PIAGGIO Liberty 50 4T 3V i-get E3 Workshop Manual

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WORKSHOP MANUAL

1Q000458

Liberty 50 i.e. 4T 3V i-get E3-E4

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Summary of Contents for PIAGGIO Liberty 50 4T 3V i-get E3

Page 1 WORKSHOP MANUAL 1Q000458 Liberty 50 i.e. 4T 3V i-get E3-E4...
Page 2: Workshop Manual
Not all the versions shown in this publication are available in every country. Availability of the individual versions must be verified with the official PIAGGIO sales network. © Copyright 2022 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited.
Page 3 Liberty 50 i.e. 4T 3V i-get E3-E4 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio group 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 PRE DE DELIVERY ECHNICAL TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS...
Page 6 INDEX OF TOPICS PRE DE DELIVERY...
Page 7 Liberty 50 i.e. 4T 3V i-get E3-E4 Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Safety locks check Make sure that the marking is on the: - Safety fasteners - Fastening screws Safety fasteners: - Upper fastening of rear shock absorber - Rear shock absorber lower fastener...
Page 8 Liberty 50 i.e. 4T 3V i-get E3-E4 Pre-delivery - Horn - Starter TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATELY CHARGING THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS USED FOR THE FIRST TIME WITH SHORTEN THE LIFE OF THE BATTERY. WARNING KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
Page 9: Static Test
Liberty 50 i.e. 4T 3V i-get E3-E4 Pre-delivery Static test Static control after the test drive: - 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 SINCE THE TYRES MAY BURST.
Page 10 Liberty 50 i.e. 4T 3V i-get E3-E4 Pre-delivery AFTER THE PROVIDED MAINTENANCE PROGRAM IS INDICATED TO PROCEED WITH THE MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 5,000 Km (3,106 mi) OR 5 MONTHS. CAUTION THE FOLLOWING INFORMATION IS RELATIVE TO THE DELIVERY THE VERSION. WINDSHIELD BRACKETS PREPARATION - Check the correct sequence of components, as indicated below;...
Page 11 Liberty 50 i.e. 4T 3V i-get E3-E4 Pre-delivery - Fit the biggest conical washer and the expanda- ble plastic cylinder; - Add the smallest conical washer as indicated be- low; - Complete the sequence with the flat washer, the grower washer and the fixing screw. PRE DE - 11...
Page 12 INDEX OF TOPICS ECHNICAL...
Page 13: 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 spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
Page 14: Engine Identification Number
Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data checking that the frame registration number stamped on the vehicle corresponds with that on the vehicle documentation. CAUTION NOTE THAT ALTERING SERIAL NUMBERS MAY BE PUNISHABLE WITH SEVERE LEGAL PEN- ALTIES (IMPOUNDING OF VEHICLE, ETC.). FRAME IDENTIFICATION NUMBER: The frame identification number is inside the front case under a snap-on cover.
Page 15 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data VEHICLE IDENTIFICATION (DELIVERY VERSION) Specification Desc./Quantity Frame prefix ZAPCA6100 Frame number prefix (version with front luggage rack) ZAPCA6101 Engine prefix CA61M Vehicle data CAUTION THE FOLLOWING INDICATIONS REFER TO THE EURO 3 VERSION. VEHICLE TECHNICAL DATA Specification Desc./Quantity...
Page 16: Vehicle Data
12V - 10 Ah Sealed battery Engine Data CAUTION THE FOLLOWING INDICATIONS REFER TO THE EURO 3 VERSION. ENGINE SPECIFICATIONS Specification Desc./Quantity Engine Single-cylinder, 4-stroke Piaggio i-Get Bore 39 mm Travel 41.8 mm Engine capacity 50 cm³ Max. power 2.4 kW at 7,500 rpm MAX torque 3.1 Nm at 7,250 rpm...
Page 17: Engine Specifications
Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data ENGINE SPECIFICATIONS Specification Desc./Quantity Engine Single-cylinder, 4-stroke Piaggio i-Get Bore 39 mm Travel 41.8 mm Engine capacity 50 cm³ Max. power 2.3 kW at 7,500 rpm MAX torque 3.0 Nm at 6,000 rpm Compression ratio 12 ±...
Page 18 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data Specification Desc./Quantity height 1,095 mm Kerb weight 106 kg Maximum weight limit 290 kg DIMENSIONS AND MASS (EURO 4 VERSION) Specification Desc./Quantity length 1,945 mm width 690 mm Wheelbase 1370 mm height 1,095 mm Kerb weight...
Page 19: Frame And Suspension
Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data Capacities CAPACITY Specification Desc./Quantity Engine oil ~ 850 cm³ Transmission oil 100 cm³ Fuel tank capacity 6 ± 0.5 litres (1 l of which is reserve) CAUTION THE FOLLOWING INFORMATION IS RELATIVE TO THE DELIVERY THE VERSION. CAPACITY Specification Desc./Quantity...
Page 20 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data Specification Desc./Quantity Rear suspension Single-chamber shock absorber. Brakes BRAKES Specification Desc./Quantity Front brake Ø 240 mm disc brake with dual piston floating calliper. Rear brake Ø 140 mm mechanically operated drum brake controlled from LH handlebar lever.
Page 21: Overhaul Data
Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data Name Torque in Nm Magneto flywheel - Crankshaft 52 - 58 Nm Starter motor - Crankcase 11 - 13 Nm Rocker axes lock plate - Head 3 - 4 Nm Cylinder head nuts - Cylinder 6 - 7 + 90°...
Page 22 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data - Measure the diameter of the bearings on the pis- ton. Characteristic Pin seat diameter 13 +0.005 + 0.010 mm N.B. THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP»...
Page 23: Piston Rings
Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data - maximum clearance allowed after use 0.06 mm oil scraper ring - standard coupling clearance oil scraper ring - maximum clear- 0.04 to 0.16 mm ance allowed after use 0.17 mm Piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di-...
Page 24 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE Name Description Dimensions Initials Quantity Transmissionside half- 14 +0 -0.005 shaft Flywheel-side halfshaft 16 +0 -0.005 Connecting rod 14.8 +0.05 -0 Spacer tool 45.00 / Fits and clearan- ces D = 0.15 - 0.30...
Page 25 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data Measure the bearings along X and Y axes Characteristic Crankshaft bearing, transmission side 20 -0.012 -0.025 mm Crankshaft bearing, flywheel side 17 +0.007 0 mm - Check that the crankshaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
Page 26: Cylinder Head
Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure. N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC- TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN- SERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE- DED.
Page 27: Cylinder Head Check
Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data - Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn.
Page 28 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data Measure the unloaded spring length. • Standard length: 31.3 mm • Limit allowed after use: 29.3 - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V".
Page 29 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data TANDARD DIAMETER Specification Desc./Quantity Intake 3.970 to 3.985 mm Exhaust 3.960 to 3.975 mm INIMUM DIAMETER PERMITTED Specification Desc./Quantity Intake 3.958 mm Exhaust 3.945 mm - Calculate the clearance between the valve and the valve guide. - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the «V»...
Page 30: Camshaft Bearings
Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem. INTAKE Specification Desc./Quantity Standard clearance 0.015 - 0.042 mm Admissible limit 0.06 mm EXHAUST Specification Desc./Quantity...
Page 31 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data -Using a gauge, measure the cam height. CAM HEIGHT Specification Desc./Quantity Standard intake cam height 24.59 mm Standard exhaust cam height 23.86 mm - Check the axial clearance of the camshaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new...
Page 32 Liberty 50 i.e. 4T 3V i-get E3-E4 Technical Data Slot packing system Characteristic Compression ratio 11.5 to 12 : 1 PISTON PROTRUSION CHECK Name Measure A Thickness Cylinder base gasket 0.4 2.2 to 2.45 Cylinder base gasket 0.5 2.45 to 2.7 DT - 32...
Page 33: Index Of Topics
INDEX OF TOPICS TOOL OOLING...
Page 34 Liberty 50 i.e. 4T 3V i-get E3-E4 Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y008 Clamp to extract 17 mm ø bearings 001467Y009 Bell for OD 42-mm bearings 001467Y010 Driver for OD 25 mm bearings 001467Y013 Extraction pliers for ø...
Page 35 Liberty 50 i.e. 4T 3V i-get E3-E4 Tooling Stores code Description 001467Y034 Calliper to extract ø 15-mm bearings 004499Y Camshaft bearing extractor 004499Y001 Bell for bearing extractor 004499Y002 Bearing extractor screw 004499Y006 Ring for bearing extractor 004499Y027 Bearing extractor part 004499Y034 Bearing extractor part 008119Y009...
Page 36 Liberty 50 i.e. 4T 3V i-get E3-E4 Tooling Stores code Description 020004Y Punch for removing steering bearings from headstock 020055Y Wrench for steering tube ring nut 020162Y Flywheel extractor 020171Y Punch for Ø 17 mm roller bearing 020209Y Hook for springs 020288Y Fork for fitting the piston on the cylinder TOOL - 36...
