Service Station Manual Aprilia Mojito 50cc

SERVICE STATION MANUAL
854220
MOJIT0 50 2T
SERVICE STATION
MANUAL
MOJIT0 50 2T
The descriptions and illustrations given in this publication are not binding; While the basic characteristics
as described and illustrated in this manual remain unchanged, aprilia 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 shown in this publication are available in all countries. The availability of individual models
should be confirmed with the official aprilia sales network.
© Copyright 2008 aprilia. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. aprilia - After-sales service.
aprilia trademark is property of Piaggio & C. S.p.A.
SERVICE STATION MANUAL
MOJIT0 50 2T
- This manual provides the main information to carry out regular maintenance operations on your vehicle.
- This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been
deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all aprilia Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of need
or further queries on repair and check procedures, consult aprilia CUSTOMER DEPARTMENT, which
will be prepared to provide any information on the subject and any further communications on updates
and technical changes related to the vehicle.
NOTE 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
PRE-DELIVERY PRE DE
TECHNICAL DATA DT
TOOLING TOOL
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
CHASSIS CHAS
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery MOJIT0 50 2T
Carry out the listed checks before delivering the motorcycle.

WARNING
HANDLE FUEL WITH CARE.
Aesthetic inspection
- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt
Tightening torques inspection
- Safety fasteners:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
Electrical system
- Main switch
- Headlamps: high beam lights, low beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
- Saddle electric opening switch (if present)
PRE DE - 6
MOJIT0 50 2T Pre-delivery
- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if
required, program the control unit/s again: consult the technical service website to know about available
upgrades and details regarding the operation.
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 THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-

TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; 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 THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
Levels check
- Hydraulic braking system fluid level
- Rear hub oil level
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
- Response to throttle control
- Stability when accelerating and braking
PRE DE - 7
Pre-delivery MOJIT0 50 2T
- Front and rear brake efficiency

- Front and rear suspension efficiency
- Abnormal noise
Static test
Static check after test drive:

- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)
Functional inspection
- Hydraulic braking system

- Brake levers stroke
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Locks checking
- Tyre pressure check
- Installation of mirrors and any possible accessories
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY
BURST.
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 8
INDEX OF TOPICS
TECHNICAL DATA DT
Technical Data MOJIT0 50 2T
Safety rules
CARBON MONOXIDE
If you need to keep the engine running in order to carry out any procedure, please ensure that you do
so in an open or very well ventilated area.
Never let the engine run in an enclosed area.
If you do work in an enclosed area, make sure to use a smoke-extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
FUEL
FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN
BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE OPERATIONS IN A WELL VENTILATED AREA
WITH THE ENGINE OFF. DO NOT SMOKE WHILE REFUELLING OR WHEN CLOSE TO FUEL
VAPOURS, AVOID CONTACT WITH NAKED FLAMES, SPARKS OR ANY OTHER SOURCE THAT
MAY CAUSE FUEL TO CATCH FIRE OR EXPLODE.
CAUTION
DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.

CAUTION
KEEP OUT OF THE REACH OF CHILDREN.

HIGH-TEMPERATURE COMPONENTS
The engine and the components of the exhaust system can get very hot and remain hot for some time
even after the engine has been switched off.
Before handling these components, make sure that you are wearing insulating gloves or wait until the
engine and the exhaust system have cooled down.
TRANSMISSION OIL AND USED FORK OIL
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.

THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR
LONG PERIODS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.
CAUTION
DT - 10
MOJIT0 50 2T Technical Data
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

CAUTION

BRAKE FLUID
CAUTION
THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING
THE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH.
ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM.
THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES.
IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH
ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
CAUTION

COOLANT
The coolant contains ethylene glycol which, under certain conditions, can become flammable. When it
burns, ethylene glycol produces invisible flames which, however, can cause burns.
CAUTION
MAKE SURE NOT TO POUR THE COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPO-
NENTS; IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES. WHEN CARRYING OUT MAIN-
TENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN IF IT IS TOXIC,
THE COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS.
NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS
AS THEY MAY DRINK IT.
CAUTION

CAUTION
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
UNDER PRESSURE AND MAY CAUSE BURNS.
HYDROGEN GAS AND BATTERY ELECTROLYTE
CAUTION
HYDROGEN GAS AND BATTERY ELECTROLYTE

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN.
WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO-
TECTIVE APPAREL.
DT - 11
IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT
COOL WATER.
IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS
OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES,
RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL-
IST AS SOON AS POSSIBLE.
IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL-
LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE-
LY.
THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGA-
RETTES OR ANY OTHER HEAT SOURCE.
ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
CAUTION

CAUTION
THE BATTERY LIQUID IS CORROSIVE.

DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS.
ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTI-
VATED.
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle follow the recommendations reported below
carefully.
CAUTION
THE USE OF NAKED FLAMES IS FORBIDDEN FOR ANY KIND OF OPERATION. BEFORE START-
ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE
ENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE
COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL
GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM
PARTS. DO NOT HOLD ANY MECHANICAL OR ANY OTHER SCOOTER PARTS WITH YOUR
MOUTH: SCOOTER COMPONENTS ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM
ARE HARMFUL AND EVEN TOXIC. UNLESS OTHERWISE INDICATED, REFIT THE UNITS FOL-
LOWING REMOVAL OPERATIONS BUT IN REVERSE ORDER. THE POSSIBLE OVERLAPPING
OF OPERATIONS REFERRED TO IN THE OTHER CHAPTERS MUST BE CARRIED OUT LOGI-
CALLY, AVOIDING ANY UNNECESSARY REMOVAL OF COMPONENTS. DO NOT POLISH MATT-
PAINTED SURFACES WITH POLISHING PASTE. NEVER USE FUEL AS SOLVENT FOR
CLEANING THE SCOOTER. DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUB-
BER AND PLASTIC PARTS AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP
INSTEAD. DISCONNECT THE BATTERY NEGATIVE LEAD (-) IF YOU INTEND TO CARRY OUT
ELECTRICAL WELDING WORK. WHEN TWO OR MORE PEOPLE WORK AT THE SAME TIME,
MAKE SURE ALL SAFETY MEASURES ARE OBSERVED EACH OF THEM.
BEFORE REMOVING COMPONENTS
• Before disassembling components, remove dirt, mud, dust and foreign bodies from the ve-
hicle.
• Use the special tools designed for this vehicle, as required.
REASSEMBLING COMPONENTS
DT - 12
CAUTION
NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH
A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED
MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT.
AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS
SEAT.
DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS.
NOTE
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
• Use only ORIGINAL Aprilia SPARE PARTS.
• Comply with lubricant and consumables usage guidelines.
• Lubricate parts (whenever possible) before reassembling them.
• When tightening nuts and screws, start either from the components with the largest diameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
• Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
• When assembling the bearings, make sure to lubricate them well.
• Check that each component is assembled correctly.
• After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
• Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of
lithium-based grease on the oil seal rims. Reassemble the oil seal and the bearings with the
brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below as non-compliance with the procedure
so described causes irreparable damage to both the connector and the cable harness: Press the rele-
vant safety hooks, if any.
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

• Grip the two connectors and disconnect them by pulling them in opposite directions.
• In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a
pressurised air jet.
• Ensure that the cables are correctly fastened to the internal connector terminals.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY
ROUND.
DT - 13
• Then fit the two connectors making sure that they couple correctly (if the relevant hooks are
provided, you will hear them "click" into place).
CAUTION
TIGHTENING TORQUE
DO NOT FORGET THAT TIGHTENING TORQUES FOR ALL FIXING ELEMENTS ON WHEELS,
BRAKES, WHEEL BOLTS AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK
THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REFIT THESE COMPONENTS. IF THESE RECOMMENDATIONS ARE
NOT COMPLIED WITH, ONE OF THE COMPONENTS MAY BECOME LOOSE AND EVEN DE-
TACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISING THE VEHICLE'S MA-
NOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Vehicle identification
Provide the chassis number when purchasing spare parts.

