Piaggio Vespa WORKSHOP Fly 50 2T Workshop Manual

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WORKSHOP MANUAL

633204

Fly

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Fly

WORKSHOP

MANUAL

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual 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/models shown in this publication are available in all countries. The availability of each

model should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

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

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

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WORKSHOP MANUAL

Fly

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.

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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

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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Fly 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 naked 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 spare parts 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 solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- 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 vehicle.

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

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Characteristics Fly

Vehicle identification

VEHICLE IDENTIFICATION

Specification Desc./Quantity

Frame prefix ZAPM44100 ÷ 1001

Engine prefix C441M ÷ 1001

Dimensions and mass

Specification

Dry weight 97 Kg

Length 1,880

Maximum height 1150 mm

Seat height 785

Width 735

Wheelbase 1,340

DIMENSIONS AND MASS

Desc./Quantity

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Fly Characteristics

Engine

ENGINE

Specification

Engine type Two-stroke, single cylinder Piaggio Hi-PER2

Bore x stroke 40 X 39.3 mm

Cubic capacity 49.40 cc

Compression ratio 10,3 :1

Carburettor DELL'ORTO PHVA 17.5

CO adjustment 3.5% ± 0.5

Engine idle speed 1800 to 2000 r.p.m.

Air filter Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and

Starting system electric starter/kick-starter

Lubrication With blend and variable oil variable according to the engine

revolutions and the throttle valve opening by means of a pump

controlled by the driving shaft with toothed belt.

Fuel supply Gravity feed, with unleaded petrol (with a minimum octane rat-

Cooling system forced coolant circulation system

Desc./Quantity

50% unleaded petrol).

ing of 95) with carburettor.

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Characteristics Fly

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator, torque server, V-

belt, automatic clutch, gear reduction unit.

Capacities

CAPACITIES

Specification Desc./Quantity

Rear hub oil Quantity: approx. 85 cc

oil mixer tank Plastic, capacity ~ 1.2 l

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

Electrical system

Specification Desc./Quantity

Type of ignition Capacitive discharge type electronic ignition, with incorporated

Ignition advance (before TDC) Fixed 17° ± 1

Recommended spark plug CHAMPION RN2C

Battery 12V-4Ah

Main fuse 7.5 A

Generator In alternate current with three output sections

Frame and suspensions

Specification

Type of chassis Welded tubular steel chassis with stamped sheet reinforce-

Front suspension Telescopic mechanical fork, 76mm travel. Rear suspension Single hydraulic shock absorber, 72.5-mm travel

Brakes

Specification

Front brake Disc brake (Ø 200 mm) with hydraulic control (lever on the right Rear brake drum brake (Ø 140 mm) with mechanical linkage.(l.h. brake

ELECTRICAL SYSTEM

high voltage coil

FRAME AND SUSPENSIONS

Desc./Quantity

ments.

FRENI

Desc./Quantity

end of the handlebar) and floating calliper.

lever).

Wheels and tyres

Specification

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

Front tyre Tubeless, 120/70-12"

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WHEELS AND TYRES

Desc./Quantity

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Fly Characteristics

Specification Desc./Quantity

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

Follow these steps to clean the sponge filters of the secondary air system:

1) Remove the snap-on plastic cover (1) on the transmission cover using a small screwdriver as a lever on the retaining tongues in order to insert one of the three slots found on that cap.

2) Wash the polyurethane sponge with water and soap, dry all components with compressed air and refit to place. Refit the intake cap respecting the angle reference.

3) Undo the two fixing screws (2) on the aluminium cover of the secondary air housing in order to reach the polyurethane sponge inside that housing; clean as indicated in point 2) and refit all elements after checking the steel tab is not deformed and/or does not guarantee correct tightness at its fitting; replace if necessary.

N.B. UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE

TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMINIUM COVERS.

CAUTION WHILE CARRYING OUT OPERATION 3), ALWAYS CHECK

THE TWO RUBBER COUPLINGS (3) ON ONE END OF THE SECONDARY AIR PIPE FOR CORRECT TIGHTNESS AND CONTINUITY; IF NECESSARY, REPLACE THEM AND USE NEW CLAMPS TO FIX THEM.

