VESPA ET4 50 Workshop Manual
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VESPA ET4 50 Workshop Manual

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WORKSHOP MANUAL
633367
ET4 50

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  • Page 1 WORKSHOP MANUAL 633367 ET4 50...
  • Page 2 WORKSHOP MANUAL ET4 50 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 WORKSHOP MANUAL ET4 50 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    ET4 50 Characteristics Rules Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

  • Page 8: Vehicle Identification

    ET4 50 Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Frame prefix ZAPC2610000001001 Engine prefix C261M Dimensions and mass DIMENSIONS AND MASS Specification Desc./Quantity Total unloaded kerb weight 105 Kg Width 710 mm Length 1780 mm Wheelbase 1275 mm Height 1090 mm...

  • Page 9: Electrical System

    ET4 50 Characteristics Engine ENGINE Specification Desc./Quantity Type single-cylinder, four-stroke Bore 39 mm Stroke 41,8 mm Cubic capacity 49.93 cm³ Compression ratio 11,5 ÷ 12 : 1 Timing system single overhead camshaft, driven by a chain to the left side.

  • Page 10: Wheels And Tyres

    ET4 50 Characteristics Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Type Unitised body made of stamped plate Front suspension Single arm suspension with swinging arm articulated to the steering tube. Hydraulic double-acting shock absorber and co- axial spring Front suspension stroke...

  • Page 11: Tightening Torques

    ET4 50 Characteristics Specification Desc./Quantity Fuel inlet hole Ø 1,2 mm Starter piston protrusion 11 mm at 24°C Tightening Torques STEERING ASSEMBLY Name Torque in Nm Upper steering ring nut 30 ÷ 40 Lower steering ring nut 8 ÷ 10 Handlebar fastening 45 ÷...

  • Page 12: Assembly Clearances

    ET4 50 Characteristics Name Torque in Nm Oil decantation labyrinth sheet screws 7 ÷ 8 Oil pump crown screw 8 ÷ 10 Screws fixing oil pump to crankcase 5 - 6 Oil sump screws 8 ÷ 10 Nm Inlet manifold screw 7 ÷...
  • Page 13 ET4 50 Characteristics Name Initials Cylinder Piston Play on fitting Piston Ø P (38,968 39,007 ÷ 39,014 38,975 ÷ 38,982 0,025 ÷ 0,039 ±0,014) Cylindre 1st oversize Ø 39,186 ÷ 39,193 39,154 ÷ 39,161 0,025 ÷ 0,039 C (39,2 ±0,014) Cylindre 1st oversize Ø...
  • Page 14 ET4 50 Characteristics Name Description Dimensions Initials Quantity Scraper ring lining 3° 39,6 x 2 0,20 ÷ 0,70 greates Crankcase - crankshaft - connecting rod END PLAY BETWEEN DRIVING SHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission side half 14 +0 -0.005...
  • Page 15 ET4 50 Characteristics N.B. MEASUREMENT «A» IS A PISTON RECESS VALUE The more the piston protrudes out of the plane generated by the top section of the cylinder, the thicker the gasket to be applied (to recover the compression ratio) and vice-versa.
  • Page 16 INDEX OF TOPICS TOOL OOLING...
  • Page 17 ET4 50 Tooling TOOLING Stores code Description 001467Y008 Pliers to extract 17 mm ø bearings 001467Y029 Bell for bearings, O.D. 38 mm 004499Y Bearing extractor. Fitted with: 1 Bell, 2 Sleeve, 3 Screw, 6 Ring, 27 Half rings, 34 Half rings...
  • Page 18 ET4 50 Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020074Y Tool to align crankshaft 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for driven pulley roller bearing 020265Y Bearing fitting base TOOL - 18...
  • Page 19 ET4 50 Tooling Stores code Description 020288Y Fork to assemble piston on cylinder 020291y Valves assembly/disassembly tool 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter TOOL - 19...
  • Page 20 ET4 50 Tooling Stores code Description 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40-mm adaptor TOOL - 20...
  • Page 21 ET4 50 Tooling Stores code Description 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020362Y 12 mm guide 020363Y 20 mm guide 020364Y 25-mm guide 020376Y Adaptor handle TOOL - 21...
  • Page 22 ET4 50 Tooling Stores code Description 020431Y Valve oil seal extractor 020432Y Tool to fit the start-up sector spring 020439Y 17 mm guide 020444Y Test probe removal / fitting tool 020448Y Pin lock fitting tool 020449Y Piston position check support...
  • Page 23 ET4 50 Tooling Stores code Description 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser TOOL - 23...
  • Page 24 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 25: Maintenance Chart

    ET4 50 Maintenance Maintenance chart AT 1000 KM OR 4 MONTHS Action Hub oil - change Valve clearance - check Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear...
  • Page 26 ET4 50 Maintenance * Refer to rules (°) Refer to predelivery operations AT 24000 KM OR 48000 KM 160' Action Engine oil - replacement Hub oil level - replacement Spark plug / electrode gap - check / replacement Air filter - clean...
  • Page 27 ET4 50 Maintenance Action Engine oil - replacement Hub oil level - replacement Spark plug / electrode gap - check / replacement Air filter - clean Oil filter (net filter) - clean Valve clearance - check Idle speed (*) - adjustment...

