PIAGGIO MSS APE 50 2012 User manual

MANUALE STAZIONE DI SERVIZIO
****** - ****** (IT-EN-FR-DE-ES-EL)
MSS APE 50 (2012)
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MANUALE
STAZIONE DI
SERVIZIO
MSS APE 50 (2012)
© Copyright 2012 - PIAGGIO & C. S.p.A. Pontedera.
All rights reserved. No part of this publication may be reproduced.
This publication has been edited by:
After sales - PIAGGIO & C. S.p.A.
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
ITALY
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MANUALE STAZIONE DI
SERVIZIO
MSS APE 50 (2012)
MANUALE STAZIONE DI SERVIZIO
Questo manuale per stazioni di servizio è stato realizzato da PIAGGIO & C. Spa per essere utilizzato
dalle officine dei concessionari e sub-agenzie Piaggio. Si presuppone che chi utilizza questa
pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei
principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni
importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno
comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro
completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per
questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il
catalogo degli attrezzi specifici.
Le descrizioni ed illustrazioni fornite nella presente pubblicazione s'intendono non impegnative;
PIAGGIO perciò si riserva il diritto, ferme restando le caratteristiche essenziali del tipo qui descritto ed
illustrato,diapportareinqualunquemomento,senzaimpegnarsiadaggiornaretempestivamentequesta
pubblicazione, le eventuali modifiche di organi, particolari o forniture di accessori, che essa ritenga
conveniente per scopo di miglioramento o per qualsiasi esigenza di carattere costruttivo o commerciale.
Nontutteleversioniriportatenellapresente pubblicazione sono disponibiliinogni Paese. La disponibilità
delle singole versioni deve essere verificata con la rete ufficiale di vendita Piaggio.
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. Refers to
specific procedures to carry out for preventing damages to the vehicle. Refers to specific procedures to
carry out for preventing damages to the vehicle. 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.
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Safeguarding the environment Sectionsmarkedwith this symbol indicate the correct use of the vehicle
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.
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INDEX OF TOPICS
GENERAL GUIDELINES GEN
CHARACTERISTICS CH
SPECIAL TOOLS ST
MAINTENANCE MA
EMISSION CONTROLO SYSTEM CO EM
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ES
ENGINE FROM VEHICLE EV
ENGINE EN
DIFFERENTIAL DI
BRAKING SYSTEM BS
STEERING COLUMN SC
SUSPENSIONS SS
CHASSIS CH
PRE-DELIVERY PD
TIME-SHEET TEMP
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INDEX OF TOPICS
GENERAL GUIDELINES GEN
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Safety guidelines
- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractor fans if necessary; never let the engine run in an enclosed area.
Exhaust gasses 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.
Petrol is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid open flames or sparks.
- Clean the blocks, the drums, and 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 blocks. Dust caused by
shoe wear is toxic since it contains asbestos.
Maintenance guidelines
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 removing these components, clean them using a non-flammable or high flash-point solvent. Lu-
bricate all the work surfaces except the tapered couplings before refitting.
After refitting, make sure that all the components have been installed correctly and work properly.
For disassembly, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts
and screws are not interchangeable with coupling members with English measurement. Using unsuit-
able coupling members and tools may damage the scooter.
When carrying out maintenance operations on the vehicle that involve the electrical system, make sure
the electrical connections have been made properly, particularly the ground connections.
MSS APE 50 (2012) General guidelines
GEN - 7
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INDEX OF TOPICS
CHARACTERISTICS CH
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Identification
The identification registration numbers are made
up of a prefix that identifies the vehicle type and a
progressive number punched on the chassis and
engine. These numbers must always be quoted in
the spare parts requests.
It is advisable to check that the identification reg-
istrationnumbers on the vehicleandon the engine
correspond with those indicated in the vehicle reg-
istration documents.
Check that the prefix and number punched on the
chassis correspond to that shown on the vehicle
documents.
Thechassisidentification numberis locatedon the
right side of the cross member under the seat.
CAUTION
BE REMINDED THAT ALTERING IDENTIFICATION REGIS-
TRATION NUMBERS MAY LEAD TO SERIOUS PENAL
SANCTIONS (IMPOUNDING OF THE VEHICLE. ETC.)
Check that the prefix and number punched on the
engine correspond to that shown on the vehicle
documents.
The identification number is punched on the left
side of the engine.
CAUTION
BE REMINDED THAT ALTERING IDENTIFICATION REGIS-
TRATION NUMBERS MAY LEAD TO SERIOUS PENAL
SANCTIONS (IMPOUNDING OF THE VEHICLE. ETC.)