NOTE
KEEP THE DIGITS LEGIBLE AT ALL TIMES AND DO NOT ALTER THEM. THIS IS ILLEGAL IN ALL
COUNTRIES. MOREOVER, ANY CHANGE TO THE IDENTIFICATION NUMBERS RENDERS THE
WARRANTY VOID.
Chassis number
The chassis number is marked on the chassis cen-
tral steel tube. Remove the cover «1» to read it.
The engine number «2» is stamped on the rear

side, near the rear brake set screw.
Dimensions and mass
WEIGHT AND DIMENSIONS

Specification Desc./Quantity
Max. length 1950 mm
DT - 14
Max. width 900 mm
Max height (to the headlamp) 1120 mm
Saddle height 750 mm
Wheelbase 1315 mm
Minimum ground clearance 140 mm
Kerb weight 97 kg
Vehicle max. load (rider + luggage) 105 kg
Vehicle max. load (rider + passenger + luggage) 180 kg (in countries where passenger transport is permitted)
Engine
ENGINE TECHNICAL DATA (MC50)

Engine M320
Engine type 2-stroke, controlled ignition
Cylinder number Horizontal, single-cylinder
Total engine capacity 49.38 cm³
Bore/stroke 40.0 mm / 39.3 mm
Compression ratio 10.5 ± 0.5:1
Start-up electric + kick starter
Clutch clutch
Gearbox automatic continuous variator
Cooling Forced air circulation cooling
Carburettor model DELLORTO PHBN 17.5
Carburettor diffuser Ø 17.5 mm
Fuel supply premium unleaded petrol as per DIN 51607, minimum octane
rating of 95 (NORM) and 85 (NOMM).
IGNITION CDI
Ignition advance 17° ± 1° before TDC
Standard spark plug CHAMPION RN1C
Spark plug electrode gap 0.6 ÷ 0.7 mm
Engine revs at idle speed 1600 ± 200 rpm
Transmission
TRANSMISSION
Variator transmission Continuous, automatic
Primary drive V-belt
Secondary transmission Gear reduction unit
Minimum engine total ratio for continuous transmission 3.7
Maximum engine total ratio for continuous transmission 0.78
Capacities
CAPACITY
Fuel capacity (reserve included) 7.5 l
Fuel reserve capacity 2l
Transmission oil capacity 130 cm³
Mixer oil capacity (reserve included) 1.4 l
Mixer oil reserve capacity 0.4 l
Seats 1 (2 in countries where passenger transport is permitted)
DT - 15
Electrical system
ELECTRICAL SYSTEM
Battery 12V - 4 Ah
Fuses 7.5 A - 15 A
(Permanent magnet) Generator 12V - 115W
BULBS AND WARNING LIGHTS (MC50)

1 Low-/high-beam light bulb 12V - 35/35W
2 Front tail light bulb 12V - 5W
3 Turn indicator bulb 12V - 10W
4 Rear tail light /rear stop light/ license plate light bulb 12 V - 5 / 21 W
5 Instrument panel lighting bulbs 12V - 1.2W
6 Tail lights and low-beam light warning light 12V - 1.2W
7 High beam warning light 12V - 1.2W
8 Turn indicator warning light 12V - 2W
9 Low mixer oil warning light 12V - 2W
10 Low fuel warning light 12V - 2W
Frame and suspensions
CHASSIS AND SUSPENSIONS

Chassis type split spar frame
Headstock angle 25°
FRONT SUSPENSION fork with rods
Front suspension travel 50 mm
Rear suspension hydraulic single shock-absorber
Rear suspension travel 67.5 mm
Brakes
BRAKES
Front brake Ø 190mm disc brake with hydraulic transmission
Rear brake Ø 110-mm disc brake with hydraulic transmission
Wheels and tyres
WHEEL RIM
Wheel rims Alloy
Front wheel 3.00 x 12"
Rear wheel rim 4.00 x 10"
TYRES
Tyre type Without inner tube (Tubeless)
Front tyre 120/70 - 12" - 51J
Rear tyre 130/70 - 10" - 59J
Front tyre standard inflation pressure 170 kPa (1.7 bar)
Rear tyre standard inflation pressure 190 kPa (1.9 bar)
DT - 16
Front tyre inflation pressure with passenger (in countries where 190 kPa (1.9 bar)
passenger transport is allowed)
Rear tyre inflation pressure with passenger (in countries where 210 kPa (2.1 bar)
passenger transport is allowed)
Tightening Torques
FRONT SUSPENSION
Name Torque in Nm
Front wheel pin nut 80
Self-locking retainer lock nut 110
Steering series retainer nut 15
REAR SUSPENSION
Name Torque in Nm
Rear wheel nut 110
Rear shock absorber upper attachment screw 40
Rear shock absorber lower attachment screw 40
SWINGING ARM
Name Torque in Nm
Swinging arm to chassis fixing nut 50
Swinging arm to joint fixing nut 80
Swinging arm to engine fixing nut 40
Screw fixing swinging arm silent-block to chassis 40
HANDLEBAR
Name Torque in Nm
Handlebar clamp fixing screw 40
Handlebar safety screw 80
BRAKING SYSTEM
Name Torque in Nm
Nut fixing rear brake lever 10
Front brake calliper fixing screw 25
Screw fixing brake pump U-bolt 9
Screws fixing brake pipe to brake pump 18
Brake pipe to brake calliper fixing screws 18
Rear brake adjustment nut 5
BODYWORK
Name Torque in Nm
Passenger grab handle fixing screw 10
Fuel tank fixing nut 7
Coil fixing screw 5
Horn fixing screw 10
Bodywork M6 fixing screws 4
Bodywork M5 fixing screws 4
Bodywork self-tapping fixing screws 3
ENGINE
Name Torque in Nm
Starter lever replacement 12 ÷ 13
Nut locking clutch unit on pulley 55 to 60
Driven pulley shaft nut 40 44
Crankshaft pulley nut 18 - 20 + 90°
hub cap screws 24 - 26
Pick-up screws 3 to 4
Stator screws 3 to 4
DT - 17
Name Torque in Nm
Flywheel nut 40 ÷ 44
Starter screws 11 to 13
Head locking nuts 10 ÷ 11
Engine crankcase coupling screws 11 ÷ 13
Muffler-cylinder fixing nut 9
Muffler-cylinder fixing screw 9
Spark plug 25 - 30
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND CYLINDER

Name Initials Cylinder Piston Play on fitting
Standard coupling M 40.005 - 40.012 39.943 - 39.95 0.055 - 0.069
Standard coupling N 40.012 - 40.019 39.95 - 39.957 0.055 - 0.069
Standard coupling O 40.019 - 40.026 39.957 - 39.964 0.055 - 0.069
Standard coupling P 40.026 - 40.033 39.964 - 39.971 0.055 - 0.069
Coupling 1st increase M1 40.205 - 40.212 40.143 - 40.15 0.055 - 0.069
Coupling 1st increase N1 40.212 - 40.219 40.15 - 40.157 0.055 - 0.069
Coupling 1st increase O1 40.219 - 40.226 40.157 - 40.164 0.055 - 0.069
Coupling 1st increase P1 40.226 - 40.233 40.164 - 40.171 0.055 - 0.069
Coupling 2nd oversize M2 40.405 - 40.412 40.343 - 40.35 0.055 - 0.069
Coupling 2nd oversize N2 40.412 - 40.419 40.35 - 40.357 0.055 - 0.069
Coupling 2nd oversize O2 40.419 - 40.426 40.357 - 40.364 0.055 - 0.069
Coupling 2nd oversize P2 40.426 - 40.433 40.364 - 40.371 0.055 - 0.069
DT - 18
INDEX OF TOPICS
TOOLING TOOL
Tooling MOJIT0 50 2T
TOOLS
Stores code Description
AP8106702 Flywheel lock calliper spanner
020261Y Starter spring fitting
AP8140276 Flywheel extractor
001467Y029 Housing for 38-mm outside diameter

bearings
004499Y034 Bearing extractor part

004499Y027 Bearing extractor part
004499Y006 Bearing extractor ring
TOOL - 20
MOJIT0 50 2T Tooling

004499Y002 Bearing extractor screw
004499Y001 Bearing extractor bell
004499Y007 Half rings
004499Y Camshaft bearing extractor
008119Y009 Tube to assemble shafts and axles
020074Y Support base for checking crankshaft

alignment
TOOL - 21

020335Y Magnetic mounting for dial gauge
020150Y Air heater support
020151Y Air heater
020171Y Punch for Ø 17 mm roller bearing
020265Y Bearing fitting base
TOOL - 22

020331Y Digital multimeter
020332Y Digital rpm indicator
020358Y 37 x 40 mm Adaptor
020360Y 52x55 mm Adaptor
020362Y 12mm oil guard guide
TOOL - 23

020363Y 20 mm guide for oil seal
020364Y 25 mm adapter
020376Y Adaptor handle
020166Y Tool for fitting the pin snap rings
020451Y starting ring gear lock
020452Y Tube for removing and refitting the driven

pulley shaft
TOOL - 24

020456Y Ø 24-mm adaptor
020477Y 37-mm Adaptor
AP8140259 Universal tool for clutch assemblies
020288Y Fork to assemble piston on cylinder
001467Y009 Bell for OD 42-mm bearings
001467Y014 Pliers to extract ø 15-mm bearings
TOOL - 25

020357Y 32 x 35-mm Adaptor
020412Y 15-mm guide
020163Y Crankcase splitting plate
001467Y007 Driver for OD 54-mm bearings
001467Y006 Pliers to extract 20 mm bearings
TOOL - 26
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance MOJIT0 50 2T
Maintenance chart
ROUTINE MAINTENANCE TABLE - MC50 MODEL

