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.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - 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
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