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WORKSHOP MANUAL
633507
DNA 50
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WORKSHOP
MANUAL
DNA 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.
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.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

WORKSHOP MANUAL
DNA 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. Any important
changes made to the vehicles or to specific fixing 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 Sections marked with 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.

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

DNA 50 Characteristics
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
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7

Characteristics DNA 50
Vehicle identification
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Frame prefix ZAPC2700000001001
Engine prefix C271M
Dimensions and mass
DIMENSIONS AND MASS

Maximum width 780 mm
Maximum length 1970 mm
Wheel base 1350 mm
Saddle height 810 mm
Dry weight 99 kg.
CHAR - 8

Engine
ENGINE
Motor Fluid-cooled, two-cycle, single-cylinder.
Engine capacity 49 cm³
Bore x stroke 40 X 39.3 mm
Compression ratio 11.3 ÷ 12.8 : 1
Supply. With high-octane, 95 N.O.R. lead-free petrol mix - oil via car-
burettor, automatic mixer (with variable capacity depending on
the engine speed and opening of throttle valve) petrol pump.
Intake By means of a compression valve on the casing
Dellorto Carburettor PHVA 17.5
Lubrication Engine lubrication (piston, cylinder, crankshaft, main bearings)
with mixer oil.
Transmission
TRANSMISSION
Transmission With automatic expandable pulley variator, torque server, V
belt, automatic clutch, gear reduction unit.
CHAR - 9

Capacities
CAPACITIES
Fuel tank Plastic, capacity ~ 9 lt. (including reserved ~ 1.2 lt.).
Oil mixer tank In plastic, of capacity ~ 1.3 lt. (including reserve ~ 0.500 lt.)
Rear hub oil ~ 85 cc
Electrical system
ELECTRICAL SYSTEM
Electronic ignition A capacitor discharge microprocessor device, with built-in HV
coil.
Spark advance (Before T.D.C.) 20°±1 at 4000 rpm
Spark plug CHAMPION RN1C
Battery 12V-4Ah
Main fuse 7.5 A
Generator In alternate current with three output sections
Frame and suspensions
FRAME AND SUSPENSIONS

Chassis Double steel diagonal beam
Front suspension Hydraulic telescopic fork
Steer torque 123 mm
Front suspension stroke 80 mm
Rear suspension With coaxial spring and hydraulic shock absorber. Chassis to
engine support with swinging arm.
Max. rear wheel travel 83 mm.
Brakes
BRAKES
Front brake 240 mm dia. disc brake with hydraulic control activated from
handlebar with right lever
Rear brake 200 mm dia. disc brake with hydraulic control activated from
handlebar with left lever
Wheels and tyres
WHEELS AND TYRES

Wheel rim Front: 3.00 x 15' light-alloy
Rear: 3.50 x 14' light-alloy
Front tyre 120/70 - 15''
Rear tyre 140/70 - 14''
Front wheel pressure: 1.8 bar
Rear tyre pressure: 2 bar
CHAR - 10

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
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
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
CHAR - 11

Tightening Torques
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut (safety locks) 35 to 40 Nm
Lower steering ring nut (safety locks) 8 to 10 Nm
Handlebar fixing pin (safety locks) 45 to 50 Nm
FRAME ASSEMBLY
Name Torque in Nm
Swinging arm-engine pin (safety locks) 33 to 41 Nm
Swinging arm-frame pin (safety locks) 64 to 72 Nm
Shock absorber - frame nut (safety locks) 20 to 25 Nm
Shock absorber-engine pin (safety locks) 33 to 41 Nm
Rear wheel axis (safety locks) 104 to 126 Nm
Bolt holding stand to the engine 18 to 19 Nm
Side stand fixing screw 12 ÷ 20
Side stand bracket fixing screw 15 ÷ 20
Rear rim fixing screw 20÷25
FRONT SUSPENSION
Name Torque in Nm
Front wheel axle 45 ÷ 50
Wheel axle clamp screw 6 ÷ 7 Nm
Lower leg screw 15 to 20 Nm
Hydraulic cartridge stem nut 15 to 18 Nm
FRONT BRAKE
Name Torque in Nm
Viti fissaggio coperchio pompa freno 1,5 ÷ 2 Nm
Brake pump support fixing screw 7 to 10 Nm
Brake fluid pump - hose fitting 13 to 18 Nm
Brake fluid tube - calliper fitting 20 to 25 Nm
Calliper tightening screw 20 to 25 Nm
Disc tightening screw (safety locks - lock with LOCTITE 6 ÷ 7 Nm
THREADLOCK MEDIUM TYPE 243)
Oil bleed screw 7 to 10 Nm
Calliper coupling screw 20 to 25 Nm
REAR BRAKE
Name Torque in Nm
Fastening screws calliper to the crankcase 20 - 25
Brake reservoir cover fixing screw 2÷4 N·m (Grimeca) - 0,8÷1,5 N·m (Brembo) - 1,5÷2 N·m (Heng-
tong)
Brake pump support fixing screw 7 to 10 Nm
Brake fluid pump - hose fitting 13 to 18 Nm
Brake fluid tube - calliper fitting 20 to 25 Nm
Oil bleed screw 7 to 10 Nm
ENGINE ASSEMBLY
Name Torque in Nm
Clutch bell nut 40 to 44 Nm
Clutch lock ring nut 55 ÷ 60
nut locking driving pulley on the crankshaft 40 to 44 Nm
Start-up lever screw 12 ÷ 13
Flywheel nut 40 to 44 Nm
Flywheel fan screws 3÷4
Half-crank case joint bolts 12 ÷ 13
Bolts holding exhaust pipe to the crankcase 22 ÷ 24
Screws holding the filter box to the crank case 4÷5
Head nuts 10 ÷ 11
Starter screws 12 ÷ 13
CHAR - 12

Name Torque in Nm
Ignition spark plug 25 ÷ 30
Hub oil drainage cap 3÷5
Oil hub level dipstick Manual
Rear hub cap screws 12 ÷ 13
Transmission cover screws 12 ÷ 13
Inlet manifold screws 8÷9
Flywheel hood fixing screws 1÷2
Cylinder hood fixing screws 3.5 ÷ 5
Stator clamping screws 3÷4
Pick-Up clamping screw 4÷5
Mixer clamping screws 3÷4
Screw fixing brake lever to the journal on the engine 12 ÷ 13
Overhaul data
Assembly clearances
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 40.2 A 0.10 to 0.25
oversize
Compression ring 2nd 40.4 A 0.10 to 0.25
Oversize
CHAR - 13

Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity
Connecting rod 11.750-0.05 A clearance E = 0.25 to
0.50
shoulder washer 0.5 ± 0.03 G clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
Half-shaft, transmission 13.75+0.040 C clearance E = 0.25 to
side 0.50 - clearance F =
0.20 to 0.75
Flywheel-side half-shaft 13.75+0.040 D clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
Lining between the 40.64 H clearance E = 0.25 to
shoulders 0.50 - clearance F =
0.20 to 0.75
Cage 11.800-0.35 B clearance F = 0.20 to
0.75
Slot packing system

- Fit the cylinder without installing the basic gasket.
- Apply a centimetre dial gauge on the special tool and zero it on the ground plane
- Fit the tool to the top of the cylinder fixing it with two nuts to the studbolts and take the piston to the
T.D.C.
- The thickness of the gasket to fit will change depending on the value detected. For this purpose, there
are three with different thicknesses
Specific tooling
CHAR - 14

020272Y Piston position check tool
SLOT PACKING SYSTEM

Name Measure A Thickness
Shimming 2.80 ÷ 3.04 0,4
Shimming 3.04 ÷ 3.24 0,6
Spacing 3,24÷3,48 0,8
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 to lubricate flexible transmissions Oil for 2-stroke engines: SAE 5W-40, API
(brake, throttle control and mixer, odom- SL, ACEA A3, JASO MA
eter)
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing
NLGI 2 Molybdenum disulphide; ISO-L-
XBCHB2, DIN KF2K-20
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
MONTBLANC MOLYBDENUM Grease for driven pulley shaft adjusting Grease with molybdenum disulphide
GREASE ring and movable driven pulley housing
AGIP GREASE PV2 Grease for the steering bearings, pin White anhydrous-calcium based grease
seats and swinging arm to protect roller bearings; temperature
range between -20 C and +120 C; NLGI
2; ISO-L-XBCIB2.
AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
CHAR - 15

INDEX OF TOPICS
TOOLING TOOL

DNA 50 Tooling
TOOLS
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
TOOL - 17

Tooling DNA 50

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
TOOL - 18

DNA 50 Tooling

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
TOOL - 19

Tooling DNA 50

020164Y Driven pulley assembly sheath
020165Y Start-up crown lock
020166Y Pin lock fitting tool
020167Y Arrest key for impeller pump
020168Y Water seal punch mount on half-crank-

case
020169Y Water pump crankshaft fitting and remov-

al spanner
TOOL - 20

DNA 50 Tooling

020170Y Water pump/mixer command gear ex-
tractor
020261Y Starter spring fitting
020262Y Crankcase splitting strip
020265Y Bearing fitting base
020325Y Brake-shoe spring calliper
020329Y MityVac vacuum-operated pump
TOOL - 21

Tooling DNA 50

020330Y Stroboscopic light to check timing
020331Y Digital multimeter
020332Y Digital rev counter
020334Y Multiple battery charger
TOOL - 22

DNA 50 Tooling

020335Y Magnetic support for dial gauge
020350Y Electrical system check instrument
020357Y 32 x 35 mm adaptor
020359Y 42x47-mm adaptor
020376Y Adaptor handle
020412Y 15 mm guide
TOOL - 23

Tooling DNA 50

020456Y Ø 24 mm adaptor
020483Y 30 mm guide
020565Y Flywheel lock calliper spanner
TOOL - 24

INDEX OF TOPICS
MAINTENANCE MAIN

Maintenance DNA 50
Maintenance chart
EVERY 2 YEARS
Action
Brake fluid - change
Coolant - change
AT 1000 KM OR 4 MONTHS
50'
Action
Hub oil - change
Oil mixer/throttle linkage - adjustment
Steering - adjustment
Brake control levers - greasing
Coolant level - check
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
AT 5000 KM OR 12 MONTHS, 25000 KM, 35000 KM AND 55000 KM

40'
Action
Hub oil level - check
Spark plug/electrode gap - replacement
Air filter - clean
Brake pads - check condition and wear
AT 10000 KM OR 24 MONTHS AND 50000 KM

95'
Action
Hub oil - change
Air filter - clean
Idle speed (*) - adjustment
Variable speed rollers - replacement
Driving belt - checking
Transmission elements - lubrication
Suspensions - check
Headlight - adjustment
(*) see the section "Idle adjustment"
MAIN - 26

DNA 50 Maintenance
AT 15000 KM AND 45000 KM

65'
Action
Hub oil level - check
Air filter - cleaning
Driving belt - replacement
SAS box (sponge) (**) - cleaning
(**) See the regulations of the "Secondary air system" section
AT 20000 KM AND 40000 KM

120'
Action
Hub oil - change
Air filter - clean
Idling speed (*) - adjustment
Cylinder cooling system - check/cleaning
Driving belt - checking
Mixer belt - replacement
Radiator - external cleaning/ check
Suspensions - check
(*) See the section "Idle adjustment"
AT 30000 KM
130'
Action
Hub oil - change
Air filter - clean
Flexible brake tubes - replacement
MAIN - 27