I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Check level every 500 km
** Replace every 2 years
*** Replace every 4 years
Km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Safety fasteners I I I I I I I I I I I I I
Spark plug I R R R R R R R R R R R R
Transmission cables and controls I I I I I I I I I I I I I
Mixer belt R R R
Drive belt I R I R I R I R
Air filter C C C C C C C C C C C C C
Rear brake shoes I I I I I I I I I I I I
Electrical system and battery I I I I I I I I I I I I I
Braking systems I I I I I I I I I I I I I
Light circuit I I I I I I I I I I I I I
Brake fluid ** I I I I I I I I I I I I I
Exhaust muffler/ silencer I I I I I I I I I I I I
Mixer I I I I I I I I I I I I I
Hub oil R I R I R I R I R I R I R
Mixer oil* I I I I I I I I I I I I I
Rear brake cam pin L L L L L L L L L L L L
Headlight A A A A A
Vehicle test and brake test - Road test I I I I I I I I I I I I I
Brake pads I I I I I I I I I I I I I
Electric starter gear pins L L L L L L
Wheels/tyres I I I I I I I I I I I I I
CVT rollers / Sliding shoes R R R R R R
Idle speed A A A A A A A
Suspension I I I I I I I I I I I I
Steering I I I I I I I I I I I I I
Braking system pipes*** I I I I I I I I I I I I I
Mixer oil pipes I I I I I I I
Fuel pipes *** I I I I I I I I I I I I I
Recommended products
RECOMMENDED PRODUCTS TABLE (MC50)

Product Description Specifications
2-stroke oil for mixer Low smoking lubricant for 2-stroke en- API TC; JASO FC; ISO-L-EGD
gines with synthetic bases and additives.
Lithium-based grease Multi-purpose, medium fibre lithium- ISO L-X-BCHA 2 - DIN 51 825 K2K-20
based grease.
Brake fluid DOT 4 Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CU-
NA NC 956 DOT4
75W-90 gear box and transmission oil Synthetic lubricant for gearboxes and SAE 75W-90; API GL4, GL5
transmissions.
MAIN - 28
MOJIT0 50 2T Maintenance
Carburettor
Adjust idle speed according to the instructions in

the scheduled maintenance table and every time
it is not regular. Before adjusting the carburettor
make sure that the lubrication requirements are
met, the spark plug is in optimum conditions, the
air filter is clean and sealed, and the exhaust sys-
tem is sealed.
• Ride a few kilometres until the regular

working temperature is reached, then
stop the engine.
• Remove the central inspection cover.
• Connect an electronic rpm indicator to
the spark plug wire.
• Start the engine and check the engine idle rpm. If the detected value is within the prescribed
parameters the rear wheel is not moved by the engine.
Specific tooling
020332Y Digital rpm indicator
Characteristic
Engine idle speed
1600 ± 200 rpm
• If the engine idle speed is not within the

specified parameters:
• Remove the left side inspection cover,
• Operate the set screw «1» located on
the carburettor. Turn it clockwise and
the number of revs increases; turn it
anticlockwise and the number of revs
reduces.
NOTE
DO NOT TURN THE AIR SET SCREW «2» TO AVOID
CHANGING THE CARBURETION ADJUSTMENT.
• Twisting the throttle grip, accelerate and decelerate a few times to check its correct operation
and if the idle speed is stable.
MAIN - 29
Spark plug
Check the spark plug according to the indications

in the scheduled maintenance table. To reach it:
• Remove the central inspection cover.

CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS

AND IN ORDER TO AVOID BURNS, LEAVE ENGINE AND
EXHAUST TO COOL OFF TO AMBIENT TEMPERATURE.
NEVER DISCONNECT THE SPARK PLUG TUBE WHILE THE ENGINE IS RUNNING. IT MAY RE-
SULT IN A STRONG ELECTRIC DISCHARGE FROM THE IGNITION SYSTEM.
• Remove the tube «1» of the spark plug
«2».
• Clean off any trace of dirt from the
spark plug base.
• Fit the special wrench to the spark
plug.
• Unscrew the spark plug and remove it
from its seat, making sure no dust or
dirt gets into the cylinder.
• Check that the spark plug electrode

and centre porcelain are free of carbon
deposits or signs of corrosion. If nec-
essary, clean using suitable spark plug
cleaners and/or a metal brush.
• Replace the spark plug if its insulator is
cracked, the electrodes show signs of
corrosion or excessive deposits or the
top of the central electrode «3» gets
rounded.
CAUTION
WHEN REPLACING A SPARK PLUG, CHECK THE PITCH
AND LENGTH OF THE THREAD. IF THE THREADED PART
IS TOO SHORT, CARBON DEPOSITS WILL BUILD UP ON
THE THREAD'S SEAT AND MAY THUS CAUSE DAMAGE
TO THE ENGINE WHEN THE CORRECT THREADED PART
IS INSTALLED. USE SPARK PLUGS OF THE SPECIFIED
TYPE ONLY; OTHERWISE, ENGINE LIFE AND PERFORM-
ANCE COULD BE COMPROMISED. CHECK THE GAP BE-
MAIN - 30
TWEEN THE ELECTRODES WITH A THICKNESS FEELER

GAUGE TO AVOID DAMAGING THE PLATINUM COATING.
• Check the gap between the electrodes

with a thickness feeler gauge.
• The gap should be 0.6 - 0.7 mm; adjust
it if necessary by carefully folding the
earth electrode.
• Make sure the washer is in good con-
ditions. Once the washer is fitted, man-
ually screw the spark plug to avoid
damaging the thread.
• Tighten to the specified torque.
CAUTION
TIGHTEN THE SPARK PLUG CORRECTLY, OTHERWISE

THE ENGINE MAY OVERHEAT AND GET IRRETRIEVABLE
DAMAGED. USE ONLY THE RECOMMENDED TYPE OF
SPARK PLUG, OTHERWISE, ENGINE DURATION AND
PERFORMANCE COULD BE COMPROMISED.
Locking torques (N*m)

Spark plug 25 - 30
• Refit the tube «1» of spark plug «2»
adequately so that it does not get de-
tached when exposed to engine vibra-
tion.
• Refit the central inspection cover.
CAUTION
MAKE SURE THE TUBE «1» ON THE SPARK PLUG «2» IS

CORRECTLY POSITIONED.
Characteristic
Standard spark plug
CHAMPION RN1C
Hub oil
Check
NOTE
USE ONLY RECOMMENDED OIL, REFER TO THE TABLE OF RECOMMENDED PRODUCTS.
MAIN - 31

stop the engine.
• Rest the vehicle on its stand.
• Remove the tap-dipstick «1» and clean
it with a cloth.
• Reinsert the tap-dipstick «1» into its
tube «2» and then pull it out again to
check the oil level.
• The oil level is correct if it reaches the

indicated mark.
CAUTION
NEVER USE THE VEHICLE WITH INSUFFICIENT LUBRI-

CANT OR WITH CONTAMINATED OR UNSUITABLE LU-
BRICANTS, AS THIS WILL ACCELERATE WEAR OF
MOVING PARTS AND CAUSE IRREPARABLE DAMAGE.
Replacement
CAUTION
WAIT A FEW MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM COOL DOWN.
To ensure long-lasting and optimal scooter per-
formance, change oil following the frequency indi-
cated in the scheduled maintenance tables.
For replacement:

stop the engine.
• Park the vehicle on its centre stand.
• Place a container with 150 cm³ mini-
mum capacity under the drainage plug
«1».
• Unscrew the filler cap «2» and the oil
drainage plug «1».
MAIN - 32
• Let the oil drain off completely from the

crankcase.
• Tighten the drainage plug «1» and
pour 130 cm³ of the recommended oil.
• Check the hub oil level.
• Tighten the filler cap «2».
CAUTION
TIGHTEN THE FILLER PLUGS SECURELY AND CHECK

THAT OIL DOES NOT SEEP.
PERIODICALLY CHECK THAT THERE IS NO OIL LEAK-
AGE FROM THE CRANKCASE COVER GASKET.
NEVER USE THE VEHICLE WITH INSUFFICIENT LUBRI-
CANT OR WITH CONTAMINATED OR UNSUITABLE LU-
BRICANTS, AS THIS WILL ACCELERATE WEAR OF
MOVING PARTS AND CAUSE IRREPARABLE DAMAGE.
75W-90 gear box and transmission oil Synthet-
ic lubricant for gearboxes and transmissions.
SAE 75W-90; API GL4, GL5
Air filter
CAUTION
THE AIR FILTER SHOULD BE INSPECTED AND CLEANED EVERY MONTH OR IN ACCORDANCE
WITH THE SCHEDULED MAINTENANCE TABLE. THIS WILL DEPEND ON THE CONDITIONS OF
USE.
IF THE VEHICLE IS USED ON DUSTY OR WET ROADS, THE CLEANING AND REPLACEMENT
OPERATIONS MUST BE CARRIED OUT MORE FREQUENTLY.
CAUTION
PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACE-
MENT. DO NOT START THE ENGINE WITHOUT THE AIR FILTER.
REMOVAL
• Rest the vehicle on its centre stand.

