gilera stalker 50 - maintenance
DESCRIPTION
Gilera Stalker 50 - MaintenanceTRANSCRIPT
GILERA WOULD LIKE TO THANK YOU
for choosing one of its products. We have prepared this manual to help you to get the very best from your scooter. Please read it carefully before ridingthe scooter for the first time. It contains information, tips and precautions for using your scooter. It also describes features, details and devices to assureyou that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new vehicle and it will serve youwell for a long time to come. This booklet forms an integral part of the scooter; should the scooter be sold, it must be transferred to the new owner.
Stalker 50
Ed. 2
The instructions given in this manual are intended to provide a clear, simple guide to using your scooter; this booklet also details routine maintenanceprocedures and regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre. The booklet also containsinstructions for simple repairs. Any operations not specifically described in this manual require the use of special tools and/or particular technicalknowledge: to carry out these operations refer to any authorised Dealer of Service Centres.
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Personal safety
Failure to completely observe these instructions will result in serious risk of personalinjury.
Safeguarding the environment
Sections marked with this symbol indicate the correct use of the vehicle to prevent dam-aging the environment.
Vehicle intactness
The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.
The signs that you see on this page are very important. They are used to highlight thoseparts of the booklet that should be read with particular care. As you can see, each signconsists of a different graphic symbol, making it quick and easy to locate the varioustopics.
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INDEX
VEHICLE...................................................................................... 7Dashboard................................................................................ 8Digital lcd display...................................................................... 8Key switch................................................................................. 9
Locking the steering wheel.................................................... 9Switch direction indicators........................................................ 9Horn button............................................................................... 10Light switch............................................................................... 10Start-up button.......................................................................... 11
Opening the saddle............................................................... 11Keys.......................................................................................... 12Identification.............................................................................. 13
USE.............................................................................................. 15Checks...................................................................................... 16Refuelling.................................................................................. 16Tyre pressure............................................................................ 18Running in................................................................................. 18Starting up the engine............................................................... 19Difficult start up......................................................................... 20Stopping the engine.................................................................. 20Catalytic silencer....................................................................... 21Automatic transmission............................................................. 22Safe driving............................................................................... 22
MAINTENANCE........................................................................... 25Hub oil level.............................................................................. 26Tyres......................................................................................... 27Spark plug dismantlement........................................................ 28Removing the air filter............................................................... 29Secondary air system............................................................... 30Intake plug................................................................................ 30Checking the brake oil level...................................................... 31Battery....................................................................................... 32Long periods of inactivity.......................................................... 33
Fuses........................................................................................ 34Front light group........................................................................ 35
Headlight adjustment............................................................. 35Front direction indicators........................................................... 36Rear optical unit........................................................................ 37Rear turn indicators................................................................... 37Rear-view mirrors...................................................................... 37Idle adjustment.......................................................................... 38Front disc brake........................................................................ 39Rear drum brake....................................................................... 40Puncture.................................................................................... 40Periods of inactivity................................................................... 40Cleaning the vehicle.................................................................. 41
TECHNICAL DATA...................................................................... 45Kit equipment............................................................................ 48
SPARE PARTS AND ACCESSORIES........................................ 49Warnings................................................................................... 50
PROGRAMMED MAINTENANCE............................................... 51
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Stalker 50
Chap. 01Vehicle
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01_01
Dashboard (01_01)
A= Digital instrument panel unit
B = Front brake control lever
C = Throttle grip
D= Starter button
E= Horn button
F= Turn indicator switch
G= Rear brake control lever
H= High/low-beam switch
01_02
Digital lcd display (01_02)
A= Low fuel warning light
B= Odometer
C= Turn indicator warning light
D= Fuel gauge
E= Mixer low oil warning light
F= High-beam warning light
G= Speedometer
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01_03
01_04
Key switch (01_03)
LOCK= Ignition blocked, key can be extracted, steering lock installed.
OFF = Ignition blocked, key can be extracted, steering lock not on.
ON = Starter position, steering lock not on, key cannot be extracted.
Locking the steering wheel (01_04)
Turn the handlebar to the left (as far as it will go), turn the key to position «LOCK»and remove the key.
CAUTION
DO NOT TURN THE KEY TO «LOCK» OR «OFF» WHILE RIDING.
01_05
Switch direction indicators (01_05)
To set the left turn indicators flashing, move lever «B» to the left; to set the right turnindicators flashing, move it to the right. The lever automatically returns to the centralposition and the indicators remain on. To turn the indicators off, press the lever towardsthe switch.
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01_06
Horn button (01_06)
Horn button «E»
01_07
01_08
Light switch (01_07, 01_08)
0 = Low beam and side light
1 = High beam and side light
P= Passing (light flash)
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01_09
Start-up button (01_09)
To start the engine, press the starter button, «P», after pulling either one of the twobrake levers.
01_10
Opening the saddle (01_10, 01_11)
Insert the key in lock «A», turn it anticlockwise and tip the saddle forward.After having tipped the saddle, place the helmet as shown in the figure.
