Piaggio Vespa WORKSHOP Fly 125 150 4T Workshop Manual

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

Fly 125 - 150 4T Characteristics

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.

CHAR - 7

Characteristics Fly 125 - 150 4T

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

Specification Desc./Quantity

Dry weight 112 kg

Overall height 1150 mm

Seat height 785

Width 735

Wheel base 1330

Lenght 1870

WEIGHT AND DIMENSIONS

CHAR - 8

Fly 125 - 150 4T Characteristics

Engine

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

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

Max. power 11.6 hp at 7750 rpm

Cooling Forced air circulation.

CHAR - 9

Characteristics Fly 125 - 150 4T

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

Specification Desc./Quantity

Start-up Electric

Spark plug (125) Champion RG6YC- NGK CR7EB

Spark plug Champion RG6YC

Frame and suspensions

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-

Brakes

Specification Desc./Quantity

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

Rear brake Ø 140 mm drum brake

ELECTRICAL COMPONENTS

FRAME AND SUSPENSION

load adjustable on 4 positions; 64 mm travel.

BRAKE

er on the far right of the handlebar) and floating

calliper.

CHAR - 10

Fly 125 - 150 4T Characteristics

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

CHAR - 11

Characteristics Fly 125 - 150 4T

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°)

CHAR - 12

Fly 125 - 150 4T Characteristics

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

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

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

TRANSMISSION

FLYWHEEL

CHAR - 13

Characteristics Fly 125 - 150 4T

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmis-

sion-side half shaft) screws
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

4 ÷ 6

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

CHAR - 14

Fly 125 - 150 4T Characteristics

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

coupling 1st over-

size

Coupling 1st over-

size

Coupling 1st over-

size

Coupling 2nd over-

size

Coupling 2nd over-

size

Coupling 2nd over-

size

Coupling 2nd over-

size

Coupling 3rd over-

size

Coupling 3rd over-

size

Coupling 3rd over-

size

Coupling 3rd over-

size

A1 62.780 ÷ 62.787 62.733 ÷ 62.740 0.040 ÷ 0.054
B1 62.787 ÷ 62.794 62.740 ÷ 62.747 0.040 ÷ 0.054
C1 62.794 ÷ 62.801 62.747 ÷ 62.754 0.040 ÷ 0.054
D1 62.801 ÷ 62.808 62.754 ÷ 62.761 0.040 ÷ 0.054
A2 62.980 ÷ 62.987 62.933 ÷ 62.940 0.040 ÷ 0.054
B2 62.987 ÷ 62.994 62.940 ÷ 62.947 0.040 ÷ 0.054
C2 62.994 ÷ 63.001 62.947 ÷ 62.954 0.040 ÷ 0.054
D2 63.001 ÷ 63.008 62.954 ÷ 62.961 0.040 ÷ 0.054
A3 63.180 ÷ 63.187 63.133 ÷ 63.140 0.040 ÷ 0.054
B3 63.187 ÷ 63.194 63.140 ÷ 63.147 0.040 ÷ 0.054
C3 63.194 ÷ 63.201 63.147 ÷ 63.154 0.040 ÷ 0.054
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

CHAR - 15

Characteristics Fly 125 - 150 4T

Name Initials Cylinder Piston Play on fitting

Coupling 1st in-

crease

Coupling 1st in-

crease

Coupling 1st in-

crease

Coupling 2nd in-

crease

Coupling 2nd in-

crease

Coupling 2nd in-

crease

Coupling 2nd in-

crease

Coupling 3rd over-

size

Coupling 3rd over-

size

Coupling 3rd over-

size

Coupling 3rd over-

size

B1 57.187 ÷ 57.194 57.140 ÷ 57.147 0.040 - 0.054
C1 57.194 ÷ 57.201 57.147 ÷ 57.154 0.040 - 0.054
D1 57.201 ÷ 57.208 57.154 ÷ 57.161 0.040 - 0.054
A2 57.380 ÷ 57.387 57.333 ÷ 57.340 0.040 - 0.054
B2 57.387 ÷ 57.394 57.340 ÷ 57.347 0.040 - 0.054
C2 57.394 ÷ 57.401 57.347 ÷ 57.354 0.040 - 0.054
D2 57.401 ÷ 57.408 57.354 ÷ 57.361 0.040 - 0.054
A3 57.580 ÷ 57.587 57.533 ÷ 57.540 0.040 - 0.054
B3 57.587 ÷ 57.594 57.540 ÷ 57.547 0.040 - 0.054
C3 57.594 ÷ 57.601 57.547 ÷ 57.554 0.040 - 0.054
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

