Gilera DNA 50 - Product View

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Workshop Manual2
Product View4
Index of Topics5
Characteristics7
Safety Rules7
Maintenance Rules7
Vehicle Identification8
Dimensions and Mass8
Engine9
Transmission9
Capacities10
Electrical System10
Frame and Suspensions10
Wheels and Tyres10
Secondary Air11
Dell'orto Carburettor 50Cc Version11
Tightening Torques12
Frame Assembly12
Front Brake12
Rear Brake12
Engine Assembly12
Overhaul Data13
Assembly Clearances13
Cylinder-Piston Assy.13
Piston Rings13
Crank Case-Crankshaft-Conecting Rod14
Slot Packing System14
Products15
Tooling16
Tools17
Maintenace25
Maintenance Chart26
At 1000 Km or 4 Months26
At 5000 Km or 12 Months, 25000 Km, 35000 Km and 55000 Km26
At 10000 Km or 24 Months and 50000 Km26
At 15000 Km and 45000 Km27
At 20000 Km and 40000 Km27
At 30000 Km27
At 60000 Km28
Checkig the Spark Advance28
Spark Plug29
Hub Oil29
Check30
Replacement31
Air Filter31
Transmissions32
Braking System33
Level Check33
Top-Up33
Headlight Adjustment34
Troubleshooting35
Poor Performance36
Rear Wheel Spins at Idle36
Starting Difficulties36
Excessive Oil Consumption/Exhaust Smoke37
Engine Tends to Cut-Off at Full Throttle37
Engine Tends to Cut-Off at Idle37
Excessive Exhaust Noise37
Transmission and Brakes38
Engine Overheating38
SAS Malfunctions38
Clutch Grabbing or Performing Inadequately38
Steering and Suspensions39
Battery39
Rear Wheel39
Heavy Steering39
Excessive Steering Play40
Noisy Suspension40
Suspension Oil Leakage40
Conceptual Diagrams43
Ignition44
Headlights and Automatic Starter Section45
Battery Recharge and Starting46
Level Indicators and Enable Signals Section47
Turn Signal Lights48
Digital Instrument Panel49
Instrument Unit Connector49
Instrument Panel49
Checks and Inspections50
Check on the Pick up50
Ignition Circuit51
Stator Check51
Checking the Recharge Coil51
Check Continuity51
Voltage Regulator Check52
Fuses54
Sealed Battery55
Dry-Charge Battery55
Battery Maintenance56
Engine from Vehicle58
Removal of the Engine from the Vehicle59
Automatic Transmission62
Transmissio Cover62
Kickstart62
Removing the Driven Pulley Shaft Bearing63
Refitting the Driven Pulley Shaft Bearing63
Removing the Driven Pulley64
Inspecting the Clutch Drum64
Removing the Clutch64
Inspecting the Clutch65
Pin Retaining Collar65
Removing the Driven Half-Pulley Bearing66
Inspecting the Driven Fixed Half-Pulley66
Inspecting the Driven Sliding Half-Pulley67
Refitting the Driven Half-Pulley Bearing68
Inspecting the Clutch Spring68
Refitting the Clutch68
Refitting the Driven Pulley69
Drive-Belt69
Removing the Driving Pulley70
Mixer Gears and Belt70
Inspecting the Rollers Case70
Refitting the Driving Pulley71
End Gear72
Removing the Hub Cover72
Removing the Wheel Axle72
Removing the Wheel Axle Bearings73
Inspecting the Hub Shaft74
Ispecting the Hub Cover74
Refitting the Wheel Axle Bearing75
Refitting the Hub Cover75
Flywheel Cover75
Removing the Stator76
Refitting the Stator76
Refitting the Flywheel Cover76
Flywheel and Starting77
Removinng the Starter Motor77
Removing the Flywheel Magneto78
Inspecting the Flywheel Components78
Cylinder Assy. and Timing System79
Refitting the Flywheel Magneto79
Refitting the Starter Motor79
Removing the Intake Manifold79
Removing the Cylinder - Piston Assy.80
Inspecting the Small End81
Inspecting the Wrist Pin81
Inspecting the Piston81
Inspecting the Cylinder82
Inspecting the Piston Rings82
Removing the Piston83
Crankcase-Crankshaft84
Inspecting the Timing System Components84
Splitting the Crankcase Halves84
Removing the Crankshaft85
Removing the Crankshaft Bearings85
Refitting the Crankshaft Bearings86
Inspecting the Crankshaft Alignment86
Refitting the Crankshaft87
Refitting the Crankcase Halves88
Lubrication89
Crankshaft Oil Seals Refitting89
Oil Pump Removal90
Oil Pump Refitting90
Fuel Supply91
Suspensions92
Removing the Front Wheel93
Refitting the Front Wheel93
Handlebar93
Front Fork Removal94
Front Fork Refitting96
Removing the Rear Wheel96
Shock Absorbers Removal96
Shock Absorbers Refitting97
Centre-Stand97
Front Brake Calliper Removal100
Front Brake Calliper Overhaul100
Front Brake Calliper Refitting102
Front Brake Disc Removal102
Front Brake Disc Refitting102
Disc Inspection102
Front Brake Pads Removal103
Front Brake Pads Refitting103
Fill104
Front Brake Pump105
Rear Brake Pump - Combined106
Cooling System107
System Bleed108
Water Pump - Overhaul108
Thermostat Removal111
Thermostat Check111
Thermostat Refitting112
Chassis113
Headlight Assy.114
Tailight Assy.114
Side Fairings115
Rear Mudguard116
Helmet Bay117
Fuel Tank118
Radiator Fan119
Expansion Tank120
Mixture Oil Tank120
Pre-Delivery121
Aesthetic Inspection122
Tightening Torques Inspection122
Levels Check123
Road Test123
Static Test124
Functional Ispection124
Time125
Crankcase127
Crankshaft128
Cylinder Assy.129
Cylinder Head Assy.130
Driven Pulley131
Oil Pump132
Final Gear Assy.133
Driving Pulley134
Transmission Cover135
Water Pump136
Starter Motor137
Flywheel Magneto138
Brake Shoes139
Carburettor140
Exhaust Pipe141
Air Cleaner142
Frame143
Legshield Spoiler144
Underseat Compartment146
Plate Holder147
Mudguard148
Tank Oil150
Rear Shock-Absorber151
Steering Column Bearings152
Handlebar Components153
Swing-Arm154
Seat155
Instrument Panel156
Front Wheel158
Fuel Pump160
Electric Devices161
Electronic Controls163
Brake Callipers165
Rear Side Fairings166
Front Suspension167
Cooling System168
Secondary Air Box169
Index170

Gilera DNA 50 - Product View

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