  • Page 28: Checking The Spark Advance

    ET4 50 Maintenance Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condi- tion. -The throttle valve should move freely in the chamber.

  • Page 29: Spark Plug

    ET4 50 Maintenance RPM LIMITER Specification Desc./Quantity 1 spark out of 7 8200 Revs/min 1 spark out of 3 8300 Revs/min Suppression of all sparks 8500 Revs/min Spark plug -Disconnect the cap and remove the spark plug. -Inspect the plug and if the insulator is chipped or damaged, renew it.

  • Page 30: Air Filter

    ET4 50 Maintenance Champion RG 4 HC Locking torques (N*m) Spark plug 10 ÷ 15 Nm Hub oil Replacement -Remove the oil filler plug. -Unscrew the drain plug (A) shown in the figure and allow the oil to drain out.

  • Page 31: Engine Oil

    ET4 50 Maintenance NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER. Engine oil Replacement -Loosen the oil filler plug. -Unscrew the gauze strainer drain plug on the fly- wheel side and allow the oil to drain completely.
  • Page 32 ET4 50 Maintenance CO check - This check can be required when engine opera- tion is irregular or while adjusting the slow running. - The test must be carried out after carefully wash- ing all carburettor components and making sure that the air filter is clean and the spark plug is in good condition.
  • Page 33 ET4 50 Maintenance 494929Y Exhaust fumes analyser 020331Y Digital multimeter MAIN - 33...
  • Page 34 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 35: Troubleshooting

    ET4 50 Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter clogged or dirty Disassemble, wash sponge with water and shampoo and im- merse in a mixture of 50% petrol and Selenia Air Filter oil. Let it drip. Wring out without squeezing it and then refit...

  • Page 36: Engine Tends To Cut Out At Full Throttle

    ET4 50 Troubleshooting Possible Cause Operation Wrong ignition advance Check flywheel keying on the crankshaft, replace control unit if necessary Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance Starting rpm too low. Starter motor faulty.
  • Page 37 ET4 50 Troubleshooting Possible Cause Operation lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. The starter remains on Check that the starter runs correctly and it is properly powered Loose nozzles Check the maximum and minimum nozzles are adequately...

  • Page 38: Noisy Suspension

    ET4 50 Troubleshooting Battery BATTERY Possible Cause Operation This device requires the most assiduous surveillance and the This device requires the most assiduous surveillance and the most diligent maintenance. most diligent maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged pe- riodically.
  • Page 39 ET4 50 Troubleshooting Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the damper. TROUBL - 39...
  • Page 40 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 41 ET4 50 Electrical system ELECTRICAL EQUIPMENT Specification Desc./Quantity Horn Headlight bulb 12V-35/35W Parking light bulb 12V-5W Key switch Front brake stop button Light switch Turn indicator switch Horn button Light switch Starter button Speedometer with fuel gauge and warning lights - 12V-1.2W reserve fuel warning light bulb, 2 x 12V-2W...
  • Page 42 ET4 50 Electrical system B=White - Bl=Blue - G=Yellow - M=Brown - N=Black - BV=White-Green - GN=Yellow-Black - Gr=Grey - Rs=Pink - R=Red - Vi=Purple - V=Green - VN=Green-Black - BN=White-Black - BBl=White-Blue - GV=Yellow-Green - Ar=Orange - GrBl=Grey-Blue - GrN=Grey-Black - BR=White-Red - RN=Red-Black - BlN=Blue-Black.
  • Page 43 ET4 50 Electrical system Headlights and automatic starter section LIGHTS Specification Desc./Quantity Voltage regulator Main fuse Magneto flywheel Key switch contacts Headlight bulb 12V-35/35W High-beam warning light 12V - 1.2W Parking light bulb 12V- 5W 2 Instrument lighting bulbs 12V- 1,2W...
  • Page 44 ET4 50 Electrical system Battery recharge and starting BATTERY RECHARGE AND STARTING Specification Desc./Quantity Magneto flywheel Starter motor Main fuse Battery 12V - 9Ah Key switch contacts Voltage regulator Electronic ignition device Starter remote control Starter button Front and rear brake light button...
  • Page 45 ET4 50 Electrical system Level indicators and enable signals section SAFETY SWITCHES Specification Desc./Quantity Voltage regulator Fuel gauge Fuel level sending unit Low fuel warning light Front and rear brake light button Horn Horn button Brake light filament 12V-21W ELE SYS - 45...
  • Page 46 ET4 50 Electrical system Turn signal lights TURN SIGNAL LIGHTS Specification Desc./Quantity Turn indicator switch Voltage regulator 4 Turn indicator bulbs 12V-10W Two (2) turn signal warning light bulbs 12V - 2W ELE SYS - 46...
  • Page 47 ET4 50 Electrical system Instruments and warning lights control board WARNING LIGHTS AND GAUGES PANEL Specification Desc./Quantity Left turn indicator warning light 12V - 2W High-beam warning light 12V - 1.2W Fuel Level indicator Instrument panel lighting bulb 12V-1,2W Headlight warning light 12V 1.2W...
  • Page 48 ET4 50 Electrical system If faulty or failed operation persists, conduct the following checks on the generator and on the sta- tor components: After a visual inspection of the electrical connec- tions, it is possible to perform measurements on the stator winding and pick-up (see table), using the specific multimeter.
  • Page 49 ET4 50 Electrical system Voltage regulator check The malfunctioning of the voltage regulator might cause the following problems depending on the type of fault: 1) Bulbs burnt out (regulator in short circuit). 2) The lighting and electrical starter system do not work (regulator interrupted).
  • Page 50 ET4 50 Electrical system As a last test it is possible to check the output volt- age from the stator: -Detach the regulator connector and interpose the tester in AC mode, between the Gray-Blue wire (4) and earth (see figure).
  • Page 51 ET4 50 Electrical system Proceed by measuring the resistance between contacts 3 (White) and 2 (Black) from the voltage regulator (with the connector detached). If the reading differs excessively from the figures shown, replace the regulator as short-circuited. b) Battery not recharging (regulator circuit inter- rupted).
  • Page 52 ET4 50 Electrical system Turn signals system check 4) TURN INDICATORS NOT WORKING If the turn indicators do not work, do the following: - Disconnect the regulator connection and insert the multimeter probes between the white cable (3) and the black one (2).
  • Page 53 ET4 50 Electrical system Sealed battery INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a normal tester. - If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge.
  • Page 54 ET4 50 Electrical system 2)Load status check After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15°...
  • Page 55 ET4 50 Electrical system 3)- Within the following 24 hours, recharge with the specific battery charger (single) or (multiple) at a density of about 1/10 of the battery nominal capacity and until the acid density is about 1.27, corre- sponding to 31º Bé, and these values are stabilised.
  • Page 56 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 57 ET4 50 Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Unscrew the 2 screws fixing the muffler to the housing; then remove the whole muffler paying at- tention to the interference between its supporting bracket and the cooling cover.
  • Page 58 INDEX OF TOPICS NGINE...