Coupling 1st over-

size

Coupling 1st over-

size

Coupling 1st over-

size

Coupling 2nd over-

size

Coupling 2nd over-

size

Coupling 2nd over-

size

Coupling 2nd over-

size

Coupling 3rd over-

size

Coupling 3rd over-

size

Coupling 3rd over-

size

Coupling 3rd over-

size

M1 57.197 ÷ 57.204 57.144 ÷ 57.151 0.046 ÷ 0.060
N1 57.204 ÷ 57.211 57.151 ÷ 57.158 0.046 ÷ 0.060
O1 57.211 ÷ 57.218 57.158 ÷ 57.165 0.046 ÷ 0.060

P1 57.218 ÷ 57.225 57.165 ÷ 57.172 0.046 ÷ 0.060
M2 57.397 ÷ 57.404 57.344 ÷ 57.351 0.046 ÷ 0.060
N2 57.404 ÷ 57.411 57.351 ÷ 57.358 0.046 ÷ 0.060
O2 57.411 ÷ 57.418 57.358 ÷ 57.365 0.046 ÷ 0.060

P2 57.418 ÷ 57.425 57.365 ÷ 57.372 0.046 ÷ 0.060
M3 57.597 ÷ 57.604 57.544 ÷ 57.551 0.046 ÷ 0.060
N3 57.604 ÷ 57.611 57.551 ÷ 57.558 0.046 ÷ 0.060
O3 57.611 ÷ 57.618 57.558 ÷ 57.565 0.046 ÷ 0.060

P3 57.618 ÷ 57.625 57.565 ÷ 57.572 0.046 ÷ 0.060

CHAR - 16

Fly 125 - 150 4T Characteristics

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

Oil scraper ring 1st

oversize

Oil scraper ring 1st

oversize

Compression ring

2nd oversize

Oil scraper ring

2nd oversize

Oil scraper ring

2nd oversize

Compression ring

3rd oversize

Oil scraper ring 3rd

oversize

Oil scraper ring 3rd

oversize

Maximum clearance after use: 1 mm

57.2 x 1 A 0.15 ÷ 0.30

57.2x1 A 0.10 ÷ 0.30

57.2x2.5 A 0.10 ÷ 0.35

57.4x1 A 0.15 ÷ 0.30

57.4x1 A 0.10 ÷ 0.30

57.4x2.5 A 0.10 ÷ 0.35

57.6x1 A 0.15 ÷ 0.30

57.6x1 A 0.10 ÷ 0.30

57.6x2.5 A 0.10 ÷ 0.35

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

Oil scraper ring 1st

oversize

Oil scraper ring 1st

oversize

Compression ring

2nd oversize

Oil scraper ring

2nd oversize

Oil scraper ring

2nd oversize

Compression ring

3rd oversize

Oil scraper ring 3rd

oversize

Oil scraper ring 3rd

oversize

62.8x1 A 0.15 ÷ 0.30

62.8x1 A 0.20 ÷ 0.40

62.8x2.5 A 0.20 ÷ 0.40

63.0 x 1 A 0.15 ÷ 0.30

63.0 x 1 A 0.20 ÷ 0.40

63.0 x 2.5 A 0.20 ÷ 0.40

63.2 x 1 A 0.15 ÷ 0.30

63.2 x 1 A 0.20 ÷ 0.40

63.2 x 2.5 A 0.20 ÷ 0.40

CHAR - 17

Characteristics Fly 125 - 150 4T

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

Flywheel-side half-

shaft

Connecting rod

with PP

Crank pin width 51.400 E

16.6 +0-0.05 A D = 0.20 - 0.50

16.6 +0-0.05 B D = 0.20 - 0.50

18 -0.10 -0.15 C 0.20 ÷ 0.50

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

Crankshaft half-

bearing

Crankshaft half-

bearing

Crankshaft catego-

ry 1 - Crankcase

category 1

Crankshaft catego-

ry 1 - Crankcase

category 2

Crankshaft catego-

ry 2 - Crankcase

category 1

Crankshaft catego-

ry 2 - Crankcase

category 2

Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40

Category B - blue 1.973 ÷ 1.976

Type C - yellow 1.976 ÷ 1.979

Category E - green 1.979 ÷ 1.982

E - E

C - C

C - C

B - B

CHAR - 18

Fly 125 - 150 4T Characteristics

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

CHAR - 19

Characteristics Fly 125 - 150 4T

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)