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01_11
01_12
Keys (01_12)
The vehicle is supplied with two keys (one spare) which serve to start the engine andunlock the saddle compartment. The keys are accompanied by a tag marked with theidentification code to be quoted when ordering duplicates.
WARNING
WE RECOMMEND KEEPING THE DUPLICATE KEY TOGETHER WITH ITS CODEIN A SAFE PLACE AND NOT ON THE VEHICLE
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01_13
01_14
Identification (01_13, 01_14)
The identification numbers consist of a prefix stamped on the chassis and on the en-gine, followed by a number. They should always be given when requesting spareparts. We recommend that you check that the prefix and chassis number stamped onthe vehicle correspond with those in the vehicle documents.
CAUTION
BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERSCAN LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE,ETC.).
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Stalker 50
Chap. 02Use
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Checks
Before using the vehicle, check:
1. That the petrol tank and oil reservoir are full.
2. The oil level in the rear hub.
3. That the tyres are correctly inflated.
4. That the headlight, rear light and turn indicators are in working order.
5. That the front and rear brakes are in working order.
6. The fluid level in the brake pump reservoir.
02_01
02_02
Refuelling (02_01, 02_02)
Fill the fuel tank «A» as shown in the diagram, with unleaded petrol with minimumoctane rating of 95. When the fuel reaches the reserve level, the warning light fittedon the instrument panel lights up; see the «Digital display» section. Top up oil tank«B» using recommended oil.The minimum oil level is shown by the oil warning lightfitted on the instrument panel; see the «Digital Display» section. Should this warninglight turn on, the oil tank should be topped-up with at least 0.5÷0.7 lt. at the next re-fuelling and in any case before travelling another 150 km. At every engine start-up(electrical start-up), the mixer low oil warning light turns on and then turns off whenthe starter button «P» is released (section «Starter button»). If the warning light failsto come on, it is faulty. Should this happen, contact an Authorised Piaggio-GileraService Centre. Should the 'mixer' device be removed and refitted, it needs to bebled. However, the ducts can remain without oil. After these operations, refill the fueltank with 3 l of a mixture with 2% of the recommended oil.Subsequent refuelling mustbe performed using petrol only.
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CAUTION
SHUT OFF THE ENGINE BEFORE REFUELLING WITH PETROL. PETROL ISHIGHLY FLAMMABLE. DO NOT LET PETROL SPILL FROM THE TANK OR WHILEREFUELLING
CAUTION
DO NOT BRING NAKED FLAMES OR CIGARETTES NEAR THE MOUTH OF THEFUEL TANK: FIRE HAZARD. ALSO AVOID INHALING HARMFUL VAPOURS.
CAUTION
THE USE OF OILS AND SPARK PLUGS OTHER THAN THOSE RECOMMENDEDCAN SHORTEN THE LIFE OF THE ENGINE.
Recommended productsAGIP CITY TEC 2T
Mixer oilsynthetic oil for 2-stroke engines: JASO FC, ISO-L-EGD
CharacteristicOil mixer tank
Plastic, with a capacity of ~ 1.2 l (including a ~0.400 l reserve).
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Tyre pressure
CAUTION
TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.INCOR-RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID-ING DANGEROUS.
TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITSSET FORTH BY LAW.
CharacteristicTyre pressure (front wheel)
Front wheel: 1,8 bar
Rear tyre pressure
2 bar
Rear tyre pressure (rider and luggage)
2.5 bar
02_03
Running in (02_03)
WARNING
DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80% OF ITSMAXIMUM SPEED. AVOID TWISTING THE THROTTLE GRIP FULLY OR KEEP-ING A CONSTANT SPEED ALONG LONG SECTIONS OF ROAD. AFTER THEFIRST 1000 KM, GRADUALLY INCREASE SPEED UNTIL REACHING THE MAX-IMUM PERFORMANCE.
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02_04
Starting up the engine (02_04)
The vehicle is equipped with automatic transmission with direct drive, so that start-upis effected by twisting the throttle grip to the minimum; to start-off from stationary po-sition, progressively twist the throttle grip. The vehicle is equipped with a fuel valveand a starter which switch on automatically as soon as the engine is started. In orderto start the engine, it is necessary to pull either the rear brake lever "B" or the frontbrake lever "C", before pressing the starting button, "A ", so as to disengage the safetyswitches.
A: Place the vehicle on its stand; check that the rear wheel is off the ground.
B: Keep the throttle closed.
C. Insert the key into the ignition switch and turn it to «ON». When turning the key to«ON», the oil warning light turns on for a few seconds indicating the correct operationof the bulb and electric circuit.
D: Push the starter button after pulling the rear brake lever «B» and/or the front brakelever «C».
CAUTION
DO NOT CARRY OUT THESE OPERATIONS IN CLOSED AREAS SINCE EX-HAUST GASES ARE TOXIC.
CAUTION
ALWAYS PLACE THE VEHICLE ON ITS STAND BEFORE KICK STARTING.