Page 37 Liberty 50 i.e. 4T 3V i-get E3-E4 Tooling Stores code Description 020291Y Tool to fit/remove valves 020306Y Punch valve seal rings fitting 020325Y Pliers for brake-shoe springs 020358Y 37 x 40 mm Adaptor 020359S 42 x 47 mm Adaptor 020360S 52 x 55 mm adaptor TOOL - 37...
Page 38 Liberty 50 i.e. 4T 3V i-get E3-E4 Tooling Stores code Description 020362Y 12 mm guide 020363Y 20-mm guide 020364Y 25-mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Valve fitting/ removal tool TOOL - 38...
Page 39 Liberty 50 i.e. 4T 3V i-get E3-E4 Tooling Stores code Description 020412Y 15-mm guide 020431Y Valve oil seal extractor 020432Y Tool for fitting the starter section spring. 020439Y 17-mm guide 020444Y Tool for installing/removing clutch on/ from driven pulley 020448Y Tool for fitting the pin snap rings TOOL - 39...
Page 40 Liberty 50 i.e. 4T 3V i-get E3-E4 Tooling Stores code Description 020449Y Support to check piston position 020450Y Tool for fitting/removing the camshaft 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020477Y Adapter 37 mm 020480Y Fuel pressure measurement kit TOOL - 40...
Page 41 Liberty 50 i.e. 4T 3V i-get E3-E4 Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020922Y Diagnosis Tool 020993Y Lock flywheel for distribution timing ad- justment TOOL - 41...
Page 42: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 43: Maintenance Chart
Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance Maintenance chart SCHEDULED MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check the level every 2,500 km (1,553 mi) km x 1,000 (mi x 1,000) 1 (0.6) 5 (3.1) EVERY...
Page 44: Recommended Products
MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 5,000 Km (3,106 mi) OR 5 MONTHS. Recommended products Piaggio Group recommends the products of its "Castrol Official Partner" for the scheduled maintenance of its vehicles.Only use lubricants and fluids which meet or exceed the performance characteristics specified.
Page 45: Spark Plug
Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance MEASUREMENT UNITS CONVERSION - FROM THE NGLO AXON SYSTEM TO THE NTERNATION- (I.S.). AL SYSTEM Specification Desc./Quantity 1 Inch (in) 25.4 Millimetres (mm) 1 Foot (ft) 0.305 Metres (m) 1 Mile (mi) 1.609 Kilometres (km) 1 US gallon (gal US) 3.785 Litres (l)
Page 46 Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance - Remove the spark plug cap. - Unscrew the spark plug. - Remove the spark plug from its housing. When refitting the plug, tighten it manually, being sure to insert it at the right angle. Use the wrench only to tighten it.
Page 47 Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance CAUTION WHEN FITTING, ENSURE THAT THE SPARK PLUG CAP IS POSITIONED AS INDICATED IN THE FIGURE. CAUTION THE FOLLOWING INDICATIONS REFER TO THE EURO 3 VERSION. LECTRICAL COMPONENTS Specification Desc./Quantity Spark plug NGK CR8EB Battery 12V - 6 Ah Sealed battery...
Page 48 Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance Check Make sure there is oil in the rear hub according to the intervals specified in the scheduled mainte- nance table. Do the following in order to check the hub oil level: 1) Stand the vehicle on its stand on flat ground.
Page 49 Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance SAE 80W-90; API GL-4 Characteristic Rear hub oil ~ 100 cm³ Replacement - Remove the filler plug / oil dipstick "A" - Prepare an adequately sized container. - Unscrew the oil drainage cap "B" and drain out all the oil.
Page 50: Air Filter
Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance Air filter - move the screws indicated. CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE TABLE. WARNING ALWAYS USE NEW GASKETS / O -RINGS; WHENEVER NEEDED, REMOVE THE AIR FILTER CASE OR REPLACE THE FILTER ELEMENT.
Page 51 Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance SAE 5W-40; JASO MA, MA2; API SL; ACEA A3 Locking torques (N*m) Engine oil drainage plug - Crankcase 25 - 28 Nm Make sure the filter and drainage plug O-rings are in good conditions. Lubricate them and refit the filter and the oil drain- age plug, screwing them up to the prescribed tor- que.
Page 52: Checking The Valve Clearance
Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance Checking the valve clearance To check valve clearance, check that the piston is to the TDC and that the reference indicated on the camshaft sprocket is horizontal. Use a feeler gauge to check that the clearance between the valve and the set screw corresponds with the indicated values.
Page 53: Level Check
Liberty 50 i.e. 4T 3V i-get E3-E4 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 54: Headlight Adjustment
Liberty 50 i.e. 4T 3V i-get E3-E4 Maintenance Headlight adjustment Proceed as follows: 1. Position the vehicle in running order and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit white screen;...
Page 55: Index Of Topics
INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 56: Poor Performance
Liberty 50 i.e. 4T 3V i-get E3-E4 Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter blocked or dirty Remove the sponge, wash with water and car shampoo, soak with specific oil for foam filter treatment. Press with your hand without squeezing, allow it to drip dry and refit Excessive drive belt wear Check it and replace, if necessary...
Page 57: Brakes Overheating
Liberty 50 i.e. 4T 3V i-get E3-E4 Troubleshooting Insufficient lubrication pressure LOW LUBRICATION PRESSURE Possible Cause Operation By-Pass remains open Check the By-Pass and replace if required. Carefully clean the By-Pass area. Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low...
Page 58: Noisy Suspension
Liberty 50 i.e. 4T 3V i-get E3-E4 Troubleshooting 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 59 Liberty 50 i.e. 4T 3V i-get E3-E4 Troubleshooting TROUBL - 59...
Page 60: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 61 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system CAUTION N.B. THE DIAGRAM SHOWS THE LAYOUT OF THE CONNEC- TORS VIEWED FROM THE CABLE INLET SIDE, AS INDI- CATED IN THE EXAMPLE. 1. Battery 2. Start-up relay 3. Starter motor 4.
Page 62 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system 11. Rear daylight running light bulb filament 12. License plate light 13. Accessories pre-installation 14. Fuel level sensor 15. Instrument panel 16. Flasher unit 17. Front stop switch 18. Rear stop switch 19.
Page 63 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Ma = Brown Ne = Black Rs = Red Ro = Pink Ve = Green Vi = Violet Gr = Grey Components arrangement Component layout on vehicle. 1. Horn 2. Voltage regulator 3.
Page 64: Ground Points
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system 12. Accessories pre-installation 13. Diagnostic port 14. Speed sensor 15. Secondary fuses 16. HV coil 17. Fall sensor 18. Starter relay 19. Lambda probe 20. Magneto flywheel 21. Engine speed sensor 22.
Page 65 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Ignition 1. Battery 6. Main fuse 7. Ignition switch 8. Secondary fuses 29. CDI control unit 37. HV coil 39. Engine speed sensor ELE SYS - 65...
Page 66 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Battery recharge and starting 1. Battery 2. Start-up relay 3. Starter motor 4. Voltage regulator 5. Magneto flywheel 6. Main fuse 7. Ignition switch 8. Secondary fuses 10. Brake light bulb filament 17.
Page 67 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Level indicators and enable signals section 9. Fall sensor 14. Fuel level sensor 29. CDI control unit 30. Side stand switch provision ELE SYS - 67...
Page 68: Devices And Accessories
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Devices and accessories 1. Battery 6. Main fuse 7. Ignition switch 8. Secondary fuses 9. Fall sensor 13. Accessories pre-installation 14. Fuel level sensor 15. Instrument panel 27. Horn button 28. Horn 29.
Page 69 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Lights and turn indicators 1. Battery 6. Main fuse 7. Ignition switch 8. Secondary fuses 11. Rear daylight running light bulb filament 12. License plate light 13. Accessories pre-installation 16. Flasher unit 19.
Page 70 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system 1. Battery 4. Voltage regulator 6. Main fuse 7. Ignition switch 8. Secondary fuses 9. Fall sensor 13. Accessories pre-installation 29. CDI control unit 30. Side stand switch provision 31. Injector 32.
Page 71: Checks And Inspections
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system 41. Diode Checks and inspections Remote controls check To check the operation of a relay: 1) Check that, given regular conditions, there is no continuity between terminals 87 and 30. 2) Apply a 12V voltage to power terminals 86 and 85 of the relay.
Page 72: Starter Button
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system STARTER BUTTON LIGHT SWITCH TURN SIGNAL SELECTOR HORN BUTTON ELE SYS - 72...
Page 73 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system SADDLE RELEASE SWITCH MODE BUTTON STOP BUTTONS STAND BUTTON Stator check Checking the stator windings WARNING THE CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED. - Remove the protection of the connector. ELE SYS - 73...
Page 74 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system - Disconnect the connector between stator and regulator with the three yellow cables as shown in the picture. - Measure the resistance between each of the yellow terminals and the other two. Electric characteristic Resistance: 0.2 - 1 Ω...