  • Page 59: Automatic Transmission

    ET4 50 Engine Automatic transmission Transmission cover - Remove the 12 fixing screws. - Remove the oil filling cap and then slide out the cover. If this operation is carried out directly on the vehi- cle, it is necessary to remove the transmission cooling coupling and the air filter housing retain- ers.

  • Page 60: Removing The Driven Pulley

    ET4 50 Engine Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

  • Page 61: Inspecting The Clutch Drum

    ET4 50 Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the inner diameter of the clutch bell. Characteristic Clutch bell diameter/standard value Ø 107+0.2 +0 mm Clutch bell diameter/max. value allowed after Ø...
  • Page 62 ET4 50 Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL CONTACT SURFACE AND MUST NOT BE DIFFER- ENT FROM ONE ANOTHER.
  • Page 63 ET4 50 Engine Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
  • Page 64 ET4 50 Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings. - Measure the inside diameter of the mobile half- pulley bushing. Characteristic Mobile driven half-pulley/ Maximum diameter allowed Ø 34.08 mm - Check the belt contact surfaces.
  • Page 65 ET4 50 Engine 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation...

  • Page 66: Refitting The Driven Pulley

    ET4 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 67: Removing The Driving Pulley

    ET4 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, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.
  • Page 68 ET4 50 Engine 20.12 mm Driving pulley/ Standard diameter: 20.021 mm Driving pulley bushing/ Diameter maximum: XXX mm Driving pulley bushing/ Standard diameter: 20 -0.020/-0.041mm Refitting the driving pulley - Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.
  • Page 69 ET4 50 Engine Refitting the transmission cover - Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and it seating in the crankcase and the return spring. - Remove the damaged components. - Grease the spring.
  • Page 70 ET4 50 Engine Removing the hub cover - Drain the rear hub oil - Remove driven pulley - Remove the rear brake shoes - Remove the 5 screws fixing the cover to the crankcase - Remove the cover with the wheel axle and pull it...
  • Page 71 ET4 50 Engine Removing the driven pulley shaft bearing - Remove the seeger ring - Heat the engine crankcase but do not direct the hot air towards the bearing - Extract the driven pulley shaft together with the bearing with a few mallet blows...
  • Page 72 ET4 50 Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents. - Check capacity ( A ) of the transmission gear (wear, deformations, etc.)
  • Page 73 ET4 50 Engine 020363Y 20 mm guide 020359Y 42x47-mm adaptor Refitting the hub bearings - Remove the wheel axle on the cover and pay at- tention not to damage the sealing lip of the oil seal - Apply a thin layer of grease on the two shim...
  • Page 74 ET4 50 Engine Gasket Locking torques (N*m) hub cap screws 24 - 26 Flywheel cover Cooling hood - Remove the manifold and the carburettor undo- ing the 2 fixing screws on the head - Remove the fastening clamp of the secondary air...