Maintenance DNA 50
Action
Suspensions - check
AT 60000 KM
160'
Action
Hub oil - change
Air filter - clean
Mixer belt - replacement
Radiator - external cleaning/ check
Odometer gear - greasing
Flexible brake tubes - replacement
Suspensions - check
Checking the spark advance
- Check to be effected at 4000 rpm with strobo-

scopic gun. The measured lead must be 17° be-
fore dead centre point.
- The rubber cap shown in the figure needs to be
removed before this check; this makes it possible
to see a reference mark in the magneto cover
N.B.
IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS
PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK
THE CORRECT KEYING OF THE FLYWHEEL ON THE
CRANKSHAFT.
Specific tooling
020330Y Stroboscopic light to check timing
MAIN - 28

DNA 50 Maintenance
Spark plug
-Put the vehicle on its centre stand;

-Disconnect the cap of the spark plug HV lead;
-Unscrew the spark plug using a pipe spanner;
-Examine the conditions of the spark plug, make sure its isolation is not damaged, measure the distance
between the electrodes using the specific feeler gauge.
-Adjust the distance if necessary carefully bending the side electrode.
If the spark plug is defective replace it with the prescribed type;
- Insert the spark plug with the correct inclination, screw it down by hand, then lock with a spanner to
the prescribed torque;
-Put the cap tightly back on the spark plug;
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD. THE SPARK PLUG MUST
BE REPLACED EVERY 5000 KM. USE OF STARTERS NOT CONFORMING OR SPARK PLUGS
NOT THOSE DESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Electrode gap
0.6 ÷ 0.7 mm
Spark plug
CHAMPION RN1C
Locking torques (N*m)

Spark plug 25 - 30 Nm
Hub oil
MAIN - 29

Maintenance DNA 50
Check
To check the hub oil level, proceed as follows:
1. Place the scooter on its stand on a level sur-

face;
2. Unscrew the dipstick «A», dry it with a clean
rag and then reinsert it, screwing it tightly
into place;
3. Unscrew the dipstick again and check that
the oil level barely reaches the 2nd notch
from the bottom;
4. Screw the dipstick back into place complete-
ly.
The screw «B» is the hub oil drainage tap.

CAUTION
USING THE ENGINE WITH INSUFFICIENT LUBRICATION

OR WITH THE WRONG LUBRICANTS MAY INCREASE
WEAR AND TEAR ON THE MOVING PARTS AND MAY
CAUSE SERIOUS DAMAGE.
CAUTION
USED OILS CONTAIN SUBSTANCES HARMFUL TO THE

ENVIRONMENT. FOR OIL REPLACEMENT, CONTACT AN
AUTHORISED SERVICE CENTRE, WHICH IS EQUIPPED
TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY
FRIENDLY AND LEGAL WAY.
N.B.
THE NOTCHES ON THE HUB OIL LEVEL DIPSTICK, EX-
CEPT THOSE INDICATING THE MAXIMUM AND MINIMUM
LEVELS, REFER TO OTHER MODELS BY THE MANUFAC-
TURER, AND HAVE NO SPECIFIC FUNCTION FOR THIS
MODEL.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Rear hub oil
Quantity: approx. 85 cc
MAIN - 30

DNA 50 Maintenance
Replacement
- Remove oil filler cap «A».

- Loosen oil draining cap «B» and allow for the
system to drain completely.
- Refit the draining cap and refill the hub with the
prescribed oil.
Characteristic
Rear hub oil
~ 85 cc
Air filter
-Remove the cap of the purifier, unscrewing the six

clamping screws and removing the filter.
Cleaning:
-Wash with water and neutral soap.
- Dry with a clean cloth and short blasts of com-
pressed air.
-Saturate with a 50% mixture of gasoline and oil.
-Drip dry the filter and then squeeze it between the
hands without wringing.
-Let it dry and refit it again.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE
PISTON AND CYLINDER.
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased ad-
hesiveness
MAIN - 31

Maintenance DNA 50
transmissions
During this phase the engine must be fuelled with

a 2% mixture (at least 0.5 litres if the tank is emp-
ty).
Remove the carburettor guard. Start the vehicle
and adjust the idle using the adjusting screw A on
the carburettor. Adjust the control wires:
Handle control: remove the rubber cap and adjust
the lead adjusting screw so that there is no play in
the gas handle.
Carburettor control: remove the rubber cap and
adjust the lead adjusting screw so that there is no
play in the shielding.
Mixer control: remove the cap on the crankcase
and adjust the adjusting screw so that when the
gas handle is released the reference mark on the
rotating plate is aligned with the reference mark on
the mixer body as shown in the figure.
Move the gas handle to the end of its stroke a few
times and make sure the adjustments have been
made correctly, then lock all the adjusting screws.
CAUTION
IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN
THE RESERVOIR BLEED THE MIXER AS FOLLOWS: RE-
FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED
TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE
MIXER PIPE FROM THE CARBURETTOR AND LOOSEN
THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE)
UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE
SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO
FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY
PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH
THE RELEVANT METAL CLIP.
AGIP CITY TEC 2T Mixer oil
synthetic oil for 2-stroke engines: JASO FC, ISO-
L-EGD
MAIN - 32

DNA 50 Maintenance
Braking system
Level check
Proceed as follows:
- Rest the vehicle on its centre stand with the han-
dlebars perfectly horizontal;
- Check the level of liquid with the related warning
light «A».
A certain lowering of the level is caused by wear
on the pads.
Top-up
Proceed as follows:
- Remove the tank cap by loosening the two
screws, remove the gasket and top up using only
the liquid specified without exceeding the maxi-
mum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR

EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
CAUTION
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE
SURE THAT IT DOES NOT COME INTO CONTACT WITH
THE PAINTWORK.
CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, IN OTH-
ER WORDS, IT ABSORBS MOISTURE FROM
MAIN - 33

Maintenance DNA 50
THE SURROUNDING AIR. IF THE CONTENT OF

MOISTURE IN THE BRAKING FLUID EXCEEDS
A CERTAIN VALUE, BRAKING WILL BE INEF-
FICIENT.
NEVER USE BRAKE LIQUID IN OPEN OR PAR-
TIALLY USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS,
THE FLUID MUST BE CHANGED EVERY 20,000
KM OR ANYWAY EVERY TWO YEARS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO
THE CHANGING OF BRAKE FLUID AND THE BLEEDING
OF AIR FROM THE CIRCUITS.
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Headlight adjustment
Proceed as follows:
1. Place the vehicle in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10 m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the scooter is perpendicular to the screen;
2. Turn on the headlight and check that the bor-
derline of the projected light beam on the screen
is not lower than 9/10 of the distance from the
ground to the centre of vehicle headlamp and high-
er than 7/10;
3. If otherwise, adjust the right headlight with screw
«A».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.
MAIN - 34

INDEX OF TOPICS
TROUBLESHOOTING TROUBL

Troubleshooting DNA 50
This section makes it possible to find the solutions to use in troubleshooting.

For each breakdown, a list of the possible causes and respective interventions is given.
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Defective fuel pump or damaged depression line Replace the pump or control lines
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Fuel filter on the tank outlet fitting dirty or clogged Clean the fitting filter
Excess of encrustations in the combustion chamber Remove the encrustations
Lack of compression wear of the piston rings or cylinder Check the worn parts and replace them
Exhaust pipe clogged due to excessive encrustations Replace the exhaust pipe and check the carburation and mixer
timer
Air filter blocked or dirty Clean according to the procedure
Starter inefficient (stays on) Check the mechanical sliding, continuity of the circuit, the pres-
ence of power and electrical wiring
Clutch slipping Check the centrifugal brake shoe assembly and /or clutch bell
and replace if necessary
Defective mobile pulley sliding Check the parts, change the faulty parts and lubricate the driv-
en pulley using only Montblanc-Molibdenum Grease (dis.
498345) grease
Transmission belt worn Replace
Roller wear; Presence of oil; Dirt Clean the speed variator, replace the rollers if worn out
Rear wheel spins at idle
REAR WHEEL
Idling rpms too high Check the idling speed and, if necessary, adjust the C.O.
Clutch fault Check the spring/friction mass and the clutch bell
Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged
Starting difficulties
DIFFICULTY STARTING
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Defective fuel pump or damaged depression line Replace the pump or control lines
Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Battery flat Check the state of the battery. If it shows signs of sulphation
replace it and bring the new battery into service charging it for
eight hours at a current of 1/10 of the capacity of the battery
itself
- Engine flooded. Start up keeping the throttle fully open alternating approximate-
ly five seconds of turning it with five seconds still. If however it
does not start, remove the spark plug, the engine over with the
throttle open being careful to keep the cap in contact with the
spark plug and the spark plug grounded but away from its hole.
Refit a dry spark plug and start the vehicle.
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Defective spark plug or with incorrect electrode gap Remove the encrustation, restore the plug gap or replace being
sure to use the types of spark plug recommended at all times.
TROUBL - 36

DNA 50 Troubleshooting

Bear in mind that many problems engines have, derive from
the use of the wrong spark plug
Intake joint cracked or with a bad seal Replace the intake joint and check its tightness on the crank-
case and on the carburettor
Purifier-carburettor fitting damaged Replace
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Excess of encrustations in the combustion chamber Remove the encrustations
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air
Dirty carburettor Wash the carburettor with solvent and dry with compressed air
Water in the carburettor Empty the tank through the appropriate bleed nipple.
Air filter dirty Clean or replace
Defective floating valve Check the proper sliding of the float and the functioning of the
valve
Tank breather hole obstructed Restore the proper tank aeration
Engine tends to cut-off at idle
ENGINE STOP IDLING

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air
Starter that stays open Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Reed valve does not close Check / replace the reed pack
Wrong idling adjustment Correctly adjust the engine idling and check the level of the
C.O.
Spark plug defective or faulty Replace the spark plug with one with the specified degree and
check the plug gap
Excessive exhaust noise
INCREASED NOISINESS
Secondary metal air pipe deteriorated Check the seal of the piping on the crankcase and on the hous-
ing, check the piping between the housing and the muffler.
Good condition of the missing secondary air circuit components Check the individual components and the piping, check the
precision of the fitting. Replace the damaged components
High fuel consumption
HIGH FUEL CONSUMPTION

Air filter blocked or dirty. Clean according to the procedure
TROUBL - 37


Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Engine overheating
ENGINE OVERHEATING
Lack of liquid in the cooling circuit. Restore the level and check the absence of losses from the
circuit
Incorrect air bleeding Repeat the operation
Thermostat remains closed Replace
Liquid leak from the radiator Replace radiator
Liquid leak from the system Overhaul of the system
Bearings shaft support impeller blocked Replace the bearings and the shaft with impeller
Breakage of mixer belt Replace the belt and check that the thermal unit has not been
damaged
SAS malfunctions
SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-
FLER
Secondary air reed blocking Replace
Secondary air filter clogging Clean the filter and the housing
Blockage of the secondary air fitting on the muffler Remove the encrustations from the joint being careful not to let
the debris fall into the muffler
Transmission and brakes
Clutch grabbing or performing inadequately
CLUTCH
Tear or irregular functioning Check that the masses open and return normally
Check that there is no grease on the masses
Check that the clutch masses' contact surface with
the clutch bell is mainly in the middle with charac-
teristics equivalent on the three masses
Check that the clutch bell is not scored or worn
abnormally
Never operate the engine without the clutch bell
Insufficient braking
INSUFFICIENT BRAKING
Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
TROUBL - 38