Carburettor

50cc Version

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Characteristics Fly

Dell'Orto

DELLORTO CARBURETTOR

Specification Desc./Quantity

Type PHVA 17.5 RD

Diffuser diameter Ø 17.5

Regulation reference number 8423

Maximum nozzle: 53

Maximum air nozzle (on the body): Ø 1.5

Tapered pin stamped code: A22

Pin position (notches from above): 1

Diffuser: 209 HA

Minimum nozzle: 32

Minimum air nozzle (on the body): Free

Initial minimum mix screw opening: 1 1/2

Starter air nozzle (on the body): Ø 1.5

Starter jet 50

Stroke of starter pin: 11 mm

Gasoline inlet hole Ø 1.5

Tightening Torques

FRONT BRAKE

Name

Brake fluid pump - hose fitting 16 ÷20 Nm

Brake fluid pipe-calliper fitting 19 ÷ 24

Calliper tightening screw 24 ÷ 27

Disc tightening screw 8 ÷ 10

Oil bleed screw 7 ÷ 10

Torque in Nm

FRONT SUSPENSION

Name

Lower fork fixing screw 15 ÷ 20

Front wheel axle nut 45 - 50

Torque in Nm

STEERING ASSEMBLY

Name

Upper steering ring nut 35 ÷ 40 Steering lower ring nut 8 ÷ 10 Handlebar fixing screw 50 ÷ 55

Torque in Nm

ENGINE ASSEMBLY

Name

Clutch bell nut (**) 40 ÷ 44

Clutch lock ring nut 55 ÷ 60

Nut locking driving pulley on crankshaft (**) 40 ÷ 44 Nm

Start-up lever screw 12 ÷ 13

Flywheel nut (**) 40 ÷ 44

Flywheel fan screws 3 ÷ 4

Half-crank case joint bolts 12 ÷ 13

Bolts holding exhaust pipe to the crankcase 22 ÷ 24

Screws holding the filter box to the crank case 4 ÷ 5

Head nuts 10 ÷ 11

Starter screws 12 ÷ 13

Ignition spark plug 25 ÷ 30 Hub oil drainage cap 3 ÷ 5 Oil hub level dipstick Manual

Rear hub cap screws 12 ÷ 13

Transmission cover screws 12 ÷ 13

Inlet manifold screws 8 ÷ 9

Torque in Nm

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Fly Characteristics

Name Torque in Nm

Flywheel hood fixing screws 1 ÷ 2

Cylinder hood fixing screws 3.5 ÷ 5

Stator clamping screws 3 ÷ 4

Pick-Up clamping screw 4 ÷ 5

Mixer clamping screws 3 ÷ 4

Screw fixing brake lever to the journal on the engine 12 ÷ 13

CHASSIS

Name Torque in Nm

Swinging arm - engine pin* 33 ÷ 41

Frame/swing-arm bolt (*) 64÷72

Shock absorber - chassis nut (*) 20 to 25 Nm

shock absorber - engine pin (*) 33 to 41 N·m

Rear wheel axle (*) 104÷126 N·m

Centre-stand mounting bracket bolt 25÷30 N·m

Centre-stand mounting bracket screw 20÷25 N·m

Side stand fixing screw 12 ÷ 20

Side stand bracket fixing screw 15 ÷ 20

Overhaul data

Assembly clearances

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDER

Name

Standard coupling M 40.005 - 40.012 39.943 - 39.95 0.055 - 0.069 Standard coupling N 40.012 - 40.019 39.95 - 39.957 0.055 - 0.069 Standard coupling O 40.019 - 40.026 39.957 - 39.964 0.055 - 0.069

Standard coupling P 40.026 - 40.033 39.964 - 39.971 0.055 - 0.069 coupling 1st oversize M1 40.205 - 40.212 40.143 - 40.15 0.055 - 0.069 coupling 1st oversize N1 40.212 - 40.219 40.15 - 40.157 0.055 - 0.069 coupling 1st oversize O1 40.219 - 40.226 40.157 - 40.164 0.055 - 0.069 coupling 1st oversize P1 40.226 - 40.233 40.164 - 40.171 0.055 - 0.069

Coupling 2nd oversize M2 40.405 - 40.412 40.343 - 40.35 0.055 - 0.069 Coupling 2nd oversize N2 40.412 - 40.419 40.35 - 40.357 0.055 - 0.069 Coupling 2nd oversize O2 40.419 - 40.426 40.357 - 40.364 0.055 - 0.069 Coupling 2nd oversize P2 40.426 - 40.433 40.364 - 40.371 0.055 - 0.069