Page 75: Voltage Regulator/Rectifier
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system - With engine off and panel set to "ON" turn on the lights, by moving the lights switch to the left, and let the battery voltage set to 12V. - Connect a ammeter clamp to the recharge positive pole (Red-Black cable) in output from the regulator. - Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter.
Page 76: Horn Control
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check fuses No. 01 and No. 05. 2) Check ignition switch contacts. 3) Check the contacts of the stop buttons and the starter button. 4) Check with the ignition switch «ON», brake engaged and start button pressed, the presence of voltage between the Purple cable of the starter relay and ground, otherwise check the wiring harness.
Page 77 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check fuses No. 01 and No. 05. 2) Check the ignition switch and horn button contacts. 3) With the ignition switch set to «ON» and the horn button pressed, check if there is voltage between the Grey-Black cable of the horn device and the ground connection.
Page 78 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check that bulbs operate properly. 2) Check fuses No. 01 and No. 05. 3) Check ignition switch contacts. 4) With the ignition switch set to «ON», check if there is voltage between the Blue-Black cable of the turn indicator switch and the ground connection.
Page 79 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Lights list BULBS Specification Desc./Quantity High beam / low beam bulb Type: Halogen (HS1) Power: 12V - 35/35W Quantity: 1 Front indicator light bulb Type: Amber spherical Power: 12V - 10W Quantity: 1 RH + 1 LH Rear indicator light bulb Type: Amber spherical...
Page 80 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Fuses MAIN FUSE The electrical system is protected by a 20A main fuse «1» located near the battery. To reach it, the battery compartment cover must be removed as indicated in the «Battery» section. MAIN FUSES TABLE Specification Desc./Quantity...
Page 81 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system To access the auxiliary fuses proceed as follows: Remove the Piaggio clip-on badge using a flat screwdriver. Unscrew the screw fixing the grille to the frame. Remove the grille by slightly pulling it upwards and releasing the seat tongues.
Page 82 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system COMPONENTS WITH CARE, DO NOT SCRATCH OR IM- PAIR THEM. CAUTION THE FOLLOWING INFORMATION IS RELATIVE TO THE DELIVERY THE VERSION. MAIN FUSE The electrical system is protected by a 20A main fuse «1»...
Page 83 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Specification Desc./Quantity Protected circuits (live): instrument panel, stop light, antitheft device pre-installation, turn indicator, horn. Fuse no. 6 Capacity: 5 A Protected circuits (live): daylight running lights, license plate light, instrument panel lighting. Fuse no.
Page 84 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Dashboard A = Speedometer B = Engine control warning light C = Turn indicator warning light D = Low fuel warning light E = Digital display F = High-beam warning light on G = Fuel gauge with petrol symbol H = Total or partial odometer I = Clock...
Page 85 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system The «MODE» key, located on the right side of the handlebar, allows to: - alternate the display of the total or trip odometer with short pressures; - alternate the trip odometer when shown, with a long pressure;...
Page 86 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system - the current hour and minutes in format «hh:mm». Set the correct time as described in the paragraph «Set functions hours/minutes». HOUR/MINUTE FUNCTION SETTING To set or adjust the time, with vehicle running or with key inserted in «ON» position, do the following: - press the «MODE»...
Page 87 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system A = Trip counter B = Speedometer C = Low oil pressure warning light (not used) D = Turn indicator warning light E = High beam warning light F = Headlight warning light G = Fuel gauge H = Low fuel warning light I = Digital clock...
Page 88: Battery Installation
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system - If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge. - If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 2) Constant voltage battery charge mode - Constant voltage charge equal to 14.40 - 14.70V - Initial charge voltage equal to 0.3 - 0.5 for Nominal capacity...
Page 89 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system 2) Electrolyte preparation. Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulphu- ric acid.
Page 90 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system The dry charge battery MF like the completely loa- ded YTX, must have a zero load voltage between 12.8 - 13.15 V Bring the battery to full charge, us- ing the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer...
Page 91 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge pro-...
Page 92 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system • Saddle opening actuator • Battery • HV coil • Injection ECU • Horn • Ignition switch • Turn signal switch • Light switch • Tail light • Main fuse • Secondary fuses •...
Page 93: Battery Positive
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system • Idle valve • Magneto flywheel SADDLE OPENING ACTUATOR 1. Key switch (Blue-Black) 2. Saddle opening button (Blue) BATTERY POSITIVE 1. Battery positive (Red) BATTERY NEGATIVE 1. Ground lead (Black) H.V. COIL (CONNECTOR A) 1.
Page 94 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system H.V. COIL (CONNECTOR B) 1. Control unit (Red-Black) INJECTION ECU 1. Fuel pump command (Green) 2. MIL warning light (Brown-White) 3. Lambda probe heater (Light blue-Red) 4. Not connected 5. Battery power (Red-White) 6.
Page 95: Ignition Switch
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system HORN (CONNECTOR B 1. Ground lead (Black) IGNITION SWITCH 1. Ground lead (Black) 2. Not connected 3. Saddle opening (Blue-Black) 4. Secondary fuses (Light blue-Red) 5. Main fuse (Red-Black) FLASHER SWITCH A.
Page 96 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system MAIN FUSE 1. Battery positive (Red) 2. Secondary fuses (Red-Black) FUSE NO. 2 1. Main fuse (Red-Black) 2. Protected circuits (Red-White) FUSE NO. 3 3. Main fuse (Red-Black) 4. Protected circuits (Red-Grey) FUSE NO.
Page 97: Instrument Cluster
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system INSTRUMENT CLUSTER 1. Not connected 2. MODE button (Grey) 3. Left turn indicator warning light (Pink) 4. Right turn indicator warning light (White-Blue) 5. High beam warning light (Purple) 6. Not connected 7.
Page 98: Licence Plate Light
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system INDICATOR LIGHTS RELAY B. Ignition switched live (White) L. Turn indicator switch (Blue-Black) RH FRONT DIRECTION INDICATOR 1. Power supply (White-Blue) 2. Ground lead (Black) LH FRONT DIRECTION INDICATOR 1. Power supply (Pink) 2.
Page 99: Fuel Pump
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system STARTER MOTOR POSITIVE 1. Starter relay (Red) STARTER MOTOR NEGATIVE 1. Ground lead (Black) FUEL PUMP 1. Activation from control unit (Green) 2. Power from control unit (Black - Green) ACCESSORIES PRE-INSTALLATION 1.
Page 100: Diagnostic Port
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system 14. Speed sensor (Light blue) SIDE STAND SWITCH PROVISION 1. Tilting sensor (Orange-Black) 2. Control unit (Orange) USB PORT FITTING 1. Ignition switched live (White) 2. Ground lead (Black) DIAGNOSTIC PORT 1.
Page 101 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system SADDLE OPENING SWITCH 1. Power supply (Red-Grey) 2. Actuator (Blue) STARTER BUTTON 1. Brake signal (White-Black) 2. Starter relay (Purple) 3. Not connected HORN BUTTON 1. Power supply (White) 2. Horn (Grey - Black) 3.
Page 102: Voltage Regulator
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system 1. Brake signal (White-Black) LEFT STOP BUTTON 1. Power supply (White) 1. Brake signal (White-Black) VOLTAGE REGULATOR 1. Main fuse (Red-Black) 2. Control unit (Green- White) 3. Ground lead (Black) 4. Magneto flywheel (Yellow) 5.
Page 103: Engine Temperature Sensor
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system ENGINE TEMPERATURE SENSOR 1. Control unit (Light blue - Green) 2. Negative from control unit (Grey-Green) SPEED SENSOR 1. Signal (Sky blue) 2. Negative from instrument panel (Light blue- Black) 3. Ground lead (Black) LAMBDA PROBE 1.
Page 104: Magneto Flywheel
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system A. Negative from control unit (Grey-Green) B. Signal (Orange-White) C. Power from control unit (Red-Black) FUEL LEVEL TRANSMITTER 1. Not connected 2. Ground lead (Black) 3. Instrument panel (White-Green) IDLE VALVE 1.
Page 105 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Error cause The battery voltage is below the minimum threshold. Troubleshooting Check the battery, the voltage regulator, the correct function of the alternator (flywheel) and the relative connectors. High power supply P0563 Error cause The battery voltage is over the maximum threshold.
Page 106 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system - Verify continuity of the wiring harness between the coil and control unit: Coil PIN 1 - control unit PIN 8. If there is no continuity, restore the wiring harness. - Check the ground connection of coil PIN 2. Repair the wiring harness if necessary. - If the above tests provided a positive result, the coil should be replaced.
Page 107 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system - If the above tests provided a positive result, the injector should be replaced. High injector voltage P0262 - short-circuit to positive. Error cause Short-circuit to positive: excessive voltage to PIN 6 of the control unit connector. Troubleshooting Short-circuit to positive: - Disconnect the control unit connector and the injector connector.