  • Page 75: Removing The Stator

    ET4 50 Engine Cooling fan - Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.
  • Page 76 ET4 50 Engine Removing the starter motor - Unscrew the screw on the power positive contact and disconnect the cable - Unscrew the 2 screws fixing the starter motor to the crankcase and recover the power wiring. Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner.
  • Page 77 ET4 50 Engine Inspecting the flywheel components - Check that the flywheel internal magnets are in good conditions. - Check that the flywheel riveted joints are correctly tightened. - Check there are no deformations that may cause rubbing on the stator and the Pick-Up.
  • Page 78 ET4 50 Engine Refitting the flywheel magneto - Refit the stator and the pick-up being careful to pass the wiring through the appropriate crankcase couplings. - Refit the flywheel to the crankshaft being careful to respect the keying, then lock rotation with the specific tool and tighten the nut to the prescribed torque.
  • Page 79 ET4 50 Engine Removing the timing system drive - Temporarily loosen the tensioner central screw and remove it together with the spring. - Unscrew the 2 retainers indicated in the figure and remove the chain tightener support being careful to recover the sealing gasket.
  • Page 80 ET4 50 Engine Removing the cam shaft - Remove the bearing clamping screw indicated in the figure. - Remove the entire camshaft with bearing using the specific tool shown in the figure. - Take out the camshaft bearing with the aid of the specific tool, being careful to mount a screw on the camshaft in order to protect its thread.

  • Page 81: Removing The Cylinder Head

    ET4 50 Engine Removing the cylinder head - Remove the cooling covers, the timing control, the camshaft and the rocking levers. - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion.

  • Page 82: Inspecting The Small End

    ET4 50 Engine Removing the cylinder - piston assy. - Remove the cylinder paying attention to the 2 cylinder centring dowels in the housing. - Remove the cylinder base gasket. To avoid damaging the piston, keep it fixed while removing the cylinder.

  • Page 83: Inspecting The Piston

    ET4 50 Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. Characteristic Standard diameter gudgeon pin 13 -0-0.004mm Minimum admissible diameter pin 12.990 mm Inspecting the piston - Calculate the piston pin coupling clearance. Fitting clearance Pin coupling clearance 13 +0.010+0.005mm 0.005 ÷...
  • Page 84 ET4 50 Engine Inspecting the cylinder - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen.

  • Page 85: Removing The Piston

    ET4 50 Engine N.B. BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
  • Page 86 ET4 50 Engine Choosing the gasket This engine is manufactured with two different head gasket solutions: - Fibre gasket drw. 969244 0.95 mm thick. - Steel gasket drw. 969393 0.3 mm thick. In order to guarantee an adequate compression ratio, the gaskets match cylinders with different heights: - Fibre gaskets with cylinder 56.45 mm high...
  • Page 87 ET4 50 Engine N.B. MEASUREMENT "A" TO BE TAKEN IS A VALUE OF PISTON RE-ENTRY, IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER. THE FURTHER THE PISTON GETS INSIDE THE CYLINDER, THE THINNER THE HEAD GASKET TO BE APPLIED SHOULD BE (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA.
  • Page 88 ET4 50 Engine Refitting the piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter. Using the piston, insert the rings perpen- dicularly to the cylinder axis. - Measure the opening, see figure, of the sealing rings using a thickness gauge.
  • Page 89 ET4 50 Engine - 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 90: Inspecting The Cylinder Head

    ET4 50 Engine The procedure is different from that indicated in the vehicle manuals: Head nuts tightening (only for stud bolts replacement) 6÷7 N*m +90° + 90° + 90° The 45° rotation reduction of the key is necessary to avoid stud bolt stretching.
  • Page 91 ET4 50 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 assembly. Inspecting the valve sealings - Measure the width of the sealing surface on the valve seats.
  • Page 92 ET4 50 Engine 5 +0+0.012mm Intake guide: Wear limit 5.022 mm - If the width of the impression on the valve seat or the diameter of the valve guide exceed the specified limits, replace the cylinder head. - Check width of the impression on the valve seat «V»...
  • Page 93 ET4 50 Engine grinding, keep the cylinder head in a horizontal position. This will prevent the lapping compound resi- dues from penetrating between the valve stem/guide coupling. CAUTION TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT.
  • Page 94 ET4 50 Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. Characteristic Standard diameter - Bearing A: Ø 12 +0.002 +0.010 Standard diameter - Bearing B: Ø 16-0.015 -0.023 mm Minimum diameter allowed - Bearing A: Ø...
  • Page 95 ET4 50 Engine Minimum admissible diameter Ø 10.970 mm Maximum diameter allowed: Ø 11.030 mm Refitting the head and timing system components - Fix the head on a workbench. - Screw the tool to fit the camshaft fully down on the bearing's inner track.
  • Page 96 ET4 50 Engine - Finish the head tightening following the proce- dure below: screw the four head nuts to an initial torque at two crossed passes. Afterwards tighten the nuts with 2 turns of 90° each to be done at two crossed passes.
  • Page 97 ET4 50 Engine - Bring the screw closer but without reaching its final locking point. - Push the tensioner pad lightly so as to check the correct timing. - Use the specific tool to lock the camshaft crown gear and tighten the screw.
  • Page 98 ET4 50 Engine Refitting the rocker-arms cover - Carry out the removal procedure but in reverse order and tighten the four fixing screws to the specified torque. N.B. FIT A NEW O-RING ON THE TAPPET COVER. Locking torques (N*m) Timing chain tensioner screws 8 ÷...
  • Page 99 ET4 50 Engine Splitting the crankcase halves - Remove the ten crankshaft coupling screws. -Separate the crankcase halves keeping the half casing driving shaft engaged on the transmission side. - Remove the crankshaft. CAUTION IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC- CIDENTALLY FALL.
  • Page 100 ET4 50 Engine - Check that the half shaft surfaces are not scored and with the aid of a gauge check the driving shaft width as indicated in the figure. Characteristic Standard measure 45 mm Removing the crankshaft bearings - Remove the flywheel bearing fitted on the driving shaft using the specific tool.
  • Page 101 ET4 50 Engine - Support the crankcase on a surface and place it with the driving shaft axle in a vertical position. - Warm the crankcase at ~ 120° C with a thermal gun (and support). - Fit the punch with guide and adaptor, place the bearing on the punch using grease (to keep it from falling).
  • Page 102 ET4 50 Engine 020074Y Support base for checking crankshaft alignment Refitting the crankcase halves -Be careful to place the two centring dowels pref- erably on the flywheel side half casing. -Insert the crankshaft on the half casing on the transmission side.
  • Page 103 ET4 50 Engine 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. - Any operation on the chain cover oil seal should be carried out placing the cover on the workbench on the covering plate side of the oil pump chain.