Initials Cylinder Piston Play on fitting

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Characteristics Fly

Piston rings

SEALING RING

Name Description Dimensions Initials Quantity

Compression ring 40 A 0.10 to 0.25

Compression ring 1st

oversize

Compression ring 2nd

Oversize

40.2 A 0.10 to 0.25

40.4 A 0.10 to 0.25

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Name

Connecting rod 11.750-0.05 A clearance E = 0.25 to

shoulder washer 0.5 ± 0.03 G clearance E = 0.25 to

Half-shaft, transmission

side

Flywheel-side half-shaft 13.75+0.040 D clearance E = 0.25 to

Lining between the

shoulders

Cage 11.800-0.35 B clearance F = 0.20 to

Description Dimensions Initials Quantity

0.50

0.50 - clearance F =

0.20 to 0.75

13.75+0.040 C clearance E = 0.25 to

0.50 - clearance F =

0.20 to 0.75

0.50 - clearance F =

0.20 to 0.75

40.64 H clearance E = 0.25 to

0.50 - clearance F =

0.20 to 0.75

0.75

Slot packing system

This type of engines foresees the use of one size of basic gaskets.

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Fly Characteristics

For 25 km/h engine type versions, use 2 gaskets between cylinder and crankcase.

Products

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

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Maintenance Fly

Replacement

- Remove the oil filler cap «A».

- Loosen the oil draining cap «B» and let the oil completely drain the tank.

- Tighten the draining cap and refill the hub with oil (approx. 75 cc).

Air filter

-Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter. Cleaning:

-Wash with water and neutral soap.

- Dry with a clean cloth and short blasts of compressed air.

-Saturate with a 50% mixture of gasoline and oil.

-Drip dry the filter and then squeeze it between the hands without wringing.

-Let it dry and refit it again.

CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,

THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

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Fly Maintenance

Checking the ignition timing

- Adjust the control cables: Mix cable: see procedure indicated in "Mixer timing". Throttle cable: adjust the set screw on the carburettor in such a way that the sheath has no backlash. Splitter control cable: adjust set screw on the throttle control to the handlebar in such a way that there is no backlash on the throttle control. Adjust all transmissions in such a way that their sheathings show no sign of backlash.

Mixer Timing

- Using the transmission set screw on the crankcase, with throttle control untwisted, adjust the reference mark on the rotating plate so that it is lined up with the reference mark on the mixer body, as shown in the figure. While doing this, the engine must be fuelled with a 2 % oil mixture (0.5 litre minimum if the reservoir is empty).

CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN

THE RESERVOIR BLEED THE MIXER AS FOLLOWS: REFILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE MIXER PIPE FROM THE CARBURETTOR AND LOOSEN THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE) UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH THE RELEVANT METAL CLIP.

Recommended products

AGIP CITY TEC 2T Mixer oil

synthetic oil for 2-stroke engines: JASO FC, ISOL-EGD

Braking system

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Maintenance Fly

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.

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 BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE

SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.

CAUTION 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

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Fly Maintenance

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 higher than 9/10 or lower than 7/10 of the distance from the ground to the centre of vehicle headlamp;

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

N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

CO check

In the event that the exhaust on the vehicle being tested does not have an exhaust gases collection port, proceed as follows:

- Remove the R.H. side fairing

- Remove the secondary air box cover with the aluminium cap by acting upon the clamp shown in the figure.

Attach the exhaust gas collection tube to the secondary air rubber manifold. Such joint must be sealed in order to guarantee accurate CO readings.

- Start the engine, adjust the idle speed to 1,700 ± 100 rpm and check the CO value is equal 3.5 ± 1%

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Maintenance Fly

- If the parameters found do not agree with the above figures, act upon the idle adjusting screw. Otherwise, check the automatic choke device

Specific tooling

020320Y Exhaust gases analyser 020332Y Digital rpm indicator

The check must be carried out after having carefully cleaned all carburettor components, with the air filter clean, and the spark plug in good conditions.

- Remove the R.H. side fairing

- Warn-up the engine by riding the vehicle on the road for at least 10 minutes

- Shut down the engine

- Remove the 2 secondary air box screws shown in the figure

− Place a plastic sheet between the one-way valve and the aluminium outlet as shown in the figure

− Ensure the one-way valve packing properly seals the aluminium outlet fitting.

