PIAGGIO Fly 150 4T, Fly 125, Fly 125 4T Workshop Manual

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WORKSHOP MANUAL

633225

Fly 125 - 150 4T

WORKSHOP

MANUAL

Fly 125 - 150 4T

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions shown in this publication are available in all countries. The availability of single versions

should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

WORKSHOP MANUAL

Fly 125 - 150 4T

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid open flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

Fly 125 - 150 4T Characteristics

CHAR - 7

Vehicle identification

VEHICLE IDENTIFICATION

Specification Desc./Quantity

Chassis prefix (125) ZAPM42100 ÷ 1001

Engine prefix (125) M421M ÷ 1001

Chassis prefix (150) ZAPM42200 ÷ 1001

Engine prefix (150) M422M ÷ 1001

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification Desc./Quantity

Dry weight 112 kg

Overall height 1150 mm

Seat height 785

Width 735

Wheel base 1330

Lenght 1870

Characteristics Fly 125 - 150 4T

CHAR - 8

Engine

ENGINE

Specification Desc./Quantity

Engine Single-cylinder, 4-stroke Piaggio LEADER

Timing system Single overhead camshaft (SOHC) with 2 valves

Valve clearance intake 0.10

outlet 0.15

Bore x stroke (125) 57 x 48.6 mm

Bore x stroke 62,6 x 48.6 mm

Cubic capacity (125) 124 cm³

Cubic capacity 150,46 cm³

Compression ratio (125) 10.6 : 1

Compression ratio 10.5: 1

Carburettor KEIHIN CVEK26

Engine idle speed approx. 1600 ÷ 1800 rpm

Start-up Electric

Maximum power to crankshaft (125) 10.5 CV at 8000 rpm

Max. power 11.6 hp at 7750 rpm

Cooling Forced air circulation.

Fly 125 - 150 4T Characteristics

CHAR - 9

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator with tor-

que server, V belt, automatic clutch, gear reduc-

tion unit and transmission housing with forced air

circulation cooling.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 61 in³ (1,000 cm³)

Rear hub oil ~ 200 cm³

Fuel tank capacity ~ 7.2 litres (of which 1.5 l is reserve)

Electrical system

ELECTRICAL COMPONENTS

Specification Desc./Quantity

Start-up Electric

Spark plug (125) Champion RG6YC- NGK CR7EB

Spark plug Champion RG6YC

Frame and suspensions

FRAME AND SUSPENSION

Specification Desc./Quantity

Chassis Steel tube chassis

Front suspension Ø 32 Hydraulic telescopic fork - travel: 76 mm

Rear suspension Single hydraulic shock-absorber with spring pre-

load adjustable on 4 positions; 64 mm travel.

Brakes

BRAKE

Specification Desc./Quantity

Front brake Disc brake (Ø 200 mm) with hydraulic control (lev-

er on the far right of the handlebar) and floating

calliper.

Rear brake Ø 140 mm drum brake

Characteristics Fly 125 - 150 4T

CHAR - 10

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheel rim Die-cast aluminium alloy; 3.50 x 12"

Front tyre Tubeless 120/70-12"

Rear wheel rim Die-cast aluminium alloy: 3.00"x12"

Rear tyre Tubeless 120/70 - 12"

Front tyre pressure 1.8 bar

Rear tyre pressure 2 bar

Rear wheel pressure (rider and passenger): 2.3 bar

Secondary air

In order to reduce polluting emissions, the vehicle is furnished with a catalytic converter in the muffler. To favour the catalytic process, an extra amount of oxygen is added via a secondary air system (SAS). This system allows more oxygen to be added to the unburned gases before they reach the converter, thus improving the action of the catalytic converter. The air enters the exhaust duct from the head, and is purified by a black filter. The system is fitted with a control valve that disables operation while decelerating to avoid unwanted noise. To ensure the best functioning of the SAS system, every 12,000 km the scooter should be taken to an Authorised Piaggio Service Centre to have the filter cleaned (Scheduled maintenance operations section). The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air.

CAUTION

Fly 125 - 150 4T Characteristics

CHAR - 11

CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE TO CARRY OUT THESE OPERATIONS.

Carburettor

125cc Version

Kehin

CARBURETTOR SETTING

Specification Desc./Quantity

Type CVEK26

Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4

Setting stamping 262A

Maximum jet 82

Maximum air jet (on the body) 85

Tapered pin stamping NELA

Throttle valve spring 130 ÷ 180 gr.

Minimum jet 35

Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 1 ¾

Starter jet 42

Starter air jet (on the body) Ø 1.5

Starter pin travel 10 mm (at 24°)

Starter resistance 20 Ohm (at 24°)

150cc Version

Kehin

CARBURETTOR SETTING

Specification Desc./Quantity

Type CVEK26

Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4

Setting stamping 265A

Maximum jet 82

Maximum air jet (on the body) 85

Tapered pin stamping NELA

Throttle valve spring 130 ÷ 180 gr.

Minimum jet 35

Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 1 ¾

Starter jet 42

Starter air jet (on the body) Ø 1.5

Starter pin travel 10 mm (at 24°)

Characteristics Fly 125 - 150 4T

CHAR - 12

Specification Desc./Quantity

Starter resistance 20 Ohm (at 24°)

Tightening Torques

LUBRICATION

Name Torque in Nm

Hub oil drainage cap 15 ÷ 17

Oil filter 4 ÷ 6

Oil pump cover screws 5 - 6

Oil pump screws 5 - 6

Pump control pulley screw 10 ÷ 14

Chain cover screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

Blow-by recovery duct fixing screws 3 - 4

HEAD AND CYLINDER

Name Torque in Nm

Ignition spark plug 12 ÷ 14

Head cover screws 11 ÷ 13

Nuts fixing head to cylinder (*) 28 ÷ 30

Head fixing screws (external) 11 ÷ 13

Starter ground screw 7 ÷ 8.5

Flywheel cover screw 1 ÷ 2

Flywheel air manifold screw 3 ÷ 4

Pressure reducer counterweight retainer 7 ÷ 8.5

Camshaft pulley screw 12 ÷ 14

Timing chain tensioner slider screw 10 ÷ 14

Starter ground support screw 11 ÷ 15

Tensioner screws 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 5 - 6

Nut fixing muffler to cylinder head 16 ÷ 18

Head intake manifold screw 11 ÷ 13

TRANSMISSION

Name Torque in Nm

Drive pulley nut 75 ÷ 83

Transmission cover screw 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screw 24 ÷ 27