DNA 50 Troubleshooting

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Brakes overheating
OVERHEATING BRAKES
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Defective piston sliding Check calliper and replace any damaged part.
Electrical system
Battery
BATTERY
Battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. If the
vehicle is not used for some time (1 month or more) the battery
needs to be recharged periodically. The battery runs down
completely in the course of 5 ÷ 6 months. If the battery is fitted
on a motorcycle, be careful not to invert the connections, keep-
ing in mind that the black ground wire is connected to the
negative terminal while the red wire is connected to the terminal
marked+. Follow the instructions in the ELECTRICAL SYSTEM
chapter for the recharging of the batteries.
Steering and suspensions
Rear wheel
POOR ROAD HOLDING

Faulty suspension Check that the rear shock absorber and/or the front fork is/are
in good working order. Replace or overhaul the front fork and/
or replace the rear shock absorbers in case of malfunction
Tyres deflated or damaged Check the correct pressure of the tyres and the condition of the
tread. Inflate to the correct pressure or replace.
Loosen the anchorage points of the front and/or rear suspen- Check the tightness between the frame, swinging arm and en-
sion unit. gine and the fixing of the wheels to the hub and/or the axle.
Check the correct tightening of the steering ring nut.
Heavy steering
STEERING HARDENING
Torque not conforming Check the tightening of the top and bottom ring
nuts.
If irregularities continue in turning the steering
even after making the above adjustments, check
TROUBL - 39


the seats in which the ball bearings rotate: replace
if they are recessed.
Excessive steering play
EXCESSIVE STEERING CLEARANCE

EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring
nuts.
If irregularities continue in turning the steering
even after making the above adjustments, check
the seats in which the ball bearings rotate: replace
if they are recessed.
Noisy suspension
NOISY SUSPENSION
Components of the front suspension damaged. Check the quiet operation in the compression or release pha-
ses of the fork and if necessary overhaul it. Check that there is
no noise or seizing during the wheel rotation; if there is, change
the wheel bearing.
Components of the rear suspension damaged. Check the absence of noise in the compression or release of
the suspension, if necessary check the proper tightness to the
swinging arm unit and the absence of rust or replace the entire
shock absorber. Check that there is no noise or seizing during
the wheel rotation; if there is noise or seizing overhaul the final
reduction assembly.
Suspension oil leakage
SUSPENSION LEAKS OIL

Rear shock absorption malfunctioning Replace the complete shock absorption unit
Hydraulic cartridge in the fork damaged. Replace the hydraulic cartridge
TROUBL - 40

INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system DNA 50
1. Electronic ignition device

2. Spark plug
3. Flywheel magneto
4. Voltage regulator
5. Main 7.5 A fuse
6. Key-switch
7. Battery
8. Starter motor
9. Starter relay
10. Starter button
11. Stoplight switch on rear brake
12. Stoplight switch on front brake
13. Turn signal switch
14. Low-oil warning light sender
15. Automatic choke
16. Thermal switch
17. Antitheft LED pre-wiring
18. Antitheft box pre-wiring
19. Phonic wheel encoder
20. Fuel level sender
ELE SYS - 42

DNA 50 Electrical system
21. Blinker switch

22. Headlight switch
23. Taillight
A. Turn signal light bulb
B. Sidelight
C. Stoplight
24. Headlight
B. Low-beam light bulb
C. High-beam light bulb
25. Horn button
26. Horn
27. Dashboard assy.
A. Low-oil warning light
B. Dashboard light bulbs
Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black,

Ro = Pink, Rs = Red, Ve = Green, Vi = Purple
Conceptual diagrams
ELE SYS - 43

Ignition
1. Electronic ignition device

2. Sparkplug
3. Magneto
6. Key switch
ELE SYS - 44

Headlights and automatic starter section
3. Flywheel magneto
5. Main 7.5 A fuse
6. Key-switch
7. Battery
15. Automatic choke
21. Blinker switch
22. Headlight switch
23. Taillight
B. Sidelight
C. Stoplight
24. Headlight
27. Dashboard assy.
ELE SYS - 45

Battery recharge and starting
3. Flywheel magneto
5. Main 7.5 A fuse
6. Key-switch
7. Battery
8. Starter motor
9. Starter relay
10. Starter button
11. Stoplight switch on rear brake
12. Stoplight switch on front brake
23. Taillight
B. Sidelight
C. Stoplight
27. Dashboard assy.
ELE SYS - 46

Level indicators and enable signals section
3. Flywheel magneto
5. Main 7.5 A fuse
6. Key-switch
7. Battery
16. Thermal switch
19. Phonic wheel encoder
20. Fuel level sender
27. Dashboard assy.
ELE SYS - 47

Turn signal lights
3. Flywheel magneto
5. Main 7.5 A fuse
6. Key-switch
7. Battery
13. Turn signal switch
23. Taillight
B. Sidelight
C. Stoplight
24. Headlight
25. Horn button
26. Horn
27. Dashboard assy.
ELE SYS - 48

Digital instrument panel
INSTRUMENT UNIT CONNECTOR

1. Rpm signal
2. Fuel signal
3. Water temperature signal
4. Spare
5. Earth
6. Phonic wheel signal
7. Oil level
8. Parking lights
9. Oil check
10. Phonic wheel supply
11. Under key positive
12. Battery positive
13. Phonic wheel earth
14. Left turn indicator
15. Right turn indicator
16. High beam lamp
INSTRUMENT PANEL
ELE SYS - 49

1. Rpm counter
2. Fuel warning lamp
3. Oil mix warning lamp
4. Parking light lamp
5. High beam lamp
6. Turn indicator lamp
7. Temperature indicator
8. Fuel level indicator
9. Speedometer
10. Odometer
11. Digital display buttons
Checks and inspections
Checks to be made in the case of ignition irregularities and/or no spark on the spark plug
1. Check the condition of the spark plug (clean it with a metal brush, remove the encrustations, blast
it with compressed air and, if necessary, replace it).
2. Without removing the stator, carry out the following checks:
CHECK ON THE PICK UP

1 Red and white cable 90±140 ohm
After visually checking the electrical wiring, perform measurements on the loading reel, the pickup (see
chart) and the continuity using the appropriate tester.
If checks on the loading reel, pickup and continuity show abnormalities, replace the stator; otherwise
replace the central unit. Remember that disconnections due to replacement of the central unit must be
done with the engine off.
Specific tooling
ELE SYS - 50

CHECKING THE RECHARGE COIL

1 Yellow/Red cable 800±1100 ohm
CHECK CONTINUITY
1 White cable-frame continuity
2 White cable-engine continuity
Ignition circuit
All the control operations of the system that require

the disconnection of cables (checks of the con-
nections and the devices making up the ignition
circuit) must be done with the engine off: if this is
not done, the controls might be irreparably dam-
aged.
Stator check
- Using a tester, check the resistance between the

red-ground and green-ground terminal.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERA-
TURE LEADS TO VALUES HIGHER THAN THOSE STATED.
Electric characteristic
Stator : green - ground
~ 1 Ω (Stator)
Pick-Up: red - ground
approx. 170 Ω (Pick-Up)
ELE SYS - 51

Voltage regulator check
The malfunctioning of the voltage regulator might cause the following problems depending on the type
of fault:
1. The lighting system bulbs burn out.
2. The lighting system bulbs stop working.
3. The battery overcharges (the main fuse blows).
4. Non-recharging of the battery.
5. Non functioning of the turn indicators.
Operations
FAULT 1
Replace the regulator because it is definitely faul-
ty.
FAULT 2
Make sure the bulbs work properly.
With the vehicle running check for battery voltage
on the yellow-black wire of the high beam/low
beam switch. If there is no voltage make sure volt-
age is coming correctly from the stator: without
disconnecting the regulator connector and with the
vehicle running, use a tester to measure the alter-
nate voltages between the connection of the grey-
blue wire and black wire make sure it is within the
indicated values, if not replace the stator.
If no irregularities occur during these checks re-
place the regulator.
If replacement of the regulator does not restore
correct operation, carry out the checks of the elec-
trical system.
Specific tooling
Characteristic
Voltage distributed at 3000 rpms
25 to 30V
FAULT 3
After checking that there are no short circuits in the system towards the earth, replace the regulator
because it is certainly inefficient and replace it with a protective fuse.
Following the replacement, measure the current and the recharging voltage on the battery end.
ELE SYS - 52

FAULT 4
Start the vehicle and make sure that when the
tester is placed between the connection of the red
wire and yellow one on the stator, the voltage de-
livered by the generator is within the indicated
value. In the event of a fault check the continuity
of the stator or continue with the checks.
Insert an ammeter between the stator (red wire)
and the battery and use a tester to make sure that
the current delivered at 3000 rpm and the battery
maintained between 12 and 13 V is as indicated.
If the measured values are lower than those pre-
scribed, replace the regulator otherwise replace
the battery.
N.B.
BEFORE CARRYING OUT THE CHECKS ON THE REGU-
LATOR AND RELATIVE SYSTEM, IT IS ALWAYS GOOD
PRACTICE TO CHECK THAT THERE IS CONTINUITY BE-
TWEEN THE BLACK CABLE AND THE GROUND.
N.B.
TO KEEP THE BATTERY BETWEEN 12 AND 13V, CAUSING
CURRENT ABSORPTION BY THE SYSTEM, A 12V - 35W
BULB CONNECTED BETWEEN THE + BATTERY AND
GROUND CAN BE USED.
Specific tooling
Characteristic
Distributed current
1.5 to 2A
Voltage distributed at 3000 rpms
25 to 30V
FAULT 5
If the turn indicators do not work, do the following:
• Without removing the connector from

the voltage regulator, move the key-
controlled switch to ON and verify the
presence of intermittent voltage be-
tween contact 7 and the ground. If
there is voltage, the failure must be at-
tributed to the flashing indicator switch
ELE SYS - 53

or the wiring, otherwise carry on with

tests.
• With the engine off, remove the regu-
lator connector, and insert the ends of
the tester between contact 5 and the
ground.
• Move the key controlled switch to ON
and check there is battery voltage. If no
voltage is detected, check the wiring
and the contacts on the key switch and
on the battery.
• Repeat the same procedure with the

ends of the tester inserted between
contact 5 (+) and 6 (-) and check the
presence of the battery voltage with the
key switch at on. If this does not hap-
pen, check the regulator's ground ca-
ble.
• If these last two tests have a positive result replace the regulator because it is certainly not
functioning properly.
Specific tooling
Fuses
The electrics are protected by a fuse located on

the right side next to the battery well. To replace it,
remove the transparent protection mounted on the
fuse holder. The ignition system, front headlight
and rear taillight are not protected by fuses.
CAUTION
BEFORE REPLACING THE BLOWN FUSE,
SEARCH AND ELIMINATE THE BREAKDOWN
THAT HAS LED TO THE BLOW OUT.
NEVER TRY TO REPLACE A FUSE USING DIF-
FERENT MATERIAL (FOR EXAMPLE A PIECE
OF ELECTRIC WIRE) OR A FUSE FOR A HIGH-
ER AMPERAGE THAN THE INDICATED ONE.
Electric characteristic
ELE SYS - 54