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02_05
Difficult start up (02_05)
If there is a problem you can follow the instructions below:
1.Carburettor flooded. Place the vehicle on the centre stand and check that the reartyre is off the ground. Open the throttle fully and press the starter button for five sec-onds and then stop for five seconds. If the engine does not start after a few attempts,let the engine sit for a few minutes and then repeat the above operations. In any casedo not operate the starter motor longer than 20" in an attempt to start the engine.
2. Battery or starter motor inefficiency. Put the scooter on its stand "E"; make surethat the rear wheel is off the ground, turn the key switch «D» to «ON» and use thekick-starter «F».
3. Empty fuel tank. After refuelling the scooter, start the engine by pressing the starterbutton «A» with the throttle at a minimum to provide maximum aspiration for the tap.If the vehicle cannot be started by any of these procedures, contact an AuthorisedPiaggio-Gilera Service Centre.
CAUTION
ALWAYS PLACE THE VEHICLE ON ITS STAND BEFORE KICK STARTING.
02_06
Stopping the engine (02_06)
Stop acceleration, then turn the key switch "D" to "OFF " to turn off the engine (ex-tractable key).
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Catalytic silencer
CAUTION
TAMPERING WITH THE CATALYTIC MUFFLER MAY CAUSE SEVERE DAMAGETO THE ENGINE.
CAUTION
WHEN PARKING THE VEHICLE, DUE TO THE HIGH TEMPERATURES THE CAT-ALYTIC CONVERTER CAN REACH, ALWAYS BE CAREFUL THAT THE MUF-FLER DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS, TOAVOID SERIOUS BURNS.
CAUTION
DO NOT SWITCH OFF THE ENGINE WHILE THE VEHICLE IS MOVING. UN-BURNED FUEL COULD ENTER THE CATALYTIC CONVERTER AND BURN,CAUSING IT TO OVERHEAT AND POSSIBLY DESTROYING IT.
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02_07
Automatic transmission (02_07)
To ensure simple, pleasurable riding, the vehicle is equipped with automatic trans-mission with regulator and centrifugal clutch. The system is designed to give the bestpossible performance in terms of both acceleration and consumption, on level groundand uphill, thanks to the adjustments made to engine speed and transmitted torque.If you have to stop on an uphill slope (traffic lights, traffic jam, etc.) only use the braketo keep the vehicle still, leaving the motor running at idling speed. Using the motor tokeep the vehicle still can cause the clutch to overheat. This problem is due to thefriction of the clutch parts on the clutch bell. It is therefore recommended to avoidconditions of prolonged clutch slippage leading to clutch overheating (for example, aswell as the situation described above, riding uphill fully laden on steep slopes or start-ing off on slopes greater than 25%, etc.):
1. Do not continue riding in such conditions.
2. Let the clutch cool down with the motor at idling speed for a few minutes.
Safe driving
WARNING
SOME SIMPLE TIPS ARE PROVIDED BELOW THAT WILL ENABLE YOU TO USEYOUR SCOOTER ON A DAILY BASIS IN GREATER SAFETY AND WITH MOREPEACE OF MIND.<
Your ability and your knowledge of the vehicle form the basis of safe riding. We rec-ommend trying out the vehicle in traffic-free zones to get to know your vehiclecompletely.ALWAYS DRIVE WITHIN YOUR LIMITS
1. Before riding off, remember to put on your helmet and fasten it correctly.
2. Reduce speed and ride cautiously on uneven roads.
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3. Remember that after riding on a long stretch of wet road without using the brakes,the braking effect is initially lower. Given these conditions, it is a good idea to operatethe brakes from time to time.
4. Do not brake hard on a wet surface, on dirt tracks or on any slippery road surface.
5. If you have to brake, use both brakes in order to divide the braking action betweenboth wheels.
6. Avoid starting off by mounting the scooter while it is still resting on its stand. In anycase, the rear wheel should not be turning when in comes into contact with the ground,in order to avoid abrupt departures.
7. If the vehicle is used on roads covered with sand, mud, snow mixed with salt, etc.,clean the brake disc frequently with mild detergent in order to prevent abrasive sub-stances from building up within the holes, which can result in early wear of the brakepads.
8. Any elaboration that modifies the vehicle's performances, such as tampering withoriginal structural parts is strictly forbidden by law, and renders the vehicle not con-forming to the approved type and therefor dangerous to ride.
CAUTION
DO NOT FORGET THAT DRIVING IN A STATE OF DRUNKENNESS, OR WHENUNDER THE EFFECT OF DRUGS OR CERTAIN MEDICINES, CAN BE EXTREME-LY DANGEROUS FOR ONESELF AND FOR OTHERS.
CAUTION
ANY CHANGES TO THE VEHICLE PERFORMANCE AS WELL AS ALTERATIONSTO ORIGINAL STRUCTURAL PARTS IS STRICTLY FORBIDDEN BY LAW, ANDRENDERS THE VEHICLE NO LONGER CONFORMING TO THE APPROVED TYPEAND DANGEROUS FOR RIDING.