Clutch unit nut on driven pulley 45 ÷ 50

FLYWHEEL

Name Torque in Nm

Flywheel fan screws 3 ÷ 4

Stator assembly screws (°) 3 ÷ 4

Flywheel nut 52 ÷ 58

Pick-up screw 3 ÷ 4

(°) Apply LOCTITE 243 threadlock

Fly 125 - 150 4T Characteristics

CHAR - 13

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmis-

sion-side half shaft) screws

4 ÷ 6

Oil filter on crankcase fitting 27 ÷ 33

Rear brake cam tightening screw 11 ÷ 13

Engine-crankcase coupling screws 11 ÷ 13

Pre-filter cap 24 ÷ 30

Starter motor fixing screw 11 ÷ 13

Muffler to crankcase fixing screws 24 ÷ 27

Engine oil drainage cap 24 ÷ 30

STEERING ASSEMBLY

Name Torque in Nm

Steering upper ring nut 35 ÷ 40

Steering lower ring nut 8 ÷ 10

Handlebar fixing screw 50 ÷ 55

FRAME

Name Torque in Nm

Engine arm bolt - frame arm 33 ÷ 41

Engine-swinging arm bolt 33 ÷ 41

Frame arm-engine arm bolt 60 ÷ 64

Centre stand pin 32 ÷ 40

Bolts mounting rocker arm silent-block 36 ÷ 44

FRONT SUSPENSION

Name Torque in Nm

Lower fork fixing screw 15 ÷ 20

Front wheel axle nut 45 - 50

FRONT BRAKE

Name Torque in Nm

Brake fluid pump - hose fitting 16 ÷20 Nm

Brake fluid tube- calliper fitting 19 ÷ 24

Calliper tightening screw 24 ÷ 27

Disc tightening screw 8 ÷ 10

Oil bleed screw 7 ÷ 10

REAR SUSPENSION

Name Torque in Nm

Rear wheel axle 104 ÷ 126

Lower shock absorber clamp 33 ÷ 41

Shock absorber/frame nut: 20 ÷ 25

shock absorber to crankcase clamping bracket 20 - 25

Overhaul data

Assembly clearances

Characteristics Fly 125 - 150 4T

CHAR - 14

Cylinder - piston assy.

Version 150

COUPLING BETWEEN (AXIS-WERKE) PISTON AND CYLINDER (150)

Name Initials Cylinder Piston Play on fitting

Coupling A 62.580 ÷ 62.587 62.533 ÷ 62.540 0.040 ÷ 0.054 Coupling B 62.587 ÷ 62.594 62.540 ÷ 62.547 0.040 ÷ 0.054 Coupling C 62.594 ÷ 62.601 62.547 ÷ 62.554 0.040 ÷ 0.054 Coupling D 62.601 ÷ 62.608 62.554 ÷ 62.561 0.040 ÷ 0.054

Coupling 1st over-

size

A1 62.780 ÷ 62.787 62.733 ÷ 62.740 0.040 ÷ 0.054

coupling 1st over-

size

B1 62.787 ÷ 62.794 62.740 ÷ 62.747 0.040 ÷ 0.054

Coupling 1st over-

size

C1 62.794 ÷ 62.801 62.747 ÷ 62.754 0.040 ÷ 0.054

Coupling 1st over-

size

D1 62.801 ÷ 62.808 62.754 ÷ 62.761 0.040 ÷ 0.054

Coupling 2nd over-

size

A2 62.980 ÷ 62.987 62.933 ÷ 62.940 0.040 ÷ 0.054

Coupling 2nd over-

size

B2 62.987 ÷ 62.994 62.940 ÷ 62.947 0.040 ÷ 0.054

Coupling 2nd over-

size

C2 62.994 ÷ 63.001 62.947 ÷ 62.954 0.040 ÷ 0.054

Coupling 2nd over-

size

D2 63.001 ÷ 63.008 62.954 ÷ 62.961 0.040 ÷ 0.054

Coupling 3rd over-

size

A3 63.180 ÷ 63.187 63.133 ÷ 63.140 0.040 ÷ 0.054

Coupling 3rd over-

size

B3 63.187 ÷ 63.194 63.140 ÷ 63.147 0.040 ÷ 0.054

Coupling 3rd over-

size

C3 63.194 ÷ 63.201 63.147 ÷ 63.154 0.040 ÷ 0.054

Coupling 3rd over-

size

D3 63.201 ÷ 63.208 63.154 ÷ 63.161 0.040 ÷ 0.054

COUPLING BETWEEN (RIGHT WAY) PISTON AND CYLINDER (150)

Name Initials Cylinder Piston Play on fitting

Coupling A 62.580 ÷ 62.587 62.541 ÷ 62.548 0.032 ÷ 0.046 Coupling B 62.587 ÷ 62.594 62.548 ÷ 62.555 0.032 ÷ 0.046 Coupling C 62.594 ÷ 62.601 62.555 ÷ 62.562 0.032 ÷ 0.046 Coupling D 62.601 ÷ 62.608 62.562 ÷ 62.569 0.032 ÷ 0.046

COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER

(125)

Name Initials Cylinder Piston Play on fitting

Coupling A 56.980 ÷ 56.987 56.933 ÷ 56.940 0.040 - 0.054 Coupling B 56.987 ÷ 56.994 56.940 ÷ 56.947 0.040 - 0.054 Coupling C 56.994 ÷ 57.001 56.947 ÷ 56.954 0.040 - 0.054 Coupling D 57.001 ÷ 57.008 56.954 ÷ 56.961 0.040 - 0.054

Coupling 1st in-

crease

A1 57.180 ÷ 57.187 57.133 ÷ 57.140 0.040 - 0.054

Fly 125 - 150 4T Characteristics

CHAR - 15

Name Initials Cylinder Piston Play on fitting

Coupling 1st in-

crease

B1 57.187 ÷ 57.194 57.140 ÷ 57.147 0.040 - 0.054

Coupling 1st in-

crease

C1 57.194 ÷ 57.201 57.147 ÷ 57.154 0.040 - 0.054

Coupling 1st in-

crease

D1 57.201 ÷ 57.208 57.154 ÷ 57.161 0.040 - 0.054

Coupling 2nd in-

crease

A2 57.380 ÷ 57.387 57.333 ÷ 57.340 0.040 - 0.054

Coupling 2nd in-

crease

B2 57.387 ÷ 57.394 57.340 ÷ 57.347 0.040 - 0.054

Coupling 2nd in-

crease

C2 57.394 ÷ 57.401 57.347 ÷ 57.354 0.040 - 0.054

Coupling 2nd in-

crease

D2 57.401 ÷ 57.408 57.354 ÷ 57.361 0.040 - 0.054

Coupling 3rd over-

size

A3 57.580 ÷ 57.587 57.533 ÷ 57.540 0.040 - 0.054

Coupling 3rd over-

size

B3 57.587 ÷ 57.594 57.540 ÷ 57.547 0.040 - 0.054

Coupling 3rd over-

size

C3 57.594 ÷ 57.601 57.547 ÷ 57.554 0.040 - 0.054

Coupling 3rd over-

size

D3 57.601 ÷ 57.608 57.554 ÷ 57.561 0.040 - 0.054

PISTON TO CAST IRON CYLINDER COUPLING (125)