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

AGIP GP 330 Grease (brake control levers,

throttle grip)

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

AGIP GREASE MU3 Grease for odometer transmis-

sion gear case

Oil for 4-stroke engines

for increased adhesiveness

Calcium complex soap-based

grease with NLGI 2; ISO-L-

XBCIB2

JASO MA Synthetic oil

Soap-based lithium grease with

NLGI 3; ISO-L-XBCHA3, DIN

K3K-20

CHAR - 20

INDEX OF TOPICS

TOOLING TOOL

Tooling Fly 125 - 150 4T

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

TOOL - 22

Fly 125 - 150 4T Tooling

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

TOOL - 23

Tooling Fly 125 - 150 4T

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

TOOL - 24

Fly 125 - 150 4T Tooling

Stores code Description

020331Y Digital multimeter

020332Y Digital rev counter

020333Y Single battery charger

020334Y Multiple battery charger

TOOL - 25

Tooling Fly 125 - 150 4T

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

TOOL - 26

Fly 125 - 150 4T Tooling

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

TOOL - 27

Tooling Fly 125 - 150 4T

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

TOOL - 28

020426Y Piston fitting fork

Fly 125 - 150 4T Tooling

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

TOOL - 29

Tooling Fly 125 - 150 4T

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

TOOL - 30

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance Fly 125 - 150 4T

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'

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'

Engine oil - replacement

Action

Action

MAIN - 32

Fly 125 - 150 4T Maintenance

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'

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

Action

MAIN - 33

Maintenance Fly 125 - 150 4T

(*) 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'

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

Action

300'

MAIN - 34

AFTER 72,000 KM

Fly 125 - 150 4T Maintenance

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).

MAIN - 35

Maintenance Fly 125 - 150 4T

- 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

MAIN - 36

Fly 125 - 150 4T Maintenance

MAIN - 37

Maintenance Fly 125 - 150 4T

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

MAIN - 38

Fly 125 - 150 4T Maintenance

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.

MAIN - 39

Maintenance Fly 125 - 150 4T

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.

MAIN - 40

Fly 125 - 150 4T Maintenance

- 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

MAIN - 41

Maintenance Fly 125 - 150 4T

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.

MAIN - 42

Fly 125 - 150 4T Maintenance

- 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

MAIN - 43

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Fly 125 - 150 4T Troubleshooting

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

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

Excess of encrustations in the combustion cham-

ber

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-

Wrong valve adjustment Adjust the valve clearance properly

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

Valve seat distorted Replace the head assembly

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

Descale the cylinder, the piston, the head and the

place the damaged parts and lubricate the driven

pulley moveable guide with Montblanc Molybde-

Replace the worn parts

valves

num Grease

the valves

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-

Clutch fault Check the springs / clutch masses

essary.

TROUBL - 45

Troubleshooting Fly 125 - 150 4T

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

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

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

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

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

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

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

Check the starter motor and the kick-starter unit

refill

pipe by applying a vacuum to the suction pipe

ment, replace if necessary.

switch pressed; replace if necessary

pressed air

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

TROUBL - 46

Replace the piston cylinder unit or just the piston

rings

Fly 125 - 150 4T Troubleshooting

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

TROUBL - 47

Troubleshooting Fly 125 - 150 4T

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.

TROUBL - 48

Fly 125 - 150 4T Troubleshooting

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

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring

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.

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.

TROUBL - 49

Troubleshooting Fly 125 - 150 4T

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.

TROUBL - 50

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system Fly 125 - 150 4T

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.)