• Undo and remove the four screws in-
dicated.
MAIN - 33
• Fully turn the kick-start pedal and keep

it down.
• Slide off the entire filter from below.
Cleaning
CAUTION
DO NOT USE PETROL OR FLAMMABLE SOLVENTS FOR THE WASHING OF THE FILTER ELE-
MENT, TO AVOID THE RISK OF FIRE OR EXPLOSION.
• Separate the retaining net «1» from the
support «2».
• Remove the filtering element «3»
• Wash the filtering element with clean,
non-flammable or high-volatility sol-
vents, and let it dry properly.
• Apply the recommended product on
the whole surface.
CAUTION
WHEN CLEANING THE FILTERING ELEMENT, CHECK

THAT IT IS NOT TORN. OTHERWISE, REPLACE THE FIL-
TERING ELEMENT.
Oil for filter sponges Special product for im-
pregnating sponge filtering elements.
-
Transmissions
Check that the throttle grip works correctly

CAUTION
DO NOT USE THE SCOOTER IF THE THROTTLE GRIP CABLE IS DAMAGED, TWISTED OR
COILED. THIS MAY INTERFERE WITH THE THROTTLE GRIP NORMAL OPERATION.
Make sure the front fork rotation does not press the throttle grip and engage gears. Furthermore, make
sure that the throttle grip goes back to idle position smoothly and automatically when released.
MAIN - 34
Headlight adjustment
CAUTION
DO NOT USE THE VEHICLE IF THE LIGHTS ARE NOT

WORKING PROPERLY.
DO NOT USE THE VEHICLE IF THE LIGHTS ARE NOT
PROPERLY ADJUSTED: YOU MAY BLIND THE DRIVERS
COMING TOWARDS YOU AND, IN ADDITION, DECREASE
THE POSSIBILITY TO SEE AN OBSTACLE ON THE
STREET WHILE DRIVING AT NIGHT.
DECREASING THE VEHICLE'S SPEED WHILE DRIVING AT
NIGHT IS ALWAYS RECOMMENDED: IN THIS WAY, YOU
WILL HAVE TIME TO AVOID ANY OBSTACLES AND
ADAPT YOUR SIGHT TO THE LOW VISIBILITY CAUSED BY
THE DARK.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY
RESULT IN A COLLISION WITH ANOTHER VEHICLE AND,
CONSEQUENTLY, IN THE RISK OF SERIOUS INJURY OR
EVEN DEATH.
NOTE
THE PROCEDURE HEREIN DESCRIBED COMPLIES WITH
THE ITALIAN STANDARD DEFINING THE MAXIMUM
HEIGHT OF VEHICLES' LIGHTS.
LOCAL REGULATIONS MUST BE COMPLIED WITH WHILE
USING VEHICLES IN OTHER NATIONS.
• For a quick check of the correct direc-

tion of the front light beams, place the
vehicle ten metres from a vertical wall
and make sure the ground is level.
• Turn on the low-beam light, sit on the
vehicle and check that the light beam
projected to the wall is a little below the
headlight horizontal straight line (about
9/10 of the total height).
To adjust the light beam:
• Park the vehicle on its centre stand on

safe and level ground.
• Unscrew the nut «1» and adjust the
front headlight assembly «2».
• Adjust the light beams, screw the nut
«1».
NOTE
IN COMPLIANCE WITH LOCAL LEGISLATION, SPECIFIC
PROCEDURES MUST BE FOLLOWED WHEN ALIGNING
THE LIGHTS.
MAIN - 35
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

MOJIT0 50 2T Electrical system
KEY
1. Multiple connectors
2. Instrument panel
3. Low fuel warning light
4. Turn indicator warning light
5. Tail light warning light
6. Instrument panel lighting bulbs
7. High-beam warning light
8. Oil level warning light
9. Fuel level gauge
10. Checking diode
11. Horn
12. Key switch
13. Left light switch
14. Right light switch
15. Rear light
16. Left rear turn indicator
17. Rear twin bulb
18. Right rear turn indicator
19. Fuel level sensor
ELE SYS - 37
Electrical system MOJIT0 50 2T
20. Oil level switch

21. Rear stop switch
22. Front stop switch
23. Start-up relay
24. Starter motor
25. Battery
26. Fuses
27. Regulator
28. Pick up
29. Generator
30. Spark plug
31. Transducer
32. Automatic starter
33. Front headlamp
34. Front two-filament bulb
35. Tail light bulb
36. Front right turn indicator
37. Front left turn indicator
38. License plate light pre-installation
39. -
40. -
41. -
42. -
43. -
44. -
45. -
CABLE COLOURS
Ar:Orange Az:Sky blue B: Blue Bi: White G: Yellow Gr:Grey M: Brown N: Black R: Red V: Green
Vi:Purple Ro: Pink
Checks and inspections
Ignition circuit
CAUTION
THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-
CONNECTED.
Check spark plug for correct conditions, clean it and remove deposits. Replace it, if necessary.
ELE SYS - 38
Pick-Up Check
• With engine off disconnect the control unit connector.

• Measure the resistance present between the Red and White cables.
Electric characteristic
Pick-up resistance
170 Ω
Battery recharge circuit
With engine running at high revs, measure the voltage present at the battery poles.
Recharge voltage
12V at 2000 rpm
Stator check
CAUTION
THE FOLLOWING CHECKS SHOULD BE CARRIED OUT BY SELECTING THE ALTERNATING

CURRENT FUNCTION ON THE TESTER.
• Disconnect the current generator connector.
• Start the engine and make it run at a high number of revs.
• Measure the voltage between the terminal corresponding to the Yellow-Grey cable connec-
tor and the generator ground connection.
• Repeat the check by measuring voltage.
Generator voltage
25 ÷ 35V at 2000 rpm
Generated current
2A at 6000 rpm
Start up system check

CAUTION
CONNECTED.
• Check the fuses and the key switch contacts.
• Check the continuity of the Green-Red cable between 7.5 A fuse and stop button.
ELE SYS - 39
• Check the stop button contacts.

• Check the continuity between the start-up button Green-Red cable and the stop button
Green-Yellow cables.
• Check the start-up button contacts.
• Check the continuity between the start-up button Green-Red cable and the start-up remote
control switch.
• Check the start-up remote control switch.
• Check the continuity of the Red cable between remote control and battery and from remote
control and starter motor.
• Check the starter motor is earthed.
Horn control
CAUTION
CONNECTED.
• Check continuity of the Green-Red cable that connects the horn button to the 7.5 A fuse.
• Check that the horn switch works properly.
• Check continuity of the Grey cable that connects the switch to the horn.
• Check that the horn is earthed.
Turn signals system check

CAUTION
CONNECTED.
• Check that bulbs operate properly.
• Check continuity of the Blue-Black cable which connects the turn indicator switch to the
voltage regulator.
• With key switch set to «ON», check if there is voltage between the Blue-Black cable and the
ground connection.
• Check that the turn indicator switch works properly.
• Check continuity of the Red and Sky Blue cables which connect the switch to the bulbs.
level indicators
CAUTION
ELE SYS - 40
CONNECTED.
• Check continuity of the Green-Red cable which connects the instrument panel to the 7.5 A
fuse.
• Check continuity of the Grey-Green cable which connects the instrument panel to the fuel
level probe.
Lights list
BULBS AND WARNING LIGHTS

1 Low-/high-beam light bulb 12V - 35/35W
2 Front tail light bulb 12V - 5W
3 Turn indicator bulb 12V - 10W
4 Rear tail light /rear stop light/ license plate light bulb 12 V - 5 / 21 W
5 Instrument panel lighting bulbs 12V - 1.2W
6 Tail lights and low-beam light warning light 12V - 1.2W
7 High beam warning light 12V - 1.2W
8 Turn indicator warning light 12V - 2W
9 Low mixer oil warning light 12V - 2W
10 Low fuel warning light 12V - 2W
CAUTION
CONNECTED.
Check tail lights and panel lightning
• Disconnect the connector from the voltage regulator and check there is continuity between
the Green cable and the Yellow cables of the tail light bulbs.
• Repeat the check between the Green cable of the voltage regulator connector and the in-
strument panel Yellow cable.
High/low-beam light check

• Check continuity of the Green cable between the voltage regulator and the light switch.
• Check that the light switch operate properly.
• Check continuity of the Black cable between the light switch and the low-beam bulb.
• Check continuity of the White cable between the light switch and the high-beam bulb.
Fuses
CAUTION
ELE SYS - 41
DO NOT REPAIR FAULTY FUSES.

USE RECOMMENDED FUSES ONLY. USING FUSES OF UNSUITABLE RATING MAY DAMAGE
ELECTRICAL SYSTEM OR SHORT CIRCUIT.
FUSE DISTRIBUTION
1 7.5 A Fuse From key-switch to: start-up relay and circuit, fuel level
sensor and circuit, horn, stop light and circuit, low mixer
oil sensor and circuit.
2 15A Fuse From battery to key-switch, generator:
Sealed battery
Commissioning sealed batteries
If the motorcycle is provided with a sealed battery, the only maintenance required is to check if it is
charged and to recharge it, if necessary. These operations should be carried out before delivering the
vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery,
it is therefore necessary to check the battery charge and recharge it, if required, before storing the
motorcycle and afterwards every 6 months.
INSTRUCTIONS FOR BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE
1. Voltage check
2. • Before installing the battery on the vehicle, check the open circuit voltage with a standard
tester.
• If voltage is over 12.60V, the battery can be installed without any refresh.
• If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
• Constant-voltage charge equal to 14.40-14.70V
• Initial charge current equal to 0.3-0.5 of the battery rated capacity
• Charge time:
• 10 to 12 h recommended Minimum 6 h Maximum 24 h
3. Constant-voltage battery charge mode
• Charge current equal to 1/10 of the battery rated capacity
4. Constant-current battery charge mode
Dry-charge battery
Where available
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IF IT ACCIDENTALLY
COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR
APPROX. 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.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ELE SYS - 42
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.