Name Initials Cylinder Piston Play on fitting

Coupling M 56.997 ÷ 57.004 56.944 ÷ 56.951 0.046 ÷ 0.060 Coupling N 57.004 ÷ 57.011 56.951 ÷ 56.958 0.046 ÷ 0.060 Coupling O 57.011 ÷ 57.018 56.958 ÷ 56.965 0.046 ÷ 0.060 Coupling P 57.018 ÷ 57.025 56.965 ÷ 56.972 0.046 ÷ 0.060

Coupling 1st over-

size

M1 57.197 ÷ 57.204 57.144 ÷ 57.151 0.046 ÷ 0.060

Coupling 1st over-

size

N1 57.204 ÷ 57.211 57.151 ÷ 57.158 0.046 ÷ 0.060

Coupling 1st over-

size

O1 57.211 ÷ 57.218 57.158 ÷ 57.165 0.046 ÷ 0.060

Coupling 1st over-

size

P1 57.218 ÷ 57.225 57.165 ÷ 57.172 0.046 ÷ 0.060

Coupling 2nd over-

size

M2 57.397 ÷ 57.404 57.344 ÷ 57.351 0.046 ÷ 0.060

Coupling 2nd over-

size

N2 57.404 ÷ 57.411 57.351 ÷ 57.358 0.046 ÷ 0.060

Coupling 2nd over-

size

O2 57.411 ÷ 57.418 57.358 ÷ 57.365 0.046 ÷ 0.060

Coupling 2nd over-

size

P2 57.418 ÷ 57.425 57.365 ÷ 57.372 0.046 ÷ 0.060

Coupling 3rd over-

size

M3 57.597 ÷ 57.604 57.544 ÷ 57.551 0.046 ÷ 0.060

Coupling 3rd over-

size

N3 57.604 ÷ 57.611 57.551 ÷ 57.558 0.046 ÷ 0.060

Coupling 3rd over-

size

O3 57.611 ÷ 57.618 57.558 ÷ 57.565 0.046 ÷ 0.060

Coupling 3rd over-

size

P3 57.618 ÷ 57.625 57.565 ÷ 57.572 0.046 ÷ 0.060

Characteristics Fly 125 - 150 4T

CHAR - 16

Piston rings

SEALING RINGS (125)

Name Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 ÷ 0.30

Oil scraper ring 57x1 A 0.10 ÷ 0.30 Oil scraper ring 57x2.5 A 0.10 ÷ 0.35

Compression ring

1st oversize

57.2 x 1 A 0.15 ÷ 0.30

Oil scraper ring 1st

oversize

57.2x1 A 0.10 ÷ 0.30

Oil scraper ring 1st

oversize

57.2x2.5 A 0.10 ÷ 0.35

Compression ring

2nd oversize

57.4x1 A 0.15 ÷ 0.30

Oil scraper ring

2nd oversize

57.4x1 A 0.10 ÷ 0.30

Oil scraper ring

2nd oversize

57.4x2.5 A 0.10 ÷ 0.35

Compression ring

3rd oversize

57.6x1 A 0.15 ÷ 0.30

Oil scraper ring 3rd

oversize

57.6x1 A 0.10 ÷ 0.30

Oil scraper ring 3rd

oversize

57.6x2.5 A 0.10 ÷ 0.35

Maximum clearance after use: 1 mm

SEALING RINGS (150)

Name Description Dimensions Initials Quantity

Compression ring 62.6x1 A 0.15 ÷ 0.30

Oil scraper ring 62.6x1 A 0.20 ÷ 0.40 Oil scraper ring 62.6x2.5 A 0.20 ÷ 0.40

Compression ring

1st oversize

62.8x1 A 0.15 ÷ 0.30

Oil scraper ring 1st

oversize

62.8x1 A 0.20 ÷ 0.40

Oil scraper ring 1st

oversize

62.8x2.5 A 0.20 ÷ 0.40

Compression ring

2nd oversize

63.0 x 1 A 0.15 ÷ 0.30

Oil scraper ring

2nd oversize

63.0 x 1 A 0.20 ÷ 0.40

Oil scraper ring

2nd oversize

63.0 x 2.5 A 0.20 ÷ 0.40

Compression ring

3rd oversize

63.2 x 1 A 0.15 ÷ 0.30

Oil scraper ring 3rd

oversize

63.2 x 1 A 0.20 ÷ 0.40

Oil scraper ring 3rd

oversize

63.2 x 2.5 A 0.20 ÷ 0.40

Fly 125 - 150 4T Characteristics

CHAR - 17

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

16.6 +0-0.05 A D = 0.20 - 0.50

Flywheel-side half-

shaft

16.6 +0-0.05 B D = 0.20 - 0.50

Connecting rod

with PP

18 -0.10 -0.15 C 0.20 ÷ 0.50

Crank pin width 51.400 E

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS

Name Description Dimensions Initials Quantity

Crankshaft Category 1 28.998 ÷ 29.004 Crankshaft Class 2 29.004 ÷ 29.010 Crankcase Category 1 32.953 ÷ 32.959 Crankcase Category 2 32.959 ÷ 32.965

Crankshaft half-

bearing

Category B - blue 1.973 ÷ 1.976

Crankshaft half-

bearing

Type C - yellow 1.976 ÷ 1.979

Crankshaft half-

bearing

Category E - green 1.979 ÷ 1.982

Crankshaft catego-

ry 1 - Crankcase

category 1

E - E

Crankshaft catego-

ry 1 - Crankcase

category 2

C - C

Crankshaft catego-

ry 2 - Crankcase

category 1

C - C

Crankshaft catego-

ry 2 - Crankcase

category 2

B - B

Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40

Characteristics Fly 125 - 150 4T

CHAR - 18

Slot packing system

- Provisionally fit the piston into the cylinder, without any base gasket.

- Fit a dial gauge on the specific tool

- Set the dial gauge to zero at a contrast plane with an average precharge, for example 5 mm. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.

- Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation)

- Calculate the difference between the two measurements: use the chart below to identify the thickness of the cylinder base gasket to be used for refitting. By correctly identifying the cylinder base gasket thickness, an adequate compression ratio is maintained.

- Remove the specific tool and the cylinder.