ELE SYS - 52

Fly 125 - 150 4T Electrical system

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

ELE SYS - 53

Electrical system Fly 125 - 150 4T

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

ELE SYS - 54

Fly 125 - 150 4T Electrical system

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

ELE SYS - 55

Electrical system Fly 125 - 150 4T

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

ELE SYS - 56

Fly 125 - 150 4T Electrical system

Specification Desc./Quantity

8 Zip tie
9 Horn

Specification Desc./Quantity

1 Zip tie

FRONT INSTALLATION 2

ELE SYS - 57

Electrical system Fly 125 - 150 4T

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

ELE SYS - 58

Fly 125 - 150 4T Electrical system

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

ELE SYS - 59

Electrical system Fly 125 - 150 4T

REAR INSTALLATION 2

Specification Desc./Quantity

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

Conceptual diagrams

ELE SYS - 60

Fly 125 - 150 4T Electrical system

Ignition

Specification Desc./Quantity

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

IGNITION

ELE SYS - 61

Electrical system Fly 125 - 150 4T

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

ELE SYS - 62

Fly 125 - 150 4T Electrical system

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

ELE SYS - 63

Electrical system Fly 125 - 150 4T

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

ELE SYS - 64

Fly 125 - 150 4T Electrical system

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

ELE SYS - 65

Electrical system Fly 125 - 150 4T

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

ELE SYS - 66

Fly 125 - 150 4T Electrical system

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:

ELE SYS - 67

Electrical system Fly 125 - 150 4T

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.

ELE SYS - 68

Fly 125 - 150 4T Electrical system

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.

ELE SYS - 69

Electrical system Fly 125 - 150 4T

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.

ELE SYS - 70

Fly 125 - 150 4T Electrical system

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

ELE SYS - 71

Electrical system Fly 125 - 150 4T

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

ELE SYS - 72

Fly 125 - 150 4T Electrical system

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.

ELE SYS - 73

Electrical system Fly 125 - 150 4T

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;

ELE SYS - 74

Fly 125 - 150 4T Electrical system

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.

ELE SYS - 75

Electrical system Fly 125 - 150 4T

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.

ELE SYS - 76

Fly 125 - 150 4T Electrical system

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

ELE SYS - 77

Electrical system Fly 125 - 150 4T

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

ELE SYS - 78

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle Fly 125 - 150 4T

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

ENG VE - 80

Fly 125 - 150 4T Engine from vehicle

- 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

ENG VE - 81

Engine from vehicle Fly 125 - 150 4T

- 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.

See also

Exhaust assy. Removal

ENG VE - 82

INDEX OF TOPICS

ENGINE ENG

Engine Fly 125 - 150 4T

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- To remove the transmission cover it is necessary
to remove the rear plastic cover first by inserting a
screwdriver in the corresponding slotted holes.
Using the clutch bell lock wrench, remove the driv­en pulley axle locking nut and recover the washer.

- Remove the cap/dipstick from the engine oil filling
hole.

- Remove the 10 screws and the earth cable fas­tened under one of them.

- Remove the transmission cover. If this operation
is performed directly on the vehicle, it is necessary
to remove the cooling air coupling and the three air
filter housing retainers.

Specific tooling

020423Y driven pulley lock wrench

CAUTION

Maybe a first batch of vehicles features an air
manifold bulkhead with the tail highlighted in the
figure. While removing the transmission cover,
take care not to deform this tongue with the fixed
driving half-pulley.

ENG - 84

Fly 125 - 150 4T Engine

Air duct

- Unscrew the Torx screws fixing the air manifold
bulkhead and remove the bulkhead.

- Remove the 3 screws, then take out the manifold
as well as the filter.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Use the specific tools to remove the bearing from
the crankcase.

CAUTION

USE AN APPROPRIATE REST SURFACE TO
AVOID DAMAGING THE COVER PAINT.

Specific tooling

020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm

ENG - 85

Engine Fly 125 - 150 4T

Refitting the driven pulley shaft bearing

- Heat up the crankcase inside with the hot air gun.

- Insert the bearing in its housing, refit the Seeger
ring.

N.B.

ALWAYS REPLACE THE BEARING WITH A
NEW ONE UPON REFITTING.

Specific tooling

020151Y Air heater
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide

Removing the driven pulley

- Remove the spacer, the clutch bell and the whole
driven pulley unit.

N.B.

THE UNIT CAN ALSO BE REMOVED WITH THE
DRIVING PULLEY MOUNTED.

