Gilera Runner RST 50 SP Guide

SERVICE STATION MANUAL
639189
Runner RST 50 SP

SERVICE STATION
MANUAL
Runner RST 50 SP
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.
Not all versions/models shown in this publication are available in all countries. The availability of single
versions should be checked at the official Piaggio sales network.
"©Copyright2007-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL
Runner RST 50 SP
Thisworkshop manual has been drawn upby Piaggio & C. Spa tobe used by the workshops ofPiaggio-
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. Any
important changes made to the vehicles or to specific repair operations will be promptly reported by
updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment
and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific
tools, along with the specific tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked with this symbol indicatethe correct use of thevehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME

INDEX OF TOPICS
CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
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.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling
members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.
Runner RST 50 SP Characteristics
CHAR - 7

Vehicle identification
Frame prefix: ZAPC46100
Engine prefix: M461M
Dimensions and mass
DIMENSIONS
Specification Desc./Quantity
Total weight when empty and ready for road 103 kg (95 kg dry)
Length 1840 mm
Width 750 mm
Wheelbase 1270 mm
Height 1210 mm
Engine
MOTORE
Specification Desc./Quantity
Type of engine One-cylinder 2 speed Piaggio Hi-PER2 PRO
Bore x stroke 40 X 39.3 mm
Compression ratio 11.3 ÷ 12.8 : 1
Engine capacity 49 cm³
Carburettor DELL'ORTO PHVA 17.5 ID
CO adjustment 3.5% ± 0.5
Engine idle speed 1800 to 2000 r.p.m.
Air filter Sponge impregnated with fuel mixture (50% SELENIA air filter
oil and 50% unleaded petrol).
Starting system electric starter/kickstarter
Lubrication With blend and variable oil variable according to the engine
revolutions and the throttle valve opening by means of a pump
controlled by the driving shaft with toothed belt.
Fuel supply: With the fuel pump in depression, lead-free gasoline (with 95
octane minimum) by means of the carburettor
Cooling system Through circulation of cooling liquid
Characteristics Runner RST 50 SP
CHAR - 8

Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission With automatic expandable pulley variator, torque server, V
belt, automatic clutch, gear reduction unit.
Capacities
CAPACITY
Specification Desc./Quantity
Gas tank In plastic, 7 lt. capacity (approximate value) including the ~ 1.7
l. reserves.
Oil tank mixer In plastic, 1.6 l. capacity (approximate value) including the ~
0.6 l. reserves.
Rear hub oil Quantity: approx. 75 cm³
Electrical system
IMPIANTO ELETTRICO
Specification Desc./Quantity
Type of ignition Capacitive discharge type electronic ignition, with incorporated
high voltage coil
Ignition advance (before dead centre.) 16° ± 1° AT 4000 rpm
Sparkplug (One-cylinder two-stroke liquid cooled) CHAMPION RN1C
Battery 12V-4Ah
Main fuse 7.5 A
Generator In alternate current with three output sections
Frame and suspensions
FRAME
Specification Desc./Quantity
Chassis type Welded tubular steel chassis with stamped sheet reinforce-
ments
Front suspension Hydraulic fork with upside down rods
Front fork stroke 73 mm
Front stroke 66 mm
Rear suspension single hydraulic shock absorber, coaxial helical spring. Frame
engine attachment with swinging arm.
Rear suspension stroke 63.5 mm
Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 220 mm disc brake with hydraulic linkage (r.h. brake lever).
Rear brake Ø 175 mm disc (hydraulically controlled via lever on left hand-
side of handlebar)
Runner RST 50 SP Characteristics
CHAR - 9

