PIAGGIO MSS APE 50 Guide

MANUALE STAZIONE DI SERVIZIO
677276 - 677281 (IT-EN-FR-DE-ES-EL)
MSS APE 50

MANUALE
STAZIONE DI
SERVIZIO
MSS APE 50
© Copyright 2010 - 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
www.piaggio.com

MANUALE STAZIONE DI
SERVIZIO
MSS APE 50
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.
Safeguarding the environment Sectionsmarkedwiththis 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.

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
BRAKING SYSTEM BS
STEERING COLUMN SC
SUSPENSIONS SS
CHASSIS CH
PRE-DELIVERY PD
TIME-SHEET TEMP

INDEX OF TOPICS
GENERAL GUIDELINES GEN

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.
General guidelines MSS APE 50
GEN - 8

INDEX OF TOPICS
CHARACTERISTICS CH

Identification
VEHICLE IDENTIFICATION
Vehicle Chassis prefix Engine prefix
APE 50 TL6T TL3T
APE 50 EUROPA TL5T TL3T
APE 50 mix ZAPC80000 C801M
APE 50 EUROPE (EURO 2) ZAPC80000 C801M
Characteristics
SIZES
Sizes (mm) Deck Van
(1) Length 2670 2560
(2) Width 1250
(3) Height 1530 1560
(4) Wheelbase 1590
(5) Track 1100
(6) Turning spokes 2400 2400
(7) Rear cantilever 760 660
SIZES - LOAD COMPARTMENT
Sizes (mm) Deck Van
(8) Length 1420 -
(9) Width 1200 -
WEIGHTS
(*) = besides the driver.
Characteristics MSS APE 50
CH - 10

Kilograms (kg) Deck Van
Kerb vehicle weight 270 300
Useful load capacity (*) 200 170
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 Characteristics
CH - 11

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 - CHASSIS
Specification Desc./Quantity
Chassis stamped plate unitised body and a single central longitudinal
arm (integrated structure).
Seats in driving cab One.
TECHNICAL DATA - ENGINE
Specification Desc./Quantity
Engine Single-cylinder, 2-stroke with rotating timing and with three
transfer ducts, with transmission and differential grouped on
the axis of the rear wheels.
Engine capacity 49.8 cm³
Bore x Stroke 38.4 mm x 43 mm
Compression ratio (10÷10.5):1
Ignition advance 15°±2° before TDC
Carburettor Dell'orto SHBC 18/16A.
Fuel 2% petrol-oil mixture (20 c.c. of oil per litre of regular petrol for
cars). Recommended oil: see "recommended products" table
Spark plug PIAGGIO P82M; BOSCHW5AC; CHAMPIONL82C;
LODGE2HN; AC430Z.
Characteristics MSS APE 50
CH - 12

Specification Desc./Quantity
Consumption (CUNA) ~2.7 litres per 100 km.
Km range Around 370 Km.
GEAR RATIO
Specification Desc./Quantity
Gear ratio First 1/54.17
Gear ratio Second 1/29.75
Gear ratio Third 1/19.28
Gear ratio Fourth 1/13.35
Gear ratio Reverse 1/76.47
STEERING
Specification Desc./Quantity
Steering Steering tube pivoted on the arm with front wheel-holder oscil-
lating clamp.
SUSPENSION
Specification Desc./Quantity
Front - rear suspension Made using integrated helicoidal springs and hydraulic shock
absorber.
TYRES
Specification Desc./Quantity
Wheel rim 2.10"
Front tyre pressure 1.5 bar.
Rear tyre pressure 2.5 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
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 ÷ 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
MSS APE 50 Characteristics
CH - 13

FRONT SUSPENSION UNIT
Name Torque in Nm
Wheel locking centre nut 75 to 90 Nm
Nuts fixing the wheel rim to the drum 20 to 28 Nm
Shock absorber lower anchoring nut 100 to 130 Nm
Shock absorber upper fixing nut 30 to 40 Nm
Steering upper seat 30 to 40 Nm
Steering upper bearing ring nut 50 to 60 Nm
REAR SUSPENSION UNIT
Name Torque in Nm
Nuts fixing the shoe support to the wheel hub 22 to 28 Nm
Nut fixing the wheel hub to the swinging arm 50 to 70 Nm
Nut for shock absorber lower and upper anchorage 30 to 40 Nm
Nut for anchoring the swinging arm to the chassis 40-50 Nm
Wheel locking centre nut 80 to 100 Nm
Nuts fixing the wheel rim to the drum 20 to 28 Nm
GENERAL PART
Name Torque in Nm
Brake pump to the chassis 12 to 20 Nm
Handlebar fixing bolt 35 to 60 Nm
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
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
Characteristics MSS APE 50
CH - 14

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",whichareallowedforamaximumreadingof0.02mm.Inthecaseofeccentricitiesnotmuchgreater
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.
Specific tooling
020074Y Crankshaft Alignment Check Tool
MSS APE 50 Characteristics
CH - 15

Piston - Pin
PISTON - PIN ASSEMBLY CLEARANCE
Name Description Dimensions Initials Quantity
Piston - pin assembly
clearance (mm) 0
Characteristics MSS APE 50
CH - 16

INDEX OF TOPICS
SPECIAL TOOLS ST

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
ST - 18

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 Special tools
ST - 19

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
ST - 20