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

Characteristic

Max. value clutch bell

Max. value: Ø 134.5 mm

Clutch bell standard value

Standard value: Ø 134 - 134.2 mm

ENG - 86

Fly 125 - 150 4T Engine

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2
bearings (inner diameter 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft assembly on the support to
check the crankshaft alignment.

- Using a feeler pin gauge and the magnetic base,
measure the bell eccentricity.

- Repeat the measurement in 3 positions (Central,
internal, external).

- If faults are found, replace the bell.

Specific tooling

020074Y Support base for checking crankshaft
alignment

020335Y Magnetic support for dial gauge

Characteristic

clutch bell inspection: Limit eccentricity.

Admissible limit eccentricity: 0.15 mm

Removing the clutch

- Prepare the locking tool for the driven pulley with
the pins half-screwed in the tool set to «C».

ENG - 87

Engine Fly 125 - 150 4T

- Fit the driven pulley unit in the tool so as the bolt
get into the masses clutch support holes. After­wards make the support screw make contact with
a minimum force.

- Using the specific wrench, inserted 46 mm from
the side, remove the clutch central locking nut.

- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).

CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE
TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE
SPECIFIC TOOL.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch
020444Y009 46x55 Wrench

Inspecting the clutch

- Check the thickness of the clutch mass friction
material.

- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.

N.B.

UPON RUNNING-IN, THE MASSES MUST EX­HIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE AN­OTHER.
VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.

CAUTION

DO NOT OPEN THE MASSES USING TOOLS
TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.

Characteristic

Check minimum thickness

1 mm

ENG - 88

Fly 125 - 150 4T Engine

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

- Remove the 3 guide pins and the movable half­pulley.

Removing the driven half-pulley bearing

- Remove the retaining ring using two flat blade
screwdrivers.

- Using a hammer and pin, knock the ball bearing
out as shown in the figure.

- Remove the roller bearing using the specific ex­tractor.

N.B.

REST THE HALF-PULLEY ON A WOOD SUR­FACE TO AVOID DAMAGING THE THREADED
RINGLET OF THE DRIVEN PULLEY UPON RE­MOVING IT.

Specific tooling

020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020439Y 17 mm guide

ENG - 89

Engine Fly 125 - 150 4T

Inspecting the driven fixed half-pulley

- Measure the external diameter of the pulley bush­ing.

Characteristic

Minimum diameter permitted

Ø 40.96 mm

Standard diameter

Ø 40.965 mm

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two O­rings.

- Measure the inside diameter of the mobile half­pulley bushing.

Characteristic

Minimum admissible diameter

Ø 41.08 mm

Standard diameter

Ø 41.035 mm

Refitting the driven half-pulley bearing

- Assemble a new roller case using the specific
punch, fit the bearing with the label facing outward
and insert it completely up to the punch on the half­pulley.

N.B.

REST THE HALF-PULLEY ON A WOOD SUR­FACE TO AVOID DAMAGING THE THREADED
RINGLET OF THE DRIVEN PULLEY UPON RE­MOVING IT.

Specific tooling

020424Y Driven pulley roller casing fitting
punch

ENG - 90

Fly 125 - 150 4T Engine

- To assemble the new ball bearing insert it com­pletely down in its housing with the specific punch
and finally assemble the Seeger ring.

Specific tooling

020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020439Y 17 mm guide

Refitting the driven pulley

- Check that the faying surfaces between the 2
half-pulleys and the belt do not show any signs of
wear, scoring and grease.

- Insert the new oil seals and O-rings on the mov­able half-pulley.

- Assemble the half-pulley on the ringlet with the
appropriate protection sheath.

- Make sure the pins and collar are not worn, re­assemble the pins and collar.

- Use a greaser with a curved spout to lubricate the
driven pulley unit with around 6 g of grease. This
operation must be done through one of the holes
inside the bushing until grease comes out of the
opposite hole. This operation is necessary to avoid
the presence of grease beyond the O-rings.

Specific tooling

020263Y Sheath for driven pulley fitting

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel
revolving ring

Soap-based lithium grease containing NLGI 2 Mo­lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20

ENG - 91

Engine Fly 125 - 150 4T

Inspecting the clutch spring

- Measure the unloaded length of the spring of the
movable driven half-pulley.