Wheels and tyres
WHEELS AND TIRES
Specification Desc./Quantity
Front wheel rim In diecast aluminium alloy - 3.00x14"
Rear wheel rim In diecast aluminium alloy - 3.50x13"
Front tire 120/70 - 14'' 55L Tubeless
Rear tire 140/60 - 13'' 57L Tubeless
Secondary air
To clean the sponge filters of the secondary air
system, proceed as follows:
Unscrew the two studs ( 2) of the aluminium lid of
the secondary air box to access the polyurethane
sponge contained inside the box; after cleaning
with water and neutral soap, dry the sponge with
a clean cloth and reassemble the system, check-
ing that the steel blade is not warped and/or does
not guarantee the seal on its strike surface; re-
place if necessary.
N.B.
UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE
TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMI-
NIUM COVERS.
CAUTION
DURING THE OPERATION, CHECK THE INTEGRITY AND
SEAL OF THE TWO SLEEVES (3) IN RUBBER LOCATED
AT THE ENDS OF THE SECONDARY AIR HOSE; IF NEC-
ESSARY, REPLACE THEM USING NEW CLAMPS TO FAS-
TEN.
Carburettor
50cc Version
Dell'Orto
DELL'ORTO CARBURETTOR
Specification Desc./Quantity
Type PHVA 17.5 ID
Diffuser diameter Ø 17.5
Reference number of adjustment 8439
Maximum nozzle: 53
Maximum air nozzle (on the body): Ø 1.5
Tapered pin stamped code: A22
Pin position (notches from above): 1
Diffuser: 209 HA
Characteristics Runner RST 50 SP
CHAR - 10

Specification Desc./Quantity
Minimum nozzle: 32
Minimum air nozzle (on the body): Free
Secondary minimum air hole Ø 2.5
Initial minimum mix screw opening: 1 1/2
Starter jet 50
Starter air nozzle (on the body): Ø 1.5
Stroke of starter pin: 11 mm
Fuel inlet hole Ø 1.0
Tightening Torques
TORQUE IN NMBY TYPE OF TIGHTENED MATERIAL
Name Torque in Nm
M4 Ø 8.8 steel screw on plastic with metallic spacers 2
M4 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 2
M4 Ø 8.8 steel screw Iron, steel 3
M5 Ø 8.8 steel screw on plastic with metallic spacers 4
M5 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 4
M5 Ø 8.8 steel screw Iron, steel 6
M6 Ø 8.8 steel screw on plastic with metallic spacers 6.5
M6 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 6.5
M6 Ø 8.8 steel screw Iron, steel 10.5
M7 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 10.5
M7 Ø 8.8 steel screw Iron, steel 17
M8 Ø 8.8 steel screw on brass, copper, aluminium and their
alloys 16
M8 Ø 8.8 steel screw Iron, steel 26
M10 Ø 8.8 steel screw Iron, steel 52
M12 Ø 8.8 steel screw Iron, steel 100
M14 Ø 8.8 steel screw Iron, steel 145
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 30 ÷ 40
Lower steering ring-nut 50 ÷ 60 (therefore to loosen by 90 ÷100)
Handlebars stud * 65 ÷ 70
FRAME ASSEMBLY
Name Torque in Nm
Swinging arm - engine pin* 33 ÷ 41
Frame - swing arm bolt * 33 ÷ 41
Shock-absorber - frame nut * 20 ÷ 25
Shock-absorber - engine bolt * 33 ÷ 41
Wheel axle pin* 100 ÷ 125
Stand pin 18.5 ÷ 19
Stand screws 18.5 ÷ 19
*: safety torque
FRONT SUSPENSION
Name Torque in Nm
Fork nut * 20 ÷ 25
Fork screw 20 ÷ 25
Front wheel axle * 45 ÷ 50
*: safety torque
Runner RST 50 SP Characteristics
CHAR - 11

FRONT BRAKE
Name Torque in Nm
Brake fluid pump - hose fitting 13 to 18 Nm
Brake fluid pipe-calliper fitting 20 ÷ 25
Support calliper tightening screw* 20 ÷ 25
Front disc tightening screw* 12 ÷ 15
Oil bleed screw 7 to 10 Nm
*: safety torque
REAR BRAKE
Name Torque in Nm
Calliper tightening screw 20 ÷ 25
Brake fluid tube- calliper 13 ÷ 18
Brake fluid pump - hose fitting 13 to 18 Nm
Disc tightening screw 6 ÷ 6.5
Rear wheel axle 100 ÷ 125
Rear wheel hub screw 20 ÷ 25
Oil bleed screw 7 to 10 Nm
N.B.
IN ORDER TO ENSURE AN ADEQUATE LOCKING TORQUE, LUBRICATE THE NUTS BEFORE
ASSEMBLING THEM.
ENGINE ASSEMBLY
Name Torque in Nm
Head tightening nut 10 ÷ 11
Coolant bleed screw 1 ÷ 2
Temperature sensor 6 ÷ 8
Temperature sensor at the ECU 18 ÷ 22
Crankcase closure screw 12 ÷ 13
Transmission cover closing screw 12 ÷ 13
Pick-up screw 3 ÷ 4
Stator screw 3 ÷ 4
Suction connection screw 7 ÷ 8
Starter screw 12 ÷ 13
Mixer screw 3 ÷ 5
Rear hub cap screw 12 ÷ 13
Driving pulley nut 40÷ 44*
Driven pulley nut 40÷ 44*
Oil drain rear hub screw 3 ÷ 5
Clutch nut 55 ÷ 60
Mixer strip screw 3 ÷ 4
Ignition spark plug 11 ÷ 14
Head union screw 3 ÷ 4
Flywheel cover screw 1 ÷ 2
Flywheel tightening nut 40÷ 44*
Transmission strip cap screw 3 ÷ 4
Transmission cooling cap screw 3 ÷ 4
Water pump rotor 0.5 ÷ 0.4
Muffler -cylinder nut 9 ÷ 11
Engine - muffler screw 22 ÷ 24
Fuel injector to the head studs 3 ÷ 4
Crankcase compressor studs 3 ÷ 4
* Use new nuts
Overhaul data
Assembly clearances
Characteristics Runner RST 50 SP
CHAR - 12