Page 108 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system - Disconnect the control unit connector and the pump connector. - Check the pump connector PIN 2 ground insulation (corresponding to control unit connector PIN 1). If there is no insulation, restore the wiring harness. High fuel pump voltage P0232 - short-circuit to positive.
Page 109 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Troubleshooting Open circuit: - Disconnect control unit and sensor connectors and carry out the check procedure. - Check the continuity of the wiring harness between the sensor connector and control unit connector: Sensor PIN 1- control unit PIN 16 and sensor PIN 2- control unit PIN 7.
Page 110 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Troubleshooting Short-circuit to positive: - With the sensor connector and the control unit connector disconnected, verify that the fault is shorted with the battery positive of one of the three PIN of the sensor connector and restore the wiring harness. LAMBDA PROBE 1.
Page 111 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Low lambda probe voltage P0031 - open circuit or short-circuit to negative. Error cause Open circuit or short-circuit to negative: interruption of the circuit or null voltage at PIN 3 of the control unit connector.
Page 112 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Open circuit or short-circuit to negative: interruption of the circuit or null voltage at PIN 1 of the valve connector. Troubleshooting Open circuit: - Perform the check of the valve and control unit connectors. - Check the continuity of the wiring harness between the control unit connector and valve connector: Control unit PIN 17 - valve PIN 1 and control unit PIN 9 - valve PIN 1.
Page 113: Injection Warning Light
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system INJECTION WARNING LIGHT Function Indicates a fault of the injection system. ELECTRICAL ERRORS Low MIL warning light voltage P1651 - open circuit or short-circuit to negative. Error cause Open circuit or short-circuit to negative: interruption of the circuit or null voltage at PIN 2 of the control unit connector.
Page 114: Diagnostic Trouble Codes (Dtc)
Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system - After refitting, delete the error and reset the adaptive parameters. - Keep the engine running at idle speed for 15 minutes. Diagnostic trouble codes (DTC) ERROR CODES - ENGINE INJECTION SYSTEM Key: N: Warning light off F: Light on continuously: L: Light flashing Pcode Description...
Page 115 Liberty 50 i.e. 4T 3V i-get E3-E4 Electrical system Pcode Description Details Recovery Warning Lamp P0118 Engine temperature sensor open cir- 100°C Engine Temper- cuit or short circuit to positive ature CC Vbatt P0117 Engine temperature sensor short cir- CC gnd 100°C Engine Temper- cuit to ground ature...
Page 116: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 117 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle Exhaust assy. Removal CAUTION FREE THE CABLES OF THE LAMBDA PROBE BEFORE REMOVING THE SILENCER, PUTTING THIS CABLE HARNESS UNDER AN EXCESSIVE VOLTAGE MAY DAMAGE IT. - Remove the lambda probe wiring harness cover. - Disconnect the probe.
Page 118 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle - Release the nuts fixing the silencer to the crank- case. - To refit, proceed in reverse order, tightening the nuts and screws to the specified tightening torques. Locking torques (N*m) Silencer to crankcase fixing screws 24 to 27 Nut fixing silencer to cylinder head 16 - 18 Removal of the engine from the vehicle CAUTION...
Page 119 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle - Disconnect the frame engine-ground. - Disconnect the engine idling valve connector. - Disconnect the engine temperature sensor. - Disconnect the injector. ENG VE - 119...
Page 120 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle - Remove the injector support bracket wiring har- ness fastening clamp. - Disconnect the throttle position sensor. - Disconnect the H.V. coil. - Remove the wiring harness securing bracket lo- cated above the starter motor..
Page 121 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle - Remove the starter motor's ground. - Remove the starter motor power. - Loosen the clamp fastening the throttle body to the intake d. - Remove the filter housing from the crankcase. ENG VE - 121...
Page 122 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle - Remove the fastening clamp of the vapour re- covery pipe. - Disconnect the flywheel connector. - Remove the rear screw fixing the wiring harness support bracket. - Remove the front screw fixing the wiring harness support bracket.
Page 123 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle - Release the rear brake cable from the fixing bracket to the crankcase. - Remove the retainer fixing the cable to the crank- case. - Remove the fastener clamp of the wiring harness to the rear mudguard.
Page 124 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle - Remove the screw securing the swing arm-en- gine. - Remove the screw securing the swing arm- frame. - Remove the fixing screw from the bracket with silent block to the frame. - To refit, proceed in reverse order, observing the prescribed locking torques.
Page 125 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine from vehicle Characteristic Product quantity on inside dust gaiter ~ 1 cm³ Product quantity on outside dust gaiter ~ 3 cm³ ENG VE - 125...
Page 126 INDEX OF TOPICS NGINE...
Page 127: Automatic Transmission
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - Remove the air duct. - Undo the screws fixing the transmission cover to the crankcase.
Page 128 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - there are two anti-tampering screws mounted on the transmission cover, to remove them, proceed as follows. - Use an engraving burin or a punch to make a small incision in the head of the first screw to be removed.
Page 129 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Complete the hole, without drilling right through cover, using a 5 mm diameter, helical drill bit for steel WARNING WHILE DRILLING WITH THE HELICAL BIT, TAKE CARE NOT TO DAMAGE OR SCRATCH THE CASE. - the depth of the hole must be sufficient to ac- commodate the tapered left hand tap.
Page 130 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the screw. - Next, remove the second screw, followed by the complete transmission cover. - Remove the transmission cover. N.B. USE A MALLET ON THE APPROPRIATE COUPLINGS TO REMOVE THE COVER. ENG - 130...
Page 131: Removing The Driven Pulley Shaft Bearing
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Air duct - Undo the engine oil dipstick and remove it. - Loosen the air duct fixing screws. - Remove the air duct. Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.
Page 132: Removing The Driven Pulley
Liberty 50 i.e. 4T 3V i-get E3-E4 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.
Page 133: Inspecting The Clutch Drum
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the driven pulley assembly releasing the transmission belt. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Make sure that the clutch housing is not worn or damaged.
Page 134 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Insert the driven pulley unit inside the tool and support the central screw by slightly compressing the spring of the pulley unit. CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW IS TIGHTENED UP TOO FAR.
Page 135 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FACING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
Page 136 Liberty 50 i.e. 4T 3V i-get E3-E4 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 137 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings. - Measure the inside diameter of the mobile half- pulley bushing. Characteristic Mobile driven half-pulley/ Maximum diameter admissible Ø...
Page 138 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller bearing Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation - Measure the free length of the spring Characteristic Standard length...
Page 139: Refitting The Driven Pulley
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE NUT IN CONTACT WITH THE CLUTCH Locking torques (N*m)
Page 140: Removing The Driving Pulley
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Using the specific tool, tighten the clutch housing to the prescribed torque. Specific tooling 020565Y Flywheel lock calliper spanner Locking torques (N*m) Clutch housing - Driven pulley shaft 40 - 44 Nm Drive-belt - Make sure the drive belt is not damaged and does not have cracks in the toothed grooves.
Page 141 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the drive and the plastic fan. - Remove the special tool. - Remove the stationary half-pulley. - Remove the bendix after having removed the drive belt. ENG - 141...
Page 142 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the movable half-pulley unit complete with rollers, back-plate and spacer free fitted on it. - Disassemble the movable drive half-pulley unit and proceed with the check of the components. Inspecting the rollers case 1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation.
Page 143 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inside diameter «A». - Measure outside diameter «B» of the pulley slid- ing bushing shown in the figure. CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING.
Page 144 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine ORDER TO AVOID WRONG TIGHTENING AND CONSE- QUENTLY DAMAGING THE CRANKSHAFT KNURLING. Specific tooling 020451Y starting ring gear lock Locking torques (N*m) Drive pulley - Crankshaft 18 - 20 Nm + 90° Refitting the transmission cover - Make sure the centring dowels are in their seats.
Page 145 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Reposition the air duct in its seat. - Tighten the air duct fixing screws. - Reposition the engine oil dipstick. End gear Removing the hub cover - Drain the hub oil. - Release the rear brake shoe retainer springs.
Page 146 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the rear brake shoes. - Unscrew the hub cover fixing screws. - Remove the hub cover. - Recover the external shim washer on the inter- mediate gear. ENG - 146...
Page 147 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the wheel axle from its seat. - Remove the intermediate gear and recover the internal shim washer. - Acting from the opposite side, remove the driven pulley shaft. Removing the wheel axle bearings - Remove the oil seal and the seeger ring.
Page 148 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Removing the driven pulley shaft bearing - Removal of the seal ring of the driven pulley shaft on the transmission side. - Remove the Seeger ring on the reduction gear unit side. ENG - 148...
Page 149 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Heat the bearing's seat of the driven pulley shaft using the specific tool. - Remove the bearing. Specific tooling 020151Y Air heater Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings.
Page 150 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface - Heat up the hub cover using the thermal gun. - Preassemble the bearing on the specific punch using grease and then insert the bearing in its seating - Refit the seeger ring and the oil seal using the 42...