Characteristic

Standard length:

106 mm

Refitting the clutch

- Check the thickness of the clutch mass friction
material.

-The masses must not show traces of lubricants;
otherwise, check the driven pulley unit.

N.B.

UPON RUNNING-IN, THE MASSES MUST EX­HIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE AN­OTHER. VARIOUS CONDITIONS CAN CAUSE
THE CLUTCH TO TEAR.

CAUTION

DO NOT OPEN THE MASSES USING TOOLS
SO AS TO PREVENT A VARIATION IN THE RE­TURN SPRING LOAD.

Characteristic

Minimum thickness permitted:

1 mm

- Support the driven pulley spring compressor ap­propriate tool with the control screw in vertical axis.

- Arrange the tool with the medium length pins
screwed in position "C" on the inside.

- Introduce the adapter ring 11 with the chamfering
facing upwards.

- Insert the clutch on the adapter ring.

- Lubricate the end of the spring that abuts against
the servo-system closing collar.

- Insert the spring with its plastic holder in contact
with the clutch.

ENG - 92

Fly 125 - 150 4T Engine

- Insert the driving belt into the pulley unit accord­ing to their direction of rotation.

- Insert the pulley unit with the belt into the tool.

- Slightly preload the spring.

- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to tighten the
clutch nut.

- Place the tool in the clamp with the control screw
on the horizontal axis.

- Fully preload the spring.

- Apply the clutch fixing nut and tighten it to the
prescribed torque using the special 46x55 wrench.

- Loosen the tool clamp and insert the belt accord­ing to its direction of rotation.

- Lock the driven pulley again using the specific
tool.

- Preload the clutch return spring with a traction/
rotation combined action and place the belt in the
smaller diameter rolling position.

- Remove the driven pulley /belt unit from the tool.

N.B.

DURING THE SPRING PRELOADING PHASE,
BE CAREFUL NOT TO DAMAGE THE PLASTIC
SPRING STOP AND THE BUSHING THREAD­ING.

N.B.

FOR DESIGN REASONS, THE NUT IS SLIGHT­LY ASYMMETRIC; THE FLATTEST SURFACE
SHOULD BE MOUNTED IN CONTACT WITH
THE CLUTCH.

Specific tooling

020444Y Tool for fitting/ removing the driven
pulley clutch

020444Y011 adapter ring
020444Y009 46x55 Wrench

Locking torques (N*m)

Nut locking clutch unit on pulley 55 ÷ 60 Nm

ENG - 93

Engine Fly 125 - 150 4T

Refitting the driven pulley

- Reassemble the clutch bell and spacer.

Drive-belt

During the wear checks foreseen in the scheduled
maintenance services at 6,000 km; 18,000 km;
etc., check that the rim bottom of the toothing does
not show signs of incisions or cracking (see figure):
The rim bottom of the tooth must not have incisions
or cracking; if it does, change the belt.

- Check that the driving belt is not damaged.

- Check the width of the belt.

BELT SIZE

Specification Desc./Quantity

Minimum width 21.5 mm
Standard width 22.5 ± 0.2 mm

ENG - 94

Fly 125 - 150 4T Engine

Removing the driving pulley

- Lock the driving pulley with the specific tool as
shown in the figure. - Disassemble the central nut
and the Belleville washer, remove the drive and
the 2 washers. - Remove the stationary half pulley
and the steel washer.

Specific tooling

020368Y driving pulley lock wrench

- Remove the belt and slide the movable half-pul­ley with the relevant bush, taking care of the falling
free assembled rollers.

- Remove the return rollers plate with the relative
guide pads.

Inspecting the rollers case

- Check that the internal bushing is not abnormally worn and measure inner diameter.

N.B.

DO NOT LUBRICATE OR CLEAN THE BUSHING.

BUSHING ROLLER CONTAINER

Specification Desc./Quantity

Maximum allowable diameter Ø 26.121 mm

Standard diameter Ø 26+0 +0.021 mm

BUSH SLIDE PULLEY

Specification Desc./Quantity

Minimum diameter permitted Ø 25.950 mm

Standard diameter Ø 26-0.020 -0.041 mm

VARIABLE SPEED ROLLERS

Specification Desc./Quantity

Minimum diameter permitted Ø 18.5 mm

Standard diameter Ø 26±0.1 mm

ENG - 95

Engine Fly 125 - 150 4T

- Check the guide shoes for the variator back-plate
are not worn.

- Check there is no wear in the roller housing, and
the surfaces in contact with the belt on either of the
pulley halves.

Refitting the driving pulley

- Reassemble the parts of the unit (internal lining,
fixed half-pulley, external lining, drive and nut),
spread threadlock on the thread and screw the nut
to the prescribed torque.

-Avoid the half-pulley rotation using a calliper
spanner

N.B.

REPLACE THE NUT WITH A NEW ONE AT EV­ERY REFIT

Specific tooling

020368Y driving pulley lock wrench

Recommended products

Loctite 243 Medium strength threadlock

Loctite 243 medium-strength threadlock

Locking torques (N*m)

Locking torque 75 ÷ 83

ENG - 96

Fly 125 - 150 4T Engine

Refitting the transmission cover

- Check the presence of the 2 centring dowels and
the correct installation of the sealing gasket for the
oil sump on the transmission cover.

- Replace the cover tightening the 10 screws at the
specified torque.

- Refit the oil loading cap/bar.

- refit the steel washer and the driven pulley nut.

- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.

- Replace the plastic cover.

Specific tooling

020423Y driven pulley lock wrench

Locking torques (N*m)

Transmission cover screws 11 ÷ 13 Driven pul­ley shaft nut 54 ÷ 60

End gear

Removing the hub cover

- Empty the rear hub through the oil drainage tap
located inside the hub cover

- Remove the brake shoe and relevant spring

- Remove the 7 flanged screws as shown in the
figure.

- Remove the rubber cover and the brake pad lever
sliding unscrewing the relevant retaining screw to
reach the rear of the cover

- Take off the hub cover and relevant gaskets

ENG - 97

Engine Fly 125 - 150 4T

Removing the wheel axle

Remove the intermediate gear and the complete
hub cover.

Removing the hub bearings

- Check the state of the bearings being examined
(wear, clearance and noisiness). If faults are de­tected, do the following.

- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).

Specific tooling

001467Y009 Driver for OD 42 mm bearings
001467Y013 Pliers to extract ø 15-mm bearings

Removing the wheel axle bearings

- Take out the clip on the outside of the gearbox
cover.

- Remove the bearing with the adequate tools ad­equately supporting the hub cover, as shown in the
figure.

Specific tooling

020376Y Adaptor handle
020364Y 25-mm guide

ENG - 98

Fly 125 - 150 4T Engine

With the appropriate tools, remove the oil seal as
shown in the figure.

Specific tooling

020376Y Adaptor handle
020359Y 42x47-mm adaptor

Removing the driven pulley shaft bearing

If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven
pulley.

- Extract the driven pulley shaft from its bearing.

- Remove the oil guard using a screwdriver, working from inside the bearing and being careful not to
damage the housing, make it come out of the belt transmission side.

- Remove the seeger ring shown in the figure
With the sectional punch, remove the driven pulley

shaft bearing.

Specific tooling

020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020363Y 20 mm guide

See also

Removing the driven pulley

Inspecting the hub shaft

- Check the three shafts for wear or distortion of
the toothed surfaces, the bearing housings, and
the oil seal housings.

- In case of anomalies, replace the damaged com­ponents.

ENG - 99

Engine Fly 125 - 150 4T

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and the
brake camshaft. - If faults are found, replace the hub cover.

Refitting the driven pulley shaft bearing

- Heat up the parts using the specific heat gun

Specific tooling

020150Y Air heater support
020151Y Air heater

- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of
the hub cover using the adequate tools

Specific tooling

020376Y Adaptor handle

- Refit the Seeger ring with the opening facing the
bearing as shown in the figure and fit a new oil
guard flush with the crankcase.

Refitting the wheel axle bearing

- Heat up the parts using the specific heat gun

Specific tooling

020151Y Air heater
020150Y Air heater support

-The wheel axle bearing on the cover, should be assembled with the specific tools

Specific tooling

020364Y 25-mm guide
020360Y Adaptor 52 x 55 mm
020376Y Adaptor handle

ENG - 100