Gilera DNA 50 Manuals

Manuals and User Guides for Gilera DNA 50. We have 1 Gilera DNA 50 manual available for free PDF download: Workshop Manual

Gilera DNA 50 Workshop Manual (171 pages)

633507

Brand: Gilera | Category: Motorcycle | Size: 6.92 MB

Workshop Manual
2
Product View
4
Index of Topics
5
Characteristics
7
Safety Rules
7
Maintenance Rules
7
Vehicle Identification
8
Dimensions and Mass
8
Engine
9
Transmission
9
Capacities
10
Electrical System
10
Frame and Suspensions
10
Wheels and Tyres
10
Secondary Air
11
Dell'orto Carburettor 50Cc Version
11
Tightening Torques
12
Frame Assembly
12
Front Brake
12
Rear Brake
12
Engine Assembly
12
Overhaul Data
13
Assembly Clearances
13
Cylinder-Piston Assy.
13
Piston Rings
13
Crank Case-Crankshaft-Conecting Rod
14
Slot Packing System
14
Products
15
Tooling
16
Tools
17
Maintenace
25
Maintenance Chart
26
At 1000 Km or 4 Months
26
At 5000 Km or 12 Months, 25000 Km, 35000 Km and 55000 Km
26
At 10000 Km or 24 Months and 50000 Km
26
At 15000 Km and 45000 Km
27
At 20000 Km and 40000 Km
27
At 30000 Km
27
At 60000 Km
28
Checkig the Spark Advance
28
Spark Plug
29
Hub Oil
29
Check
30
Replacement
31
Air Filter
31
Transmissions
32
Braking System
33
Level Check
33
Top-Up
33
Headlight Adjustment
34
Troubleshooting
35
Poor Performance
36
Rear Wheel Spins at Idle
36
Starting Difficulties
36
Excessive Oil Consumption/Exhaust Smoke
37
Engine Tends to Cut-Off at Full Throttle
37
Engine Tends to Cut-Off at Idle
37
Excessive Exhaust Noise
37
Transmission and Brakes
38
Engine Overheating
38
SAS Malfunctions
38
Clutch Grabbing or Performing Inadequately
38
Steering and Suspensions
39
Battery
39
Rear Wheel
39
Heavy Steering
39
Excessive Steering Play
40
Noisy Suspension
40
Suspension Oil Leakage
40
Conceptual Diagrams
43
Ignition
44
Headlights and Automatic Starter Section
45
Battery Recharge and Starting
46
Level Indicators and Enable Signals Section
47
Turn Signal Lights
48
Digital Instrument Panel
49
Instrument Unit Connector
49
Instrument Panel
49
Checks and Inspections
50
Check on the Pick up
50
Ignition Circuit
51
Stator Check
51
Checking the Recharge Coil
51
Check Continuity
51
Voltage Regulator Check
52
Fuses
54
Sealed Battery
55
Dry-Charge Battery
55
Battery Maintenance
56
Engine from Vehicle
58
Removal of the Engine from the Vehicle
59
Automatic Transmission
62
Transmissio Cover
62
Kickstart
62
Removing the Driven Pulley Shaft Bearing
63
Refitting the Driven Pulley Shaft Bearing
63
Removing the Driven Pulley
64
Inspecting the Clutch Drum
64
Removing the Clutch
64
Inspecting the Clutch
65
Pin Retaining Collar
65
Removing the Driven Half-Pulley Bearing
66
Inspecting the Driven Fixed Half-Pulley
66
Inspecting the Driven Sliding Half-Pulley
67
Refitting the Driven Half-Pulley Bearing
68
Inspecting the Clutch Spring
68
Refitting the Clutch
68
Refitting the Driven Pulley
69
Drive-Belt
69
Removing the Driving Pulley
70
Mixer Gears and Belt
70
Inspecting the Rollers Case
70
Refitting the Driving Pulley
71
End Gear
72
Removing the Hub Cover
72
Removing the Wheel Axle
72
Removing the Wheel Axle Bearings
73
Inspecting the Hub Shaft
74
Ispecting the Hub Cover
74
Refitting the Wheel Axle Bearing
75
Refitting the Hub Cover
75
Flywheel Cover
75
Removing the Stator
76
Refitting the Stator
76
Refitting the Flywheel Cover
76
Flywheel and Starting
77
Removinng the Starter Motor
77
Removing the Flywheel Magneto
78
Inspecting the Flywheel Components
78
Cylinder Assy. and Timing System
79
Refitting the Flywheel Magneto
79
Refitting the Starter Motor
79
Removing the Intake Manifold
79
Removing the Cylinder - Piston Assy.
80
Inspecting the Small End
81
Inspecting the Wrist Pin
81
Inspecting the Piston
81
Inspecting the Cylinder
82
Inspecting the Piston Rings
82
Removing the Piston
83
Crankcase-Crankshaft
84
Inspecting the Timing System Components
84
Splitting the Crankcase Halves
84
Removing the Crankshaft
85
Removing the Crankshaft Bearings
85
Refitting the Crankshaft Bearings
86
Inspecting the Crankshaft Alignment
86
Refitting the Crankshaft
87
Refitting the Crankcase Halves
88
Lubrication
89
Crankshaft Oil Seals Refitting
89
Oil Pump Removal
90
Oil Pump Refitting
90
Fuel Supply
91
Suspensions
92
Removing the Front Wheel
93
Refitting the Front Wheel
93
Handlebar
93
Front Fork Removal
94
Front Fork Refitting
96
Removing the Rear Wheel
96
Shock Absorbers Removal
96
Shock Absorbers Refitting
97
Centre-Stand
97
Front Brake Calliper Removal
100
Front Brake Calliper Overhaul
100
Front Brake Calliper Refitting
102
Front Brake Disc Removal
102
Front Brake Disc Refitting
102
Disc Inspection
102
Front Brake Pads Removal
103
Front Brake Pads Refitting
103
Fill
104
Front Brake Pump
105
Rear Brake Pump - Combined
106
Cooling System
107
System Bleed
108
Water Pump - Overhaul
108
Thermostat Removal
111
Thermostat Check
111
Thermostat Refitting
112
Chassis
113
Headlight Assy.
114
Tailight Assy.
114
Side Fairings
115
Rear Mudguard
116
Helmet Bay
117
Fuel Tank
118
Radiator Fan
119
Expansion Tank
120
Mixture Oil Tank
120
Pre-Delivery
121
Aesthetic Inspection
122
Tightening Torques Inspection
122
Levels Check
123
Road Test
123
Static Test
124
Functional Ispection
124
Time
125
Crankcase
127
Crankshaft
128
Cylinder Assy.
129
Cylinder Head Assy.
130
Driven Pulley
131
Oil Pump
132
Final Gear Assy.
133
Driving Pulley
134
Transmission Cover
135
Water Pump
136
Starter Motor
137
Flywheel Magneto
138
Brake Shoes
139
Carburettor
140
Exhaust Pipe
141
Air Cleaner
142
Frame
143
Legshield Spoiler
144
Underseat Compartment
146
Plate Holder
147
Mudguard
148
Tank Oil
150
Rear Shock-Absorber
151
Steering Column Bearings
152
Handlebar Components
153
Swing-Arm
154
Seat
155
Instrument Panel
156
Front Wheel
158
Fuel Pump
160
Electric Devices
161
Electronic Controls
163
Brake Callipers
165
Rear Side Fairings
166
Front Suspension
167
Cooling System
168
Secondary Air Box
169
Index
170

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Gilera DNA 50 Workshop Manual (171 pages)

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