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Stalker 50
Chap. 03Maintenance
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03_01
03_02
Hub oil level (03_01, 03_02)
Check that there is oil in the rear hub
Recommended productsAGIP ROTRA 80W-90
Rear hub oilSAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
CharacteristicRear hub oil
Quantity: approx. 75 cm³
Do the following to check the correct level:
1) Stand the vehicle on the centre-stand on flat ground;
2) Remove the dipstick «A», and dry it with a clean cloth. Reinsert it, screwing it in allthe way;
3) Remove the stick and check that the oil level is slightly over the second notchstarting from the lower end;
4) Screw the dipstick back in, checking that it is locked in place.
Recommended productsAGIP ROTRA 80W-90
Rear hub oilSAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
-Remove the oil filler cap «A».
- Unscrew the oil drainage cap "B" and drain out all the oil.
- Screw in the drainage cap again and fill the hub with the prescribed oil.
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CharacteristicRear hub oil
Quantity: ~80 cm³
03_03
Tyres (03_03)
Periodically check the inflation pressure of each tyre. Tyres have tread wear indicatorsand must be replaced as soon as these indicators are visible on the tread; should thisoccur, go to an authorised workshop or to a workshop properly equipped for refitting.
CAUTION
TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.INCOR-RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID-ING DANGEROUS.
TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITSSET FORTH BY LAW.
CharacteristicTyre pressure (front wheel)
Front wheel: 1,8 bar
Rear tyre pressure
2 bar
Rear tyre pressure (rider and luggage)
2.5 bar
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3 Maintenance
03_04
03_05
Spark plug dismantlement (03_04, 03_05)
Proceed as follows:
Once the spark plug access cover placed on the central cover is removed, disconnectthe HV cable spark plug and remove the plug with the box-spanner supplied.
When refitting the spark plug, tighten it by hand, being sure to insert it at the rightangle; Use the wrench only to fasten it.
When refitting the cover, follow the procedure in the reverse order, taking care thatthe fitting teeth of the spark plug cover are introduced into the corresponding placeson the central cover.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. THE USEOF SPARK PLUGS OF DIFFERENT THERMAL GRADE FROM THAT REQUIREDOR WITH INAPPROPRIATE THREADS MAY SERIOUSLY DAMAGE THE ENGINE.
Characteristicrecommended spark plug:
CHAMPION RN2C
Electrode gap
0.6 ÷ 0.7 mm
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03_06
Removing the air filter (03_06)
Undo the 6 cross-slotted screws «A». Remove the cover and take it out from its seat.Remove the filtering element and wash it with water and neutral soap; then dry it witha clean rag and short blasts of compressed air. Immerse a sponge in a mixture of 50%petrol and 50% specified oil. remove it from the solution, compress it with your handswithout wringing out, let it drain and refit.
DRIVING WITH AN AIR FILTER WHICH IS NOT CORRECTLY LUBRICATED WITHOIL OR INCORRECTLY FITTED, MAY CAUSE SERIOUS DAMAGE TO THE EN-GINE AND THE CATALYTIC CONVERTER.
AN OIL FILTER WHICH IS TOO DIRTY CAUSES A VARIATION IN THE ENGINECARBURETION WITH SUBSEQUENT CHANGES IN THE VEHICLE BEHAVIOUR(E.G. UNSTABLE MINIMUM) AND POSSIBLE DAMAGE OF THE CATALYTICCONVERTER.
CAUTION
IN CASE OF RIDING ON DUSTY ROADS IT IS ADVISABLE TO CLEAN THE AIRFILTER MORE FREQUENTLY THAN INDICATED IN THE RELEVANT CHAPTERON SCHEDULED MAINTENANCE.
Recommended productsAGIP FILTER OIL
Oil for air filter spongeMineral oil with specific additives for increased adhesiveness
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3 Maintenance
03_07
Secondary air system (03_07)
Remove the two screws «A» from the aluminium SAS cover. Release the metal tubefrom the rubber housing on the cover without extracting the tube from the cover/sleeve.Remove the tab and plastic cover, extract the sponge and wash it in water and soap.Dry it with compressed air before refitting it, making sure to correctly fit the lamella inthe housing on the two plastic and aluminium covers. Every time you remove the filter,replace the housing O-ring seal located on the cover.
CONTACT AN AUTHORISED PIAGGIO-GILERA SERVICE CENTRE TO CARRYOUT THESE OPERATIONS.
03_08
Intake plug (03_08)
Remove the cap of the transmission cover operating on the corresponding releaseslots with a plain slot screwdriver. Wash the sponge in water and soap without re-moving it from its seat. Dry it with compressed air before refitting it taking care to doso at the correct angle.
CAUTION
WARNING. SHOULD THERE BE PROBLEMS DURING THE IDLE SPEED AD-JUSTMENT OPERATION, IT MAY BE NECESSARY TO ADJUST THE LEVEL OFEXHAUST EMISSIONS (CO). TURN TO AN AUTHORISED PIAGGIO SERVICECENTRE TO CARRY OUT THESE OPERATIONS.
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03_09
03_10
Checking the brake oil level (03_09, 03_10)
The brake fluid reservoir is equipped with a sight glass «A» made of transparent ma-terial; the quantity of liquid contained in the sight glass indicates the level of liquid inthe reservoir.