− Refit the aluminium outlet onto the SAS box as shown in the picture.

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Fly Maintenance

- Attach the special tool and move the joints as shown in the figure.

- Start the engine, adjust the idle speed to 1,700 ± 100 rpm and check the CO value is equal 3.5 ± 1%

- If the parameters found do not agree with the above figures, act upon the idle adjusting screw. Otherwise, check the automatic choke device.

Specific tooling

020320Y Exhaust gases analyser 020332Y Digital rpm indicator 020625Y Kit for sampling gas from the exhaust

manifold

SAS filters inspection and cleaning

After removing the spark plug cap, remove the RHS fairing, by loosening the three fixing screws «B» shown in the figure. Remove the SAS aluminium cover fixing screws «A». Detach the metal hose from its rubber housing on the cover, without detaching it from the cover/bellow. Hence remove plate and plastic cover, extract the sponge and wash it with soap. Dry with compressed air before refitting, ensuring to correctly positioning the plate in the housing machined on the plastic and aluminium covers. Whenever removing the part, always replace the O-ring located on the special housing on the cover.

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

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Fly Troubleshooting

This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given.

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed air

Excess of encrustations in the combustion chamber Remove the encrustations

Lack of compression wear of the piston rings or cylinder Check the worn parts and replace them

Exhaust pipe clogged due to excessive encrustations Replace the exhaust pipe and check the carburation and mixer

Air filter blocked or dirty Clean according to the procedure

Starter inefficient (stays on) Check the mechanical sliding, continuity of the circuit, the pres-

ence of power and electrical wiring

Clutch slipping Check the centrifugal brake shoe assembly and /or clutch bell

and replace if necessary

Defective mobile pulley sliding Check the parts, change the faulty parts and lubricate the driv-

en pulley using only Montblanc-Molibdenum Grease (dis.

Driving belt worn Replace

Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air

Fuel filter on vacuum operated cock blocked Clean the cock filter

Roller wear; Presence of oil; Dirt Check the cap with filter is fitted to the transmission cover;

clean the speed variator, replace the rollers if worn out

timer

498345) grease

Rear wheel spins at idle

REAR WHEEL

Possible Cause

Idling rpm too high Check the idling speed and, if necessary, adjust the C.O.

Clutch fault Check the spring/friction mass and the clutch bell

Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged

Operation

Starting difficulties

DIFFICULTY STARTING

Possible Cause

Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air

Faulty fuel cock Check that, at ignition and with throttle untwisted, no petrol

flows out the delivery pipe; otherwise, replace the vacuum-op-

Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

Defective spark plug or with incorrect electrode gap Check and if necessary replace the spark plug and the elec-

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

- Engine flooded. Start the vehicle keeping the throttle fully open alternately making the engine run for approx. five seconds and stopping for

other five seconds. If however it does not start, remove the

spark plug, the engine over with the throttle open being careful

Operation

erated cock

power supply

trode gap

itself

TROUBL - 37

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Troubleshooting Fly

Possible Cause Operation

to keep the cap in contact with the spark plug and the spark plug grounded but away from its hole. Refit a dry spark plug

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

Faulty spark plug Remove the encrustation, restore the plug gap or replace being

sure to use the types of spark plug recommended at all times.

Bear in mind that many problems engines have, derive from

Intake joint cracked or with a bad seal Replace intake joint and check for correct sealing on the head

Purifier-carburettor fitting damaged Replace

and start the vehicle.

the use of the wrong spark plug

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation

Excess of encrustations in the combustion chamber Remove the encrustations

Engine tends to cut-off at full throttle

ENGINE STOP FULL THROTTLE

Possible Cause Operation

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air

Dirty carburettor Wash the carburettor with solvent and dry with compressed air

Water in the carburettor Empty the tank through the appropriate bleed nipple.