Fuse
7.5 A
Sealed battery
Putting the watertight battery into operation
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.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
-Constant voltage equal to 14.40÷14.70V
-Initial charge voltage equal to 0.3÷0.5 for nominal capacity
-Duration of the charge: 10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the battery
-Duration of the charge: 5 h
WARNING
-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF
RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON-
TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Dry-charge battery
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-
TAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF
COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP-
PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF REACH OF CHILDREN
Use of dry-cell batteries :
1. Having removed the short, closed tube and removed the caps, put into the elements sulphuric
acid of the type for specific weight 1.26 accumulators corresponding to 30° Bé at a temperature
of no less than 15°, until you reach the upper level.
ELE SYS - 55

2. Leave to stand for at least 2 hours; afterwards top-up to the level with sulphuric acid.
3. Within twenty four hours, recharge with the special (single or multiple) battery charger that re-
charges at an intensity the same as approximately 1/10 the rated capacity of the said battery. At
the end of the charge, make sure that the density of the acid is around 1.27, corresponding to 31°
Bé and that these values are stabilised.
4. Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.
5. Once the above operations have been performed, install the battery in the vehicle ensuring that
it is wired up properly..
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE
THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE-
SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO
ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.
Specific tooling
020333Y Single battery charger
1 Hold the vertical tube

2 Look at the level
3 The float must be freed
Battery maintenance
The battery is an electrical device which requires careful monitoring and diligent maintenance. The
maintenance rules are:
1) Check the level of the electrolyte
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical
system: the battery works overcharged and is subject to quick wear.
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° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
ELE SYS - 56

The battery runs down completely in the course of three months. If it is necessary to refit the battery in
the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked
(-) must be connected to the -negative clamp while the other two red wires marked (+) must be con-
nected to the clamp marked with the +positive sign.
3) Recharging the battery
Remove the battery from the vehicle removing the negative clamp first.
The normal bench charging must be carried out with the specific (single or multiple) battery charger,
placing the battery charger selector on the type of battery to be recharged. The connections to the power
supply must be made by connecting to the corresponding poles (+ with+ and -with -).
4) Battery cleaning
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS
AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST
USED SHORTENS THE LIFE OF THE BATTERY.
Specific tooling
020333Y Single battery charger
ELE SYS - 57

INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

DNA 50 Engine from vehicle
Removal of the engine from the vehicle
1. Disassemble the complete muffler.

2. Disassemble the rear wheel.
3. Disassemble the carburettor casing using the
four screws.
4. Disassemble the air filter using the two set
screws as shown in the figure.
5. Remove the three brake hose supports and dis-
assemble the calliper using the 5 screws as shown
in the photo.
6. Drain the cooling system by collecting the cool-
ant in a container and disconnecting the related
hose to the engine
7. Disconnect the electrical system connection
from the magneto, choke, thermistor and starter.
8. Disconnect the accelerator and mixer control
drives.
9. Disconnect the mixer oil, carburettor and vac-
uum pump hoses on the carburettor.
10. Disconnect the HV lead from the spark plug.
11. Remove the rear shock absorber set bolt from
the engine.
12. Unscrew the nut on the right side, then remove
the set pin for the engine-rocker arm from the left
side.

Engine-swinging arm bolt 33 ÷ 41 Shock absorb-
er-engine pin 33 to 41 Nm Rear wheel axle nut 104
÷ 126
ENG VE - 59

Engine from vehicle DNA 50
ENG VE - 60

INDEX OF TOPICS
ENGINE ENG

Engine DNA 50
questa sezione è in lavorazione
Automatic transmission
Transmission cover
- Unscrew the 14 screws and remove the trans-

mission cover using a mallet.
N.B.
THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT
FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY
AND THE BEARING HOUSED ON THE CRANKCASE.
Kickstart
- Upon refitting, apply the recommended grease to

the bushing, to the spring and along the toothed
sector.
- Use the special tool for the charging of the spring,
as shown in the figure.
- Refit the seeger ring after checking that it is in
good condition.
Specific tooling
020261Y Starter spring fitting
AGIP GREASE MU3 Grease for odometer
transmission gear case
Soap-based lithium grease with NLGI 3; ISO-L-
XBCHA3, DIN K3K-20
ENG - 62

DNA 50 Engine
- Remove the screws shown in the figure and re-

move the engine starting lever.
- For the assembly, work in reverse and tighten the
screws to the prescribed torque..

Starter lever replacement 12 to 13 Nm
- Remove the seeger ring located on the exterior

of the crankshaft.
- Dismantle the dog gear from its seat, slackening
the tension that the toothed sector applies to it by
means of the spring; to do this, it is necessary to
rotate the toothed sector slightly (see the figure).
CAUTION
WHILE REMOVING THE TOOTHED SECTOR, BE VERY
CAREFUL OF THE SPRING TENSION: IT COULD CONSTI-
TUTE A HAZARD FOR THE OPERATOR.
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.
N.B.
IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-
AMETER EXTRACTOR CAN BE USED.
Refitting the driven pulley shaft bearing
-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.
N.B.
WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.
CAUTION
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED
SURFACE.
ENG - 63

Engine DNA 50
Removing the driven pulley
- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the
whole of the driven pulley assembly.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE
PULLEY MOUNTED.
Specific tooling
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
use
Ø 107.5 mm
Eccentricity measured /max.
0.20 mm
Removing the clutch
- Equip the tool with long pins screwed into position

«A» from the outside, insert the entire driven pulley
in the tool and put the central screw under stress.
CAUTION
THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW
IS TIGHTENED UP TOO FAR.
ENG - 64

DNA 50 Engine
- Using a 34 mm socket wrench remove the clutch

locking nut.
- Loosen the central screw thereby undoing the
driven pulley unit
- Separate the components.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
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 EX-
HIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE AN-
OTHER.
VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
ENG - 65

Engine DNA 50
- Remove the three guide pins and the mobile half

pulley.
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.
Specific tooling
001467Y029 Bell for bearings, O.D. 38 mm
- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch
housing by means of the special tool.
N.B.
PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO
DEFORM THE SLIDING SURFACE OF THE DRIVING BELT
Specific tooling
020363Y 20 mm guide
Inspecting the driven fixed half-pulley
- Check that there are no signs of wear on the work

surface of the belt. If there are, replace the half-
pulley..
- Make sure the bearings do not show signs of un-
usual wear.
- Measure the external diameter of the pulley bush-
ing.
Characteristic
ENG - 66

DNA 50 Engine
Stationary driven half-pulley/Standard diame-

ter
Ø 33.965 to 33.985 mm
Stationary driven half-pulley / Minimum diam-
eter admitted after use
Ø 33.96 mm
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.

- Insert the new oil seal and O-rings on the mobile
half-pulley.
- Fitting the half-pulley on the bushing.
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This
operation must be done through one of the holes inside the bushing until grease comes out of the
opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.
AGIP GREASE SM 2 Grease for the tone wheel revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
ENG - 67

Engine DNA 50
Refitting the driven half-pulley bearing
- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.
- Fit the new roller bearing with the wording visible
from the outside.
CAUTION
PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT
DAMAGE TO THE THREADED END WHILE THE BEARINGS
ARE BEING FITTED.
Specific tooling
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
- Measure the free length of the spring
Characteristic
Standard length
118 mm
Minimum length allowed after use
XXXX
Refitting the clutch
- Preassemble the driven pulley group with spring,

sheath and clutch.
- Position the spring with the sheath
- Insert the components in the tool and preload the
spring being careful not to damage the plastic
sheath and the end of the threaded bar.
ENG - 68

DNA 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
NUT IN CONTACT WITH THE CLUTCH

Nut locking clutch unit on pulley 55 ÷ 60 Nm
Refitting the driven pulley
-Refit the driven pulley assembly, the clutch bell

and the nut, using the specific tool.
Specific tooling

Driven pulley shaft nut 40 to 44 Nm
Drive-belt
- Make sure the driving belt is not damaged and

does not have cracks in the toothed grooves.
- Check the width of the belt.
Characteristic
Transmission belt/Minimum width
17.5 mm
ENG - 69

Engine DNA 50
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.
Specific tooling
020451Y Starting ring gear lock
Mixer gears and belt
- Remove gear and belt.

CAUTION
PAY PARTICULAR ATTENTION TO NOT TOUCHING OR
BENDING THE BELT BECAUSE THIS COULD BREAK SUD-
DENLY DURING OPERATION.
CAUTION
ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET
INTO THE INNER BUSHING OF THE MIXER CONTROL
GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON
THE CRANKCASE PIN.
N.B.
REPLACE THE BELT EVERY 20000 KM.
Inspecting the rollers case
1) Check that the bushing and the sliding rings of

the mobile pulley do not show signs of scoring or
deformation.
2) Check the roller running tracks on the contact
pulley; there must not be signs of wear and check
the condition of the contact surface of the belt on
the half-pulleys (mobile and stationary).
3) Check that the rollers do not show signs of
marked facetting on the sliding surface and that
the metallic insert does not come out of the plastic
shell borders.
ENG - 70

DNA 50 Engine
4) Check the integrity of the sliding blocks of the

contact plate.
- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inside
diameter «A».
- Measure outside diameter «B» of the pulley slid-
ing bushing shown in the figure.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHING.
Characteristic
Driving pulley / Maximum diameter:
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.
N.B.
IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO
THAT THE WORDS CAN BE READ IN CASE IT DOES NOT
SHOW A FITTING SIDE.
- Refit the components of the assembly (roller con-

tainer assembly with bushing, limiting washer, sta-
tionary half-pulley, cooling fan belt with drive,
washer and nut).
- With the specific tool, tighten the lock nut to 20
Nm and then perform a final 90° locking in order to
prevent the rotation of the driving pulley.
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
CAUTION
UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-
MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN
ENG - 71

Engine DNA 50
ORDER TO AVOID WRONG TIGHTENING AND CONSE-

QUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling
020451Y Starting ring gear lock

Crankshaft pulley nut 18 to 20 + 90° Nm
End gear
Removing the hub cover
• Remove the transmission cover

• Remove the clutch assembly
• Discharge the rear hub oil.
• Remove the 5 screws indicated in the figure.
• Remove the hub cover with driven pulley shaft.
See also
Refitting the clutch
Removing the wheel axle
- Remove the intermediate gear and the complete

gear wheel axle.
- When removing the intermediate gear pay atten-
tion to the various shim adjustments.
ENG - 72

DNA 50 Engine
Removing the wheel axle bearings
- Remove the oil seal and the seeger ring.

- Remove the bearing by pushing from the outside
towards the inside of the gear compartment, using
the appropriate punch.
Specific tooling
020363Y 20 mm guide
Removing the driven pulley shaft bearing
- Remove the seeger ring inside the cover.