Cylinder - piston assy.
CYLINDER-PISTON FITTING
Name Initials Cylinder Piston Play on fitting
Standard fitting M 39.997-40.004 39.943-39.95 0.047-0.061
Standard fitting N 40.004-40.011 39.95-39.957 0.047-0.061
Standard fitting O 40.011-40.018 39.957-39.964 0.047-0.061
Standard fitting P 40.018-40.025 39.964-39.971 0.047-0.061
1st oversize fitting M1 40.197-40.204 40.143-40.15 0.047-0.061
1st oversize fitting N1 40.204-40.211 40.15-40.157 0.047-0.061
1st oversize fitting O1 40.211-40.218 40.157-40.164 0.047-0.061
1st oversize fitting P1 40.218-40.225 40.164-40.171 0.047-0.061
2nd oversize fitting M2 40.397-40.404 40.343-40.35 0.047-0.061
2nd oversize fitting N2 40.404-40.411 40.35-40.357 0.047-0.061
2nd oversize fitting O2 40.411-40.418 40.357-40.364 0.047-0.061
2nd oversize fitting P2 40.418-40.425 40.364-40.371 0.047-0.061
Piston rings
SEALING RINGS
Name Description Dimensions Initials Quantity
Compression ring 40 A 0.10 to 0.25
Compression ring 1st
oversize 40.2 A 0.10 to 0.25
Compression ring 2nd
Oversize 40.4 A 0.10 to 0.25
Runner RST 50 SP Characteristics
CHAR - 13

Crankcase - crankshaft - connecting rod
PISTON - TEST PROBE
Name Descripti
on Dimensio ns Initials Quantity
Piston Ø 12
+0.007
+0.012
P 0.002 ÷
0.011
Test probe Ø 12
+0.005
+0.001
Q 0.002 ÷
0.011
ROD SMALL END - ROLLER CASING -
TEST PROBE
Name Descripti
on Dimensio ns Initials Quantity
Connect-
ing rod Ø 17 +0.011
0.001
G 0.002 ÷
0.012
Roller cas-
ing Ø 2.5 0 0.007 F 0.002 ÷ 0.012
Test probe Ø 12 +
0.005 +
0.001
H 0.002 ÷
0.012
FITTING CATEGORY ROD SMALL END -
ROLLER CASING - TEST PROBE
Name Descripti
on Dimensio ns Initials Quantity
Rod small
end Cat. 3 Ø 17 + 0.011 + 0.007
Rod small
end Cat. 2 Ø 17 + 0.007 + 0.003
Rod small
end Cat. 1 Ø 17 +0.003 -0.001
Roller cas-
ing Cat. 1 Ø 2.5 0 -0.002
Roller cas-
ing Cat. 2 Ø 2.5 -0.002 -0.004
Roller cas-
ing Cat. 3 Ø 2.5 -0.004 -0.006
Roller cas-
ing Cat. 1 Op- tional Ø 2.5 -0.001 -0.003
Roller cas-
ing Cat. 2 Op- tional Ø 2.5 -0.003 -0.005
Roller cas-
ing Cat. 3 Op- tional Ø 2.5 -0.005 -0.007
Test probe +0.005
+0.001
AXIAL PLAY CONNECTING ROD - CRANKSHAFT
Name Description Dimensions Initials Quantity
Connecting rod 11.75 0 -0.05 A 0.25 ÷ 0.50
Shoulder washer 0.5 ±0.03 G 0.25 ÷ 0.50
Semi-shaft, trans. side 13.75 +0.04 0 C 0.25 ÷ 0.50
Semi-shaft, flywheel
side 13.75 +0.04 0 D 0.25 ÷ 0.50
Characteristics Runner RST 50 SP
CHAR - 14