Commissioning dry-charged batteries:
1)- Remove the short closed tube and the caps,
then pour sulphuric acid into the cells using the
type specified for batteries, with a specific gravity
of 1.26, corresponding to 30° Bé, at a minimum
temperature of 15°C until the upper level is
reached.
2) - Leave to rest for at least 2 hours; then, restore
the level with sulphuric acid.
3)- Within the following 24 hours, recharge with the
specific battery charger (single) or (multiple) at a
intensity of about 1/10 of the battery nominal ca-
pacity, checking that the acid density is about 1.27,
corresponding to 31º 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) - After performing the above mentioned opera-
tions, fit the battery on the vehicle, observing the
correct connections with the wiring harness.
1 Keep the pipe straight
2 Visual inspect the level
3 The float must be released
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VE-
HICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE
(WITH CLOSED END) NEAR THE + POSITIVE TERMINAL
WITH THE CORRESPONDING LONG TUBE (WITH OPEN
END), THAT YOU FIND FITTED TO THE VEHICLE, TO EN-
SURE THAT THE GASES THAT FORM CAN ESCAPE
PROPERLY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
Battery maintenance
The battery is an electrical device which requires careful monitoring and diligent maintenance. The
maintenance rules are:
1) Electrolyte level check
ELE SYS - 43
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level. If water topping is required too often, check the vehicle 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 vehicle is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
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 earth wire (black) marked
(-) must be connected to the - negative terminal while the other two red wires marked (+) must be
connected to the terminal marked with the + positive sign.
3) Battery recharge
Remove the battery from the vehicle disconnecting the negative terminal first.
Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),
setting the battery charger selector to the type of battery to be recharged. Connections to the power
supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).
4) Cleaning the battery
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
CAUTION
DRINKING WATER CONTAINS MINERALS THAT CAN BE HARMFUL TO THE BATTERY: USE
DISTILLED WATER ONLY.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT
IS FIRST USED DETERMINES PREMATURE DAMAGE TO THE BATTERY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
ELE SYS - 44
Battery installation
Where available
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)

WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IF IT ACCIDENTALLY
COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR
APPROX. 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.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quick-
ly as possible to run the subsequent activation
phases.
2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulphu-
ric acid.
3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
to break the seals. The electrolyte should start to
flow inside the battery.
Note: Do not tilt the container to prevent the flow
of electrolyte from pausing or stopping.
4) Control the flow of electrolyte
ELE SYS - 45
Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.
Note: If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container
two or three times. Do not remove the container from the battery.
5) Take out the container.
Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte
remains in the container. Now, gently pull the container out from the battery, only do this when the
container is completely empty, and proceed immediately to the next point.
6) Battery closing.
Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure
that the strip is levelled with the top part of the battery.
Note: To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Place the battery down for 1 - 2 hours prior to the charging from the battery.
7) Recharging the new battery

With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeop-
ardising its useful life on vehicle.
The dry-charged MF batteries, like the completely
charged YTX batteries must have a zero load volt-
age comprised between 12.8 - 13.15 V. Complete-
ly charge the battery using the charger 020648Y :
a - select the type of battery with the red switch on
the left of the panel battery charger panel
b - select NEW on the yellow timer
c - connect the clamps of the battery charger to the
battery poles (black clamp to negative pole (-) and
red clamp to positive pole (+)).
ELE SYS - 46
d - Press the red button, as shown in figure.
e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-
ure.
f - Check the ignition of the green LED indicated

with a red arrow in figure.
g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED
has taken place
ELE SYS - 47
h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less
than 12.8 V, proceed with a new recharge of the
battery starting from point c of the recharge pro-
cedure of the new battery, otherwise go to point i
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,
disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
ELE SYS - 48
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle MOJIT0 50 2T
Removal of the engine from the vehicle

CAUTION
BEFORE CARRYING OUT THE OPERATIONS BELOW, BEAR IN MIND THAT THE ENGINE MUST
BE REMOVED FROM THE CHASSIS TOWARDS THE BOTTOM; AFTERWARDS ARRANGE AND
POSITION THE NECESSARY TOOLS.
• Remove the tail section.
NOTE
GET A HOIST AND BELTS FOR LIFTING AND HANDLEBAR LOCKING.
• Lock with the belt the handlebar to the
footrest.
• Fasten the belts to the chassis rear
section.
• Lift the hoist arm until the belts are taut.
• Unscrew and remove the lower screw

fixing the engine shock absorber.
• Unscrew the throttle valve cover.
ENG VE - 50
MOJIT0 50 2T Engine from vehicle
• Remove the throttle cable from the car-

burettor.
• Disconnect the automatic starter con-

nector.
• Loosen the clamp and disconnect the

fuel delivery pipe.
CAUTION
MARK THE REMOVAL OF THE FUEL DELIVERY PIPE AND

THE DIFFUSER TO AVOID INVERSION UPON REFITTING.

diffuser pipe.
ENG VE - 51

oil mixture pipe.
CAUTION
FOLD AND SCREW WITH SELF-LOCKING CLAMP THE

MIXTURE OIL PIPE TO PREVENT OIL LEAKS.
• Slide battery breather pipes, fuel tank

and carburettor off the riding eyelet.
• Unscrew and remove the brake lever

set screw.
• Remove the rear brake.
ENG VE - 52
MOJIT0 50 2T Engine from vehicle
• Unscrew screw «1» and remove the

brake cable sealing clamp.
• Unscrew and remove the screw «2».

• Disconnect the ground lead «3».
• Remove the tube «4» from the spark

plug «5».
• Disconnect the three connectors indi-

cated: pick-up, starter and current gen-
erator.
ENG VE - 53
• Working on the right side, unscrew and

remove the nut «6».
• Slide the pin from the opposite side.
• Remove the engine together with the

centre stand and the rear wheel.
• When refitting the engine onto the scooter, carry out the reverse order operations of the
removal respecting the tightening torques shown in the «Specifications» Chapter.
• Check the mixture oil level and if necessary top it up with the recommended type.
• Check the functioning of the accelerator and the electrical devices.
CAUTION
PAY SPECIAL ATTENTION WHEN POSITIONING THE THROTTLE CONTROL TRANSMISSION

PROPERLY.
ENG VE - 54
INDEX OF TOPICS
ENGINE ENG
Engine MOJIT0 50 2T
Automatic transmission
Transmission cover
- Loosen the 15 screws and remove the transmis-

sion cover with the aid of a mallet.
NOTE
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
- 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.
- 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 ÷ 13
ENG - 56
MOJIT0 50 2T Engine
- 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
Grease Jota 3 FS Mineral oil and lithium soap
based grease.
Green, ISO6743-9 DIN 51502
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.
NOTE
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 bearing outer plate, after
slightly heating the crankcase from the inside.
NOTE
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 - 57
Engine MOJIT0 50 2T
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.
NOTE
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
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 housing diameter/standard value
Ø 107+0.2 +0 mm
clutch housing diameter/max. value allowed
after use
Ø 107.5 mm
Eccentricity measured /max.
0.20 mm
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.
NOTE
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL FACING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID
VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
ENG - 58
MOJIT0 50 2T Engine
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.
- 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
AP8140259 Tool for fitting/ removing the driv-
en pulley clutch
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
- Remove the three guide pins and the mobile half

pulley.
ENG - 59
Engine MOJIT0 50 2T
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 SEAL RING.
Specific tooling
001467Y029 Housing for 38-mm outside diam-
eter bearings
- Remove the ball bearing retention snap ring.
- Expel the ball bearing from the side of the clutch
housing by means of the special tool.
NOTE
PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO
DEFORM THE SLIDING SURFACE OF THE DRIVE BELT
Specific tooling
020376Y Sleeve for adaptors
020363Y 20mm oil seal 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 outside diameter of the pulley bush-
ing.
Characteristic
Stationary driven half-pulley/Standard diame-
ter
Ø 33.965-33.985 mm
Stationary driven half-pulley / Minimum diam-
eter admitted after use
Ø 33.96 mm
ENG - 60
MOJIT0 50 2T Engine
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
admissible
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.
- 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 g 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.
Molybdenum disulphide grease Lithium grease with molybdenum disulphide
Grey black grease.
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 24 mm Ø punch
ENG - 61
Engine MOJIT0 50 2T
020362Y 12mm oil guard guide

020171Y Punch for Ø 17 mm roller bearing
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
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 shank.
- 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 to 60
ENG - 62
MOJIT0 50 2T Engine
Refitting the driven pulley
-Refit the driven pulley assembly, the clutch hous-

ing and the nut, using the specific tool.
Specific tooling

Driven pulley shaft nut 40 44
Drive-belt
- Make sure the drive belt is not damaged and does

not have cracks in the toothed grooves.
- Check belt for correct width.
Characteristic
Drive belt/Minimum width:
17.5 mm
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
ENG - 63
Engine MOJIT0 50 2T
Mixer gears and belt
- Remove the gear and the 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.
NOTE
REPLACE THE BELT AS INDICATED IN THE SCHEDULED
MAINTENANCE TABLE.
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.
4) Check the integrity of the sliding shoes 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:
ENG - 64
MOJIT0 50 2T Engine
19,60 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.
NOTE
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.
NOTE
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
ORDER TO AVOID WRONG TIGHTENING AND CONSE-
QUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling

Crankshaft pulley nut 18 - 20 + 90°
End gear
ENG - 65
Engine MOJIT0 50 2T
Removing the hub cover
- Drain the rear hub oil

- Remove driven pulley
- Remove the rear brake shoes
- Remove the 5 screws fixing the cover to the
crankcase
- Remove the cover with the wheel axle and pull it
out
- Remove the intermediate gear with the appropri-
ate shim washers
Removing the wheel axle bearings
- Remove the oil seal and the seeger ring.

- Fix the hub cover properly to avoid damaging the
sealing surface with the housing
- Remove the wheel axle bearing using the specific
tool
Specific tooling
020477Y 37-mm Adaptor
ENG - 66
MOJIT0 50 2T Engine
Removing the driven pulley shaft bearing
- Remove the seeger ring

- Heat the engine crankcase but do not direct the
hot air towards the bearing
- Extract the driven pulley shaft together with the
bearing with a few mallet blows
- Pull out the driven pulley shaft bearing from the

engine crankcase using a specific tool.
NOTE
USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALL-
ER INTERNAL DIAMETER
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
ENG - 67
Engine MOJIT0 50 2T
Inspecting the hub shaft
- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and
the oil seal housings.
- If faults are found, replace the damaged compo-
nents.
- Check capacity (A) of the transmission gear
(wear, deformations, etc.)
- Check the pulley shaft seating: Superficial wear
(B) may indicate irregularities in the crankcase
seats or in the pulley shaft capacities
Inspecting the hub cover
- Check that the fitting surface is not dented or dis-

torted.
- 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
020452Y Tube for removing and refitting the
driven pulley shaft
ENG - 68
MOJIT0 50 2T Engine
- Slightly warm the hub cover and insert the bear-

ing with the relative punch.
- Fit the circlip with the concave or radial part on
the bearing side.
NOTE
FIT THE BALL BEARING WITH THE SHIELD FACING THE
OIL SEAL.
Specific tooling
020151Y Heat gun
Refitting the wheel axle bearing
- Support the hub cover on a wooden surface

- Heat up the hub cover using the thermal gun.
- Preassemble the bearing on the specific punch
using grease and then insert the bearing in its
seating
- Refit the seeger ring and the oil seal using the 42
x 47 mm punch
NOTE
POSITION THE OIL SEAL WITH THE SEALING LIP FACING
THE HUB INTERNAL SIDE
Specific tooling
020150Y Heat gun support
020151Y Heat gun
ENG - 69
Engine MOJIT0 50 2T
Refitting the hub bearings
- Refit the wheel axle on the cover, paying atten-

tion to not damage the oil seal lip
- Apply a thin layer of grease on the two washer of
the intermediary gear and fit one of them on the
cover, so that it doe not interfere with the wheel
axle gear when the lay is inserted
Refitting the ub cover
- Apply product recommended for surfaces on the

hub cap and refit cap on the crankcase
- Fit the 5 screws and tighten them to the specified
torque.
NOTE
CLEAN THE CONTACT SURFACES OF THE HUB COVER
AND THE HALF CRANKCASE OF RESIDUE FROM PREVI-
OUS GASKETS BEFORE APPLYING A NEW ONE.
Loctite 510 Medium-strength paste sealant.
Pink

hub cap screws 24 - 26
Flywheel cover
Cooling hood
- Remove the four fixings shown in the figure.

- Remove the fan cover
ENG - 70
MOJIT0 50 2T Engine
- Remove the oil piping retention band from the

hood
- Remove the 2 screws shown in the picture
Cooling fan
- Remove the cooling fan by acting on the three

fixings indicated in the figure.
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 carrying out the removal procedure in reverse, tightening the retainers to
the specified torque.
NOTE
THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE
CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM-
BLY.
ENG - 71
Engine MOJIT0 50 2T
Pick-up screws 3 to 4 Stator screws 3 to 4
Flywheel and starting
Removing the starter motor
Remove the two clamps shown in the figure
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
AP8140276 Flywheel extractor
ENG - 72
MOJIT0 50 2T Engine
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.
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.
NOTE
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 ÷ 44
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.

- Fit the starter motor on the crankcase and lock
the 2 screws to the prescribed torque.
NOTE
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.

Starter screws 11 to 13
Cylinder assy. and timing system
ENG - 73
Engine MOJIT0 50 2T
Removing the intake manifold
Use an anti-tampering TORX spanner to remove

the two clamping screws of the intake manifold
Removing the cylinder head
Remove the 4 screws shown in the figure
Removing the cylinder - piston assy.
Remove the cylinder very carefully
ENG - 74
MOJIT0 50 2T Engine
Remove the snap rings and remove the pin

CAUTION
AFTER EACH REMOVAL OPERATION REPLACE THE PIN
RETENTION SNAP RINGS
Inspecting the small end
- Measure the internal diameter of the connecting

rod small end using an internal micrometer.
NOTE
IF THE DIAMETER OF THE CONNECTING ROD SMALL
END EXCEEDS THE MAXIMUM DIAMETER ADMISSIBLE,
SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE
THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE
AND CRANKSHAFT" CHAPTER".
Characteristic
Connecting rod small end: standard diameter
17 +0.011-0.001
Connecting rod small end: maximum allowa-
ble 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
ENG - 75
Engine MOJIT0 50 2T
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
- 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
ENG - 76
MOJIT0 50 2T Engine
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
feeler gauge as shown in the photograph
- If the values are higher than the values prescri-
bed in the chart, substitute the rings
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.
NOTE
REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM
THE REMOVAL OPERATIONS
Specific tooling
020166Y Tool for fitting the pin snap rings

Head locking nuts 10 ÷ 11
- 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 PISTON
CROWN TOWARDS THE EXHAUST OPENING.
THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON
THE PISTON WITH THE SPECIFIC TOOL
ENG - 77
Engine MOJIT0 50 2T
Inspecting the timing system components

CAUTION
CHECK THE CORRECT REED UNIT SEAL; NO LIGHT
MUST PASS BETWEEN THE SUPPORT AND REED.
Crankcase - crankshaft
ENG - 78
MOJIT0 50 2T Engine
Splitting the crankcase halves
Remove the eight crankcase union fasteners.
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 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
NOTE
THE HALF RINGS MUST BE INSERTED ON THE BEAR-
INGS WITH A FEW MALLET BLOWS
Specific tooling
004499Y001 Bearing extractor bell
004499Y006 Bearing extractor ring
004499Y002 Bearing extractor screw
004499Y007 Half rings
ENG - 79
Engine MOJIT0 50 2T
- Using the specific tool remove any bearings left

on the half crankcase
Specific tooling
001467Y007 Driver for OD 54-mm bearings
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 equipment shown, check that the

eccentricities of the surfaces of Ø «A»-«B»-«C»
are within 0.03 mm. (maximum reading limit on the
dial gauge); also check the eccentricity of Ø «D»,
for which a maximum reading of 0.02 mm is per-
mitted. If the eccentricity is not much higher than
what is required, straighten the shaft, pushing a
wedge between the counterweights or tightening
them in a clamp (equipped with aluminium bushes)
depending on the requirements.
Specific tooling
020074Y Support base for checking crankshaft
alignment
ENG - 80
MOJIT0 50 2T Engine
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 - 81
Engine MOJIT0 50 2T
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 Medium-strength paste sealant.
Pink
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 crankshaft
If this is not within the maximum limit allowed, re-
peat the crankcase coupling procedure
Specific tooling
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
ENG - 82
MOJIT0 50 2T Engine
Lubrication
Oil pump
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
Removing the carburettor
The carburettor removal can be carried on even with the engine on the vehicle.
ENG - 83
Engine MOJIT0 50 2T

fuel pipe.
• Unscrew the throttle valve cover.
• Remove from the carburettor the gas

cable.
• Disconnect the automatic starter con-

nector.
• Loosen the carburettor sealing clamp

to the filter casing.
ENG - 84
MOJIT0 50 2T Engine
• Unscrew and remove both fixing

screws to the inlet manifold.
• Remove the carburettor.
ENG - 85
INDEX OF TOPICS
SUSPENSIONS SUSP
MOJIT0 50 2T Suspensions
Front
FRONT FORK DIAGRAM
Key:
1. 115 O-ring
2. Special washer
3. 13x24x2.5 washer
4. Self-locking M12 lower nut
5. Bushing
6. Nylon bushing
7. Cap
8. D20 cap
9. Bushing
10. Self-locking M8 lower nut
11. M8x35 TE screw
12. 8.4x17 washer
13. D 28 cap
14. Bushing
15. Nylon bushing
16. Fork shock absorber
17. Shock absorber upper cover
SUSP - 87
Suspensions MOJIT0 50 2T
18. Shock absorber lower cover

19. M12x50 TEPF screw
20Plate
21Connecting rod
22. Bare fork
23. M5 Clip
Removing the front wheel
• Rest the vehicle on its centre stand.

• Set a support under the scooter in such a way that the wheel is able to move freely and the
scooter does not fall.
CAUTION
MAKE SURE THE MOTORCYCLE IS STABLE AND FIRM.

• Remove the brake calliper.
• Unscrew and remove the wheel bolt
lock-nut together with the washer.
CAUTION
NEVER TOUCH THE FRONT BRAKE LEVER ONCE THE

FRONT WHEEL IS REMOVED. DOING SO MAY CAUSE THE
CALLIPER PISTONS TO COME OUT AND THE BRAKE
FLUID TO SEEP THROUGH.
• Hold the front wheel and manually re-

move off the wheel bolt.
• Observe the position of the speedom-
eter transmission to proper refit it.
SUSP - 88
• Observe the position of the washer and

recover to proper refit it.
• Remove the front wheel.
Front wheel hub overhaul
WHEEL RIM INSPECTION
• Make sure that the rim is not deformed

or cracked. Replace it if necessary.
• Check wheel eccentricity. If tolerance
limits are exceeded, check the rim and
the bearings. If necessary, replace the
wheel.
Characteristic
Eccentricity limits:
Vertical: 2 mm (0.07874 in)
Horizontal: 2 mm (0.07874 in)
• Check the wheel balance.

• Check wheel on the wheel balancer and turn it several times, paying attention to its position
when it stops. If the wheel is steadily balanced, it will not always stop at the same point. If
it always stops at the same point, the wheel is not balanced and must be balanced. Place
weights on the lightest part of the wheel so that it does not stop any more at a particular
point after being turned several times.
Refitting the front wheel
Follow the removal procedures but in reverse order, taking into consideration the prescribed locking
torque.

Front wheel pin nut 80
Front fork
SUSP - 89
Removal
• Remove the handlebar.
CAUTION
DO NOT APPLY FORCE ON THE CABLES, PIPES, WIRES OR ELECTRIC CONNECTORS.
• Slide off and remove the rubber gasket «1».
• Unscrew and remove the tightening nut «2».
• Unscrew and remove the adjustment nut «3».
CAUTION
WHEN REMOVING THE FORK, PAY ATTENTION TO COLLECT ALL THE BALLS OF THE BEAR-
INGS. THE BALLS ARE NOT CAGED AND THEY AUTOMATICALLY FALL WHEN THE FORK IS
REMOVED.
• Remove the fork from the steering tube.
• Remove the inside ring «4» and the balls «5» from the upper bearing «6».
• Remove the inside ring «7» and the balls «8» from the lower bearing «9».
• Wash all the bearing parts thoroughly, including the outside rings «10» and «11».
• Check all the parts for wear and remove them if necessary.
Refitting
NOTE
GREASE ABUNDANTLY ON ALL THE COMPONENTS OF THE BEARINGS, HOLDING THE BALL
IN THEIR EXTERNAL RING
SUSP - 90
• Follow the removal procedures but in reverse order, taking into consideration the prescribed
locking torques.
CAUTION
WHEN REFITTING, PAY ATTENTION TO THE AMOUNT OF BALLS TO BE FITTED.

• 21 BALLS «5» FOR THE UPPER BEARING «6».
• 25 BALLS «8» FOR THE LOWER BEARING «9».
Steering series retainer nut 15 Self-locking retainer lock nut 110
Front shock absorber
Removal

• For the shock absorber removal, un-
screw and remove the two fixing
screws on both sides
SUSP - 91
Shock absorbers
Removal
• Follow the removal operations in reverse order for the fitting, screwing the nuts to the pre-
scribed torque.

Rear shock absorber upper attachment screw 40 Rear shock absorber lower attachment
screw 40
CAUTION
HOLD THE REAR PART OF THE FRAME.

CAUTION
PLACE A SUPPORT OF SUITABLE THICKNESS UNDER THE REAR WHEEL TO PREVENT THE
ENGINE FROM FALLING.
• Park the vehicle on its centre stand.
• Remove the tail section and unscrew
nut «1» fixing the shock absorber to the
chassis.
• Unscrew nut «2» fixing the shock ab-

sorber to the engine.
SUSP - 92
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Braking system MOJIT0 50 2T
FRONT BRAKING SYSTEM DIAGRAM
Key:
1. Bare front wheel
2. Front tyre 120/70-12"
3. Bearing
4. Pulling element
5. Sealing ring D40x50x4
6. D190 brake disc
7. M8x25 TBEI screw
8. M12x1.25 low self-locking nut
9. Front wheel pin
10. 12.2x22x2 plain metal washer
11. Front wheel spacer
12. Tubeless valve
13. Odometer gear
14. Front brake calliper
15. Brake calliper cover
16. Pads-torque
17. Bleeding+hood
18. Pin+calliper spring
19. Calliper service kit
BRAK SYS - 94
MOJIT0 50 2T Braking system
20. Oil pipe screw

21. Front brake pipe
22. 10x14x1.6 washer*
23. M8X25 TE flanged screw*
24. Cable guide
26. M4x10 TCEI screw*
REAR BRAKING SYSTEM DIAGRAM
Key:
1. Bare rear wheel
2. Branches
3. Rear tyre 130/70-10"
4. M6x30 TE flanged screw
5. Panel nut
6. Tubeless valve
7. Nut
8. Cap
9. Rear brake cam
10. Rear brake lever set screw
11. Cable riding
12. Brake cable hooking peg
BRAK SYS - 95
13. Rear brake lever

14. Front brake cable
15. Split pin
16. Ring
17. 6.6x18x1.6 washer*
18. 6.5x10x19 spacer*
19. Compressed cylindric propeller spring *
20. Shoes return spring
21. Plate
22. Sealing ring
23. M6X35 TE flanged screw*
24. Cable riding
25. Rear wheel pin washer
Interventions rules
When pads are worn, the brake fluid level in the

reservoir decreases to automatically compensate
pad wear.
The front brake fluid reservoir «1» is located on the
end section to the right of the handlebar next to the
front brake lever.
CAUTION
NEVER USE THE VEHICLE IF ANY SYSTEM PART IS LEAK-

ING.
CAUTION
WHEN THE BRAKE PADS ARE WORN, THE BRAKE FLUID LEVEL PROGRESSIVELY DECREA-
SES IN ORDER TO COMPENSATE FOR THEIR WEAR.
If the fluid does not reach the "MIN" reference
mark:
• Check brake pads for wear.
If there is no need to replace any pads/discs,

check the braking system to determine the cause
of the problem, by checking:
• brake pipe condition. Mainly check if

there are broken or cracked areas;
BRAK SYS - 96
• the connections are properly tight-

ened;
• the connections may exhibit leaks;
• the calliper and the reservoir may ex-
hibit leaks;
• the bleed screw may exhibit leaks. If
dripping is detected, tighten to the ap-
propriate tightening torque;
• the fuel tank caps for possible leaks
and the gaskets conditions.
After repairing the brake:
• Check and bleed the system.

• Top-up the reservoir with a proper
brake fluid.
Front brake calliper
Removal
• Undo the two screws indicated and re-

move the brake calliper.
NOTE
SHOULD IT BE NECESSARY TO REPLACE THE CALLIP-
ER, FIRST LOOSEN THE JOINT CONNECTING THE PIPE
TO THE BRAKE CALLIPER.
Refitting
• Follow the removal operations in reverse order for the fitting, screwing the locking screws
to the prescribed torque using the recommended product.
Loctite 243 Medium strength threadlocking sealant .
Blue

Front brake calliper fixing screw 25
• If the brake pipe calliper has been disconnected:
CAUTION
BRAK SYS - 97
ALWAYS USE NEW GASKET WASHERS FOR THE BRAKE PIPE JOINT.
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.

Brake pipe to brake calliper fixing screws 18
Front brake pads
Removal
• Remove the brake calliper.

• Remove the lock and slide the pad re-
taining pin.
• Remove the pads.

CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER; OTHERWISE, THE CAL-
LIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE.
• Check friction material for appropriate
thickness. If thinner than the minimum
value, replace it.
Characteristic
Friction material minimum thickness
1.5
BRAK SYS - 98
• In case of uneven wear, replace the

brake pads when the friction material
thickness difference is 0.5 mm
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY

ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
Refitting
• Follow the removal operations in reverse order for the fitting, screwing the locking screws
to the prescribed torque.
Front
NOTE
IF THE HYDRAULIC SYSTEM CONTAINS AIR, THE LATTER WILL ABSORB THE MAJORITY OF
THE MAIN BRAKE CYLINDER'S STRENGTH AND, BY DOING SO, IT WILL REDUCE THE CALLI-
PER'S BRAKING EFFICIENCY. IF THE BRAKE CONTROL IS "SPONGY" AND THE BRAKES ARE
LESS EFFICIENT, YOU WILL KNOW THERE IS AIR IN THE SYSTEM.
CAUTION
SINCE THESE CONDITIONS ARE EXTREMELY DANGEROUS BOTH FOR THE VEHICLE AND
THE DRIVER, THE HYDRAULIC SYSTEM MUST MANDATORILY BE PURGED AFTER REINSTAL-
LING THE BRAKES AND COMPLETING STANDARD MAINTENANCE OPERATIONS.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY
QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS
BRAKE FLUID IN THE RESERVOIR.
Brake fluid DOT 4 Synthetic brake fluid.
SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4
• Remove the protection cap «1» from

the bleeder spout «2».
BRAK SYS - 99
• Connect a glass pipe to the bleed plug

«2».
CAUTION
DO NOT GET THE BRAKE PADS OR DISCS DIRTY WITH

BRAKE FLUID.
• Keep the free part of the glass tube in

a clean container.
• Pull the brake lever «5» slowly to the
end of the stroke two or three times.
Then keep it completely pulled.
CAUTION
LOOSEN THE BLEED PLUG SPOUT «2» AND CHECK THE

RESERVOIR BRAKE FLUID LEVEL «6». DO NOT EMPTY
THE RESERVOIR COMPLETELY SINCE THIS MAY FUR-
THER CAUSE AIR TO ENTER THE BRAKING SYSTEM.
• Loosen the bleed plug spout «2» and check if there are bubbles in the glass tube.
CAUTION
BEFORE RELEASING THE BRAKE LEVER «5», CLOSE THE BLEED PLUG «2» TO PREVENT
WATER FROM ENTERING THE BRAKE SYSTEM.
• When homogeneous brake fluid comes out, without bubbles, it means that the air has been
removed from the brake system. Thoroughly close the bleed valve 2" and tighten it with the
suitable force.
NOTE
REPEAT THE LAST THREE OPERATIONS UNTIL THE BUBBLES HAVE BEEN COMPLETELY
REMOVED.
• Refit the protective plug "1" on the spout of the bleed valve "2".
• Check the brake fluid level.
CAUTION
AFTER THE REINSTALLATION, PULL THE BRAKE LEVER REPEATEDLY AND MAKE SURE THE
BRAKING SYSTEM IS WORKING PROPERLY.
CAUTION
BRAK SYS - 100

PAY SPECIAL ATTENTION TO THE DISC AND THE FRICTION MATERIAL AND MAKE SURE
THEY ARE NEITHER DIRTY NOR GREASY, ESPECIALLY AFTER MAINTENANCE OR INSPEC-
TION OPERATIONS.
Rear drum brake
• Remove the rear wheel.

• Hold the lower shoe and slide it with the
upper one.
For fitting:
• First assembly two shoes and the

springs then place them on the pin and
on the cam.
To replace the transmission:
• Remove the front handlebar cover.

• Loosen the brake set screw
• Release the transmission from its
clamps to the engine and from its
clamps to the chassis.
• Adjust the drum brake activation point.

Rear brake adjustment nut 5
To adjust the drum brake:
• Unscrew the lock nut.

• Adjust the activation point of the rear
drum brake by acting on the set screw.
1
• With the brake lever released, the
wheel should rotate freely.
BRAK SYS - 101

INDEX OF TOPICS
CHASSIS CHAS
MOJIT0 50 2T Chassis
Taillight assy.
• Undo and remove the two fixing screws

retroreflector to the support.
• Undo and remove the three fixing

screws retroreflector to the support.
• Remove the support.
• Undo and remove the rear chassis tail

section fixing screw.
• Undo and remove the fixing screws of
the rear light unit to the tail section.
• Disconnect the cable harness connec-
tor and remove the rear light unit.
Footrest
• Unscrew and remove the fuel level

sensor cover fixing screw.
• Remove the cover.
CHAS - 103
Chassis MOJIT0 50 2T
• Working on both sides, unscrew and

remove the four footrest fixing screws.

remove the two footrest fixing screws.
• Remove the footrest.
Tail guard
• Lift the saddle.

• Remove the side cases.
• Remove the rear light unit.
• Undo and remove the five fixing screws
of the passenger grab handle.
• Remove the passenger grab handle
from the tail section.
CAUTION
HANDLE THE PLASTIC OR PAINTED COMPONENTS WITH

CARE. DO NOT SCRATCH OR SPOIL THEM.
• Working on both sides, undo and re-

move the upper tail section four fixing
screws.
CHAS - 104
• Working on both sides, undo and re-

move the front tail section two fixing
screws.
• Disconnect the two rear turn indicator

cable harness connectors.
Fuel tank
For complete tank removal:
• Remove the footrest.

• Disconnect the fuel level sensor con-
nector.
• Release the sealing clamp and slide
the fuel tank flexible breather pipe.
• Operating from both sides, unscrew

and remove the two spoiler fixing
screws.
• Remove the spoiler.
CAUTION
ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF. FUEL VAPOURS ARE HARMFUL TO
HEALTH. BEFORE ANY OPERATION, MAKE SURE THAT THE ROOM WHERE YOU ARE HAS
CHAS - 105
ADEQUATE AIR VENTILATION. DO NOT INHALE FUEL VAPOURS. DO NOT DISPOSE OF FUEL
INTO THE ENVIRONMENT.
• Prepare the container with a capacity
higher than the reservoir's and place it
under the scooter.
• Release the clamp and slide the fuel
pipe from the joint and empty the tank.
• Loosen the lower sealing clamp of the

fuel filler.
• Unscrew and remove the tank four fix-

ing screws.

remove the four fixing screws of the
bodywork support bracket.
• Remove the bracket.
• Remove the fuel tank.
CHAS - 106
FUEL FILLER
• Remove the right side case.

• Remove the tank cover.
• Remove the mixer oil reservoir cap.
• Undo and remove the two filler fixing
screws.
• Remove the filler cover.
• Slide off the fuel filler down and extract it from the
right side.
• Release the clamp «1» and disconnect the fuel
pipe «2».
• Remove the fuel filler.
For fuel sensor removal:
• Unscrew and remove the fuel level

sensor cover fixing screw.
• Remove the cover.
CHAS - 107
• Disconnect the electrical connector.

• Unscrew and remove the four fixing
nuts.
• Remove the fuel level sensor.
Side Cowlings
• Lift the saddle.

remove right and left inspection cover
four fixing screws.
• Remove the covers.
CHAS - 108
A
Air filter: 33
B
Battery: 39, 42, 45
Brake: 97, 98, 101
Brake calliper: 97
Brake pads: 98
Bulbs:
C
Carburettor: 29, 83
Clutch: 58, 59, 62
Cooling fan: 71
Crankcase: 78, 79, 82
Crankshaft: 78–81
Cylinder: 18, 73, 74, 76
E
Electrical system: 6, 16, 37
F
Fork: 89
Front wheel: 88, 89
Fuel: 105
Fuses: 41
H
Handlebar:
Headlight: 35
Horn: 40
Hub oil: 31
I
Identification: 14
M
Maintenance: 28
Maintenance Table:
R
Recommended products: 28
S
Shock absorber: 91
Shock absorbers: 92
Spark plug: 30
Starter motor: 72, 73
T
Tank: 105
Technical data: 10
Transmission: 15, 56
Tyres: 16
W
Warning lights:
Wheel rim:

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Service Station Manual Aprilia Mojito 50cc

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SERVICE STATION MANUAL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

Carry out the listed checks before delivering the motorcycle.

HANDLE FUEL WITH CARE.

Tightening torques inspection

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-

- Front and rear brake efficiency

Static check after test drive:

- Hydraulic braking system

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.

KEEP OUT OF THE REACH OF CHILDREN.

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

KEEP OUT OF THE REACH OF CHILDREN.

KEEP OUT OF THE REACH OF CHILDREN.

KEEP OUT OF THE REACH OF CHILDREN.

HYDROGEN GAS AND BATTERY ELECTROLYTE

KEEP OUT OF THE REACH OF CHILDREN.

THE BATTERY LIQUID IS CORROSIVE.

DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

Provide the chassis number when purchasing spare parts.

The engine number «2» is stamped on the rear

Dimensions and mass

WEIGHT AND DIMENSIONS

ENGINE TECHNICAL DATA (MC50)

BULBS AND WARNING LIGHTS (MC50)

Frame and suspensions

CHASSIS AND SUSPENSIONS

Wheels and tyres

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDER

020261Y Starter spring fitting

AP8140276 Flywheel extractor

001467Y029 Housing for 38-mm outside diameter

004499Y034 Bearing extractor part

Stores code Description

004499Y001 Bearing extractor bell

004499Y007 Half rings

004499Y Camshaft bearing extractor

008119Y009 Tube to assemble shafts and axles

020074Y Support base for checking crankshaft

Stores code Description

020150Y Air heater support

020151Y Air heater

020171Y Punch for Ø 17 mm roller bearing

020265Y Bearing fitting base

Stores code Description

020332Y Digital rpm indicator

020360Y 52x55 mm Adaptor

020362Y 12mm oil guard guide

Stores code Description

020376Y Adaptor handle

020166Y Tool for fitting the pin snap rings

020451Y starting ring gear lock

020452Y Tube for removing and refitting the driven

Stores code Description

020477Y 37-mm Adaptor

AP8140259 Universal tool for clutch assemblies

020288Y Fork to assemble piston on cylinder

001467Y009 Bell for OD 42-mm bearings