Located under the right side seat.
MANUFACTURER'S PLATE KEY:
1. Manufacturer of the vehicle.
2. Type-approval number.
3. Vehicle Identification Number V.I.N.
4. Noise level (dB) under prescribed engine (Rpm)
5. Type of engine.
6. Vehicle code.
MSS APE 50 (2012) Characteristics
CH - 9
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7. Country of production.
COLOUR LABEL:
This colour label indicates:
1. Original paintwork manufacturer
2. Paintwork colour
3. Paintwork code
Characteristics
SIZES
N. millimetres (mm) TOP CROSS LONG Deck SHORT deck VAN
1 Length 2660 2700 2660 2490 2500
2 Width 1260 1260 1260 1260 1260
3 Height 1550 1610 1550 1550 1590
4 Wheelbase 1590 1590 1590 1590 1590
5 Deck length 1422 1427 1427 1257 1257
6 Deck width 1262 --- 1211 1211 1211
WEIGHTS
Kilograms (kg) TOP CROSS LONG Deck SHORT deck VAN
Kerb vehicle weight 230 245 230 230 260
Load capacity besides the driver 205 190 205 205 175
Characteristics MSS APE 50 (2012)
CH - 10
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SIZES - APE 50 EUROPA
Sizes (mm) Deck Short deck Van Cross
(1) Length 2660 2520 2560 2580
(2) Width 1250 1250 1250 1270
(3) Height 1530 1530 1560 1580
(4) Wheelbase 1590 1590 1590 1590
(5) Turning spokes 2400 2400 2400 2400
SIZES - LOAD COMPARTMENT - APE 50 EUROPA
Sizes (mm) Deck Short deck Van Cross
(8) Length 1420 1270 1260 1270
(9) Width 1200 1200 1200 1200
(10) Height - - 960 -
Top box size - - - 900x460x300
WEIGHTS - APE 50 EUROPA
(*) = besides the driver.
Kilograms (kg) Deck Short deck Van
Total dry weight 220 215 250
Useful load capacity (*) 200 205 170
SIZES - APE 50 EUROPE 2 - APE 50 MIX
Sizes (mm) Long deck
base Short deck base Van Cross Top long deck
(1) Length 2660 2490 2500 2700 2660
(2) Width 1260 1260 1260 1260 1260
(3) Height 1550 1550 1590 1610 1550
(4) Wheelbase 1590 1590 1590 1590 1590
MSS APE 50 (2012) Characteristics
CH - 11
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SIZES - LOAD COMPARTMENT - APE 50 EUROPE 2 - APE 50 MIX
Sizes (mm) Long deck
base Short deck base Van Cross Top long deck
(8) Length 1427 1257 1257 1427 1422
(9) Width 1211 1211 1211 1211 1262
WEIGHTS - APE 50 EUROPE 2 - APE 50 MIX
(*) = besides the driver.
Kilograms (kg) Long Deck Short deck Van Cross Top
Total dry weight 230 230 260 245 230
Useful load capacity (*) 205 205 175 190 205
TECHNICAL DATA
Specification Desc./Quantity
Fuel system Mixer petrol - oil through automatic carburettor/mixer (with
slave bearing to the engine speed and throttle valve opening)
and a gravity system.
Lubrication Carried out by the oil mixer for: piston, cylinder, crankshaft,
bearing of the flywheel side bench.
Water cooling, Arrangement for in cab heating system.
Heating Arrangement for in cab heating system.
Electronic ignition Consists of a capacitive discharge type device with H.V. coil
AT built-in. The system allows you to obtain a spark with a high
voltage value, reached in very short time, and with a much re-
duceddischargeduration,soitresultsinregularoperationeven
withadirtysparkplug,easycoldstarting,excellentcombustion,
limitedwearofthe electrodesandinalterabilityofthe timingdue
to the lack of components subject to wear.
Transmission From the crankshaft to the rear wheels through the clutch,
gearbox - differential - axle shaft.
Clutch Multiple discs in oil bath.
Transmission With four speeds with always driven gears.
Characteristics MSS APE 50 (2012)
CH - 12
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Specification Desc./Quantity
N.B.: THERE ARE 3 SPEEDS IN THE VERSION WITH
SPEED LIMITED TO 25 km/h.
Differential Connected to the gearbox shaft by cylinder gears, planetary
and satellite gears are bevel. The differential box is connected
to the two axle shafts that transmit the motion to the wheels.
The differential is equipped with a gear reversing device.
Exhaust silencer Combined, expansion and absorption type with double Cata-
lytic Converter and secondary air system (SAS box).