Characteristic

Compression ratio (125)

10.6 : 1

Compression ratio

10.5: 1

SHIMMING SYSTEM (125)

Specification Desc./Quantity

Value measured 0 ÷ 0.1

Thickness 0.8 ± 0.05

Value measured 0.1 ÷ 0.3

Thickness 0.6 ± 0.05

Value measured 0.3 - 0.4

Thickness 0.4 ± 0.05

Fly 125 - 150 4T Characteristics

CHAR - 19

SHIMMING SYSTEM (150)

Specification Desc./Quantity

Value measured 1 ÷ 1.1

Thickness 0.8 ± 0.05

Value measured 1.1 ÷ 1.3

Thickness 0.6 ± 0.05

Value measured 1.3 ÷ 1.4

Thickness 0.4 ± 0.05

Products

TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications

AGIP ROTRA 80W-90 rear oil hub SAE 80W/90 Oil that exceeds the

requirements of API GL3 specifi-

cations

AGIP CITY HI TEC 4T Oil to lubricate flexible transmis-

sions (brakes, throttle control

and odometer)

Oil for 4-stroke engines

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives

for increased adhesiveness

AGIP GP 330 Grease (brake control levers,

throttle grip)

Calcium complex soap-based

grease with NLGI 2; ISO-L-

XBCIB2

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,

JASO MA Synthetic oil

AGIP GREASE MU3 Grease for odometer transmis-

sion gear case

Soap-based lithium grease with

NLGI 3; ISO-L-XBCHA3, DIN

K3K-20

Characteristics Fly 125 - 150 4T

CHAR - 20

INDEX OF TOPICS

TOOLING TOOL

TOOLS

Stores code Description

001330Y Tool for fitting steering seats

001467Y009 Driver for OD 42 mm bearings

001467Y013 Pliers to extract ø 15-mm bear-

ings

002465Y Pliers for circlips

005095Y Engine support

008564Y Flywheel extractor

Tooling Fly 125 - 150 4T

TOOL - 22

Stores code Description

020004Y Punch for removing fifth wheels

from headstock

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crank-

shaft alignment

020150Y Air heater support

020151Y Air heater

020193Y Oil pressure gauge

Fly 125 - 150 4T Tooling

TOOL - 23

Stores code Description

020262Y Crankcase splitting strip

020263Y Sheath for driven pulley fitting

020287Y Clamp to assemble piston on cyl-

inder

020306Y Punch for assembling valve seal

rings

020329Y MityVac vacuum-operated pump

020330Y Stroboscopic light for timing con-

trol

Tooling Fly 125 - 150 4T

TOOL - 24

Stores code Description

020331Y Digital multimeter

020332Y Digital rev counter

020333Y Single battery charger

020334Y Multiple battery charger

Fly 125 - 150 4T Tooling

TOOL - 25

Stores code Description

020335Y Magnetic support for dial gauge

020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor

020360Y Adaptor 52 x 55 mm

020363Y 20 mm guide

020364Y 25-mm guide

Tooling Fly 125 - 150 4T

TOOL - 26

Stores code Description

020368Y driving pulley lock wrench

020375Y Adaptor 28 x 30 mm

020376Y Adaptor handle

020382Y011 adapter for valve removal tool

020409Y Multimeter adaptor - Peak volt-

age detection

Fly 125 - 150 4T Tooling

TOOL - 27

Stores code Description

020412Y 15 mm guide

020414Y 28-mm guide

020423Y driven pulley lock wrench

020424Y Driven pulley roller casing fitting

punch

020425Y Punch for flywheel-side oil seal

020426Y Piston fitting fork

Tooling Fly 125 - 150 4T

TOOL - 28

Stores code Description

020427Y Piston fitting band

020428Y Piston position check support

020430Y Pin lock fitting tool

020431Y Valve oil seal extractor

020434Y Oil pressure control fitting

020444Y Tool for fitting/ removing the driv-

en pulley clutch

Fly 125 - 150 4T Tooling

TOOL - 29

Stores code Description

020565Y Flywheel lock calliper spanner

020622Y Transmission-side oil guard

punch

494929Y Exhaust fumes analyser

020625Y Kit for sampling gas from the ex-

haust manifold

Tooling Fly 125 - 150 4T

TOOL - 30

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

EVERY 2 YEARS

Action

Brake fluid - change

EVERY 3000 KM

Action

Engine oil - level check/ top-up

AFTER 1000 KM

80'

Action

Engine oil - replacement Hub oil - change Oil filter (net filter) - clean Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - test ride

(*) See instructions in the «Idle speed adjustment» section

AT 6000 KM OR 12 MONTH, 18000 KM, 54000 KM

150'

Action

Engine oil - replacement Hub oil level - check Spark plug electrode gap - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Variable speed rollers/pads - check Driving belt - checking Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - test ride

AT 12000 KM OR 24 MONTHS AND AT 60000 KM

160'

Action

Engine oil - replacement

Maintenance Fly 125 - 150 4T

MAIN - 32

Action

Hub oil level - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Centre stand - lubrication Secondary air filter - cleaning Tyre pressure and wear - check Vehicle and brake test - test ride

(*) See section «Adjusting the idle speed»

AFTER 24000 KM AND AFTER 48000 KM

205'

Action

Engine oil - replacement Hub oil - change Air filter - clean Engine oil - change Oil filter (net filter) - clean Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Cylinder ventilation system - cleaning Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Secondary air filter - cleaning Centre stand - lubrication Vehicle and brake test - test ride

Fly 125 - 150 4T Maintenance

MAIN - 33

(*) See instructions in «Idle speed adjustment» section

AT 30000 KM, AT 42000 KM AND AT 66000 KM

125'

Action

Engine oil - replacement Hub oil level - check Spark plug electrode gap - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Slide pads and variator rollers - check Driving belt - checking Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - test ride

AFTER 36000 KM

300'

Action

Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Flexible brake tubes - replacement Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Secondary air filter - cleaning Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - test ride

(*) See instructions in «Idle speed adjustment» section

AFTER 72,000 KM

300'

Maintenance Fly 125 - 150 4T

MAIN - 34

Action

Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment Cylinder ventilation system - check Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Flexible brake tubes - replacement Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Secondary air filter - cleaning Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - test ride

(*) See instructions in «Idle speed adjustment» section

Checking the spark advance

- To check ignition advance, use the stroboscopic light with induction pincers connected to the spark plug power wire.

- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug).

- Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines).

- Start the engine and check that the light works properly and the rpm indicator can read also the high rpm (e.g. 8000 rpm).

- If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive load on the spark plug power line (10 ÷ 15 KΩ in series to HV wire).

Fly 125 - 150 4T Maintenance

MAIN - 35

- Operating on the flash bulb phase difference calibrator, make the reference on the flywheel cover coincide with the fan reference as shown in the photograph. Read the advance degrees indicated by the stroboscopic light and compare them with those specified.

Characteristic

Ignition advance 150 check

10° ± 1° at 2000 rpm - 26° ± 1° at 6000 rpm

Ignition advance 125 check

15° ± 1° at 2000 rpm - 28° ± 1° at 6000 rpm

Spark advance variation

ADVANCE VARIATION

Specification Desc./Quantity

Operation threshold First threshold : 9000±50

Second threshold : 9300±50

Reactivation threshold First threshold : 8900±50

Second threshold : 9200±50

Spark elimination First threshold : 1 spark on 7

Second threshold : 2 sparks on 3

Maintenance Fly 125 - 150 4T

MAIN - 36

Fly 125 - 150 4T Maintenance

MAIN - 37

Braking system

Level check

Proceed as follows:

- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;

- Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the pads.

Proceed as follows:

- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;

- Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the pads.

