Braking system Refitting Insert the new brake pads in their seat. - Fit the retainer plate of the pads. - Insert the pin. - Insert the cotter pin. BRAK SYS - 207...
Page 208 NRG 50 Braking system - Put the brake calliper back into its place and tighten the screws to the specified torque. - Put the mudguard support bracket back into its place, screwing the relative screws and reinstall the previously removed mudguard.
Page 209: Front Brake Pump
NRG 50 Braking system - DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL. N.B. DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP. WARNING BRAKE FLUID IS HYGROSCOPIC; WHICH MEANS THAT IT ABSORBS MOISTURE FROM THE SURROUNDING AIR.
Page 210 NRG 50 Braking system - Disconnect the electrical connections. -First loosen the screw coupling the hydraulic hose of the front braking system. - Unscrew and remove the screws of the U-bolt fastening the front brake pump to the handlebar. - Unscrew and remove the coupling screw of the front brake pipe.
Page 211 NRG 50 Braking system Refitting - Insert and manually tighten the screw coupling the front brake pipe in the pump. - Fit the front brake pump and tighten to the speci- fied torque the screws of the U-bolt. - Tighten to the specified torque the screw coupling the hydraulic hose to the front brake pump.
Page 212 NRG 50 Braking system - Refill the circuit with the specific brake fluid and, with the vehicle at a standstill, carry out the stroke of the brake lever and, if necessary, bleed the in- stallation. Rear brake pump - combined...
Page 213 NRG 50 Braking system - Unscrew and remove the screws of the U-bolt fastening the rear brake pump to the handlebar. - Remove the U-bolt. - Remove the pump and disconnect the coupling of the rear brake pipe. In this way the brake pump can be removed.
Page 214 NRG 50 Braking system - Tighten to the specified torque the hydraulic hose coupling to the rear brake pump. - Connect the electrical connections. - Refill and bleed the rear brake system. BRAK SYS - 214...
Page 215: Index Of Topics
INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 216: Radiator Removal
NRG 50 Cooling system RADIATOR - REMOVAL To remove the radiator: - remove the front shield. - first drain the coolant. - Remove the metallic clamps of the radiator pipes. - Disconnect the pipes. - Remove the expansion tank. COOL SYS - 216...
Page 217 NRG 50 Cooling system - Unscrew and remove the screws fastening the radiator to the upper and lower bracket. - Remove the radiator. RADIATOR - FITTING Fit the radiator. - Insert and tighten the screws fastening the radi- ator to the upper and lower bracket.
Page 218 NRG 50 Cooling system - Put the expansion tank. - Connect the pipes. - Using the appropriate gripper, apply new clamps on the pipes. - Refit the front shield. - Fill with the coolant tank in the specified amount. COOL SYS - 218...
Page 219 NRG 50 Cooling system System bleed Refill the circuit through the expansion tank up to the maximum level. - Connect a rubber tube to the bleeding fitting on the big end and insert it in the opening of the ex- pansion tank.
Page 220: Water Pump - Overhaul
NRG 50 Cooling system Water pump - overhaul - Remove the pick-up/coolant inlet hose clamp - Remove the transmission cover - Remove the mixer - Setup the special as shown in the picture N.B. WHEN SECURING THE TOOL, PAY ATTENTION NOT TO OVERLOAD THE PLASTIC IMPELLER.
Page 221 NRG 50 Cooling system - With the aid of the special tool, loosen the impel- ler shaft turning the spanner clockwise (left-hand- ed thread) - As the thread is fully disengaged, extract the shaft with the aid of pliers. Specific tooling...
Page 222 NRG 50 Cooling system - Insert the shaft, with bearings, into its housing by pushing and turning it at the same (turn anticlock- wise for tightening) - Turn it rapidly to the end of the threading. - Should this operation prove difficult, do not carry on;...
Page 223 NRG 50 Cooling system - Release the thermostat. Check 1) Visually check that the thermostat is not dam- aged. 2) Fill a metallic container with approx. 1 litre of water. Immerge the thermostat, and keep it in the centre of the bowl.
Page 224 NRG 50 Cooling system Refitting Fit the thermostat as high as possible on the big end so that the by-pass section is as small as pos- sible. - Re-install anything that was previously removed. COOL SYS - 224...
Page 225 INDEX OF TOPICS CHAS HASSIS...
Page 226 NRG 50 Chassis Seat REMOVAL To remove the saddle, proceed as follows: - open and tilt it completely to be able to reach the screws. - Unscrew and remove the fixing screws. - Extract the saddle. FITTING Put the saddle keeping it open and screw the fixing screws.
Page 227 NRG 50 Chassis - Remove the rear-view mirror. FITTING Put the rear-view mirror. - Tighten the screw fastening the rear-view mirror to the handlebar. - Fit the screw cap. CHAS - 227...
Page 228 NRG 50 Chassis Rear handlebar cover REMOVAL To remove the rear handlebar cover, first remove: - front handlebar cover - Unscrew and remove the central screw fixing the rear handlebar cover to the handlebar. - Unscrew and remove the side screws fixing the rear handlebar cover to the handlebar.
Page 229 NRG 50 Chassis FITTING Place the handlebar cover on the handlebar and connect the connectors. - Tighten the side screws fixing the rear handlebar cover to the handlebar. - Tighten the central screws fixing the rear han- dlebar cover to the handlebar.
Page 230: Front Handlebar Cover
NRG 50 Chassis Front handlebar cover REMOVAL First remove: - The rear-view mirrors - Unscrew the front handlebar cover fastening screws and remove them. - Remove the front handlebar cover. FITTING Bring the front handlebar cover into place. - Tighten the screws fixing the front handlebar cov- er to the rear one.
Page 231 NRG 50 Chassis Frame central cover REMOVAL To remove the central frame cover, proceed as follows: Unscrew the three fastening screws of the central frame cover at the fuel tank cap holder. - Unscrew and remove the two screws securing the central frame cover to the footrest.
Page 232 NRG 50 Chassis FITTING Position the central frame cover - Screw the two fastening screws of the central frame cover into the footrest. - Replace the fuel tank cap. Screw the three fastening screws of the central frame cover to the fuel tank cap holder.
Page 233 NRG 50 Chassis Legshield REMOVAL To remove the front shield, first remove: - the central frame cover - the footrest - the side covers of the footpeg (spoilers). - Unscrew and remove the screws fixing the shield to the leg shield back plate.
Page 234 NRG 50 Chassis - Unscrew and remove the screws fastening the shield to the leg shield back plate, located under. - Unscrew and remove the screws fastening the shield to the leg shield back plate, located under the turn indicator unit.
Page 235 NRG 50 Chassis FITTING Position the front shield so that you can connect the connectors. - Connect the connectors. - Bring the shield flush with the back plate. - Screw the shield fixing screws to the shield back plate. - Reposition the radiator cover.
Page 236 NRG 50 Chassis - Tighten the radiator cover screw. - Tighten the front shield fixing screws to the back plate. Re-install anything previously removed: - the central frame cover - the footrest - the side covers of the footpeg (spoilers).
Page 237 NRG 50 Chassis - Open and remove the plug of the coolant tank. - Unscrew and remove the screws (located under the previously removed footrest) fastening the leg shield back plate to the chassis. - Remove the leg shield back plate.
Page 238 NRG 50 Chassis - Screw the screws (located under the previously removed footrest) fastening the leg shield back plate to the chassis. - Screw the screw fastening the coolant tank to the leg shield back plate. - Refit the coolant tank plug.
Page 239 NRG 50 Chassis - Unscrew and remove the screws fastening the rear light assembly. - Disconnect the connector. FITTING Connect the connector and bring the light assem- bly close. - Screw the screws fastening the rear light assem- bly. CHAS - 239...
Page 240: License Plate Light
NRG 50 Chassis Re-install anything that was previously removed: - the saddle. - the side fairings. License plate light REMOVAL To access the licence plate light, do the following: - unscrew the licence plate light screw; - Remove the complete licence plate light;...
Page 241 NRG 50 Chassis - Extract the light bulb holder; CAUTION DO NOT PULL THE ELECTRICAL CABLES WHEN TAKING OUT THE BULB HOLDER. - Remove the lamp for the licence plate light and replace it. FITTING Put a new light bulb in the light bulb holder.
Page 242 NRG 50 Chassis - Screw the bulb holder fixing screws; - Put the licence plate light fixture and screw its fixing screw; Footrest REMOVAL To remove the footrest, first remove: - the central frame cover - Disconnect the fuel level indicator connector.
Page 243 NRG 50 Chassis - Unscrew and remove the central screw fastening the footrest. - Unscrew and remove the lateral screws fastening both the chrome plated protections and the foot- rest. - Remove the chrome plated protections and then the footrest.
Page 244 NRG 50 Chassis FITTING Position the footrest. - Fit the chrome plated protections. - Screw the lateral screws fastening the chrome plated protections and the footrest. - Screw the central screw fastening the footrest. CHAS - 244...
Page 245: Side Fairings
NRG 50 Chassis - Connect the fuel level indicator connector. - Reinstall the previously removed chassis central cover. Side fairings To remove the side fairings, first remove: - the saddle. - Unscrew and remove the screws fastening the taillight upper cover and the side fairings.
Page 246 NRG 50 Chassis - Remove the taillight upper cover. - Unscrew and remove the screws fastening the side fairings. - Unscrew and remove the (lateral) screws fasten- ing the side fairings. - Unscrew and remove the screws (located on the taillight support) fastening the side fairings.
Page 247 NRG 50 Chassis - Remove the side fairings. FITTING Position the side fairings. - Fit the taillight upper cover. - Screw all the screws fastening the side fairings, including those of the taillight upper cover. CHAS - 247...
Page 248 NRG 50 Chassis - Reinstall the previously removed saddle. License plate holder REMOVAL To remove the licence plate support, first remove: - the side fairings. - the rear light assembly. Unscrew the lateral screws fastening the licence place support. - Unscrew the lower screws fastening the licence place support.
Page 249 NRG 50 Chassis - Disconnect the electrical connections. - Disconnect the licence plate light connector and remove the licence plate support. FITTING Sustain the licence plate support, bringing it close to its position and connect the licence plate light connector.
Page 250 NRG 50 Chassis - Bring the licence plate support close. - Screw the lower screws fastening the licence place support. Screw the lateral screws fastening the licence plate support and reinstall everything that was pre- viously removed. Air filter REMOVAL...
Page 251 NRG 50 Chassis - Unscrew and remove the screw of the throttle control retaining clamp. - Disconnect the fuel pipe. - Cut the clamp of the sleeve and release the air filter. FITTING Put the air filter and connect the sleeve applying a new clamp.
Page 252: Rear Mudguard
NRG 50 Chassis - Screw the retaining clamp screw of the throttle control. - Put the fuel pipe back in its position. - Reinstall the rear mudguard. Rear mudguard REMOVAL To remove the rear mudguard, proceed as follows: - Unscrew the screws fastening the engine cover to the mudguard.
Page 253 NRG 50 Chassis - Extract the engine cover. - Unscrew the lateral screws fastening the mud- guard to the carter. - Unscrew the screw fastening the filter box and the mudguard to the carter. - Unscrew the screws fastening the mudguard to the relative support plate .
Page 254 NRG 50 Chassis - Extract the mudguard. FITTING Position the rear mudguard. - Screw the screws fastening the mudguard to the relative bracket. - Screw the screw fastening the filter box and the mudguard to the carter. CHAS - 254...
Page 255 NRG 50 Chassis - Screw the lateral screws fastening the mudguard to the carter. - Put the engine cover. - Screw the screws fastening the engine cover to the mudguard. Helmet bay REMOVAL To remove the helmet compartment, first remove: - the saddle.
Page 256 NRG 50 Chassis - Unscrew the fastening screws of the terminal box. - Unscrew the screw located in the battery com- partment. - Unscrew the screw located in the helmet com- partment. - Remove the plug of the mixer oil tank.
Page 257 NRG 50 Chassis - Now the helmet compartment can be released. FITTING Put the helmet compartment. - Insert the plug of the mixer oil tank. - Screw the screw located in the helmet compart- ment. CHAS - 257...
Page 258 NRG 50 Chassis - Screw the screw located in the battery compart- ment. - Screw the fastening screws of the terminal box. - Screw the screws fixing the helmet compartment to the chassis and reinstall everything that was previously removed.
Page 259 NRG 50 Chassis - Unscrew and remove the lateral screws fastening the shield to the footpeg lateral covers. - Unscrew and remove the lower screws fastening the shield to the footpeg lateral covers. - Remove the side covers of the footpeg.