- Remove the oil seal from the outside.
- Remove the centring dowels and position the
cover on a plane.
- Position the special tool on the internal track of
the bearing and remove said bearing with the aid
of a press.
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
- Position the special tube on the internal raceway
of the bearing and from the shaft toothed side as
indicated in the figure. Expel the driven pulley shaft
with the aid of a press.
Specific tooling
driven pulley shaft
ENG - 73

Engine DNA 50
Inspecting the hub shaft
- Check that the three shafts exhibit no wear or

deformation on the toothed surfaces, at the bear-
ing housings and at the oil guards.
- In case of anomalies, replace the damaged com-
ponents.
- Check that the fitting surface is not dented or dis-
torted.
- If faults are found, replace the hub cover.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing
- Support the inner track of the bearing from the

outside of the hub cover with the specific tool posi-
tioned under the press and insert the driven pulley
axle.
- Refit the oil seal flush with the cover.
Specific tooling
driven pulley shaft
• Heat the hub cover and insert the bearing with

the specific punch.
• Fit the snap ring with the concave or radial part
on the bearing side.
N.B.
FIT THE BALL BEARING WITH THE SHIELD FACING THE
OIL SEAL.
Specific tooling
020151Y Air heater
020439Y 17 mm guide
ENG - 74

DNA 50 Engine
Refitting the wheel axle bearing
- Heat the half crankcase on the transmission side

using a thermal gun.
- After lubricating its outer strip, insert the bearing
with the special adapter with the aid of a hammer.
- Refit the seeger ring and the oil seal using the 42
x 47 mm adapter and the handle.
Specific tooling
020151Y Air heater
020363Y 20 mm guide
Refitting the ub cover
- Refit the whole wheel axle.

- Refit the intermediate gear paying attention to the
two shim thicknesses.
- Apply LOCTITE 510 for surfaces to the hub cov-
ers and refit the same with driven pulley shaft.
- Refit the 5 screws and tighten them to the speci-
fied torque.
N.B.
CLEAN THE CONTACT SURFACES OF THE HUB COVER
AND THE HALF CRANKCASE OF RESIDUE FROM PREVI-
OUS GASKETS BEFORE APPLYING A NEW ONE.

Locking torque: 11 to 13 Nm
Flywheel cover
ENG - 75

Engine DNA 50
Removing the stator
- Remove the three stator fixings shown in the

photo
- Remove the two pick-up fixings shown in the
photo
- Remove the stator with the wiring
Refitting the stator
- Refit the stator and flywheel proceeding in the

inverse direction, tightening the studs to the pre-
scribed torque.
THREAD THE CABLE OF THE STATOR INTO THE SPECIF-
IC HOUSING OF THE CRANKCASE AND MAKE SURE
THAT IT IS LOCKED BY THE TAB OF THE RETURN LINE
OF THE COOLING SYSTEM.

Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4
Refitting the flywheel cover
• Fit the rubber seal on the flywheel con-

nector and around the inlet coolant
hose.
ENG - 76

DNA 50 Engine
• Keeping the flywheel connector rubber

clamp on the coolant inlet hose, refit
the flywheel cover paying attention in
inserting the strap in the groove.
• Tighten the 4 studs, noting that the two
longer golden screws are inserted in
the 2 top holes and are also responsi-
ble for restraining the secondary air-
box.
Flywheel and starting
Removing the starter motor
• Remove the central stand by unscrewing the 3

set screws of the engine support
• Remove the set screws indicated in the figure
ENG - 77

Engine DNA 50
Removing the flywheel magneto
- Lock the rotation of the flywheel using the calliper

spanner.
- Remove the nut.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
- Extract the flywheel with the extractor.
Specific tooling
020162Y Flywheel extractor
Inspecting the flywheel components
- Check the condition of the flywheel and any dis-

tortions that might cause rubbing on the stator and
on the Pick-Up.
ENG - 78

DNA 50 Engine
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key

properly.
- Lock the flywheel nut at the prescribed torque
- Check the Pick-Up air gap.
- The air gap may not be modified in the fitting of
the Pick-Up.
- Other values derive from deformations visible on
the Pick-Up support.
N.B.
A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO
A VARIATION IN THE IGNITION ADVANCE SUCH AS TO
CAUSE PINGING, KNOCKING ETC.

Flywheel nut 40 to 44 N.m
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.

- Fit the starter on the crankcase, locking the two
screws to the prescribed torque.
N.B.
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.

Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
Removing the intake manifold
Use an anti-tampering TORX spanner to remove

the two clamping screws of the intake manifold
ENG - 79

Engine DNA 50
Removing the cylinder head
Remove the 4 screws shown in the figure
Removing the cylinder - piston assy.
Remove the cylinder very carefully
Remove the snap rings and remove the pin

CAUTION
AFTER EACH REMOVAL OPERATION REPLACE THE PIN
RETENTION SNAP RINGS
ENG - 80

DNA 50 Engine
Inspecting the small end
- Measure the internal diameter of the small end

using an internal micrometer.
N.B.
IF THE DIAMETER OF THE ROD SMALL END EXCEEDS
THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF
WEAR OR OVERHEATING REPLACE THE CRANKSHAFT
AS DESCRIBED IN THE "CRANKCASE AND CRANK-
SHAFT" CHAPTER".
Characteristic
Rod small end: standard diameter
17 +0.011-0.001
Rod small end: maximum allowable diameter
17,060 mm
Inspecting the wrist pin
- Check the wrist pin external diameter using a mi-

crometer
Characteristic
Wrist pin: standard diameter
12 +0.005 +0.001 mm
Inspecting the piston
- Measure the bearings on the piston using a bore

meter
- Calculate the piston-pin coupling clearance.
Characteristic
Wrist pin housing: standard diameter
12 +0.007 +0.012
Wrist pin housing: standard clearance
0.002 ÷ 0.011 mm
ENG - 81

Engine DNA 50
- Measure the outer diameter of the piston, per-

pendicular to the pin axis.
- Take the measurement in the position shown in
the figure
To classify the cylinder-piston fitting, check the ap-
propriate table
See also
Inspecting the cylinder
- Check that the cylinder does not show seizures.

Otherwise, replace it or adjust it respecting the al-
lowable increases
- Measure the internal diameter of the cylinder with
a bore meter, according to the directions given in
the figure
- Check that the fitting surface with the head is not
dented or distorted.
To classify the cylinder-piston fitting, check the ap-
propriate table
See also
Inspecting the piston rings
- Alternatively insert the two sealing rings in the

cylinder
Using the piston, insert the seals perpendicularly
to the cylinder axis.
- Measure the opening of the sealing rings using a
thickness gauge as shown in the photograph
- If the values are higher than the values prescri-
bed in the chart, substitute the rings
ENG - 82

DNA 50 Engine
Removing the piston
- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.
-Push detail 2 into detail 1 until the stop and extract detail 2.
- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3
all the way in.
N.B.
REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM
THE REMOVAL OPERATIONS
Specific tooling
020166Y Pin lock fitting tool

Locking head nuts: 10 to 11 N·m
- Use new wrist pin snap rings.
- Use new cylinder base gasket.
- Before refitting carefully clean all the surfaces.
- Use oil to be mixed during the fitting of the piston
and the cylinder.
CAUTION
POSITION THE ARROW PRINTED ON THE PIS-
TON CROWN TOWARDS THE EXHAUST
OPENING.
THE WRIST PIN SNAP RINGS MUST BE POSI-
TIONED ON THE PISTON WITH THE SPECIFIC
TOOL
AGIP CITY TEC 2T Oil
Recommended oil
ENG - 83

Engine DNA 50
Inspecting the timing system components

CAUTION
CHECK THE CORRECT REED UNIT SEAL; NO LIGHT
MUST PASS BETWEEN THE SUPPORT AND LAMELLA.
Crankcase - crankshaft
Splitting the crankcase halves
Remove the eight crankcase union fasteners.
ENG - 84

DNA 50 Engine
Install the special strip on the half crankcase on

the flywheel side and separate the half crankcase
on the flywheel side from the transmission side
Specific tooling
Removing the crankshaft
- Install the specific tool on the half crankcase on

the transmission side using four M6 screws of an
adequate length.
- Remove the crankshaft from the transmission
side half crankcase
Specific tooling
Removing the crankshaft bearings
The bearings can stay on either the half crankcase

or the crankshaft indifferently
- Using the special tool, remove any bearings that
have been left on the crankshaft
N.B.
The half rings must be inserted on the bearings with a few mal-
let blows.
Specific tooling
004499Y001 Bearing extractor bell
004499Y006 Bearing extractor ring
004499Y002 Bearing extractor screw
004499Y007 Half rings
ENG - 85

Engine DNA 50
- Using the specific tool remove any bearings left

on the half crankcase
Specific tooling
001467Y007 Driver for OD 54 mm bearing
001467Y006 Pliers to extract 20 mm bearings
Refitting the crankshaft bearings
Heat the bearings in an oil bath at around 150°C

and fit them on the crankshaft, if necessary using
a section of tube that acts on the bearing's inner
track
Specific tooling
020265Y Bearing fitting base
Inspecting the crankshaft alignment
With the specific tool shown check that the eccen-

tricity of the surfaces of diam. «A»-«B»-« C» are
within 0.03 mm. (reading limit on the dial gauge);
in addition, check the eccentricity of diam. «D», for
which a maximum reading of 0.02 mm is permitted.
In the case where eccentricity is not much above
prescribed levels, straighten the shaft by acting
on the counterweights with a shim or tighten them
ENG - 86

DNA 50 Engine
in a clamp (with an aluminium bushing) as re-

quired..
Specific tooling
020074Y Support base for checking crankshaft
alignment
Refitting the crankshaft
- Position the transmission side half crankcase on

two wooden supports
- Using a thermal gun, heat the bearing seat to
about 120°
- Firmly insert the crankshaft until the bearing rea-

ches the end-of-stroke stop
- Let the temperature of the half crankcase settle

at the temperature of the crankshaft.
- Again install the special crankcase separation
plate NOT installing the crankshaft protection
- During the assembly phase keep the central
thrust screw loose.
- Take the four clamping screws to the end of the
stroke and loosen them again with the same angle
(e.g. 90°)
- When the temperature has settled, preload the
thrust screw of the tool manually until the ball bear-
ing clearance is cancelled out.
Specific tooling
ENG - 87

Engine DNA 50
Refitting the crankcase halves
- Prepare the coupling surface with LOCTITE 510

applying a thin layer of it after degreasing the sur-
face using a suitable solvent (e.g. trichloroethy-
lene)
- Heat the flywheel-side half crankcase with a ther-
mal gun.
Loctite 510 Liquid sealant
Gasket
- Keeping the half crankcase on the transmission

side, insert the flywheel side half crankcase with a
clean precise movement
- Insert at least three clamping screws and tighten
up rapidly
- Insert the other 5 screws and tighten them to the
specified torque.

crankcase coupling screws 11 - 13
- Move the crankcase separation plate in a position
back from the one indicated in the figure
- Install the special magnetic support with dial
gauge at the end of the crankshaft
- Check the axial clearance of the crankcase
If this is not within the maximum limit allowed, re-
peat the crankcase coupling procedure
Specific tooling
ENG - 88

DNA 50 Engine
Characteristic
Axial clearance with warm crankcase
0.10 ÷ 0.12 mm
Axial clearance with cold crankcase
0.06 to 0.08 mm
Limit value with cold crankcase
0.02 ÷ 0.03 mm
Lubrication
Crankshaft oil seals
Refitting
- Install a new flywheel-side oil seal only with the

special tool's punch
The flywheel-side oil seal is recognised by its
smaller diameter
N.B.
THE USE OF THE SPECIFIC TOOL IS NOT
COMPATIBLE WITH THE FITTED WRENCH
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
- Install a new transmission side oil seal using the
special tool with adapter ring.
The transmission-side oil seal is recognised by the
larger diameter
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
Oil pump
ENG - 89

Engine DNA 50
Removal
- Remove the 2 screws shown in the figure
Remove the tube passage seal from the crank-

case shown in the figure
Refitting
To refit, perform the steps in the reverse direction

to disassembly
Remember to drain after refitting using the screw
shown in the figure
ENG - 90

DNA 50 Engine
Fuel supply
The vehicle comes with a membrane pump con-

trolled by the depression that is generated in the
intake manifold. Therefore, the tank has an intake
in the lowest point that sends the fuel to the pump
and from here to the carburettor.
To determine the correct functioning of the pump,
the following measurements can be made on the
amounts distributed:
1) Start up the engine, bring it to normal operating
temperature and then shut it off.
2) Disconnect the fuel adduction line on the car-
burettor and insert it into a graduated tube.
3) Start up the engine without the accelerator and
keep it idle.
4) After the engine is started, count to 10 and then
turn it off.
5) Check that the quantity of fuel is not less than
the prescribed value.
Characteristic
Fuel distributed
~100cc X 10"
ENG - 91

INDEX OF TOPICS
SUSPENSIONS SUSP

DNA 50 Suspensions
Sospensioni anteriore
This section is devoted to operations that can be carried out on the suspension.
Front
Removing the front wheel
- Loosen the wheel axle set screws A

- Unscrew and extract the wheel axle B
Refitting the front wheel
- When reassembling be careful of the correct po-

sitioning of the odometer movement socket.