Top-up

Proceed as follows:

- Remove the tank cap by loosening the two screws, remove the gasket and top up using only the liquid specified without exceeding the maximum level.

CAUTION

ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.

CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.

CAUTION

BRAKE CIRCUIT FLUID IS VERY CORROSIVE; MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.

CAUTION

Maintenance Fly 125 - 150 4T

MAIN - 38

THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS.

N.B.

SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

Headlight adjustment

Proceed as follows:

1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;

2. Turn on the headlight and check that the borderline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and higher than 7/10;

3. If otherwise, adjust the right headlight with screw «A».

N.B.

THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.

Fly 125 - 150 4T Maintenance

MAIN - 39

CO check

- Remove the exhaust gases outlet cap on the exhaust pipe

- Using the supplied washer, install the exhaust gases collection kit fitting onto the pipe, as shown in the figure.

- Correctly orientate the components as shown in the picture

- Shut the gas outlet on the tool

- Start the engine and let it warm up

- Shut the engine down

- Disconnect the SAS check valve vacuum hose shown in the figure.

- Seal the connection using a conical a cap.

Maintenance Fly 125 - 150 4T

MAIN - 40

- Connect the Mitivac vacuum pump to the SAS control valve.

- Start the vacuum pump up to a pressure of -0.6 ÷ -0.8 bar so to close the valve and cut off the SAS system.

- Remove the exhaust gas collection kit cap and connect the analyzer adequately pre-heated.

- Check the analyser output and the engine rpm.

- Adjust the CO concentration.

N.B.

CHECK THAT THE RESULT IS OBTAINED WITH THE VALVE GAS IN CLOSED POSITION.

N.B.

ALSO CHECK THE CARBURETION ADJUSTMENT IS OBTAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS.

N.B.

OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN THE TANK AND THE FUEL CIRCUIT.

N.B.

IN CASE OF UNSTABLE CO, CHECK THAT THE CARBURETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYSTEM AND THE DEPRESSION SEALS WORK ADEQUATELY

N.B.

IN CASE OF 1000 PPM UNBURNED HYDROCARBONS (HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYSTEM, THE VALVE CLEARANCE AND THE EXHAUST VALVE TIGHTNESS.

Specific tooling

020329Y MityVac vacuum-operated pump 020332Y Digital rev counter 494929Y Exhaust fumes analyser 020625Y Kit for sampling gas from the exhaust

manifold

Characteristic

CO Check

3.8±0.7 to 1650±50 RPM

Fly 125 - 150 4T Maintenance

MAIN - 41

SAS filters inspection and cleaning

- Remove the shock absorber lower retainer from the engine.

- Remove the retainer clamp indicated in the photograph, the automatic starter cable harness and the carburettor to frame heater placed under the helmet compartment cover.

- Lift the vehicle with a jack as shown in the figure to be able to reach the flywheel cover screws

- Remove the screw fixing the SAS valve to the flywheel cover, indicated in the photograph.

Maintenance Fly 125 - 150 4T

MAIN - 42

- Remove the 4 flywheel cover screws indicated in the photograph and remove the flywheel cover.

- Remove the filter indicated in the photograph

- Check that the gasket is in good conditions

- Check the SAS filter housing for dents or deformations

- Clean the SAS filter carefully. Replace the filter if it is damaged or deformed. To refit, carry out the removal operations but in reverse order.

CAUTION

WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

CAUTION

NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR FILTER

Fly 125 - 150 4T Maintenance

MAIN - 43

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

Air filter blocked or dirty. Dismantle the sponge, wash with water and sham-

poo, then soak it in a mixture of 50% petrol and

50% of specific oil (Selenia Air Filter Oil), then

hand dry without squeezing, allow to drip dry and

then reassemble.

Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with com-

pressed air

Dirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol and

wash the tank, if necessary. Replace the cock as

a last resource.

Failing automatic starter on the carburettor Check the electrical wiring and mechanical move-

ment, replace if necessary.

Excessive driving belt wear Check it and replace, if necessary

Lack of compression: parts, cylinder and valves

worn

Replace the worn parts

Oil level exceeds maximum Check for causes and fill to reach the correct level

Excess of encrustations in the combustion cham-

ber

Descale the cylinder, the piston, the head and the

valves

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Muffler obstructed Replace

Inefficient automatic transmission Check the rollers and the pulley movement, re-

place the damaged parts and lubricate the driven

pulley moveable guide with Montblanc Molybde-

num Grease

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace

the valves

Valve seat distorted Replace the head assembly

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the

piston rings

Rear wheel spins at idle

REAR WHEEL ROTATES WITH ENGINE AT IDLE

Possible Cause Operation

Idling rpms too high Adjust the engine idle speed and the CO%, if nec-

essary.

Clutch fault Check the springs / clutch masses

Fly 125 - 150 4T Troubleshooting

TROUBL - 45

Starting difficulties

DIFFICULTY STARTING UP

Possible Cause Operation

Battery flat Check the state of the battery. If it shows signs of

sulphation replace it and bring the new battery into

service charging it for eight hours at a current of

1/10 of the capacity of the battery itself

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit

components

- Engine flooded. Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it and before refitting, make the motor turn so as to

expel the fuel excess taking care to connect the

cap to the spark plug, and this in turn to the ground.

If the fuel tank is empty, refuel and start up.

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clear-

ance

Rpm too low at start-up or engine and start-up

system damaged

Check the starter motor and the kick-starter unit

Altered fuel characteristics Drain off the fuel no longer up to standard; then,

refill

Vacuum operated cock failure Check that fuel is adequately supplied through the

pipe by applying a vacuum to the suction pipe

Failing automatic starter on the carburettor Check the electrical wiring and mechanical move-

ment, replace if necessary.

Start-up enabling buttons failure Check continuity using an Ohm meter, with the

switch pressed; replace if necessary

Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with com-

pressed air

Air filter obstructed or dirty. Dismantle the sponge, wash with water and sham-

poo, then soak it in a mixture of 50% petrol and

50% of specific oil (Selenia Air Filter Oil), then

hand dry without squeezing, allow to drip dry and

then reassemble.

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation

Worn valve guides Check and replace the head unit if required

Worn valve oil guard Replace the valve oil guard

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the cou-

pling seal

Worn or broken piston rings or piston rings that

have not been fitted properly

Replace the piston cylinder unit or just the piston

rings

Troubleshooting Fly 125 - 150 4T

TROUBL - 46

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Care-

fully clean the By-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump

components Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level using the recommended oil type

(Selenia HI Scooter 4 Tech)

Engine tends to cut-off at full throttle

THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE

Possible Cause Operation

Maximum jet clogged Remove the carburettor, wash with solvent and dry

with compressed air

Water or condensate in the carburettor tank Remove the tank, wash with solvent and dry with

compressed air

Level in tank too low Restore the level in the tank by bending on the float

the thrusting reed of the petrol inlet rod so as to

have the float parallel to the tank level with the

carburettor inverted.