Steering and suspensions Steering tube pivoted on the oscillating arm with helicoidal
spring and coaxial hydraulic shock absorber; rear suspension
made with two independent oscillating arms with hydraulic
shock absorber and helicoidal springs.
Brakes With expansion on the three wheels:
•Front: mechanical with control lever on the right
side handlebar.
•Rear: hydraulically driven by a pedal with direct
control brake pump.
•Safety:mechanicalagentontherearwheelswith
control lever on the footrest central longitudinal
arm, right side internal cab.
Wheels Interchangeable, with printed sheet steel rims.
Wheels: rims from 10 - 2.50"; Michelin S83 tyres 100/90 x 10"
Toolkit Keys: a box-spanner (13/21 mm), a lever for box-spanner, a
screwdriver, a jack, a jack drive rod.
ENGINE
Specification Desc./Quantity
Engine 2-stroke single-cylinder with rotating timing system
Bore 38.4 mm
Stroke 43 mm
Engine capacity 49.8 cm3
Compression ratio 10 ÷ 10.5:1
Ignition advance (before TDC) 15°± 2°
Carburettor Dell'Orto SHBC 18/16P
Engine-wheel transmission ratio 1st spe. 1/54.17
2nd spe. 1/29.75
3a spe. 1/19.28
4a spe. 1/13.35 RM. 1/76.47
N.B.: THERE ARE 3 SPEEDS IN THE VERSION WITH
SPEED LIMITED TO 25 km/h.
Maximum speed Following the applicable regulations
TYRE PRESSURE
Specification Desc./Quantity
Rear tyre pressure 2.2 bar
Front tyre pressure 1.8 bar
TYRES - APE 50 - APE 50 EUROPA - APE 50 EUROPE EURO 2 - APE 50 MIX
Specification Desc./Quantity
Wheel rim 10-2.50"
Tyre 100/90x10"
Front tyre pressure 2 bar.
Rear tyres - inflation pressure 3 bar.
Tightening torques
ENGINE - DIFFERENTIAL UNIT
Name Torque in Nm
Crankcase halves coupling nuts 13 to 15 Nm
Coil support fixing screw 3 to 5 Nm
Spark plug 14 to 18 Nm
Engine gear locking nut 50 to 55 Nm
MSS APE 50 (2012) Characteristics
CH - 13
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Name Torque in Nm
Clutch assembly locking nut 40 ÷ 45 Nm
Fan flywheel locking nut 45 to 50 Nm
Filler joint fixing nuts 5 to 7 Nm
Nuts fixing the exhaust pipe to the cylinder 5 to 7 Nm
Clutch cover fixing bolts 6 to 8 Nm
Big end fixing bolts 13 to 18 Nm
Nuts fixing the cylinder to the crankcase 13 to 15 Nm
Nuts fixing the differential unit to the engine 32 to 35 Nm
Differential crankcase halves coupling nuts 8 to 10 Nm
Engine - chassis anchoring plate fixing nuts 20 to 24 Nm
Differential oil drain plug 20 to 25 Nm
Gear control guide bushing 60 to 65 Nm
Nuts fixing the silencer to the engine support 23 to 25 Nm
Nuts fixing the elastic connection to the engine support 25 to 30 Nm
Engine front fixing bolt 25 to 30 Nm
GRUPPO SOSPENSIONE ANTERIORE
Name Torque in Nm
Front shock absorber (upper part) - Steering tube 34.3 ± 4.9 Nm
Front shock absorber (lower part) - Steering tube 112.7 ± 14.7 Nm
Brake drum - Steering tube 53.9 ± 5 Nm
Front wheel - Brake drum 23.6 ± 4 Nm
GRUPPO SOSPENSIONE POSTERIORE
Name Torque in Nm
Brake drum - Semi axle 85.8 ± 7.4 Nm
Rear wheel - Brake drum 23.6 ± 4 Nm
Shoe holder disc - Wheel hub 23.6 ± 4 Nm
Wheel hub - Rear suspension arm 58.8 ± 9.8 Nm
Rear shock absorber (upper part) - Chassis 34.3 ± 4.9 Nm
Rear shock absorber (lower part) - Wheel hub 34.3 ± 4.9 Nm
Rear suspension arm - Frame 44.1 ± 4.9 Nm
PARTE GENERALE
Name Torque in Nm
Windshield wiper - Chassis (external) 8 ± 0.5 Nm
Rear wheel- Drum 24 ± 4 Nm
Silencer - Engine head 5.9 ± 1 Nm
Silencer - Engine support 23.6 ± 1 Nm
Engine support bracket - Chassis 22 ± 2 Nm
Brake pump - Chassis 15.7 ± 4 Nm
Engine - Chassis 27.5 ± 2.5 Nm
Vehicle overhaul data
Assembly clearances
FITTING CLEARANCES
Name Description Dimensions Initials Quantity
Distance between the
ends of seal rings within
the upper and lower cyl-
inder-ring (mm)
0.2 to 0.3
Gearbox fitting clear-
ance (mm) 0.15 to 0.40
CAUTION
THE GEARBOX SHAFT FITTING CLEARANCE MUST BE VERIFIED WITH THE FEELER GAUGE.