Name Description Dimensions Initials Quantity
Spacer tool 40.64 H 0.25 ÷ 0.50
Casing 11.8 0 -0.35 B 0.20 ÷ 0.75
Shoulder washer 0.5 ±0.03 G 0.20 ÷ 0.75
Semi-shaft, trans. side 13.75 +0.04 0 C 0.20 ÷ 0.75
Semi-shaft, flywheel
side 13.75 +0.04 0 D 0.20 ÷ 0.75
Spacer tool 40.64 H 0.20 ÷ 0.75
Slot packing system
Fit the cylinder without installing the gasket to the
base.
Apply a centimetre dial gauge and reset it on an
adjusted surface.
Fit the tool on the top of the cylinder fixing it with
two nuts to the stud bolts, keeping to the torque
wrench setting and take the piston to the dead
centre position.
The thickness of the gasket to fit will change de-
pending on the value found.
Three gaskets are given with the following thick-
ness :
Specific tooling
020272Y Piston position check tool
Locking torques (N*m)
Locking head nuts: 10 ÷ 11 N·m
SHIMMING SYSTEM
Name Measure A Thickness
Shimming 2.80 ÷ 3.04 0,4
Shimming 3.04 ÷ 3.24 0,6
Shimming 3.25 ÷ 3.48 0,8
Runner RST 50 SP Characteristics
CHAR - 15

Products
TABLE OF RECOMMENDED PRODUCTS
Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP CITY HI TEC 4T Oil for flexible transmission lubrication
(acceleration control, mixer and odome-
ter)
Syntheticoilthatpasses SAE5W-40, API
SL, ACEA A3, JASO MA specifications
AGIP CITY HI TEC 4T Oil for air filter sponge Syntheticoil thatpasses SAE5W-40, API
SL, ACEA A3, JASO MA specifications
AGIP GP 330 Grease for brake control levers, throttle,
stand White calcium complex soap-based spraygrease with NLGI2; ISO-L-XBCIB2
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
AGIP GREASE MU3 Grease for odometer transmission gear
case Soap-based lithium grease with NLGI 3; ISO-L-XBCHA3, DIN K3K-20
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
AGIP GREASE SM 2 Grease for compensating ring NLGI 2; ISO-L-XBCHB2, DIN KF2K-20
Molybdenum disulphide grease and lithi-
um soap
AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease
to protect roller bearings; temperature
rangebetween -20°Cand +120°C; NLGI
2; ISO-L-XBCIB2
AGIP PERMANENT PLUS Coolant Monoethyleneglycolantifreeze fluid, CU-
NA NC 956-16
AGIP GREASE SM 2 Greasing the driven pulley bushing Soap-based lithium grease with NLGI 2
Molybdenum Disulphide; ISO-L-
XBCHB2, DIN KF2K-20
Characteristics Runner RST 50 SP
CHAR - 16

INDEX OF TOPICS
TOOLING TOOL

TOOLING
Stores code Description
001330Y Tool for fitting steering seats
001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54 mm bearing
001467Y009 Driver for OD 42-mm bearings
001467Y013 Pliers to extract ø 15-mm bearings
001467Y014 Pliers to extract ø 15-mm bearings
Tooling Runner RST 50 SP
TOOL - 18

Stores code Description
001467Y017 Bell for bearings, OD 39 mm
001467Y021 Extraction pliers for ø 11 mm bearings
002465Y Pliers for circlips
006029Y Punch for fitting fifth wheel seat on steer-
ing tube
020004Y Punch for removing fifth wheels from
headstock
020209Y Spring hook
Runner RST 50 SP Tooling
TOOL - 19

Stores code Description
020055Y Wrench for steering tube ring nut
020074Y Support base for checking crankshaft
alignment
020150Y Air heater support
020151Y Air heater
020162Y Flywheel extractor
020163Y Crankcase splitting plate
Tooling Runner RST 50 SP
TOOL - 20