When the sight glass «A» is full, the level inside the reservoir exceeds the MIN level;when it is partially full, the level drops to the MIN level; when it is fully empty, the levelof fluid in the reservoir is below the MIN level.
The brake fluid level may fall due to wear on the brake pads. Should the level appearto be below the minimum mark, please contact your nearest PIAGGIO-GILERA Deal-er or Authorised Service Centre in order to carry out a thorough inspection of thebraking system. If you need to top up the level, follow the steps listed below. Unscrewthe 2 screws "B", remove the tank cap "C" and pour in the required quantity of fluid(the brake fluid level must be above minimum). Place the handlebar in the riding po-sition and pay attention not to tilt the vehicle in order to keep the brake fluid reservoirin horizontal position when checking the fluid level.
CAUTION
TOP UPS SHOULD ONLY BE CARRIED OUT WITH DOT 4 CLASSIFIED BRAKEFLUID.
CAUTION
THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE. THEREFORE, WHENTOPPING IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTEDPARTS OF THE VEHICLE. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC,WHICH MEANS THAT IT ABSORBS MOISTURE FROM THE SURROUNDING AIR.IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE,THIS WILL RESULT IN INEFFICIENT BRAKING.
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3 Maintenance
WARNING
IN NORMAL CLIMATIC CONDITIONS IT IS ADVISABLE TO REPLACE THEABOVE-MENTIONED FLUID EVERY 2 YEAR. NEVER USE BRAKE FLUID CON-TAINED IN CONTAINERS WHICH ARE ALREADY OPEN OR PARTIALLY USED.
03_11
Battery (03_11)
To have access to the battery it is necessary to remove the saddle («Keys» section)and the access hatch to the battery compartment unscrewing the star-head screws«A» shown in the figure
CAUTION
IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVER DISCON-NECT THE WIRING WHILE THE ENGINE IS RUNNING. DO NOT TIP THE SCOOT-ER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF BATTERYELECTROLYTE.
CAUTION
ELECTROLYTE CONTAINS SULPHURIC ACID: AVOID CONTACT WITH EYES,SKIN AND CLOTHES. IN THE CASE OF ACCIDENTAL CONTACT, RINSE WITHABUNDANT OF WATER AND CONSULT A DOCTOR.
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WARNING
SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTIONAND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENTREGULATIONS.
Long periods of inactivity
Battery performance will decrease if the vehicle is not used for a long time. This is theresult of the natural phenomenon of battery discharging plus residual absorption byvehicle components with constant power consumption. Poor battery performance mayalso be due to environmental conditions and the cleanness of the poles. In order toavoid difficult starts and/or irreversible damage to the battery, follow any of thesesteps:
- At least once a month start the engine and run it slightly above idle speed for 10-15minutes. This keeps all the engine components, as well as the battery, in good workingorder.
- Take your vehicle to a garage (as indicated in the "Vehicle not used for extendedperiods" section) to have the battery removed. Have the battery cleaned, charged fullyand stored in a dry, ventilated place. Recharge at least once every two months.
N.B.
THE BATTERY MUST BE CHARGED WITH A CURRENT EQUAL TO 1/10 OF THERATED CAPACITY OF THE BATTERY AND FOR NOT LONGER THAN 10 HOURS.CONTACT AN AUTHORISED SERVICE CENTRE TO CARRY OUT THIS OPERA-TION SAFELY. WHEN REFITTING THE BATTERY MAKE SURE THE LEADS ARECORRECTLY CONNECTED TO THE TERMINALS.
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3 Maintenance
WARNING
DO NOT DISCONNECT THE BATTERY CABLES WITH THE ENGINE RUNNING,THIS CAN CAUSE PERMANENT DAMAGE TO THE VEHICLE ELECTRONIC CON-TROL UNIT.
WARNING
SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTIONAND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENTREGULATIONS.
03_12
Fuses (03_12)
The electrical system is protected by a plug fuse «B» located to the left of the batterycompartment. The ignition system, headlight and the rear light are not fuse-protected.Before replacing a blown fuse, find and solve the problem that caused it to blow. Donot replace the fuse with any alternative form of conductor
CAUTION
IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVER DISCON-NECT THE WIRING WHILE THE ENGINE IS RUNNING. DO NOT TIP THE SCOOT-ER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF BATTERYELECTROLYTE.
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03_13
03_14
03_15
Front light group (03_13, 03_14)
To access the headlight bulb, remove the rear cover, by taking out the two bag hookscrews. Turn the bulb holder anticlockwise and take out the bulb. To refit follow thesame steps but in reverse order.
Headlight adjustment (03_15, 03_16, 03_17)
Proceed as follows:
1. Place the vehicle in running order and with the tyres inflated to the prescribed pres-sure, 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 borderline of the projected light beam onthe screen is not lower than 9/10 of the distance from the ground to the centre ofvehicle headlamp and higher than 7/10;
3. Otherwise, adjust the headlight with screws «A» to remove the covers on the shieldback plate. Then, undo the headlight set screw «B».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS RE-GARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THESTATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE ve-hicle IS USED.