Engine tends to cut-off at idle

THE ENGINE TENDS TO STOP AT IDLE SPEED

Possible Cause Operation

Incorrect idle adjustment Adjust using the rpm indicator

Incorrect timing Time the system and check the timing system

components

The starter remains on Check: electric wiring, circuit not interrupted, me-

chanical movement and power supply; replace if

necessary

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit

components

Pressure too low at the end of compression Check the thermal group seals and replace worn

components

Minimum nozzle dirty Wash the nozzle with solvent and dry with com-

pressed air

High fuel consumption

EXCESSIVE FUEL CONSUMPTION

Possible Cause Operation

Air filter blocked or dirty. Clean according to the procedure

Starter inefficient Check: electric wiring, circuit continuity, mechani-

cal sliding and power supply

Fly 125 - 150 4T Troubleshooting

TROUBL - 47

Possible Cause Operation

Loose nozzles Check the maximum and minimum nozzles are

adequately fixed in their fittings

Incorrect float level Restore the level in the tank by bending on the float

the thrusting reed of the petrol inlet rod so as to

have the float parallel to the tank level with the

carburettor inverted.

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Slippage or irregular functioning Check that there is no grease on the masses.

Check that the faying surface between the clutch

masses and the clutch bell is mainly in the middle

and with equivalent specifications on the three

masses.

Check that the clutch bell is not scored or worn

abnormally

Never run the engine without the clutch bell

Insufficient braking

INEFFICIENT OR NOISY BRAKING

Possible Cause Operation

Worn brake pads or shoes Replace the brake pads or shoes and check for

brake disk or drum wear conditions.

Front brake disk loose or deformed Check the brake disc screws are locked; use a dial

gauge and a wheel mounted on the vehicle to

measure the axial shift of the disc.

Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system,

(there must be no flexible movement of the brake

lever).

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump

seals, replace

Excessive backlash in the rear brake control cable Adjust the backlash with the appropriate adjuster

located on the back part of the crankcase.

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Rubber gaskets swollen or stuck Replace gaskets.

Compensation holes on the pump clogged Clean carefully and blast with compressed air

Brake disc slack or distorted Check the brake disc screws are locked; use a dial

gauge and a wheel mounted on the vehicle to

measure the axial shift of the disc.

Troubleshooting Fly 125 - 150 4T

TROUBL - 48

Possible Cause Operation

Defective piston sliding Check calliper and replace any damaged part.

Electrical system

Battery

BATTERY

Possible Cause Operation

Battery The battery is the electrical device in the system

that requires the most frequent inspections and

thorough maintenance. If the vehicle is not used

for some time (1 month or more) the battery needs

to be recharged periodically. The battery runs down completely in the course of 5 ÷ 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keeping in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+. Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the

batteries.

Turn signal lights malfunction

TURN INDICATOR NOT WORKING

Possible Cause Operation

Electronic ignition device failure With the key switch set to "ON" jump the contacts

1 (Blue-Black) and 5 (Orange) on the control unit

connector.

If by operating the turn indicator control the lights

are not steadily on, replace the control unit; other-

wise, check the cable harness and the switch.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the seats in which the ball bearings rotate:

if they are recessed or if the balls are squashed,

replace them.

Fly 125 - 150 4T Troubleshooting

TROUBL - 49

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation

Excessive steering backlash Check the tightening of the top ring nut. If irregu-

larities continue in turning the steering even after

making the above adjustments, check the seats in

which the ball bearings rotate: replace if they are

recessed.

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

Noisy suspension If the front suspension is noisy, check: that the

front shock absorber works properly and the ball

bearings are good condition. Finally, check the

locking torque of the wheel axle nut, the brake cal-

liper and the disc. Check that the swinging arm

connecting the engine to the chassis and the rear

shock absorber work properly.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Oil leakage from suspension Replace the rear shock absorber or the front fork

cartridge.

Troubleshooting Fly 125 - 150 4T

TROUBL - 50

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Legend:

1. Front L.H. turn signal light

2. Immobiliser antenna

3. Electronic ignition device with choke and turn signal controls

4. Horn button

5. Turn signal switch

6. Headlight switch

7. Stop switch on rear brake

8. Double-filament bulb 12V - 55/60W

9. Front sidelight bulb

10. High-beam warning light

11. Engine oil pressure warning light

12. Turn signal warning light (L.H.)

Electrical system Fly 125 - 150 4T

ELE SYS - 52

13. Low-fuel warning light

14. Turn signal warning light (R.H.)

15. Dashboard light bulbs

16. Headlamp warning light

17. Odo/speedometer with warning lights and gauges - Red socket light bulbs 2W; black socket light

bulbs 1.2W

18. Headlight

19. 2 fuse holders with 4 fuses (7.5 A)

20. Stop switch on front brake

21. Start button

22. Immobiliser diagnostic outlet

23. Key-switch

24. Front R.H. turn signal light

25. Wire harness

26. Fuel level sender

27. Fuse holder assembly

28. Rear R.H. turn signal light

29. License plate light bulb

30. License plate lamp

31. Battery

32. Starter relay

33. Starter motor

34. Engine oil pressure sensor

35. Pick-up

36. Automatic choke device

37. Carburettor heater

38. H.T. coil

39. Taillight assembly

40. Stop and taillight bulb

41. Voltage regulator

42. Rear L.H. turn signal light

43. 4 amber light bulbs for turn signal lamps

44. Relay

45. Horn Wiring

- Colour coding: B = White Bl = Blue G = Yellow

Fly 125 - 150 4T Electrical system

ELE SYS - 53

Mr = Brown N = Black BV = White-Green GN = Yellow-Black Gr = Grey Rs = Pink R = Red Vi = Purple V = Green VN = Green-Black BN = White-Black BBl = White-Blue GV = Yellow-Green Ar = Orange Az = Light Blue GrBl = Gray-Blue GrN = Grey-Black RBl = Red-Blue GR = Yellow-Red BlN = Blue-Black

Electrical system installation

Electrical system Fly 125 - 150 4T

ELE SYS - 54

Front side

FRONT INSTALLATION 1

Specification Desc./Quantity

1 Strap Insert the strap through the hole in the chas-

sis 2 Zip tie 3 Fixing Fold the chassis strap over the cables

Fly 125 - 150 4T Electrical system

ELE SYS - 55

FRONT INSTALLATION

Specification Desc./Quantity

1 Front R.H. turn signal light 2 Fuse holder box 3 Front L.H. turn signal light 4 Light remote control switch 5 Ignition key-switch 6 Control device ignition 7 Immobiliser diagnostic outlet

Electrical system Fly 125 - 150 4T

ELE SYS - 56

Specification Desc./Quantity

8 Zip tie 9 Horn

FRONT INSTALLATION 2

Specification Desc./Quantity

1 Zip tie

Fly 125 - 150 4T Electrical system

ELE SYS - 57

Back side

REAR INSTALLATION

Specification Desc./Quantity

1 Cable harness fairlead 2 Breather tube 3 Heater conductors and automatic choke pro-

tective sheath 4 Voltage regulator 5 HV coil 6 Earth node 7 Starter remote control 8 License plate light connector