Page 151: Flywheel Cover
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Refitting the ub cover - Apply product recommended for surfaces on the hub cap and refit cap on the crankcase. - Tighten the screws to the prescribed torque. N.B. CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF RESIDUE FROM PREVI- OUS GASKETS BEFORE APPLYING A NEW ONE.
Page 152 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Undo the engine temperature sensor. - Remove the engine temperature sensor. - Undo the cooling fan cover fixing screws. - Remove the cooling fan cover. ENG - 152...
Page 153: Cooling Fan
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Unscrew the fixing screws of the intake side cov- - Remove the intake side upper cover. - Remove the exhaust side lower cover. - To refit, proceed in reverse order. N.B. WHEN REFITTING THE COVER, TAKE CARE NOT TO DAM- AGE THE STATOR WIRING.
Page 154: Removing The Stator
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Removing the stator - Remove the magneto flywheel. - Undo the fixing screws of the pick-up lock plate. - Undo the screws fixing stator to the crankcase. - Remove the stator. Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque.
Page 155: Removing The Starter Motor
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Flywheel and starting Removing the starter motor - Undo the screws fixing the starter motor to the crankcase. - Remove the starter motor. Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner.
Page 156 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Extract the flywheel with the extractor. Specific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor Inspecting the flywheel components - Check that the flywheel internal magnets are in good conditions. - Check that the flywheel splines exhibit no loos- ening.
Page 157: Intermediate Gear
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Intermediate gear - Check that the keying toothing on the crown and the starter motor are in good conditions. - Check that the Bendix opens and returns ade- quately. Refitting the flywheel magneto - Refit the stator and the pick-up being careful to pass the wiring through the appropriate crankcase couplings.
Page 158: Removing The Intake Manifold
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Refitting the starter motor - Install the starter motor in its seating in the crank- case. - Tighten the screw on the head side but do not lock it, screw the second screw inserting the earth cable (black), then tighten the 2 screws at the pre- scribed torque.
Page 159 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Removing the rocker-arms cover - Remove the cooling cover. - Undo the tappet cover fixing screws. - Remove the tappet cover complete with O-ring and recover the spark plug adapter gasket. Removing the timing system drive - Remove the cooling cover.
Page 160 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the transmission cover. - Remove the driving pulley. - Remove the oil pump. - Remove the oil pump pinion seal O-ring. CAUTION IT IS ABSOLUTELY NECESSARY TO REMOVE THE O- RING BEFORE REMOVING THE SHIM WASHER TO AVOID PINCHING AND SUBSEQUENT REDUCTION OF EFFICIEN- - Remove the shim washer.
Page 161: Removing The Cam Shaft
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Removing the cam shaft - Remove the timing system sprocket. - Undo the fastener screws of the rocker axed re- tainer plate. - Remove the retaining plate. - Remove the axes and recover the rockers. - Remove the camshaft lock seeger ring.
Page 162: Removing The Cylinder Head
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Screw the specific tool on the camshaft. Specific tooling 020450Y Tool for fitting/removing the camshaft - Screw the external nut of the specific tool to ex- tract the camshaft. - Extract the camshaft complete with bearing from its seat.
Page 163 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Gradually loosen the fixing nuts of the head on the cylinder in crossed sequence. - Remove the head complete with valve. - Remove the head gasket and recover the align- ment dowels. N.B.
Page 164: Removing The Valves
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Removing the valves - Remove the cylinder head. - Fix the specific tool in a vice. - Lock the movable cursor on the head of the valve to be removed and put the spring in compression. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool...
Page 165 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Acting from the opposite side, remove the valve from its seat. - Remove the oil seals with the specific tool. - Remove the lower cap. Specific tooling 020431Y Valve oil seal extractor Removing the cylinder - piston assy.
Page 166: Inspecting The Small End
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the snap ring, slide off the pin. - Remove the piston. - Remove the piston ring from the piston. N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR- ING REMOVAL. Inspecting the small end - Measure the internal diameter of the connecting rod small end using an internal micrometer.
Page 167: Inspecting The Piston
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine 13 +0.025+0.015mm Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. Characteristic Standard diameter: gudgeon pin 13 -0 -0.004mm Minimum admissible diameter: gudgeon pin 12.990 mm Inspecting the piston - Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis.
Page 168 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Inspecting the cylinder - Using a bore gauge, measure the cylinder inner diameter to the quota «A» indicated in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified according to their diameter.
Page 169: Removing The Piston
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine SEALING RINGS Name Description Dimensions Initials Quantity 1st Compression ring 39 x 1 0.08 to 0.20 2nd Compression ring 39 x 1 0.05 to 0.20 Oil scraper ring 39 x 2 0.20 - 0.70 Removing the piston - Place the piston on the rod and insert the pin until it stops on the retainer ring on the opposite side.
Page 170 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Place the ring into position using a punch. - Rest the tool on the piston paying attention that the 90° chamfered side faces upwards as shown in the figure. - Proceed with the fitting of the ring acting on the punch of the specific tool.
Page 171 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Refitting the piston rings - Fit the oil scraper ring starting from the spring, taking care that the spring ends do not superim- pose. Fit the two piston rings so that their gaps and that of the oil scraper ring are never aligned.
Page 172: Inspecting The Cylinder Head
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Inspecting the cylinder head - Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn.
Page 173 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole unit.
Page 174 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Inspecting the valve housings - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide. - Take the measurement at three different heights in the rocker arm push direction. Characteristic Exhaust guide: Standard diameter 5 +0+0.012mm...
Page 175 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Measure the diameter of the valve stems in the three positions indicated in the diagram. TANDARD DIAMETER Specification Desc./Quantity Intake 3.970 to 3.985 mm Exhaust 3.960 to 3.975 mm INIMUM DIAMETER PERMITTED Specification Desc./Quantity Intake...
Page 176 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Inspecting the valve stem guide clearance Measure the valve guides ALVE GUIDE DIAMETER Specification Desc./Quantity Valve guide Standard diameter: 4 + 0.012 mm Valve guide Maximum admissible diameter: 4 + 0.022 mm - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem.
Page 177: Inspecting The Cam Shaft
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Inspecting the cam shaft - Inspect the camshaft for signs of abnormal wear on the cams. CAMSHAFT BEARINGS Specification Desc./Quantity Standard diameter - Bearing A: Ø 12 mm +0.002 +0.010 mm Standard diameter - Bearing B: Ø...
Page 178 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Measure the external diameter of the rocking lev- er pins - Check the rocker pins do not show signs of wear or scoring. - Measure the internal diameter of each rocker - Check that the pad in contact with the cam is not worn.
Page 179 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Partially tighten the fixing nuts of the head to the cylinder in crossed sequence. - Partially tighten the external screws fixing the head to the cylinder. - Insert the camshaft complete with bearing in its seat.
Page 180 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Place the rockers and the rocker axes in their seats. - Place the lock plate of the rocker axes in its seat. - Tighten the fixing screw of the plate to the pre- scribed torque.
Page 181 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Locking torques (N*m) Cylinder head nuts - Cylinder 6 - 7 + 90° + 90° (*) Cylinder head screws - Crankcase 8 - 10 Nm Refitting the timing chain - Insert the timing chain pads in their correspond- ing housings, the screw and the spacer as indica- ted in the figure.
Page 182 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Slightly press on the chain tensioner pad to check that the timing system is correct. - Using the specific tool, tighten the screw fixing the sprocket timing on the camshaft to the prescri- bed torque.
Page 183: Crankcase - Crankshaft
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Crankcase - crankshaft - First remove the following units: • Driving pulley • Oil pump • Flywheel complete with stator • Cylinder-piston-head unit • Starter motor Splitting the crankcase halves - Remove the ten crankshaft coupling screws. -Separate the crankcase halves keeping the half casing driving shaft engaged on the transmission side.
Page 184: Removing The Crankshaft
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Check the correct radial clearance of the con- necting rod by holding the driving shaft with your hands and, with a dial gauge fitted to the rod small end, measuring the clearance, move the connect- ing rod vertically as shown in the figure.
Page 185 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Refitting the crankshaft bearings - Support the crankcase on a surface and place it with the driving shaft axle in a vertical position. - Warm the crankcase at ~ 120° C with a thermal gun (and support).
Page 186 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Inspecting the crankshaft alignment To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure. N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC- TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN- SERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-...
Page 187 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Fit the gasket recommended for surfaces on the half casing on the transmission side after greasing the two faying surfaces carefully. -Insert the flywheel half casing. - Fit the screws and tighten them to the specified torque.
Page 188 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Studs - Using two nuts, fitted as nut and lock nut, remove and then drive from the seat. - Proceed with a thorough cleaning of the threaded seat on the crankcase. - Screw the new stud bolts up to the driving depth indicated. CAUTION SHOULD THE CRANKCASE OR THE CYLINDER STUD BOLTS BE REPLACED, IT IS NECESSARY TO CARRY OUT THE INITIAL TIGHTENING at 6 - 7 Nm PLUS OTHER TWO TURNS OF 135°...