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03_16
03_17
03_18
Front direction indicators (03_18)
Use a Phillips screwdriver on the screw «C» shown in the figure. The bulb has abayonet fitting, to remove it press gently, and turn it anticlockwise about 30° and thenwithdraw it. To refit follow the same steps but in reverse order.
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03_19
Rear optical unit (03_19)
In order to reach the rear tail light bulb remove the 2 «D» retaining screws. The bulbhas a bayonet fitting, to remove it press gently and turn it anticlockwise about 30° andthen withdraw it. To refit follow the same steps but in reverse order.
03_20
Rear turn indicators (03_20)
Use a Phillips screwdriver on the screw «C» shown in the figure. The bulb has abayonet fitting, to remove it press gently, and turn it anticlockwise about 30° and thenwithdraw it. To refit follow the same steps but in reverse order.
03_21
Rear-view mirrors (03_21)
To adjust the stem position, lift the rubber protection and loosen the nut «A» with anopen wrench (opening 13 mm); adjust the stem to the best position and tighten thescrew. The rear-view mirror is fitted on a stem with a ball "joint" «B». The mirror canbe adjusted to the desired position manually.
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3 Maintenance
03_22
03_23
Idle adjustment (03_22, 03_23)
To adjust idle speed it is necessary to reach the set screw located in the carburettor.
To carry out this adjustment it is necessary to reach the catalytic muffler as shown inthe picture, or else by lifting the saddle and removing the hatch located at the bottomof the helmet compartment.
Turn the set screw for clearance adjustment of the throttle control transmission, thenreplace the rubber protection cap. Adjust idle speed with the rear wheel off the ground(vehicle on stand) and with a warm engine. turn the knob-type head screw in or outuntil the engine idles smoothly (around 1800/2000rpm.), i.e. without the rear wheelbeing moved by the engine.
CAUTION
DURING IDLE SPEED ADJUSTMENT PAY SPECIAL ATTENTION NOT TOTOUCH THE CATALYTIC MUFFLER TO AVOID BURNS.
SHOULD THERE BE PROBLEMS DURING THE IDLE SPEED ADJUSTMENT OP-ERATION, IT MAY BE NECESSARY TO ADJUST THE LEVEL OF EXHAUSTEMISSIONS (CO). THIS OPERATION MUST BE CARRIED OUT AT AN AUTHOR-ISED PIAGGIO-GILERA SERVICE CENTRE.
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03_24
Front disc brake (03_24)
The brake disc and pad wear is automatically compensated, therefore it has no effecton the functioning of the front and rear brakes. For this reason it is not necessary toadjust the brakes. An excessively elastic brake lever stroke may indicate the presenceof air in the braking circuit or an irregular brake operation. In this case, mainly due tothe importance of brakes to guarantee safe riding conditions, the vehicle should betaken to an Authorised Piaggio-Gilera Service Centre in order to be checked.
CAUTION
THE BRAKING ACTION SHOULD BEGIN AFTER ABOUT 1/3 OF THE BRAKELEVER STROKE.
CHECK THE BRAKE PADS REGULARLY (EVERY 5000 KM). IF THE THICKNESSOF ONE OR BOTH PADS IS IN THE REGION OF 1.5 MM, BOTH PADS MUST BECHANGED. THIS OPERATION MUST BE CARRIED OUT AT AN AUTHORISEDPIAGGIO-GILERA SERVICE CENTRE. AFTER REPLACING THE BRAKE PADSDO NOT USE THE VEHICLE BEFORE HAVING USED THE BRAKE LEVER SEV-ERAL TIMES IN ORDER TO ALLOW THE PADS TO SETTLE AND THE LEVERSTROKE TO BE SET TO THE CORRECT POSITION.
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03_25
Rear drum brake (03_25)
Actuate on the set screw «A» indicated on the figure bearing in mind that the wheelmust rotate freely when the control lever is in neutral.
CAUTION
THE BRAKING ACTION SHOULD BEGIN AFTER ABOUT 1/3 OF THE BRAKELEVER STROKE.
03_26
Puncture (03_26)
The vehicle is equipped with Tubeless tyres. When there is a puncture, Tubeless tyres-unlike balloon tyres- go flat very slowly. This offers greater riding safety. A tyre thatgoes flat very slowly can be repaired with an "INFLATE AND REPAIR" spray. Tyresshould be later fully repaired at an Authorised Piaggio-Gilera Service Centre.
03_27
Periods of inactivity (03_27)
We recommend carrying out the following operations:1. General cleaning of the vehicle.
2. With the engine off and the piston at the bottom dead centre position, remove thespark plug, and pour 1÷ 2 cm³ of recommended oil through its opening. Press theengine start pedal 3 or 4 times letting the engine perform a few revolutions slowly,then replace the spark plug.
3. Drain off all the vehicle fuel; spread antirust grease on the unpainted metal parts;keep the wheels off the ground, by resting the chassis on two wooden wedges.
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4. For the battery, follow the procedures described in the «Battery» section.