Electrical system Fly 125 - 150 4T

ELE SYS - 58

REAR INSTALLATION 1

Specification Desc./Quantity

1 H.T. Cable 2 Zip tie 3 To the automatic choke device 4 To the heater 5 Rear R.H. turn signal light 6 Taillight 7 Rear L.H. turn signal light

Fly 125 - 150 4T Electrical system

ELE SYS - 59

REAR INSTALLATION 2

Specification Desc./Quantity

1 Zip tie 2 Starter motor earth 3 Starter motor positive outlet 4 Flywheel connection

Conceptual diagrams

Electrical system Fly 125 - 150 4T

ELE SYS - 60

Ignition

IGNITION

Specification Desc./Quantity

1 electronic control unit 2 Magneto flywheel 3 Pick - up 4 HV coil 5 Spark plug 6 Voltage regulator

Fly 125 - 150 4T Electrical system

ELE SYS - 61

Headlights and automatic starter section

LIGHTS AND AUTOMATIC STARTER

Specification Desc./Quantity

1 electronic control unit 2 Carburettor heater 3 Automatic starter 4 Key switch 5 Main fusible 15A 6 Battery 12V-9Ah 7 Headlamp relay 8 Light switch 9 High-beam fuse 7,5A 10 Low-beam and dashboard lights fuse 7,5A 11 Low-beam light bulb 12V - 55W 12 High-beam light bulb 12V-55W 13 High-beam lamp warning light 12V - 1.2W 14 Front side-light bulb 12V - 5W 15 Four dashboards illuminating bulbs 12V - 1,2W 16 Taillight bulb 12V - 5W 17 License plate bulb 12V - 5W 18 Low-beam fuse 7,5A

Electrical system Fly 125 - 150 4T

ELE SYS - 62

Battery recharge and starting

BATTERY CHARGER AND STARTING

Specification Desc./Quantity

1 Magneto flywheel 2 Voltage regulator 3 Pick - up 4 Main fusible 15A 5 Battery 12V-9Ah 6 Starter relay 7 Starter motor 8 Start up button 9 Front and rear brake light button 10 Brake light filament 12V-21W 11 Fuse 7.5 A 12 Key switch 13 electronic control unit

Fly 125 - 150 4T Electrical system

ELE SYS - 63

Level indicators and enable signals section

CONSENSUSES AND LEVEL INDICATORS

Specification Desc./Quantity

1 electronic control unit 2 Battery 12V-9Ah 3 Main fusible 15A 4 Key switch 5 Engine oil pressure sensor 6 Low oil pressure warning light 12V - 1,2W 7 Reserve fuel light 12V-1,2W 8 Fuel gauge 9 Fuel level sender 10 Fuse 7.5 A 11 Immobilizer aerial 12 Low engine oil pressure sensor 13 Immobiliser LED 14 Front and rear brake light button 15 Taillight bulb 12V - 5W 16 Starter motor 17 Starter relay 18 Start up button

Electrical system Fly 125 - 150 4T

ELE SYS - 64

Turn signal lights

TURN INDICATORS AND HORN

Specification Desc./Quantity

1 electronic control unit 2 Indicators switch 3 4 Turn indicator bulbs 12V-10W 4 Turn signal warning light bulbs 12V - 2W 5 Main fusible 15A 6 Battery 12V-9Ah 7 Horn 8 Fuse 7.5 A 9 Key switch 10 Horn button

Fly 125 - 150 4T Electrical system

ELE SYS - 65

Instruments and warning lights control board

4 PIN CONNECTOR

Specification Desc./Quantity

1 Ground lead (-) 2 High-beam warning light 3 Left turn indicator 4 Engine oil warning light

5 PIN CONNECTOR

Specification Desc./Quantity

1 Instrument panel lighting and headlamp

warning light 2 Right turn indicator 3 Low-fuel warning light 4 + permanent power supply 5 Fuel gauge

Checks and inspections

Electrical system Fly 125 - 150 4T

ELE SYS - 66

Immobiliser

The electric ignition system is fed with direct current and is protected by an anti-theft immobilizer integrated to the control unit. The ignition system consists of:

- electronic control unit

- immobilizer aerial

- master and service keys with built-in transponder

- HV coil

- diagnosis LED The diagnosis LED also works as a blinking light to deter theft. This function is activated every time the key switch is turned to «OFF», and it remains active 48 hours so as not to affect the battery charge. When the ignition switch is set to «ON», the theft deterring blinker function is deactivated. Subsequently, a flash confirms the switching to «ON». The duration of the flash depends on the electronic control unit program (see figure).

Whenever the LED is off and remains so, even when switching it to «ON», it is necessary to check if:

- the battery is charged

- 15A main fuse is working correctly. Connect the immobilizer tester to the diagnosis socket (see ET4 125 manual) located behind the front left fuse box flap. If the serial LED remains off, check the electronic control unit supply as follows:

Fly 125 - 150 4T Electrical system

ELE SYS - 67

Detach the connector from the ECU and check the following:

- Presence of battery potential difference between terminal 4 (Red/Blue) and earth

- Presence of battery potential difference between terminals 4 (Red/Blue) and 8 (black), as shown in the figure.

- Presence of battery potential difference between terminals 5 and 8 with the key-switch onto «ON». If no anomalies are found, replace the electronic control unit.

Virgin circuit

If the ignition system has not been programmed, the engine can be started but it will run limited to 2000 rpm. When trying to accelerate, some evident loss of power may be felt. Program the system with the MASTER (Brown) and SERVICE (Blue) keys as follows:

- Insert the MASTER key, turn it to "ON" and keep it in that position for 2 seconds (limit values: 1 ÷ 3 seconds).

- Alternatively insert all the available black keys and turn each one of them to "ON" for 2 seconds.

- Insert the MASTER key again and turn it to "ON" for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys (blue) can be programmed at one time. Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start.

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Once the control unit has been programmed, the control unit is inseparably matched with the MASTER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stored one is deleted. If a service key setting is lost, it is essential to carefully check the efficiency of the high voltage system: Shielded cap resistance ~ 5000 Ω. In any case, it is advisable to use resistive spark plugs as shown in the figure.

Diagnostic codes

The flash indicating the switching to "ON" (0.7-sec flash) can be followed by a phase of programmed failure warnings. That is, the LED is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-sec flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:

2-FLASH CODE

Example with programmed electronic control unit, no transponder and/or aerial malfunction

Ignition disabled-Vehicle immobilised 3-FLASH CODE

Example with programmed electronic control unit, aerial working properly and unknown transponder code.