Front wheel axle 45 ÷ 50 Wheel axle clamp
screw 6 ÷ 7 Nm
Handlebar
SUSP - 93

Suspensions DNA 50
Removal
- Remove the drives and disconnect the electrical

terminals.
- Remove the bracket using the four screws.
Front fork
Removal
Pump unit disassembly

- Disassemble the front brake calliper using the
two screws.
- Remove the front wheel.
- Remove the front bumper
- Loosen the four set screws of the fork leg to the
plates and front cover indicated in the photo in or-
der to be able to remove the pump unit from below.
During disassembly be careful to support the cover
only with the brackets anchored to the fork leg.
SUSP - 94

DNA 50 Suspensions
Disassembling the complete fork

- Remove the front wheel.
- Remove the front brake calliper. Take out the
brake hose and the speedometer lead from the
support bracket anchored on the lower plate.
- Remove the handlebar support bracket and bring
the handlebar forward without disconnecting the
drives.
- Loosen the four front cover support screws on the
fork legs.
- Loosen the two pump unit set screws on the up-
per plate, remove ring nut A and pull out the upper
plate.
- Remove ring nut B, extract the rubber protection
and the washer.
- Remove the complete fork from the bottom being
careful to support the cover only with the brackets
anchored to the fork legs.
- Use the extractor to remove the bearing from the
seat in the chassis.
- Remove the roller bearing and sealing ring of the
lower plate
See also
Front
brake calliper
Handlebar
SUSP - 95

Suspensions DNA 50
Refitting
For the assembly proceed in the opposite order of the disassembly making sure to lubricate the seats
and bearing with recommended grease.
Specific tooling
020055Y Wrench for steering tube ring nut
AGIP GREASE PV2 Grease for control levers on the engine
White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °C
and +120 °C; NLGI 2; ISO-L-XBCIB2

Locking torque: 50 to 60 Nm
Removing the rear wheel
- Use a screwdriver as a lever between the drum

and the cover.
-Straighten the split pin and remove the cap.
-Remove the wheel acting on the central fixing
point.
WARNING
-ALWAYS USE NEW SPLIT PINS FOR REFITTING.
Shock absorbers
Removal
To replace the shock absorber you just need to

remove the battery access flap to get and remove
the shock absorber/ frame anchorage nut. Then
remove the shock absorber/engine anchorage
nut.
SUSP - 96

DNA 50 Suspensions
Refitting
When refitting, tighten the shock absorber/frame anchorage nut and the shock absorber/engine pin at
the prescribed torque.

Shock absorber/frame nut torque 20 to 25 Nm Shock absorber/engine pin torque 33 to 41 N·m
Centre-stand
Extracting the pin securing the stand to the bracket
- Remove the stand support bracket from the en-

gine.
- Drill a 5 mm hole in the bracket so that the pin
«P» can come out.
Assembly and caulking stand pin to the bracket
- Caulk the end of the pin «P» between the two

punches shown in the figure.
- After caulking it must be possible for the stand to
turn freely.
N.B.
UPON REFITTING USE NEW O-RING AND PIN, GREASE
THE SPRING ATTACHMENTS AND THE PIN.
Replacing the complete stand
SUSP - 97

Suspensions DNA 50
- Work on the screws shown in the figure.

- When refitting, secure to the prescribed torque.

Stand screw torque 18.5 to 19 Nm
SUSP - 98

INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Braking system DNA 50
questa sezione è in lavorazione
Front brake calliper
Removal
• Check that the brake piping, gasket

and fitting are in good condition. If you
see any oil on the brake calliper and/on
the components of the system, it is
necessary to replace them.
• - Disconnect the oil line from the cal-
liper, collecting the oil in a container.
• - Remove the two clamps highlighted
in the diagram.
Overhaul
Proceed as follows:
1) remove the two male hexagonal screws (1) and
take out the two pads (10);
2) remove the two male hexagonal screws (2) and
remove the reaction plate (3);
3) take out the fixed plate (4) from the guide;
4) remove the internal elements from the floating
body (5) with the help of short blows of com-
pressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
- that the cylinder and the floating body of the cal-
liper do not show signs of scratches or erosion,
otherwise replace the entire calliper;
- that the guides of the fixed plate are not scratched
or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.
Reassembly
BRAK SYS - 100

DNA 50 Braking system
1) insert the pistons (6) and the sealing rings (7) in

the body;
2) place the guide rubbers (8) and refit the fixed
plate (4);
3) assemble the reaction plate (3) tightening the
screws (2), insert the brake pad check spring (9)
and then the pads, fixing them with the corre-
sponding screws (1);
5) place the calliper on the disc and lock it to the
strut by tightening the fixing screws;
6) fix the pipe joint on the calliper at the prescribed
torque.
Functioning
This is a floating type calliper.
It takes advantage of the action and reaction prin-
ciple to obtain the thrust for both pads.
The body and the reaction plate body work inte-
grally and can move axially with respect of the
fixed plate that is integral to the strut.
The pistons, forced by pressure to push the pad to
the disk, cause the reaction plate to push in turn
the other pad towards the disc.
The brake pad lock spring
1. Pad fixing screws
2. Reaction plate fixing screws
3. Reaction plate
4. Fixed plate
5. Floating body
6. Piston
7. Piston sealing rings
8. Guide protection rubbers
9. Brake pad check spring
10. Pads
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EV-
ERY TIME THE CALLIPER IS SERVICED.

Calliper tightening screw 24 ÷ 27 Brake fluid
pipe-calliper fitting 19 ÷ 24
BRAK SYS - 101

Refitting
• Refit the pincer on the support and

tighten the screws at the prescribed
torque.
• Refit the tube complete with fitting with
new copper gaskets.
• Bleed the air from the system.

Brake fluid tube calliper 20 ÷ 25 Nm Fastening
screws calliper to the crankcase 20 - 25 Oil bleed
screw 7 to 10 Nm
Front brake disc
Removal
- Remove the front wheel undoing the axle clamp-

ing.
- Undo the five disc clamps.

Disc tightening screw 8 ÷ 10
Refitting
-When refitting, position the disc correctly making sure that it rotates in the right direction.

Disc tightening screw 8 - 12
Disc Inspection
Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt
and must not show signs of deep scoring.
Characteristic
New rear disc thickness
4.0 mm
Disc thickness at wear limit (front)
BRAK SYS - 102

3.5 mm
• Using the appropriate tool, measure
how much the disc protrudes when the
wheel is fitted properly. The protrusion,
measured near the external edge of
the disc, must be less than 0.1 mm.
• If a value is measured other than the
specified value, remove the front wheel
(Front/Rear Suspension chapter) and
check the protrusion of the disc. Maxi-
mum permissible out of true is 0.1 mm.
If the value measured is greater, re-
place the disc and repeat the check.
• If the problem persists, check and re-
place the wheel hub if necessary.
Specific tooling
Front brake pads
Removal
Proceed as follows:
- Remove the front calliper.
- Loosen the two pins shown in the figure that lock
the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the pads.
Characteristic
Minimum value
1.5 mm
See also
Front
brake calliper
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
BRAK SYS - 103

- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-
TING, GENTLY EXPAND THE PADS.
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock

Screw tightening calliper to the support 20 ÷ 25 Pad fastening pin 19.6 ÷ 24.5
Fill
-Once the bleed valve is closed, fill the system with

brake liquid to the maximum level.
-Undo the bleed screw.
-Apply the tube of the special tool to the bleed
screws.
When bleeding it is necessary to fill the oil tank in
continuation while working with a MITYVAC pump
on the bleed screws until no more air comes out of
the system.
The operation is finished when just oil comes out
of the bleed screws.
-Do up the bleed screw.
-When the operation is over, tighten up the oil
bleed screw to the prescribed torque.
N.B.
IF AIR CONTINUES TO COME OUT DURING
PURGING, EXAMINE ALL THE FITTINGS:
IF SAID FITTINGS DO NOT SHOW SIGNS OF
BEING FAULTY, LOOK FOR THE AIR INPUT
AMONG THE VARIOUS SEALS ON THE PUMP
AND CALLIPER PISTONS.
CAUTION
- DURING THE OPERATIONS, THE VEHICLE MUST BE ON
THE STAND AND LEVEL.
N.B.
DURING PURGING FREQUENTLY CHECK THE LEVEL TO
PREVENT AIR GETTING INTO THE SYSTEM THROUGH
THE PUMP.
WARNING
BRAK SYS - 104

- BRAKING CIRCUIT FLUID IS HYGROSCOPIC.

IT ABSORBS HUMIDITY FROM THE SUR-
ROUNDING AIR.
IF THE LEVEL OF HUMIDITY IN THE BRAKING
FLUID EXCEEDS A GIVEN VALUE, BRAKING
EFFICIENCY WILL BE REDUCED.
THEREFORE, ALWAYS USE FLUID FROM
SEALED CONTAINERS.
UNDER NORMAL DRIVING AND CLIMATIC
CONDITIONS YOU SHOULD CHANGE THIS
LIQUID EVERY TWO YEARS.
IF THE BRAKES ARE USED INTENSELY AND/
OR IN HARSH CONDITIONS, CHANGE THE
FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID
MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS
SEAT ON THE CALLIPER.
CAREFULLY DRY THE CALLIPER AND DE-
GREASE THE DISC SHOULD THERE BE OIL
ON IT.
Specific tooling
020329Y MityVac vacuum-operated pump
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid

Oil bleed screw 8÷12
Front brake pump
- Drain the brake fluid from the circuit using the bleed screw located on the calliper and operating the
brake lever until more fluid comes out.
- Remove the handlebar pump using the two stand set screws indicated in the figure.
- disconnect the hose and put the brake fluid in a container
- On refitting, perform the operation in reverse.

- Tighten the hydraulic line to the prescribed torque
and bleed the system.

Brake fluid pump - hose fitting 20 ÷ 25 Nm
BRAK SYS - 105

Rear brake pump - combined
- Drain the brake fluid from the circuit using the bleed screw located on the calliper and operating the
brake lever until more fluid comes out.
- Remove the handlebar pump using the two stand set screws indicated in the figure.
- disconnect the hose and put the brake fluid in a container
- On refitting, perform the operation in reverse.

- Tighten the hydraulic line to the prescribed torque
and bleed the system.

Brake fluid pump - hose fitting 20 ÷ 25 Nm
BRAK SYS - 106

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

Cooling system DNA 50
System bleed
1. Fill the circuit through the expansion tank to

the maximum level.
2. Fasten the rubber line to the drain fitting on
the head and thread it into the expansion
tank mouth..
3. Loosen the fitting and restore the tank level.
4. Start up the engine and wait until only cool-
ant exits from the line, then tighten the fitting
on the head..
5. Turn off the engine, restore the level of liquid
to the maximum level, then close the expan-
sion tank..
6. Heat up the engine to normal operating tem-
perature in order to eliminate any air forma-
tion in the main lines..
7. Stop the engine and let it cool, then check
that the level of coolant in the expansion tank
to the maximum;; refill it.
Water pump - overhaul
- Ensure the shaft is not abnormally worn and the

bearings not noisy. Otherwise, replace shaft and
bearings
- Carefully clean oil seal and bearing housings
COOL SYS - 108

DNA 50 Cooling system
- Use a new oil seal to refit

- Position the new oil seal on the special tool with
the main lip facing the bearings as shown in the
picture
- Lubricate the oil seal and push it home using the

special tool as shown in the picture
Specific tooling
020168Y Water seal punch mount on half-
crankcase
- Insert the shaft, with bearings, into its housing by

pushing and turning it at the same (turn anticlock-
wise for tightening)
- Turn it rapidly to the end of the threading.
- Should this operation prove difficult, do not carry
on; instead, start over by reheating the crankcase
N.B.
FAILURE TO OBSERVE THIS RULE MAY RESULT IN DAM-
AGE TO THE THREAD OF THE COPPER INSERT ON THE
IMPELLER, OR SEPARATION OF THIS FROM THE IMPEL-
LER ITSELF.
Specific tooling
020169Y Water pump crankshaft fitting and re-
moval spanner
Using the air heater, warm up the water pump
bearing housing, without directing the air flow di-
rectly against the oil seal
- Lubricate the end of the water pump shaft on the
oil seal side, using the recommended product.
AGIP GREASE MU3 Grease for odometer
transmission gear case
COOL SYS - 109

Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20
- Remove the pick-up/coolant inlet hose clamp

- Remove the transmission cover
- Remove the mixer
- Setup the special as shown in the picture
N.B.
WHEN SECURING THE TOOL, PAY ATTENTION NOT TO
OVERLOAD THE PLASTIC IMPELLER.
Specific tooling
020167Y Arrest key for impeller pump
- Remove the mixer/water pump drive-belt with the
two sprockets
- Remove the split ring from the shaft together with

the bearings
- Remove the steel washer
- Using the air heater, warm up the crankcase in

the area around the water pump bearings as
shown in the picture.
COOL SYS - 110

DNA 50 Cooling system
- With the aid of the special tool, loosen the impel-

ler shaft turning the spanner clockwise (left-hand-
ed thread)
- As the thread is fully disengaged, extract the
shaft with the aid of pliers.
Specific tooling
020169Y Water pump crankshaft fitting and re-
moval spanner
- Using the special hook, remove the sealing ring from its housing as shown in the picture.
Specific tooling
020209Y Spring hook
Thermostat
Removal
• Detach the coolant hose from the

head, partially draining the system.
• Remove the cylinder head.
• Remove the two fixing screws and
hence the thermostat.
Check
1) Visually check that the thermostat is not dam-

aged.
2) Fill a metallic container with approx. 1 litre of
water.
Immerge the thermostat, and keep it in the centre
of the bowl.
Immerge the multimeter temperature probe, and
keep it close to the thermostat.
Heat up the bowl using the thermal gun.
Check the thermostat opening start temperature:
Heat up until the thermostat is completely open.
COOL SYS - 111

3) Replace the thermostat if not working properly.

CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-
THER THE THERMOSTAT NOR THE THERMOMETER
TOUCHES THE CONTAINER.
Specific tooling
020151Y Air heater
Characteristic
Thermostat check: Opening start temperature
60±2°C
Refitting
• Refit the thermostat onto the head, fol-

lowing the removal operations in the
reverse order, and paying attention in
inserting the groove on the thermostat
on the reference on the head.
COOL SYS - 112

INDEX OF TOPICS
CHASSIS CHAS

Chassis DNA 50
Headlight assy.
- Remove the 9 screws shown in the figure.

- Remove the rubber caps and disconnect the con-
nectors from the bulbs.
- Remove the headlamp unit set screws and pull
the unit out from the top.
Taillight assy.
Remove the two screws and take out the whole

unit.
CHAS - 114

DNA 50 Chassis
Side fairings
Rear side panels

- Remove the saddle.
- Remove the passenger footrest.
- Remove the screws indicated in the photo and
then the side panels.
Front side panels:

Remove the screws shown in the photo and then
disconnect the joint between the side panels and
the lower central cover.
When reassembling be sure to screw the shortest
threaded screw in position A.
CHAS - 115

Chassis DNA 50
Lower central covering:

- Remove the front side frames and the helmet
compartment.
- Remove the connectors A, rear brake hose B
from the left brake pump, the accelerator control
lead C, then pull it all out from the slot in the lower
central cover.
Air filter
- Remove the protective crankcase of the carbu-

rettor by removing the four screws.
- Remove the two screws shown in the photo then
disconnect the air manifold at the carburettor and
remove it.
When refitting, be careful to correctly install the air
manifold into the air filter housing.
Rear mudguard
Rimuovere il carter di protezione carburatore

agendo sulle quattro viti.
Rimuovere il parafango agendo sulle due viti indi-
cate in figura.
CHAS - 116

DNA 50 Chassis
Helmet bay
- Remove the saddle and the left rear side panel.

- Open the helmet compartment, remove the ex-
pansion cap and the gas tank cover, then screw
the cap back on.
- Remove the two screws inside the helmet com-
partment indicated in the photo.
- Remove the saddle opening drives on both sides
using the two screws indicated in the photo.
- Remove the five screws connecting the two com-
partment guards indicated in the photo.
- Remove the fuel cap, separate the two guards
enough to let the fuel intake pipe pass and then
remove the compartment from the top.
CHAS - 117

Chassis DNA 50
Fuel tank
- Remove the helmet compartment.

- Remove the from side frames and the lower central covering.
- Remove the lower radiator support using the two screws and the pump guard indicated in the photo.
Disconnect the three hoses A towards the engine

unit, then remove the fuel pump using the two
screws B indicated in the photo.
Remove the two expansion tank support screws,

remove the two radiator set screws, and without
draining the cooling system, pull the radiator out
from the bottom and the expansion tank from the
chassis unit.
Remove the fuel level connector
CHAS - 118

DNA 50 Chassis
Remove the four fuel tank set screws shown in the

photo, then pull the tank out from the front.
When reassembling make sure to secure the split-

ter block support with the left front set screws of
the tank.
Radiator fan
- Remove the front side panels and the lower cen-

tral covering
- Drain the coolant and then disconnect the four
hoses A.
- Remove the two screws B and pull the radiator
out of its seat on the lower bracket.
CHAS - 119

Chassis DNA 50
Expansion tank
- Remove the helmet compartment.

- Remove the tow support screws shown in the
figure
- Disconnect the two hoses collecting the coolant
in a container
Mixture oil tank
- Remove the saddle, remove the battery cover,

disconnect the mix oil level connector and unscrew
the screw shown in the photo.
- Pull the tank out from the top, collect the oil in a
container and disconnect the oil supply hose.
Battery
Remove the saddle, unscrew the screw indicated

in the photo and remove the cover.
CHAS - 120

INDEX OF TOPICS
PRE-DELIVERY PRE DE

Pre-delivery DNA 50
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection

Lock check
- Safety locks
- clamping screws
Safety locks
Rear shock absorber upper fixing

Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
Electrical system:
- Main switch
- Headlamps: high beam, low beam, position and parking lights and the respective warning lights
- Adjusting the headlights according to the regulations currently in force
- Rear light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator
- Instrument panel warning lights
- Horn
- Starter
PRE DE - 122

DNA 50 Pre-delivery
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS
AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO EN-
SURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO
BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic braking system fluid level.
- Rear hub oil level
- Engine coolant level.
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
PRE DE - 123

Pre-delivery DNA 50
Static test
Static control after the test ride:

- Starting when warm
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional check up:

Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 124

INDEX OF TOPICS
TIME TIME

Time DNA 50
This section is devoted to the time necessary to

carry out repairs.
The description and code for each operation is in-
dicated.
Engine
ENGINE
Code Action Duration
1 001001 Engine to chassis - Replacement
TIME - 126

DNA 50 Time
Crankcase
CRANKCASE
1 001133 Engine crankcase - Replacement
TIME - 127

Time DNA 50
Crankshaft
CRANKSHAFT
1 001117 Crankshaft - Replacement
2 001118 Main bearings - Replacement
3 001099 Oil seal, flywheel side - Replacement
4 001100 Oil seal, clutch side - Replacement
TIME - 128

DNA 50 Time
Cylinder assy.
CYLINDER / PISTON
1 001002 Cylinder piston - Replacement
2 001107 Cylinder / piston - Inspection / clean-
ing
TIME - 129

Time DNA 50
Cylinder head assy.
HEAD ASSEMBLY
1 001013 Intake manifold - Replacement
2 001056 Head gasket - change
3 001057 Thermostat - Replacement
4 001093 Spark plug - Replacement
5 001126 Head - Replacement
6 007010 Bleed valve - Replacement
7 001178 Disc pack - Replacement
8 001083 Thermistor - Replacement
TIME - 130

DNA 50 Time
Driven pulley
DRIVEN PULLEY
1 001110 Driven pulley - Replacement
2 001022 Clutch - Replacement
3 001155 Clutch bell housing - Replacement
4 001012 Driven pulley - Service
TIME - 131

Time DNA 50
Oil pump
OIL MIX PUMP

1 001018 Mixer - Replacement
2 001019 Mixer belt - replacement
3 001028 Mix movement gear socket - Re-
placement
TIME - 132

DNA 50 Time
Final gear assy.
FINAL REDUCTION GEAR

1 001010 Geared reduction unit - Service
2 001156 Gear reduction unit cover - Replace-
ment
3 003065 Gear box oil - Replacement
4 004125 Rear wheel axle - Replacement
TIME - 133

Time DNA 50
Driving pulley
DRIVING PULLEY
1 001011 Driving belt - Replacement
2 001066 driving pulley - Replacement
3 001017 Starter sprocket wheel - Replace-
ment
4 001086 Driving half-pulley - replace
5 001177 Variator rollers / shoes - Replace-
ment
TIME - 134

DNA 50 Time
Transmission cover
TRANSMISSION COVER
1 001096 Transmission crankcase cover - Re-
placement
2 001131 Transmission air intake - Replace-
ment
3 001132 Transmission air inlet pipe - Replace-
ment
4 001135 Transmission cover bearing - Re-
placement
5 004179 Stand buffer - Replacement
TIME - 135

Time DNA 50
Water pump
WATER PUMP
1 001113 Water pump - Replacement
2 001062 Water pump command shaft - Re-
placement
3 007019 Connection water pump pipe / return
pipe - Replacement
TIME - 136

DNA 50 Time
Starter motor
STARTER MOTOR AND KICK STARTER

1 001020 Starter motor - Replacement
2 001021 Kick starter - Inspection
3 001084 Starter lever - Replacement
4 008008 Starter spring pack - Replacement
5 005045 Starter motor cable harness - Re-
placement
TIME - 137

Time DNA 50
Flywheel magneto
FLYWHEEL MAGNETO
1 001058 Flywheel - Replacement
2 001067 Stator - Replacement
3 001173 Rotor - Replacement
4 001087 Flywheel cover - Replacement
TIME - 138

DNA 50 Time
Brake shoes
BRAKE SHOES
1 002002 Rear brake shoe(s) - Replacement
TIME - 139

Time DNA 50
Carburettor
CARBURETTOR
1 001063 Carburettor - Replacement
2 007020 Carburettor heating tubing - replace-
ment
3 003058 Carburettor - Adjustment
TIME - 140

DNA 50 Time
CARBURETTOR INSPECTION
1 001081 Automatic choke - Replacement
2 001008 Carburettor - Inspection
Exhaust pipe
TIME - 141

Time DNA 50
MUFFLER
1 001009 Muffler - Replacement
2 001095 Muffler guard - Replacement
3 001136 Exhaust emissions - Adjustment
Air cleaner
AIR FILTER
1 001014 Air filter - Replacement / cleaning
2 001015 Air filter box - Replacement
3 004122 Air cleaner carburettor fitting - Re-
placement
TIME - 142

DNA 50 Time
Frame
CHASSIS
1 001053 Stand bolt - Replacement
2 004004 Stand - Replacement
3 004001 Frame - replace
4 004015 Footrest - Replacement
5 004171 Stand support plate - Replacement
6 004143 Footrest support - replace
TIME - 143

Time DNA 50
Legshield spoiler
FRONT SHIELD
1 004065 Front shield rear section - Replace-
ment
2 004064 Front shield - Replacement
3 003087 Wheel housing - Replacement
4 004167 Grill / radiator cover - Replacement
5 004176 Air vent - Replacement
TIME - 144

DNA 50 Time
Side fairings
CENTRAL COVER
1 004053 Spoiler - Replacement
2 004178 Footrest - Replacement
3 004011 Central chassis cover - Replacement
TIME - 145

Time DNA 50
Underseat compartment
HELMET COMPARTMENT
1 004059 Spark plug inspection flap - Replace-
ment
2 004016 Helmet compartment - Replacement
3 005046 Battery cover - Replacement
TIME - 146

DNA 50 Time
Plate holder
LICENSE PLATE HOLDER

1 005022 Rear turn indicators - Replacement
2 005068 Rear turn indicator bulb - Replace-
ment
3 005005 Taillight - Replacement
4 005023 Rear tail light support - Replacement
5 005091 Turn indicator glass - Replacement
TIME - 147

Time DNA 50
Mudguard
MUDGUARDS
1 004009 Rear mudguard - Replacement
2 004052 Bumper - Replacement
3 004002 Front mudguard - Replacement
TIME - 148

DNA 50 Time
Fuel tank
FUEL TANK
1 004005 Fuel tank - Replacement
2 005010 Tank float - Replacement
3 004011 Central chassis cover - Replacement
4 004072 Fuel filter - Replacement
5 004110 Fuel tank hose - Replacement
6 004168 Fuel tank cap - Replacement
7 004170 Tank filler neck - Replacement
TIME - 149

Time DNA 50
Tank oil
OIL TANK
1 004017 Oil reservoir - Replacement
2 005018 Oil reservoir float - Replacement
3 004095 Oil reservoir cock - Replacement
4 004091 Oil reservoir hose - Replacement
TIME - 150

DNA 50 Time
Rear shock-absorber
REAR SHOCK ABSORBER

1 003007 Rear shock absorbers - Replace-
ment
TIME - 151

Time DNA 50
Steering column bearings
STEERING FIFTH WHEELS

1 003002 Steering fifth wheel - Replacement
2 003073 Steering clearance - Adjustment
3 004119 Bearing / upper steering fifth wheel -
Replacement
TIME - 152

DNA 50 Time
Handlebar components
HANDLEBAR COMPONENTS
1 003001 Handlebar - Replacement
2 002060 Complete throttle control - Replace-
ment
3 002059 Right hand grip - Replacement
4 005017 Stop switch - Replacement
5 003059 Counterweight - Replacement
6 002024 Front brake pump - replace
7 002037 Brake or clutch lever - Replacement
8 002047 Front brake fluid and air bleeding
system - Replacement
9 003061 Accelerator transmission - Adjust-
ment
10 004066 Driving mirror - Replacement
11 002071 Left hand grip - Replacement
12 002067 Rear brake pump - Replacement
13 002080 Rear brake oil bleeding system - Re-
placement
TIME - 153

Time DNA 50
Swing-arm
SWINGING ARM
1 001072 Engine / frame swinging arm fitting -
Replacement
TIME - 154

DNA 50 Time
Seat
SEAT
1 004003 Saddle - Replacement
2 004054 Seat lock hook - Replacement
3 002083 Saddle opening transmission - Re-
placement
TIME - 155

Time DNA 50
Instrument panel
INSTRUMENT UNIT AND HANDLEBAR COVER

1 005014 Odometer - Replacement
2 004018 Handlebar front section - Replace-
ment
3 004019 Handlebar rear section - Replace-
ment
4 005078 Odometer glass - Replacement
TIME - 156

DNA 50 Time
Turn signal lights
FRONT LIGHT
1 005067 Front turn indicator bulb - Replace-
ment
2 005008 Front headlamp bulbs - Replacement
3 005002 Front headlamp - Replacement
4 005012 Front turn indicator - Replacement
TIME - 157

Time DNA 50
Front wheel
FRONT WHEEL
1 002041 Front brake disc - Replacement
2 003040 Front wheel bearings - Replacement
3 003037 Front wheel rim- Replacement
4 003047 Front tyre - replace
5 004123 Front wheel - Replacement
6 003038 Front wheel axle - Replacement
7 005089 Tone wheel - Replacement
Grease tone wheel or drive

Please take note that the code has been intro-
duced:
900001 - Tone wheel / drive greasing - 15'.
Never mistake the codes 002011 (movement sen-
sor replacement) and 005089 (tone wheel replace-
ment) in the event of noise of the indicated
components. The grease recommended is TUTE-
LA MRM 2 (soap-based lithium grease with Mo-
lybdenum disulphide).
In the following points we indicate with an arrow
the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 158

DNA 50 Time
Rear wheel
REAR WHEEL
1 001071 Rear wheel rim - Replacement
2 001016 Rear wheel - Replacement
3 002070 Rear brake disc - Replacement
4 004126 Rear wheel tyre - Replacement
5 002028 Rear wheel hub - Replacement
TIME - 159

Time DNA 50
Fuel pump
FUEL PUMP
1 004073 Fuel pump - Replacement
2 004137 Pump / carburettor hose - Replace-
ment
3 004086 Petrol pump depression tube - Re-
placement
TIME - 160

DNA 50 Time
Electric devices
BATTERY
1 005007 Battery - Replacement
2 005024 Battery fuse - Replacement
3 005025 Fuse holder - Replacement
4 005011 Start-up remote control switch - Re-
placement
TIME - 161

Time DNA 50
ELECTRICS
1 001023 Control unit - Replacement
2 001094 Spark plug cap - Replacement
3 005001 Electrical system - Replacement
4 005009 Voltage regulator - Replacement
5 005136 Resistance - Replacement
6 005044 Front lights cable unit- Replacement
TIME - 162

DNA 50 Time
Electronic controls
ELECTRICAL COMMANDS
1 005041 Starter button - Replacement
2 005040 Horn button - Replacement
3 005016 Key switch - Replacement
4 004096 Lock series - Replacement
5 004010 Antitheft lock - replace
6 005003 Horn - Replacement
7 005006 Light switch or turn indicators - Re-
placement
8 005039 Headlight switch - Replacement
TIME - 163

Time DNA 50
Transmissions
SPLITTER
1 002012 Splitter - Replacement
2 002058 Mix / splitter transmission complete -
Replacement
3 002057 Carburettor / splitter transmission
complete - Replacement
4 002054 Throttle or splitter transmission com-
plete - Replacement
TIME - 164

DNA 50 Time
Brake callipers
BRAKE CALLIPERS
1 002007 Front brake pads - Replacement
2 002021 Front brake piping - Replacement
3 002039 Front brake calliper - Replacement
4 002002 Rear brake pads - Replacement
5 002020 Rear brake disc piping - Replace-
ment
6 002048 Rear brake calliper - Replacement
TIME - 165

Time DNA 50
Rear side fairings
REAR COVERS
1 004159 Plates / Stickers - Replacement
2 004056 Upper rear light cover - Replacement
3 004036 Lower chassis cover - Replacement
4 004085 Fairing (1) - Replacement
5 004129 Rear fairing - Replacement
TIME - 166

DNA 50 Time
Front suspension
FORK
1 003010 Front suspension - Service
2 003051 Complete fork - replace
3 003048 Fork oil seal - Replacement
4 003041 Fork stanchion - Replacement
TIME - 167

Time DNA 50
Cooling system
COOLING SYSTEM
1 007001 Expansion tank - Replacement
2 007002 Water cooling radiator - Replace-
ment
3 001052 Coolant and air bleed - Replacement
4 007024 Expansion tank cap - Replacement
5 007013 Expansion tank / radiator connecting
hose - Replacement
6 007003 Delivery line and coolant return - Re-
placement
7 001170 Air deflector - Replacement
TIME - 168

DNA 50 Time
Secondary air box
SECONDARY AIR SYSTEM

1 001163 Muffler secondary air connection -
Replacement
2 001165 Secondary air reed - Replacement
3 001164 Crankcase secondary air connection
- Replacement
4 001161 Secondary air filter - Replacement /
Cleaning
5 001162 Secondary air housing - Replace-
ment
TIME - 169

A
Air filter: 31, 116
B
Battery: 39, 46, 55, 120
Brake: 95, 100, 102, 103, 105, 106, 139, 165
C
Carburettor: 11, 140
E
Engine stop:
F
Fuel: 37, 91, 118, 149, 160
Fuses: 54
H
Headlight: 34, 114
Hub oil: 29
I
Identification: 8
Instrument panel: 49, 156
M
Maintenance: 7, 26
S
Shock absorbers: 96
Spark plug: 29
T
Tank: 118, 120, 149, 150
Transmission: 9, 38, 62, 135
Tyres: 10

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WORKSHOP MANUAL

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ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

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This section describes the general specifications of the vehicle.

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Dimensions and mass

DIMENSIONS AND MASS

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Frame and suspensions

FRAME AND SUSPENSIONS

Wheels and tyres

WHEELS AND TYRES

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To clean the sponge filters of the secondary air

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Cylinder - piston assy.

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Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Slot packing system

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020272Y Piston position check tool

SLOT PACKING SYSTEM

TABLE OF RECOMMENDED PRODUCTS

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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

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Stores code Description

001467Y021 Extraction pliers for ø 11 mm bearings

002465Y Pliers for circlips

006029Y Punch for fitting fifth wheel seat on steer-

020004Y Punch for removing fifth wheels from

020209Y Spring hook

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Stores code Description

020074Y Support base for checking crankshaft

020150Y Air heater support

020151Y Air heater

020162Y Flywheel extractor

020163Y Crankcase splitting plate

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