Page 189: Crankshaft Oil Seals
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Conceptual diagrams LUBRICATION BASIC CIRCUIT DIAGRAM LEGEND: 1. mesh filter 2. oil pump 3. crankshaft 4. camshaft 5. rockers 6. timing system chain Crankshaft oil seals Removal - Check that the chain contrast pad is not worn. -Otherwise, replace the pad or fit it inverted to make it work on the other side.
Page 190: Oil Pump
Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Extract the flywheel oil seal from the crankcase being careful not to damage or score the crank- case. Refitting - Apply engine oil on the oil seal and it seating on the crankcase.
Page 191 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Removal - Remove the driving pulley. - Remove the engine oil sump. - Undo the screws fixing the door to the crankcase. - Remove the door using the appropriate fusion attachments. - Remove the door complete with lubrication chain tensioner.
Page 192 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Lock the rotation of the oil pump control sprocket using an adequate pin and unscrew the central screw. - Remove the engine oil pump control sprocket. - Remove the lubrication chain. CAUTION IT IS ADVISABLE TO MARK THE OUTSIDE OF THE LUBRI- CATION CHAIN IN ORDER TO ENSURE, DURING REFIT-...
Page 193 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Undo the screws fixing the oil pump to the crank- case. - Remove the gasket from its housing. Inspection - Remove the two screws and remove the oil pump cover. - Remove and wash the rotors thoroughly with pet- rol and compressed air.
Page 194 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Measure distance between rotors (inner rotor/ outer rotor) with a thickness gauge in the position shown in the picture. Characteristic Admissible maximum clearance 1 0.15 mm Measure the distance between the outer rotor and the pump body (see figure).
Page 195 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Tighten the fixing screws of the engine oil pump to the prescribed torque. Locking torques (N*m) Engine oil pump - Crankcase 5 - 6 Nm - Insert the oil pump control pinion on the crank- shaft.
Page 196 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine - Lock the rotation of the sprocket using adequate pin and tighten the screw and the cup washer to the prescribed torque. N.B. FIT THE CUP WASHER SO THAT ITS OUTER (CURVED) RIM TOUCHES THE PULLEY.
Page 197 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Removing the oil sump - Remove the transmission cover. - Unscrew the oil drainage plug and drain out all the engine oil into a suitable container. CAUTION USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT.
Page 198 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Refitting the oil sump - Clean and grease the faying surfaces. - Place the engine oil sump on its seat using a new gasket. - Tighten the fixing screws of the engine oil sump to the prescribed torque.
Page 199 Liberty 50 i.e. 4T 3V i-get E3-E4 Engine Locking torques (N*m) Engine oil drainage plug - Crankcase 25 - 28 Nm ENG - 199...
Page 200: Index Of Topics
INDEX OF TOPICS INJEC NJECTION...
Page 201 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Precautions 1. Before repairing any part of the injection system, check if any faults have been stored. Do not dis- connect the battery before checking for faults. 2. The supply system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release fitting of the fuel supply pipe, check that there are no naked flames.
Page 202 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection d. connectors B: Frame ground C: Fuel system a. Faulty fuel pump b. Dirty fuel filter D: Ignition system a. Faulty spark plug b. Faulty coil c. Faulty shielded cap E: Intake circuit a.
Page 203 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Terminals setup INJECTION ECU 1. Fuel pump command (Green) 2. MIL warning light (Brown-White) 3. Lambda probe heater (Light blue-Red) 4. Not connected 5. Battery power (Red-White) 6. Injector (Red-Yellow) 7. Ground sensors (Grey-Green) 8.
Page 204 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection EMS circuit diagram 1. Battery 4. Voltage regulator 6. Main fuse 7. Ignition switch 8. Secondary fuses 9. Fall sensor 13. Accessories pre-installation 29. CDI control unit 30. Side stand switch provision 31.
Page 205: Troubleshooting Procedure
Liberty 50 i.e. 4T 3V i-get E3-E4 Injection 39. Engine speed sensor 40. Diagnostic connector 41. Diode Troubleshooting procedure Engine does not start ENGINE DOES NOT START EVEN IF PULLED Possible Cause Operation Immobilizer enabling signal System not encoded System not efficient, repair according to the indications of the self-diagnosis Faults detected by self-diagnosis Pump relay...
Page 206 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Engine stops at idle ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW Possible Cause Operation Faults detected by self-diagnosis Pump relay H.V. coil. Injector Engine speed timing sensor Air temperature Engine temperature Ignition efficiency Spark plug...
Page 207 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Possible Cause Operation Engine temperature Lambda probe Correctness of the parameters Throttle valve position sensor Stepper Engine temperature sensor Intake air temperature sensor Intake system sealing (infiltrations) Intake manifold - head Throttle body - manifold Air cleaner joint Filter housing Fuel system (low pressure)
Page 208: Fuel Supply System
Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Possible Cause Operation Intake air temperature signal Ignition advance Fuel system Fuel level in the tank Fuel pressure Fuel filter Injector flow Engine knocking PRESENCE OF KNOCKING (COMBUSTION SHOCKS) Possible Cause Operation Faults detected by self-diagnosis Pump relay H.V.
Page 209 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Key: 1. Fuel tank 2. Fuel gauge 3. Fuel tank cap 4. Fuel filler spill tray 5. Complete vent pipe 6. Complete fuel pump 7. Fuel ring 8. Fuel delivery pipe 9. Fuel pump gasket REMOVING THE COMPLETE FUEL PUMP Remove the helmet compartment.
Page 210 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection remove the fuel tank filler cap to release the pres- sure in the tank. Disconnect the fuel pump electrical connector. Disconnect the coupling between the fuel pipe and the pump. Wrap the end of the fuel pipe in a cloth to prevent fuel from escaping.
Page 211 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Mark the correct orientation of the fuel pump rela- tive to its seat on the tank with a marker pen. NOTE: Apply the marking on the fuel pump and the rela- tive seat as shown in the figure. Disengage the gasket from the tank and remove the complete fuel pump, turning it towards the side of the tank.
Page 212 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Apply the assembly marking to new fuel pump as shown in the figure. Place the complete fuel pump inside the tank. Fit the gasket, pushing downwards to ensure that it is flush with the surface of the tank. Push the fuel pump downwards to bring it against the gasket.
Page 213 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection NOTE: Ensure that the fuel pump is oriented correctly by aligning the markings made previously on the pump and on the relative seat. Fit the fastener ring of the fuel pump. Tighten the fastener ring of the fuel pump firmly, turning clockwise.
Page 214 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Mount the helmet compartment. Carefully tighten all fixing screws and connect the battery cables. REMOVING THE COMPLETE FUEL SENSOR To replace the fuel level sensor, follow the proce- dure described below. Remove the helmet compartment. Disconnect the electrical connector from the fuel level sensor.
Page 215 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Remove the fuel level sensor from the fuel tank. CAUTION FUEL IS HIGHLY FLAMMABLE. DO NOT SMOKE AND KEEP ALL NAKED FLAME AND SOURCES OF SPARKING OUT OF THE AREA: FIRE HAZARD. DO NOT INHALE THE FUEL SMOKE.
Page 216: Removing The Injector
Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Removing the injector - Remove the helmet compartment. - Disconnect the injector connector. - Remove the injector support bracket wiring har- ness fastening clamp. - Loosen the manifold fastening clamp. - Unscrew and remove the injector to manifold fix- ing screws.
Page 217 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection - Remove the injector. Refitting the injector For refitting, perform the removal operations in reverse order and lubricate the sealing OR gasket with grease for internal application before fitting the injector on the manifold. Removing the butterfly valve - Remove the throttle grip cables.
Page 218 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection - Remove the idle adjuster pipe. - Slacken clamp and remove the air intake pipe. - loosen the clamp and remove the throttle body. - Clean the throttle body according to the sched- uled maintenance.
Page 219 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Do not tamper with the stop screw under the throt- tle body. CAUTION DO NOT TAMPER WITH THE STOP SCREWS UNDER THE THROTTLE BODY, AS THE IDLE SPEED IS ADJUSTED IN THE FACTORY. Pump supply circuit 1.
Page 220: Electrical Data
Liberty 50 i.e. 4T 3V i-get E3-E4 Injection 12. Injector 13. Lambda probe heater ELECTRICAL DATA • Pump winding resistance ~ 1.5 ohm • Input current during normal functioning 1.4 - 1.8 A. • input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel pressure.) Circuit leak test Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
Page 221 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Remove the screw shown in the picture Remove the clamp fixing the piping to the filter shown in the photograph Separate the lower part of the pump mounting as shown in the picture. Remove the filter from the pump mounting INJEC - 221...
Page 222 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Inspecting the injector hydraulics - Remove the injector. Install the specific tool to check the fuel pressure and position the injector on a graduated container of at least 100 cm³. - Connect the clamps of the cable supplied to an auxiliary battery.
Page 223: Components Location
Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Components location 1. ECU 2. Fuel pump 3. Diagnostic port 4. H.V. coil. 5. Lambda probe 6. Engine speed sensor 7. TPS 8. Idle valve 9. Engine temperature sensor 10. Injector INJEC - 223...
Page 224 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection HT coil 1. Battery 2. Fuse No.1 - 20 A 3. Ignition switch 4. Fuse No.2 - 7.5A 5. Fuse No.4 - 5 A 6. H.V. coil. 7. Injection ECU 8. Lambda probe 9.
Page 225 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection - Magnetisation time The coil magnetisation time is controlled by the control unit. The ignition power is increased during the engine start-up phase. The injection system recognises the 4-stroke cycle so ignition is only commanded in the compression phase.
Page 226 Liberty 50 i.e. 4T 3V i-get E3-E4 Injection Make sure that the throttle valve with the control is supporting the stop screw. With the throttle completely closed, check that the cables have clearance in all steering positions and confirm the position at the diagnostic tool. Keep the throttle in a completely open position and confirm the position at the diagnostic tool.
Page 227: Index Of Topics
INDEX OF TOPICS SUSP USPENSIONS...
Page 228: Removing The Front Wheel
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions Front Removing the front wheel - Remove the locking nut of the wheel axle while keeping the wheel axle locked in place. - Slide off the axle and remove the wheel. CAUTION SUPPORT THE VEHICLE ADEQUATELY.
Page 229 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Remove the oil guard from the left side of the wheel. - Using the specific puller, remove the bearing. Specific tooling 001467Y013 Calliper to extract ø 15-mm bear- ings 001467Y009 Bell for OD 42-mm bearings - Remove the oil guard from the right side of the wheel.
Page 230: Refitting The Front Wheel
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions Refitting the front wheel Position the wheel with shims, position the axle and tighten to the specified torque. Locking torques (N*m) Front wheel axle 44 ÷ 49 Nm (32.5 ÷ 36.1 lbf*ft) Handlebar Removal - Remove the front cover.
Page 231: Front Fork
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Remove the locking U-bolt of the front brake pump. - Undo the screw fixing the handlebar to the steer- ing tube. - Remove the screw fixing the handlebar to the steering tube paying attention to the washers in place.
Page 232 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions Removal CAUTION SUPPORT THE VEHICLE ADEQUATELY. - First remove the handlebar cover. - Remove the handlebar. - Unscrew and remove the parts fastening the brake calliper to the fork. 2 screws - Unscrew and remove the wheel axle nut from the left side.
Page 233 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Remove the wheel axle pin; if necessary, operate from the left side with a rubber mallet. - Collect the spacer. - Sustain the wheel and remove the pin from the right side. - Remove the wheel's odometer transmission.
Page 234 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Release the odometer transmission and the front brake pipe from the internal mudguard fasteners. - Using the specific tool, unscrew and remove the upper steering ring nut. Specific tooling 020055Y Wrench for steering tube ring nut - Remove the shim.
Page 235 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Slightly lower the fork to gain access to the mud- guard fasteners. - Remove the rear clamps. 2 screws - Remove the front fastener. 1 screw - Extract the entire fork. - Remove the lower steering bearing.
Page 236 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Unscrew and remove the screws fastening the fork stem. 2 screws - Remove the upper plug cover. - Unscrew the upper plug and remove it. CAUTION WARNING KEEP THE FORK UPRIGHT TO AVOID OIL LEAKAGES. - Remove the main spring.
Page 237 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Prepare a container for draining the oil. - Remove the stanchion from the plate and drain the oil. - To separate the stanchion from the fork leg, it is necessary to fasten the internal pin to the stan- chion with a hexagonal wrench.
Page 238 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Remove the pin. - Remove the stanchion from the fork leg. - Remove the plastic guard from the stanchion. - Remove the return spring from the upper side of the stanchion. - Remove the bushing from the upper side of the fork leg.
Page 239 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Remove the circlip retaining the oil seal. - Remove the oil seal. Refitting - Using the specific tool, mount a new oil seal on the fork leg. Specific tooling 020359S 42 x 47 mm Adaptor 020376Y Adaptor handle - Insert the circlip retaining the oil seal.
Page 240 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Insert the plastic guard on the stanchion. - Insert the bushing on the stanchion, as shown in the picture. - Insert the stanchion on the fork leg, keeping its two parts horizontally to prevent the bushing from coming out.
Page 241 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Insert the inner pin. - Keep the pin locked with a hexagonal wrench. - Fit the lower screw with the specific washer and tighten to the prescribed torque. 1 screw Locking torques (N*m) Fork bottom screw 20 to 25 (14.8 to 18.4 lb*ft) - Insert the stanchion in the fork plate.
Page 242 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Insert the screws fastening the stanchion and the specific washers and tighten to the recommended torque. 2 screws Locking torques (N*m) Fork stanchion fixing screws 36 to 44 (26.6 to 32.5 lb*ft) - Pour the recommended quantity of the specific oil inside the stanchion.
Page 243 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Insert the plastic cap on the plug. - Fit the lower steering bearing on the fork. - Insert the fork from below. - Fix the odometer transmission and the front brake pipe to the plate, as shown in the image. 2 screws - Fit the mudguard.
Page 244 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Lift the fork completely. - Using the specific fork, screw and tighten the lower ring nut of the steering pipe to the recom- mended torque. Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Lower steering ring nut 12 to 14 (8.9 to 10.3 lb*ft)
Page 245: Steering Column
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Insert the wheel axle pin from the right side. - Fit the spacer on the left side, in the space be- tween the fork leg and the wheel hub. - Screw the wheel axle nut. - Keeping the nut locked, tighten the wheel axle pin to the recommended torque.
Page 246: Steering Bearing
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions Removal - Remove the handlebar. - Remove the plastic protection of the steering ring nuts. Use the specific tool to remove the steering ring nut. Specific tooling 020055Y Wrench for steering tube ring nut Refitting - Tighten the lower lock ring to the torque specified.
Page 247: Removing The Rear Wheel
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Remove the bottom bearing seat using the spe- cific tool. Specific tooling 020004Y Punch for removing steering bearings from headstock - Remove the bottom bearing seat from the steer- ing pipe. - Mount the new seats onto the frame using the specific tools.
Page 248 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Remove the rear wheel. - Align the split pin. - Remove the cotter pin and the plastic cover of the nut. - Unscrew the wheel axle nut. SUSP - 248...
Page 249: Refitting The Rear Wheel
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - Remove the wheel axle nut and its washer. - Remove the wheel hub. Refitting the rear wheel Carry out the operations in the reverse order, observing the locking torques. Locking torques (N*m) Rear wheel nut 104 to 126 (76.7 to 92.9 lb*ft) Rear wheel to hub fixing screws 20 to 25 (14.7 to 18.4 lb*ft) CAUTION...
Page 250 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions Swing-arm SWINGING ARM REMOVAL Set the vehicle on its centre stand and support the engine adequately. To remove the rear pin, undo the nut on the right side of the vehicle. Remove the pin, sliding it out from the left side of the vehicle.
Page 251: Shock Absorbers
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions Swingarm - Frame Swinging arm front 40 - 45 Nm pin - Frame 50 - 55 Nm Position the engine. Position the rear pin, inserting it from the left side of the vehicle. Insert and tighten the fixing nut Locking torques (N*m) Swinging arm rear pin - Engine...
Page 252: Centre-Stand
Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions Centre-stand REMOVAL Remove the two return springs from the centre stand. - Undo the nut shown in the figure. - Remove the pin from the right side. - Remove the centre stand. CAUTION SUPPORT THE VEHICLE ADEQUATELY.
Page 253 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - After the vehicle is perfectly placed, the clearance can be checked in the correct position, as shown in the image on the side. - With the support extended, measure the availa- ble travel to the ends, with the gauge against the vertical axis.
Page 254 Liberty 50 i.e. 4T 3V i-get E3-E4 Suspensions - If the value of the travel is equal to or lower than 18 mm, the wear of the fulcrum coupling does not require any interventions. - However, remove the pin and lubricate both the pin and the bushing with silicone grease.
Page 255: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 256 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system Front brake calliper Removal - Remove the two brake calliper fixing screws to the fork. Refitting Tighten the screws to the prescribed torque. Locking torques (N*m) Screws fastening front brake calliper 19.6 - 24.5 Front brake disc Removal - Remove the front wheel.
Page 257: Disc Inspection
Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system - Remove the disc fixing screws. Refitting Carry out the operations in the reverse order, observing the prescribed tightening torques. Recommended products Loctite 243 Medium strength thread-locking sealant. Blue Locking torques (N*m) Disc tightening screw (Apply LOCTITE 243 medium-strength threadlock) 8 - 10 Nm Front wheel axle 44 ÷...
Page 258: Front Brake Pads
Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system - Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted prop- erly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm. - If a value other than that prescribed is detected, remove the front wheel and check how much the disc protrudes.