5. Drain the petrol from the carburettor float chamber through the bleed cap.
Recommended productsAGIP CITY HI TEC 4T
Oil to lubricate flexible transmissions (brake, throttle control and mixer, odometer)Oil for 2-stroke engines: SAE 5W-40, API SL, ACEA A3, JASO MA
03_28
Cleaning the vehicle (03_28)
Use a low pressure jet of water to soften the caked dirt and mud deposited on thepainted surfaces. Once softened, sponge off mud and dirt using a car body spongesoaked in a car body shampoo and water solution (2-4% of car shampoo in water).Then rinse abundantly with water, and dry with a shammy cloth. For the outside of theengine, use petroleum, a brush and clean cloths. Petrol can damage paintwork. Re-member that any polishing with silicone wax must always be preceded by washing.
CAUTION
DETERGENTS POLLUTE WATER. THEREFORE THE VEHICLE SHOULD BEWASHED IN AN AREA EQUIPPED FOR THE COLLECTION AND PURIFICATIONOF THE LIQUIDS USED.
WARNING
NEVER WASH THE VEHICLE UNDER DIRECT SUNLIGHT, ESPECIALLY IN SUM-MER WHEN THE BODYWORK IS STILL HOT, AS THE CAR SHAMPOO MAY DRYBEFORE BEING RINSED OFF, AND COULD DAMAGE THE PAINTWORK. NEVERUSE RAGS SOAKED IN PETROL OR DIESEL OIL TO CLEAN THE PAINTED ORPLASTIC SURFACES, TO PREVENT THEM LOSING THEIR SHINE AND ME-CHANICAL CHARACTERISTICS.
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WARNING
WHEN WASHING THE ENGINE WITH A HIGH-PRESSURE WATER JET:
• ONLY USE FAN SPRAY JETS.• DO NOT PLACE THE WATER JET NOZZLE CLOSER THAN 60 CM.• DO NOT USE WATER AT TEMPERATURES OVER 40° C.• DO NOT DIRECT THE JETS DIRECTLY TO CARBURETTOR, WIRING, SLOTDIFFUSER ON THE TRANSMISSION COVER AND SCROLL COVER.
DIFFICULT STARTING
No fuel in tank Refuelling
Filters, jets or carburettor dirty orclogged.
Contact an Authorised Piaggio-Gilera Service Centre
Insufficient battery charge Kick-start. Recharge the battery.
IRREGULAR IGNITION
No spark from spark plug. Due tothe presence of high voltage, thischeck should only be carried out byan expert.
Check that the electrodes arecorrectly adjusted (0.6-0.7 mm)Check that the electrodes areclean (clean with pure petrol andmetal brush or with emery cloth).Check the spark plug insulator:Replace the spark plug if theinsulator is cracked or broken. Ifthe spark plug is in good condition,
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take your vehicle to an AuthorisedPiaggio-Gilera Service Centre.
LACK OF COMPRESSION
Threaded spark plug seat, headfixing loose; worn piston gas rings
Contact an Authorised Piaggio-Gilera Service Centre
HIGH CONSUMPTION AND LOW PERFORMANCEAir filter blocked or dirty. Clean with water and shampoo and
impregnate with petrol and specificoil (section «Removing the airfilter»)
INSUFFICIENT BRAKING
Oil on drum or disc. Worn pads/shoes
Contact an Authorised Piaggio-Gilera Service Centre
Rear brake incorrectly adjusted.Air in the brake system
Contact an Authorised Piaggio-Gilera Service Centre
INSUFFICIENT SUSPENSION
Oil leak; worn limit switch bumpers;worn shock absorber attachmentpoints
Contact an Authorised Piaggio-Gilera Service Centre
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AUTOMATIC TRANSMISSION PROBLEMS
Deteriorated roller container orbelt.
Contact an Authorised Piaggio-Gilera Service Centre
INCREASED EXHAUST NOISE
Deterioration of the SAS systemand/or of the tab
Contact an Authorised Piaggio-Gilera Service Centre
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Stalker 50
Chap. 04Technical data
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04_01
TECHNICAL DATA
Engine single cylinder; 2-stroke
Bore x stroke 40 X 39.3 mm
Cubic capacity 49.3 cm³
Compression ratio 9.4 ÷ 10.4
Ignition advance (before TDC) 17° ± 1° at 4000 rpm
Weber Carburettor 18 OM
Dellorto Carburettor PHVA 17.5ID
Max. speed According to current legislation
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TECHNICAL DATA
Maximum height 1130 mm
Overall width 785 mm
Overall length 1770 mm
Wheelbase 1230 mm
Kerb weight 85 kg
Fuel supply Petrol-oil mixture by carburettor,automatic mixer (variable flowaccording to engine speed andthrottle valve opening) and avacuum-operated cock.
Exhaust muffler Expansion-type muffler.
Electronic ignition Consisting of a capacitativedischarge microprocessor device,with separate HV coil.
Lubrication Engine lubrication (piston,cylinder, crankshaft, mainbearings) with mixer oil.
Cooling Forced air circulation.
Transmission With automatic expandable pulleyvariator, torque server, V-belt,automatic clutch, gear reductionunit.
Front brake (Ø 190 mm) disc brake withhydraulic control (lever on thehandlebar right side end).
Rear brake (Ø 110 mm) drum brake withexpanding shoes, mechanically
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4 Technical data
controlled (lever on the handlebarleft hand end).
Wheels With 3.50x12"wheel rims in lightalloy.
Rear tyre 130/70-12"
Front tyre 120/70-12"
Front suspension fork with inverted stems, withhydraulic double-acting shockabsorber.
Rear suspension hydraulic single sock absorber,helical coaxial spring. Chassis toengine support with swinging arm.
Chassis made of welded tubular steel withsheet metal reinforcement.
Fuel tank Plastic, with a capacity of 6 litres(approximate value) includingreserve of ~ 1.5 l.
Oil mixer tank Plastic, with a capacity of ~ 1.2 l(including a ~0.400 l reserve).
Rear hub oil Quantity: approx. 75 cm³
Kit equipment
Wrenches: one box-spanner (13 -21 mm); one twin screwdriver. The tools are locatedunder the seat in a specific container.
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Stalker 50
Chap. 05Spare parts and
accessories
49
Warnings
CAUTION
WE STRONGLY RECOMMEND USING ORIGINAL PIAGGIO-GILERA SPAREPARTS, THE ONLY PARTS THAT GUARANTEE THE SAME QUALITY LEVEL ASTHE ORIGINAL PARTS ASSEMBLED ON THE VEHICLE.IT SHOULD BE REMEMBERED THAT USING NON-ORIGINAL SPARE PARTSCAUSES YOUR WARRANTY RIGHTS TO EXPIRE.
CAUTION
PIAGGIO-GILERA MARKETS ITS OWN LINE OF ACCESSORIES, WHICH ARECOVERED BY A MANUFACTURER'S WARRANTY ON THE BASIS OF THEIRUSE. IT IS THEREFORE ABSOLUTELY NECESSARY TO CONTACT AN AU-THORISED PIAGGIO-GILERA DEALER OR SERVICE CENTRE TO CHOOSETHEM AND HAVE THEM CORRECTLY ASSEMBLED. THE USE OF NON-ORIGI-NAL ACCESSORIES MAY AFFECT THE STABILITY AND OPERATION OF YOURVEHICLE AND REDUCE SAFETY LEVELS WITH POTENTIAL RISKS FOR THERIDER.
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Stalker 50
Chap. 06Programmedmaintenance
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MAINTENANCE TABLEkm x 1,000 1 5 10 15 20 25 30 35 40 45 50
SAS filter I I I I I
Steering A A A A A A
Odometer gear L L
Idle speed A A A A A A
Vehicle road test I I I I I I I I I I I
Sliding blocks / variable speed rollers I I I R I I I R I I
Tyre pressure and wear I I I I I I I I I I I
Brake Pads/Shoes I I I I I I I I I I I
Headlight aiming adjustment A A A A A
Hub oil R I I I R I I I R I I
Brake fluid ** I I I I I I I I I I I
Brake control levers L L L L L L
Electrical system and battery I I I I I I I I I I I
Air filter C C C C C C C C C C
Throttle control - mixer A A A A A A
Driving belt I R I R I R I R I R
Spark plug I R I R I R I R I R
Safety locks I I I I I I
Driven pulley roller casing L L L L L
Suspensions I I I I I
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km x 1,000 1 5 10 15 20 25 30 35 40 45 50
Transmissions L L L L L
I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARYC. CLEAN, R:REPLACE, A:ADJUST, L:LUBRICATE
Clean the SAS air filter every 2 years
** Replace every 2 years
RECOMMENDED PRODUCTS TABLEProduct Description Specifications
AGIP ROTRA 80W-90 rear oil hub SAE 80W/90 Oil that exceeds therequirements of API GL3 specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions (brake,throttle control and mixer, odometer)
Oil for 2-stroke engines: SAE 5W-40, API SL,ACEA A3, JASO MA
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increasedadhesiveness
AGIP GP 330 Grease (brake control levers, throttle grip) Calcium complex soap-based grease withNLGI 2; ISO-L-XBCIB2
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO FC,ISO-L-EGD
AGIP GREASE MU3 Grease for odometer transmission gear case Soap-based lithium grease with NLGI 3; ISO-L-XBCHA3, DIN K3K-20
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TABLE OF CONTENTS
AAir filter: 29
BBattery: 32Brake: 31, 39, 40
DDisc brake: 39Display: 8
FFuses: 34
HHeadlight: 35Horn: 10Hub oil: 26
IIdentification: 13
KKey switch: 9Keys: 12
LLight switch: 10
MMaintenance: 25, 51Mirrors: 37
SSaddle: 11Spark plug: 28Start-up: 11
TTechnical Data: 45Transmission: 22Turn indicators: 37Tyre pressure: 18Tyres: 27
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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 theright, 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 shown in this publication are available in all Countries. The availability of single versions should be checked at the official Piaggio sales network.
"© Copyright 2005 - 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. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) www.piaggio.com