  • Page 104: Oil Pump

    ET4 50 Engine - Fit a new oil seal on the outer rim with the help of the specific tools below. - Fit a new O-ring and lubricate it with grease. - Install the cover on the engine crankcase, insert the three screws and place the cover in its position.
  • Page 105 ET4 50 Engine - Remove the central screw and the belleville washer - Remove the chain with the crown gear. - Remove the pinion of the crankshaft control. - Remove the oil pump by undoing the 2 screws indicated in the figure.
  • Page 106 ET4 50 Engine - Check the axial clearance of the rotors using a trued bar as reference as shown in the figure. N.B. MAKE SURE THE TRUED BAR IS POSITIONED PROPERLY ON THE TWO POINTS ON THE PUMP BODY. Characteristic Admissible maximum clearance 3 0.09 mm...

  • Page 107: Fuel Supply

    ET4 50 Engine Removing the oil sump - Remove the oil filling cap, the transmission cover, the complete driving pulley assembly with belt and pinion. - Unscrew the oil drainage cap «A» shown in the figure and drain out all the oil from the sump.

  • Page 108: Removing The Carburettor

    ET4 50 Engine - Take up the fuel by means of a graded burette. N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR- RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE.. IN THIS CASE, THE TENDENCY IS TO OB- TAIN A REDUCED FUEL FLOW RATE.
  • Page 109 ET4 50 Engine - Remove the protection, the bracket and the start- er undoing the screw shown in the figure. CAUTION THE CARBURETTOR FEATURES AN ANTIVIBRATION RUBBER BUFFER FITTED ON THE LOWER SUPPLEMENT OF THE ACCELERATING PUMP BODY. UPON REFITTING...
  • Page 110 ET4 50 Engine - Remove the cover being careful with the spring below, then remove the spring, take out the rubber protection and the diaphragm together with the pipe O-Ring. -Remove the accelerating pump jet together with the ball spring.
  • Page 111 ET4 50 Engine - Remove the sprayer tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM- AGE IT.
  • Page 112 ET4 50 Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with a degreasing solvent and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For the minimum circuit, make sure the following...
  • Page 113 ET4 50 Engine - Wash and blow the minimum nozzle properly and reassemble it. - Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindric part directed to the diffuser.
  • Page 114 ET4 50 Engine - Check the diaphragm is in good conditions and remove the remaining components of the acceler- ating pump following these steps: - Insert the O-Ring in the pipe. - Insert the diaphragm together with the pin and its spring.
  • Page 115 ET4 50 Engine - Insert the diaphragm into the throttle valve. - Insert the tapered pin together with the plastic support and the contrast spring into the throttle valve. N.B. PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH FACING THE INNER SIDE OF THE MEMBRANE TO BE ABLE TO FIT THE LOWER END OF THE THROTTLE VALVE SPRING.
  • Page 116 ET4 50 Engine - The starter should disconnect progressively by means of electrical heating. - Check the starter resistance when adjusted to the ambient temperature. Characteristic ambient temperature 24° C Electric characteristic Automatic starter resistance 6 Ω ± 5 % - Use battery to power the automatic starter and check that piston protrudes as much as possible.
  • Page 117 ET4 50 Engine - Insert rubber pipes for tank ventilation. - Insert the O-Ring, the washer, the spring and the idle flow screw in their seatings. - Refit the carburettor on the engine and connect again the accelerator cable with the sheath and the support plate and the electrical connection of the starter.
  • Page 118 ET4 50 Engine 40 ÷ 50 cm - Connect the tester thermometer to the sump, us- ing a cover with oil expressly prepared for probes. - Start the engine and before adjusting the idle speed, make sure that the oil temperature is be- tween 70÷80 °C.
  • Page 119 ET4 50 Engine loss of engine blows as the mixture is too lean (low CO), ignition failure or, incorrect timing or a clogged or unsealed exhaust valve. If it is difficult to adjust CO values, check accurately: - That the automatic starter is efficient.
  • Page 120 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 121: Removing The Front Wheel

    ET4 50 Suspensions Front Removing the front wheel - Remove the five Allen screws that fix the wheel to the hub. N.B. BEFORE REMOVING THE WHEEL HUB, REMOVE THE BRAKE CALLIPER. Front wheel hub overhaul -Remove the needle bearing by driving it out from the ball bearing side using a suitable drift.
  • Page 122 ET4 50 Suspensions -Loosen the central nut (see figure) to remove the hub. - Remove the brake calliper by removing the two screws. - Remove the split pin and the nut cap. WARNING -ALWAYS USE NEW SPLIT PINS FOR REFITTING.