Page 259 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system - Remove the pads. Refitting Carry out the operations in the reverse order, observing the prescribed tightening torques. Locking torques (N*m) Brake pad fastening screw 15 - 20 Fill Front - Remove the front handlebar cover - Remove the guard.
Page 260: Brake Fluid Level Check
Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system - Loosen the intake pipe to the modulator by about half a turn. - Move the brake pads apart until liquid pours from the modulator outlet. - Tighten the fitting to the specified torque. DO NOT RELEASE THE BRAKE LEVER UNTIL THE FITTING IS LOCKED IN PLACE.
Page 261 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system DOT 4 brake fluid Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4 Front brake pump Removal - Remove the front handlebar cover. - Remove the stop switch connectors. - Remove the two brake pump fixing screws.
Page 262: Rear Drum Brake
Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system Rear drum brake - Remove the silencer. - Remove the rear wheel hub. - Tilt the clamps to remove them. - Fit the new clamps and refit the rear wheel. - Act on the adjustment screws to adjust the clear- ance, then tighten them to the specified torque.
Page 263 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system FRENO DI STAZIONAMENTO - SMONTAGGIO Rimuovere le N.2 viti posteriori di fissaggio copri manubrio. Rimuovere N.1 vite anteriore di fissaggio copri manubrio. Rimuovere il copri manubrio anteriore. Scollegare i N.2 connettori del proiettore anteriore dal cablaggio principale.
Page 264 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system Rimuovere la vite di fissaggio del terminale man- ubrio sinistro. Rimuovere il terminale manubrio sinistro. Allentare la vite di fissaggio complessivo leva sin- istra al manubrio. Con chiave aperta allentare il controdado di reg- istro freno posteriore.
Page 265 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system Agire sul registro freno posteriore in modo da ri- durre al minimo la tensione del cavo. Estrarre la vite fissaggio complessivo leva sinistra. Svincolare il barilotto della trasmissione freno pos- teriore dalla propria sede. Liberare la trasmissione.
Page 266 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system Scollegare i N. 2 terminali dell'interruttore Stop. Rimuovere la manopola sinistra. Rimuovere la botticella dal foro del gruppo leva freno. Sfilare il gruppo leva freno sinistro dal manubrio. BRAK SYS - 266...
Page 267 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system FRENO DI STAZIONAMENTO - MONTAGGIO WARNING ATTENZIONE: VERIFICARE CHE LA TRASMISSIONE FRE- NO NON SIA FUORIUSCITA DALLA PROPRIA SEDE PRI- MA DI PROCEDERE AL RIMONTAGGIO DI UN NUOVO GRUPPO LEVA FRENO. Nuovo gruppo leva freno sinistro.
Page 268 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system Avvitare la vite di fissaggio nella stessa sede. Connettere i due terminali del cablaggio all'inter- ruttore Stop. Inserire la manopola sul manubrio. Inserire il terminale e bloccare con l'apposita vite. BRAK SYS - 268...
Page 269 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system Reinserire i due connettori del cablaggio al proiet- tore. Assemblare il copri manubrio anteriore e fissare con le N. 3 viti. Registrazione trasmissione freno posteriore. Allentare controdado e far girare la ruota posteri- ore, agire sul registro fino a percepire una leggera resistenza della ruota alla rotazione.
Page 270 Liberty 50 i.e. 4T 3V i-get E3-E4 Braking system Bloccare il controdado a completamento della pro- cedura di registrazione. BRAK SYS - 270...
Page 271 INDEX OF TOPICS CHAS HASSIS...
Page 272 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis Seat - Remove the chassis central cover. - Remove the pin lock. - Remove the pin and remove the saddle. Side fairings FRONT BUMPERS - Insert the lever into its slot and remove the bump- REAR BUMPERS - Insert the lever into its slot and remove the bump- CHAS - 272...
Page 273 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis Rear rack - Insert a lever into its slot and remove the plastic cover. - Unscrew and remove the fastening screw be- neath the plastic cover. - Unscrew and remove the fixing screws. CAUTION THE FOLLOWING INFORMATION IS RELATIVE TO THE DELIVERY THE VERSION.
Page 274 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis Locking torques (N*m) Rear luggage rack - Chassis (middle locks) Rear luggage rack - Chassis to 25 (11.8 to 18.4 lb*ft) (side locks) 15 to 20 (11.1 to 14.8 lb*ft) ANTERIORE • Rimuovere le due fascette, sfilare la copertura in gomma e scollegare i con- nettori del gruppo ottico.
Page 275: Instrument Panel
Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis Rear handlebar cover - Remove the front handlebar cover. - Undo and remove the fixing screws of the rear handlebar cover. - Disconnect the instrument assembly connector. Instrument panel - Remove the instrument assembly fixing screws. CHAS - 275...
Page 276 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis Front handlebar cover - Undo the screw on the front part. - Unscrew the rear screws. - Remove the handlebar cover. Headlight assy. - Remove the connector. CHAS - 276...
Page 277 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the rubber protection. - Remove the plastic retainer. - Remove the bulb. Frame central cover - Open the seat. - Unscrew and remove the fixing screws. CHAS - 277...
Page 278 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Unscrew and remove the fixing screws. - Remove the cover. Legshield - Remove the leg shield back plate. - Remove the footrest. - Remove the front mudguard. - Undo and remove the screw located under the badge.
Page 279 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the fixing screws to the spoilers. - Remove the shield fixing screws. - Remove the supporting bracket of the saddle opening mechanism. - Remove the guard. Knee-guard - Remove the central cover. - Remove the front side bumpers.
Page 280 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the screws under the side bumpers. - Remove screw located in the storage compart- ment. - Remove the screws on the top part of the leg shield back plate. - Remove the screws on the side under the foot- board.
Page 281 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the central screw located under the foot- rest. - Move the leg shield back plate away and remove the cable of the saddle opening lever in the storage compartment. Removing the ignition key-switch when on *off* - Remove the ignition switch contact retainer.
Page 282 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the lock retainer. Taillight assy. - Remove the luggage compartment plastic pro- tection. - Remove the rear side bumper protections. - Remove the screw below the luggage rack. - Remove the screws under the rear side bumpers. - Remove the light assembly to reach the bulbs.
Page 283 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Turn the central bulb holder to remove the stop light. - Turn bulb to remove it from its holder. - Remove the side rubber bulb holders to remove the DRL bulbs. - Remove the daytime running lights bulbs.
Page 284 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Turn the side bulb holders to remove the turn light bulbs. - Turn bulb to remove it from its holder. Footrest - Remove the chassis central cover. - Remove the passenger footrests. - Remove the front screws.
Page 285 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the screws located below the passenger footrests. - Remove the screws on the front part of the foot- board. - Remove the footrest. Side fairings - Remove the helmet compartment. - Remove the luggage rack.
Page 286 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the rear fastening screw - Remove the fairings. License plate holder - Remove the rear light assembly. - Remove the screws located beneath rear light assembly. - Remove the screws located beneath rear light assembly.
Page 287: Rear Mudguard
Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis Air filter - Remove the fixing screws of the air filter. Rear mudguard - Remove the mudguard to air filter fixing screws. - Remove the mudguard to crankcase fixing screw. Helmet bay Remove the fixing screw of the helmet compart- ment to the frame.
Page 288 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the fixing screw of the helmet compart- ment to the middle cover of the frame. - Remove the helmet compartment. spoiler - Remove the footrest. - Remove the spoiler to shield fixing screws. - Remove the fixing screws of the spoiler to the frame.
Page 289 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis Fuel tank - Remove the side fairings. - Disconnect the fuel pipe. - Disconnect the fuel pipe connector. - Disconnect the fuel level indicator connector. - Remove the fixing screws. CHAS - 289...
Page 290: Front Mudguard
Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis - Remove the front fastening screw. Front mudguard - Remove the front wheel WARNING PROPERLY SUPPORT THE VEHICLE SO AS TO ALLOW STEERING TUBE TO EXIT THE PIPE. - Remove the mudguard fixing screws. Top-case Rear CAUTION...
Page 291 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis • Aprire il bauletto e svitare le quattro viti sul fondo per rimuoverlo. Flyscreen CAUTION THE FOLLOWING INFORMATION IS RELATIVE TO THE DELIVERY THE VERSION. • Svitare le quattro viti recuperando i tap- pi e rimuovere il parabrezza.
Page 292 Liberty 50 i.e. 4T 3V i-get E3-E4 Chassis Battery - Remove the battery compartment cover fixing screws to access the battery. CHAS - 292...
Page 293 Air filter: 50, 287 Battery: 58, 66, 71, 87, 88, 292 Brake: 256, 258, 260–262 Brake fluid: 260 Bulbs: Checks: 71 Engine oil: 50 Fuel: 208, 220, 289 Fuses: 80 Headlight: 54, 276 Horn: 76 Hub oil: 47 Identification: 13 Instrument panel: 275 Maintenance: 13, 43 Mirrors: 274...
Page 294 Turn indicators: 69 Tyre pressure: Tyres: 20 Vehicle: 9, 13, 15, 117, 118...

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