Ignition disabled-Vehicle immobilised

Diagnostic code - 2 flashes

When the 2-flash code is detected, carry out the following checks:

- Check if the failure continues even after changing key (including the MASTER key). If the failure persists with any key, disconnect the aerial connector from the electronic control unit and check the aerial continuity with the multimeter.

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If it does not work, replace the aerial. If no faults are found, replace the control unit.

CAUTION

BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS TO AVOID SPOILING A NEW CONTROL UNIT UNNECESSARILY.

Specific tooling

020331Y Digital multimeter

Electric characteristic

Resistance value

~ 7 ÷ 9 Ohm

Diagnostic code - 3 flashes

If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the key switch.

- If the failure disappears when the MASTER key is used, proceed with coding a new service key (Blue).

- If the failure persists, it means that the MASTER key and the control unit are not linked; in this case, replace the control unit and then encode the keys. The immobilizer system is efficient when, after switching over to «ON», only a 0.7-sec flash is detected (see diagram). In this case, the engine can be started.

Example with programmed control unit, transponder, programmed key and working aerial. The

ignition is enabled (regular use conditions)

Ignition circuit

All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected to the Pick-Up by the chassis and the engine ground lead.

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To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.

No spark plug

When noticing no spark plug proceded as follows:

- Pick-Up inspection.

Detach the ECU connector and check for continuity between terminals 2 (Green) and 8 (Black). The inspection must include the pick-up and it's power cable. If an open circuit is found, repeat the inspection between the flywheel connector and earth. If unacceptable values are found, proceed by replacing the pick-up, otherwise repair the cable.

Electric characteristic

Pick-up resistance value

Pick-up resistance value: 105 ÷ 124 Ohm

- H.T. coil primary circuit inspection

Detach the connector from the ECU and check for continuity between terminals 3 (purple) and 8 (black) (see figure). If unacceptable values are found, repeat the inspection directly from the positive and negative terminals of the H.T. coil primary circuit. If the values are within the prescribed limit, proceed by repairing the wiring or reattaching all wirings, otherwise replace the H.T. coil.

Electric characteristic

High voltage coil primary resistance value

High voltage coil primary resistance value: 0.4 ÷

0.5 Ohm

- HV coil secondary check

Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.

Specific tooling

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020409Y Multimeter adaptor - Peak voltage detection

Electric characteristic

High voltage coil secondary resistance value

High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm

- Pick-Up

Detach the ECU connector and connect the positive terminal to connector no. 2 and the negative terminal to connector no. 8 (see figure). Crank the engine using the starter motor and check the tension produced by the pick-up. If unacceptable values are found, replace the PickUp.

N.B.

THE MULTIMETER MUST BE SELECTED TO DETECT CONTINUOUS VOLTAGE.

Electric characteristic

Pick-Up voltage value

Pick-Up voltage value: > 2 Volt

- H.V. coil

With the control unit and HV coil connected to the circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor and connect the positive terminal to the earth one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit.

THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK.

Electric characteristic

High voltage coil voltage value

High voltage coil voltage value: > 100 Volt

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Battery recharge circuit

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety fuse. This system therefore requires no connection to the key switch. The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Stator check

Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.

Electric characteristic

Ohm value:

0.7 ÷ 0.9 Ohm

Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.

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Voltage regulator check

With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator. In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.

Recharge system voltage check

Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current generated by the system with lights on and a high running engine. In case the generated current value is lower than 8A, repeat the test using a new regulator and/stator alternatively.

Choke Inspection

Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If no voltage is detected, connect the multimeter negative terminal to the ground lead and the positive terminal to the automatic starter orange cable;

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with the key switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the key switch.

If battery potential is found, repeat the inspection from the connector to the ECU. After detaching the choke device, start the engine and, while at idle, check for tension connecting the positive terminal of the multimetre to terminal 5 (Orange) and the negative to terminal 7 (White/ Black) (see figure). If no tension is found, replace the ECU; otherwise check the wiring between the choke device and the ECU.

Turn signals system check

- If the turn signal lights are faulty, proceed as follows:

- Detach the ECU connector and check for battery tension between terminal 5 (Orange) and earth, with the key-switch onto «ON».

- Check the same is present between terminals 5 (Orange) and 8 (Black).

If no tension is measured, check the wiring, otherwise proceed as follows:

- Jumper terminals 1 (Black/Blue) and 5 (Orange), see figure, and alternately operate the turn signal switch towards left and right wit the key-switch onto «ON» and check the bulbs go off. If this happens, replace the ECU, as faulty. If this does not happen, check the wiring between the ECU and the turn signal switch, hence repeat the test.

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Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, 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 vehicle and, afterwards, every six months.

INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1) Voltage check up

Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 ÷ 14.70V

-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity

- Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the battery rated capacity

- Charge time: Maximum 5 h

Dry-charge battery

WARNING

- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about 15 minutes and seek immediate medical attention. In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Seek immediate medical attention Batteries produce explosive gases; keep clear of free flames, sparks or cigarettes; ventilate the area when recharging the battery indoors. Always protect your eyes when working close to batteries.

Keep out of the reach of children.

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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 Be 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 using the specific battery charger (single) or (multiple) at a density of about 1/10 of the battery nominal capacity until fully charged; check that the acid density is about 27, corresponding to 31 Be, and that these values are stabilised.

4) - Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.

5) Once the above operations have been performed, install the battery on the vehicle ensuring that it is wired up properly.

1 Hold the vertical tube 2 Look at the level 3 The float must be freed

WARNING

- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Battery maintenance

The battery is an electrical device which requires careful monitoring and careful maintenance. The maintenance rules are:

1) Electrolyte level check

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The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle electrical system: the battery works overcharged and is subject to quick wear.

2)Load status check

After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign.

3) Recharging the battery

Remove the battery from the vehicle removing the negative clamp 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) Battery cleaning

The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.

CAUTION

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 SHORTENS THE LIFE OF THE BATTERY.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the head

- Unscrew the 2 screws fixing the muffler to the housing; then remove the whole muffler paying attention to the interference between its supporting bracket and the cooling cover.

Removal of the engine from the vehicle

- Remove the left side fairing

- Remove the helmet compartment door

- Remove the full muffler assembly.

- Remove the 3 rear brake transmission fixing screws indicated in the photograph

- Remove the throttle control cable from the carburettor, indicated in the photograph

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- Remove the fuel supply pipe from the carburettor

- Remove the fuel valve low-pressure pipe from the manifold as shown in the photograph

- Remove the flywheel wiring connector, the earth terminal and the starter motor positive cable indicated in the figure

- Remove the clamp retaining the starter wiring and the heater indicated in the figure

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- Remove the protection sheath indicated in the figure and disconnect the automatic starter and carburettor heater connections

- Unscrew the engine pin-swinging arm nut on the right-hand side of the vehicle and slide off the pin on the left hand side

- Support the vehicle adequately (with a jack) and remove the shock absorber lower clamping. The engine is now free.

PIAGGIO Fly 150 4T, Fly 125, Fly 125 4T Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual