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Gilera DNA 50 User Manual

Gilera DNA 50
170 pages
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WORKSHOP MANUAL
633507
DNA 50

Table of Contents

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Gilera DNA 50 Specifications

General IconGeneral
Engine TypeSingle cylinder, 2-stroke
Cooling SystemLiquid cooled
Fuel SystemCarburetor
Front SuspensionTelescopic fork
Front BrakeDisc
Fuel Capacity7.5 liters
Bore x Stroke40 mm x 39.3 mm
StartingElectric and kick
Transmission TypeAutomatic
Front Tire120/70-14
Seat Height770 mm
TransmissionAutomatic
Rear BrakeDisc
IgnitionCDI
Rear SuspensionMono shock absorber

Summary

Characteristics

Rules

General safety rules for maintenance operations.

Safety rules

Specific safety rules for vehicle maintenance and handling.

Vehicle identification

Details for identifying the vehicle's frame and engine prefixes.

Dimensions and mass

Specifications for vehicle width, length, wheelbase, saddle height, and weight.

Engine

Technical specifications for the motor, capacity, bore, stroke, and lubrication.

Electrical system

Components of the electrical system including ignition, battery, and generator.

Brakes

Specifications for front and rear brakes, including disc diameter and control type.

Tightening Torques

Steering Assembly

Torque specifications for steering ring nuts and handlebar pins.

Frame Assembly

Torque values for swinging arm, shock absorber, and stand fixings.

Front Brake

Torque specifications for brake pump support, fluid lines, and caliper.

Engine Assembly

Torque values for clutch bell, pulley nut, flywheel, and crankcase bolts.

Overhaul data

Details on assembly clearances and piston fitting.

Tooling

Tools

Specific tools for fitting steering seats and extracting bearings.

Maintenance

Maintenance chart

Periodic maintenance schedule based on time and mileage intervals.

Spark plug

Procedure for checking, adjusting, and replacing the spark plug.

Air filter

Instructions for removing, cleaning, and refitting the air filter.

Braking system

Procedures for checking and topping up brake fluid levels.

Troubleshooting

Engine

Troubleshooting common engine performance and starting difficulties.

Starting difficulties

Solutions for problems encountered during engine starting.

Engine overheating

Diagnosing and resolving engine overheating issues.

Insufficient braking

Troubleshooting steps for inadequate braking performance.

Electrical System

Electrical system

Overview of electrical components with numbered references.

Ignition

Details and diagrams related to the ignition system components.

Battery recharge and starting

Procedures for battery recharging and starting the vehicle.

Voltage regulator check

Troubleshooting and checking the voltage regulator's functionality.

Engine from Vehicle

Removal of the engine from the vehicle

Step-by-step instructions for engine removal, including torques.

Engine

Transmission cover

Steps for removing and refitting the transmission cover.

Removing the driven pulley

Steps for removing the driven pulley assembly.

Refitting the driven pulley

Procedure for refitting the driven pulley assembly.

Removing the crankshaft

Procedures for removing the crankshaft.

Suspensions

Front

Procedures for removing and refitting the front wheel.

Front fork

Procedures for disassembling the front fork.

Shock absorbers

Procedures for removing and refitting shock absorbers.

Centre-stand

Procedures for extracting and refitting the centre-stand pin.

Braking System

Front brake calliper

Procedures for removing and overhauling the front brake caliper.

Front brake disc

Procedures for removing, refitting, and inspecting the front brake disc.

Front brake pads

Procedures for removing, refitting, and checking front brake pads.

Fill

Procedure for filling and bleeding the brake system.

Cooling System

System bleed

Step-by-step procedure for bleeding the cooling system.

Water pump - overhaul

Procedures for overhauling the water pump.

Thermostat

Procedures for removing, checking, and refitting the thermostat.

Chassis

Headlight assy.

Procedures for removing and disconnecting the headlight assembly.

Side fairings

Procedures for removing rear and front side fairings.

Fuel tank

Procedures for removing the fuel tank and fuel pump.

Pre-delivery

Aesthetic inspection

Checks for paintwork, plastic fitting, scratches, and dirt.

Road test

Procedures for conducting a road test of the vehicle.

Functional inspection

Functional checks of braking, clutch, engine, and other systems.

Time

Engine

Time required for engine to chassis replacement.

Crankshaft

Time for crankshaft and related component replacement.

Brake callipers

Time for brake caliper and pad replacement.

Front suspension

Time for front suspension and fork component replacement.

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