  • Page 123: Front Fork

    ET4 50 Suspensions Handlebar Removal Remove the handlebar cover before carrying out this operation,. - After removing the transmissions and discon- necting the electrical terminals, remove the termi- nal fixing the handlebar to the steering. - Check all components and replace faulty parts.
  • Page 124 ET4 50 Suspensions - Use the specific tool, fitted with part 1*, and op- erate the handgrip until the pin and the Nadella are simultaneously ejected in the direction opposite the tool thrusting force. - To eject the second Nadella, use the tool fitted with part 2* instead of part 1, on the side opposite the one shown in the figure.
  • Page 125 ET4 50 Suspensions - Push, from the handgrip, the wedging washer - roller casing - seal ring unit, placing part 16 until it stops on the swinging hub - Repeat the operation described above using the tool fitted with part 16 and part 22* instead of part...
  • Page 126 ET4 50 Suspensions - Use the tool fitted with part 20* and part 21* on its stem as shown in the figure. - Push the two roller casings with the handgrip until their bottoms make contact with the pin end.

  • Page 127: Steering Column

    ET4 50 Suspensions Steering column Removal - Use the specific tool both to remove the lower seat of the upper bearing and to remove the upper seat of the lower bearing fitted on the chassis. N.B. TO REMOVE THE LOWER SEAT OF THE LOWER STEER- ING BEARING JUST USE A SCREWDRIVER AS A LEVER BETWEEN THE SEATING AND THE SLEEVE.
  • Page 128 ET4 50 Suspensions Refitting - Refit the parts in reverse order of the removal operation. CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK, LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y Punch 020037Y Punch...

  • Page 129: Removing The Rear Wheel

    ET4 50 Suspensions Refitting Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Tightening torque 30 ÷ 40 Rear Removing the rear wheel -Straighten the split pin and remove the cap. -Remove the wheel acting on the central fixing point.
  • Page 130 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 131 ET4 50 Braking system 1. Tank cover. 2 - Pump body. 3 - Brake lever. 4 - Pump plunger. 5- Oil delivery hose. 6 - Protection cap for air bleed screw. 7- Calliper. 8- Dust guard 9- Piston sealing ring.
  • Page 132 ET4 50 Braking system - Check that the cylinders of the internal and external body of the calliper do not show scratches or signs of erosion; otherwise, replace the entire calliper. CAUTION ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED.

  • Page 133: Front Brake Disc

    ET4 50 Braking system Refitting -Perform the disassembly steps in reverse order. -Fit a new O-ring. -Torque the two screws to the prescribed value. - Fit the spacer and O-ring on the wheel spindle. Locking torques (N*m) Tightening torque 20 ÷ 25...

  • Page 134: Front Brake Pads

    ET4 50 Braking system Front brake pads Removal - Pads must be replaced when the friction material thickness reaches the wear limit. - To replace: remove the protection cover, the bolt and the leaf spring. Slide off the pads and replace them once the plungers are down.

  • Page 135: Rear Drum Brake

    ET4 50 Braking system THE SEALING RINGS MUST BE IMMERSED IN THE OPER- ATING LIQUID. Refitting Before fitting, the parts must be perfectly clean and free of traces of oil, diesel fuel, grease, etc.. They should be washed thoroughly in denatured alcohol before proceeding.
  • Page 136 INDEX OF TOPICS CHAS HASSIS...

  • Page 137: Rear Rack

    ET4 50 Chassis - Remove the screw and disconnect the electric terminals. Rear rack - Tip up the saddle. - Remove the helmet compartment. - Remove the plastic fairing under the saddle after unscrewing the three screws shown in the figure.

  • Page 138: Instrument Panel

    ET4 50 Chassis Rear handlebar cover Undo the screws as shown in the figure and re- move the handlebar rear section. Instrument panel Loosen the two screws and disconnect the termi- nal block. - Remove the rubber hood and then the retaining clip as shown in the figure.
  • Page 139 ET4 50 Chassis Front handlebar cover -Remove the handlebar front fairing as shown in the figure. - To remove the handlebars, use 2 spanners (17-13 mm) as shown in the figure after detaching the LH and RH controls. Locking torques (N*m) Handlebar lock nut 45 ÷...
  • Page 140 ET4 50 Chassis The bulbs have a bayonet fitting. Simply rotate them1/4 of a turn to extract and replace them. Legshield - To replace the grille, first remove the Piaggio emblem and then the screw located underneath Footrest - Operate on the 3 screws shown in the figure once the glove-box and fairing have been removed.
  • Page 141 ET4 50 Chassis Side fairings -Remove the screws under the footboard mat, then remove the two side fairings, by disengaging the interlocking elements. License plate holder - Unscrew the 2 side screws and the 2 nuts at the back of the splash guard.