Specific tooling
Characteristics MSS APE 50 (2012)
CH - 14
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060824Y Probe
Cylinder-piston oversizes
CYLINDER - PISTON
Specification Desc./Quantity
Normal cylinder nominal sizes Ø=38.40 +0.025 - 0.005
Normal piston nominal sizes Ø=38.265 ±0.015
CYLINDER COUPLING - PISTON
Name Initials Cylinder Piston Play on fitting
Coupling 1st Oversize 38.600 to 38.620 38.455 to 38.475 0.145
Coupling 2nd Oversize 38.800 to 38.820 38.655 to 38.675 0.145
Coupling 3rd Oversize 39.000 to 39.020 38.855 to 38.875 0.145
Piston ring oversizes
SEALING RINGS
Specification Desc./Quantity
Upper seal ring (Nominal sizes) Diameter=38.40 mm
Lower seal ring (Nominal sizes) Diameter=38.40 mm
CLEARANCE UPON FITTING
Name Description Dimensions Initials Quantity
Upper sealing ring 1st Oversize 38.60 0.20 to 0.60
Lower sealing ring 1st Oversize 38.60 0.20 to 0.60
Upper sealing ring 2nd Oversize 38.80 0.20 to 0.60
Lower sealing ring 2nd Oversize 38.80 0.20 to 0.60
Upper sealing ring 3rd Oversize 39.00 0.20 to 0.60
Lower sealing ring 3rd Oversize 39.00 0.20 to 0.60
Connecting rod - roller cage fitting
CONNECTING ROD - ROLLER CAGE
Connecting rod Roller cage
1.a category 4.a category
2.a category 3.a category
3.a category 2.a category
4.a category 1.a category
CAUTION
IN CASE OF NOISE, USE CAGE OF THE CATEGORY IMMEDIATELY BELOW.
Crankshaft alignment check
With the proper equipment, check that the eccentricity of the surface of Ø "3"and "1" are contained
within 0.003 mm. (the maximum reading limit on the dial gauge clock); Also check the eccentricity of Ø
"2",whichare allowed for a maximum reading of 0.02 mm. In the case of eccentricities not muchgreater
than that prescribed, perform the straightening of the shaft by means of counterweights with a wedge,
or tightening it in a vice (equipped with aluminium bushings) as needed, for much greater eccentricities
replace the crankshaft.
MSS APE 50 (2012) Characteristics
CH - 15
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Specific tooling
020074Y Crankshaft Alignment Check Tool
Piston - Pin
PISTON - PIN ASSEMBLY CLEARANCE
Name Description Dimensions Initials Quantity
Piston - pin assembly
clearance (mm) 0
Characteristics MSS APE 50 (2012)
CH - 16
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INDEX OF TOPICS
SPECIAL TOOLS ST
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Tooling
SPECIAL TOOLS
Stores code Description
014499Y Bearing extractor
016029Y Lower Steering Bearing Fitting Tool on
the steering tube
017104Y Pliers for circlips
018119Y Axle Fitting Tool
020004Y Steering seats extraction punch
020042Y Steering tube bearing extractor
Special tools MSS APE 50 (2012)
ST - 18
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Stores code Description
020043Y Rear Wheel Hub Roller Bearing Fitting
Punch
020044Y Front Wheel Hub Roller Bearing Fitting
Punch
020055Y Steering Ring Nut Key
020057Y Tool for Starter Motor Bushing Calking
020074Y Crankshaft Alignment Check Tool
020119Y Flywheel extractor
020120Y Punch for Clutch Side Secondary Shaft
Roller Bearing
MSS APE 50 (2012) Special tools
ST - 19
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Stores code Description
020121Y Punch for Flywheel Side Secondary
Shaft Roller Bearing
020123Y Valves Sealing Rings Punch
020125Y Punch to Fit Sealing Rings
020126Y Clutch Stop Key
020127Y Transmission Spider Calking Punch
020128Y Tool to Fit Sealing Rings
020129Y Engine Clearance Gear Check Tool
Special tools MSS APE 50 (2012)
ST - 20
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