Page 260 NRG 50 Chassis - Screw the lower screws fastening the shield to the footpeg lateral covers. - Screw the lateral screws fastening the shield to the footpeg lateral covers. Re-install anything that was previously removed: - the central frame cover...
Page 261 NRG 50 Chassis - Unscrew and remove the screw of the tank plug support. - Cut the sleeve clamp. - Unscrew and remove the screw fastening the tank to the chassis. - Unscrew the screws fastening the tank support bracket.
Page 262 NRG 50 Chassis - Release the tank from the chassis. FITTING Put the tank in its seat and fit the bracket. - Screw the screws fastening the tank support bracket. - Screw the screw fastening the tank to the chas- sis.
Page 263: Front Mudguard
NRG 50 Chassis - Fit the sleeve, insert a new clamp and close it with the specific gripper. - Screw the screws of the fuel tank plug support. Reinstall anything previously removed: - the central frame cover - the footrest - the side covers of the footpeg (spoilers).
Page 264: Expansion Tank
NRG 50 Chassis Remove the front mudguard. FITTING Put the front mudguard. Tighten the front mudguard fixing screws. Expansion tank REMOVAL To remove the expansion tank, first remove: - The front shield. - Empty the coolant circuit collecting the fluid in an adequate container.
Page 265 NRG 50 Chassis - Unscrew and remove the plug of the coolant tank. - Remove the pipe clamps, disconnect them and remove the tank. FITTING Put the coolant tank. - Connect the pipes and apply new clamps. - Screw the screw fastening the coolant tank to the leg shield back plate.
Page 266 NRG 50 Chassis - Refit the coolant tank plug. - Refit the front shield. - Bleed the cooling system . Mixture oil tank REMOVAL To remove the mixer oil tank, first remove: - the upper and lower side fairings. - the helmet compartment.
Page 267 NRG 50 Chassis - Disconnect the oil pipe from the tank, making sure you have suitable caps ready for the pipe and the tank side fitting. - Detach the tank. FITTING Put the mixer oil tank. - Remove the caps previously placed over the oil...
Page 268 NRG 50 Chassis - Connect the level indicator connector. - Screw the screw fastening the mixer oil tank to the chassis. Reinstall anything previously removed: - the upper and lower side fairings. - the helmet compartment. Flyscreen REMOVAL Loosen and remove the screws fixing the top fair- ing.
Page 269: Radiator Cover
NRG 50 Chassis - Remove the top fairing. FITTING Position the top fairing. - Tighten the top fairing screws. Radiator cover REMOVAL Unscrew the fixing screw of the radiator cover. CHAS - 269...
Page 270 NRG 50 Chassis - Remove the radiator cover. FITTING Put the radiator cover. - Screw the fixing screw of the radiator cover. Battery REMOVAL To access the battery, do the following: - set the vehicle on its centre stand; - make sure that the ignition switch is set to the «OFF»...
Page 271 NRG 50 Chassis - Unscrew the fastening screw and disconnect the battery's negative terminal clamp «-». - Unscrew the fastening screw and disconnect the battery's positive terminal clamp «+». - Remove the battery by extracting it upwards. FITTING Put the new battery in its seat.
Page 272: Lower Cover
NRG 50 Chassis - Connect the positive terminal "+" of the battery, screwing the fixing screw. - Connect the negative terminal "-" of the battery, screwing the fixing screw. - Put the battery cover back, screw the relative fix- ing screws and close the saddle.
Page 273 NRG 50 Chassis - Unscrew the lateral screw fastening the lower side fairings to the chassis. - Unscrew the lower screw fastening the lower side fairings to the chassis. - Remove the lower side fairings. FITTING Fit the lower side fairings.
Page 274 NRG 50 Chassis - Screw the lower screw fastening the lower side fairings to the chassis. - Screw the lateral screw fastening the lower side fairings to the chassis. - Screw the central screw fastening the lower side fairings to the footpeg.
Page 275 Air filter: 36, 250 Battery: 44, 60, 270 Brake: 192, 195, 197, 200, 202, 204, 209, 212 Carburettor: 14, 32, 147, 151 Checks: 58 Electric: Fuel: 146, 260 Fuses: 59 Headlight: 40 Hub oil: 35 Identification: 12 Instrument panel: 55 Maintenance: 11, 31 Mirrors: 226 Recommended products: 31...

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