  • Page 142: Front Mudguard

    ET4 50 Chassis Front mudguard - Unscrew the screw as shown in the figure and remove the plastic fairing. Top-case Front - Press the spring clip with a screwdriver and with- draw the switch lock. To remove the part of the lock that is left inside the steering tube, you must first disassemble the steering tube.
  • Page 143 ET4 50 Chassis - Unscrew the 2 screws shown in the figure placed under the front grille. - Remove the 3 screws shown in the figure, placed inside the glove-box; they can be reached after opening the glove-box door. CHAS - 143...
  • Page 144 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 145 ET4 50 Pre-delivery Aesthetic inspection - Paintwork - Joins between plastic fairings - Damage - Cleanness Tightening torques inspection Fastenings check - All tightening torques - External fairing screws SAFETY LOCKS Name Torque in Nm Handlebar tightening 40 ÷ 50 Lower steering ring nut 8 ÷...
  • Page 146 ET4 50 Pre-delivery WARNING KEEP THE BATTERY WELL CLEAR OF NAKED FLAMES AND SPARKS DURING CHARGING. REMOVE THE BATTERY FROM THE VEHICLE BY DISCONNECTING THE NEGATIVE LEAD FIRST. PROTECT THE EYES WHEN WORKING WITH BATTERIES OR IN THEIR IMMEDIATE VICINITY.
  • Page 147 ET4 50 Pre-delivery CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. WARNING BE VERY CAREFUL WHEN HANDLING FUEL. PRE DE - 147...
  • Page 148 INDEX OF TOPICS TIME...
  • Page 149 ET4 50 Time Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit. 001127 Engine - Complete service 003064 Engine oil - Change 003057 Engine retainer - Tighten nuts TIME - 149...
  • Page 150 ET4 50 Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - replace Crankshaft TIME - 150...
  • Page 151 ET4 50 Time CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001099 Oil seal, flywheel side - Replacement 001100 Oil seal, clutch side - Replacement 001118 Main bearings - Replacement Cylinder assy. CYLINDER ASSY. Code Action Duration 001002 Cylinder piston - Replacement Cylinder head assy.
  • Page 152 ET4 50 Time HEAD Code Action Duration 001056 Head gasket - change 001045 Valves - Replacement 001079 Head parts - Disassembly / assembly 001126 Head - Replacement 001049 Valves - Adjustments Rocker arms support assy. CAMSHAFT SUPPORT Code Action Duration...

  • Page 153: Cylinder Head Cover

    ET4 50 Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001088 Head cover gasket - change 001097 Cooling hood - Replacement 001089 Head cover - change TIME - 153...

  • Page 154: Driven Pulley

    ET4 50 Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001110 Driven pulley- Replacement 001012 Driven pulley - Overhaul 003065 Gear casing oil - Replacement 001022 Clutch - Replacement 003072 Clutch assembly - Wear check 001156 Reduction gearing cover - Replace-...
  • Page 155 ET4 50 Time Oil pump OIL PUMP Code Action Duration 001051 Belt/Timing chain - change 001112 Oil pump - change 001042 Oil pump - overhaul 001121 Chain cover oil seal - Replacement 001122 Oil pump chain - change 001125 Chain guide pads - change...
  • Page 156 ET4 50 Time Final gear assy. REDUCTION GEAR Code Action Duration 001010 Gear reduction unit - Inspection 004125 Rear wheel axle - Replacement TIME - 156...
  • Page 157 ET4 50 Time Driving pulley DRIVING PULLEY Code Action Duration 001006 Driving pulley - Overhaul 001086 Driving half-pulley - replace 001066 Driving pulley - Removal and refitting 001011 rear-view belt - Replacement TIME - 157...

  • Page 158: Transmission Cover

    ET4 50 Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - re- place 001132 Transmission air intake pipe - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement TIME - 158...

  • Page 159: Starter Motor

    ET4 50 Time Starter motor STARTER MOTOR - START UP LEVER Code Action Duration 001020 Starter motor - change 001017 Starter sprocket wheel - replace 005045 Starter motor with cables unit - Re- plac. 001084 Starter lever - Replacement 008008...

  • Page 160: Flywheel Magneto

    ET4 50 Time Flywheel magneto FLYWHEEL FAN Code Action Duration 001067 Stator - Fitting and Refitting 001058 Flywheel - Replacement 001102 Net oil filter - change / Cleaning 001109 Cooling fan - Replacement 001087 Flywheel cover - Replacement TIME - 160...

  • Page 161: Fuel Tank

    ET4 50 Time Carburettor FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 004110 Fuel tank hose - Replacement 005010 Tank float - Replacement 004007 Fuel valve - Replacement 004109 Fuel tank breather - Replacement TIME - 161...
  • Page 162 ET4 50 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement TIME - 162...

  • Page 163: Air Cleaner

    ET4 50 Time Air cleaner AIR FILTER Code Action Duration 001014 Air filter - Replacement /Cleaning 001015 Air filter box - Replacement TIME - 163...
  • Page 164 ET4 50 Time Frame FRAME Code Action Duration 004001 Frame - replace 004023 Shield rim - Replacement 004012 Rear fairings - Removal and refitting 004059 Spark plug inspection flap - Replace- ment 006001 Frame - Painting 006032 Door - Painting...
  • Page 165 ET4 50 Time Centre-stand STAND Code Action Duration 004004 Stand - Replacement 001053 Stand bolt - Replacement 001072 Swinging arm - Engine-chassis con- nection - Replacement TIME - 165...
  • Page 166 ET4 50 Time Rear cover GLOVE COMPARTMENT Code Action Duration 004081 Glove box door - Replacement 004083 Glove box - Replacement Plate holder TIME - 166...
  • Page 167 ET4 50 Time NUMBER PLATE HOLDER Code Action Duration 005032 Licence plate light glass - Replace- ment 005031 Licence plate light bulb - Replace- ment 005048 Licence plate holder - Replacement Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement...
  • Page 168 ET4 50 Time Rear shock-absorber FRONT SHOCK ABSORBER COVER Code Action Duration 003011 Front shock absorber - Removal and Refitting 003044 Shock absorber cover - Replace- ment 006038 Shock absorber cover - Painting TIME - 168...
  • Page 169 ET4 50 Time REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting Steering column bearings TIME - 169...

  • Page 170: Handlebar Covers

    ET4 50 Time STEERING COLUMN BEARINGS Code Action Duration 003002 Steering fifth wheel - Replacement 003073 Steering clearance - Adjustment Handlebar covers ODOMETER - HANDLEBAR COVERS Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace-...
  • Page 171 ET4 50 Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 003001 Handlebar - Removal and refitting 004066 Driving mirror - Replacement 003075 Handlebar left control - Replacement...
  • Page 172 ET4 50 Time HANDLEBAR COMPONENTS Code Action Duration 002037 Brake or clutch lever - Replacement 002059 Right hand grip - Replacement 003067 Front brake fluid - Renewal 003074 Handlebar right control - Replace- ment 002047 Front brake fluid and air bleeding...

  • Page 173: Turn Signal Lights

    ET4 50 Time Turn signal lights REAR RED LAMP Code Action Duration 005066 Rear light bulbs - Replacement 005028 Rear light assembly glass - Replace- ment 005068 Rear turn indicator bulb - Replace- ment 005005 Taillight - Replacement 005022 Rear turn indicators - Replacement...

  • Page 174: Rear Wheel

    ET4 50 Time Grease tone wheel or drive Please take note that the code has been in- troduced: 900001 - Tone wheel / drive greasing - 15'. Never mistake the co- des 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated components.
  • Page 175 ET4 50 Time Code Action Duration 003063 Tyre pressure - Check 006018 Wheel rim - Paintwork Electric devices HEADLIGHT Code Action Duration 005008 Front headlamp bulbs - Replacement 005002 Front headlamp - Replacement 005012 Front turn indicator - Replacement 005067...

  • Page 176: Electrical Devices

    ET4 50 Time ELECTRICAL DEVICES Code Action Duration 001069 HV coil - Replacement 001094 Spark plug cap - Replacement 005009 Voltage regulator - Replacement 005001 Electrical system - Removal and re- fitting 005035 Headlight remote control - Replace- ment 001023...
  • Page 177 ET4 50 Time ELECTRIC DEVICES Code Action Duration 005003 Horn - Replacement 005006 Light switch or turn indicators - Re- placement 005039 Headlight switch - Replacement 005040 Horn button - Replacement 005041 Starter button - Replacement 004010 Antitheft lock - replace...
  • Page 178 ET4 50 Time ELECTRIC DEVICES Code Action Duration 005007 Battery - Replacement 005011 Start-up remote control switch - Re- placement 005019 Fuse terminal block - Replacement 005024 Battery fuse - Replacement 005025 Battery fuse holder - Replacement TIME - 178...
  • Page 179 ET4 50 Time Transmissions TRANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement 002053 Rear brake transmission complete - Replacement 002043 Rear brake cable - Replacement 003060 Rear brake cable - Adjustment 002021 Front brake piping - Replacement...

  • Page 180: Brake Callipers

    ET4 50 Time Brake callipers BRAKE CALIPER Code Action Duration 003035 Shock absorber support and brake calliper - Replacement 002039 Front brake calliper - Removal and Refitting 002011 Odometer movement sensor - Re- placement 003036 Shock abs. and brake caliper support...
  • Page 181 ET4 50 Time Footrests MATS Code Action Duration 004015 Footrest - Removal and Refitting 004078 Front/rear footboard rubber cover - Replacement 004075 Front mat - Replacement TIME - 181...
  • Page 182 ET4 50 Time Steering column STEERING Code Action Duration 003045 Steering tube - Replacement 003010 Front suspension - Service 002041 Brake disc - Replacement 003040 Front wheel bearings - Replacement 001064 Odometer reel - Replacement 003033 Front wheel hub- Replacement...

  • Page 183: Braking System

    ET4 50 Time Helmet bay HELMET CARRIER Code Action Duration 004016 Helmet compartment - Removal and Refitting 004071 Battery compartment - Replacement 005046 Battery cover - Replacement 001027 Body / air cleaner union - Replace- ment Braking system TIME - 183...
  • Page 184 ET4 50 Time BRAKE LEVER Code Action Duration 002002 Shoes - Rear brake pads - Replace- ment TIME - 184...
  • Page 185 Air filter: 30 Battery: 38, 44, 53 Brake: 131, 133–135, 180 Carburettor: 10, 28, 108, 112, 161 Engine oil: 31 Fuel: 36, 107 Headlight: 139 Hub oil: 30 Identification: 8 Instrument panel: 138 Maintenance: 7, 25 Odometer: Saddle: Spark plug: 29 Stand: Tank: Transmission: 9, 37, 59, 69, 158...

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