Air filter dirty Clean or replace

Defective floating valve Check the proper sliding of the float and the functioning of the

Tank breather hole obstructed Restore the proper reservoir aeration

Engine tends to cut-off at idle

ENGINE STOP IDLING

Possible Cause

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air

Starter that stays open Check: electric wiring, circuit continuity, mechanical sliding and

Reed valve does not close Check / replace the reed pack

Wrong idling adjustment Correctly adjust the engine idling and check the level of the

Spark plug defective or faulty Replace the spark plug with one with the specified degree and

Excessive exhaust noise

valve

Operation

power supply

C.O.

check the plug gap

INCREASED NOISINESS

Possible Cause

Secondary metal air pipe deteriorated Check there are no leaks on the hoses on the crankcase and

the housing, check that there is a cap with filter and it is correctly

fitted to the transmission cover

Good condition of the missing secondary air circuit components Check the individual components and the piping, check the

precision of the fitting. Replace the damaged components

TROUBL - 38

Operation

Page 39

Fly Troubleshooting

High fuel consumption

HIGH FUEL CONSUMPTION

Possible Cause Operation

Air filter blocked or dirty. Clean according to the procedure

Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

SAS malfunctions

SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-

FLER

Possible Cause Operation

Secondary air reed blocking Replace Secondary air filter clogging Clean the filter and the housing

Blockage of the secondary air fitting on the muffler Remove the encrustations from the joint being careful not to let

power supply

the debris fall into the muffler

Transmission and brakes

Clutch grabbing or performing inadequately

CLUTCH BRAKES

Possible Cause

Slippage or irregular functioning Check that the masses open and return normally

Check that there is no grease on the masses

Check that the clutch masses' contact surface with the clutch

bell is mainly in the middle with characteristics equivalent on

Check that the clutch bell is not scored or worn abnormally

Never operate the engine without the clutch bell

Check the cap with filter is fitted to the transmission cover

Insufficient braking

BRAKING SYSTEM MALFUNCTION

Possible Cause

Poor braking The rear (drum type) brake is adjusted by regulating the special

adjustment (on the wheel) bearing in mind that, with the control

levers in the rest position, the wheels must turn freely.

The braking action should begin when the brake levers are

If it is not possible to remove any problems by simply adjusting the transmissions, check the brake pads and front brake disc, the brake shoes and the rear drum. If you encounter excessive

wear or scoring, make the necessary replacements.

Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be

Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump breakdown, replace

The brake fluid has lost its properties Replace the front brake fluid and top up to the correct level in

Defective sliding of the cables in their sheathes Lubricate or substitute

Brake noise Check the wear of the brake pads and/or shoes

Operation

the three masses

Operation

pressed by about a third.

Check the brake pad wear.

no flexible movement of the brake lever).

the pump

TROUBL - 39

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Troubleshooting Fly

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective piston sliding Check calliper and replace any damaged part.

Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the

wheel correctly fitted or the concentricity of the rear drum.

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, keep-

ing 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.

Steering and suspensions

Rear wheel

Possible Cause

Idle speed set too high Adjust idle speed. Adjust C.O. if necessary

Faulty clutch Check springs / frictional weights and clutch housing.

Heavy steering

Possible Cause

Torque not conforming Check the tightening of the top and bottom ring nuts.

Excessive steering play

REAR WHEEL

Operation

STEERING HARDENING

Operation

If irregularities continue in turning the steering even after mak-

ing the above adjustments, check the seats in which the ball

bearings rotate: replace if they are recessed.

EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring nuts.

TROUBL - 40

EXCESSIVE STEERING CLEARANCE

Possible Cause

Operation

If irregularities continue in turning the steering even after mak-

ing the above adjustments, check the seats in which the ball

bearings rotate: replace if they are recessed.

Page 41

Fly Troubleshooting

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

NOISY SUSPENSION If the front suspension is noisy, check: the efficiency of the front

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Oil leakage from suspension Service the pumping members and check the sleeves and

shock absorbers; the condition of the ball bearings and relevant

lock-nuts, the limit switch rubber buffers and the movement

bushings.

sealing rings are in good conditions. Replace the damaged

parts

TROUBL - 41

Page 42

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 43

Fly Electrical system

ELECTRICAL SYSTEM DIAGRAM

Specification

1 Stop button on rear brake 2 Light switch 3 Turn indicator switch 4 Horn button 5 Horn 6 Front turn indicator bulbs Front turn indicator bulbs 12V-10W x 2 7 Front left turn indicator 8 Heater control device 9 Magneto flywheel 10 Electronic ignition device 11 Starter motor

Desc./Quantity

ELE SYS - 43

Page 44

Electrical system Fly

Specification Desc./Quantity

12 Fuse box 13 Battery 12V - 4Ah 14 rear left turn indicator 15 Rear turn indicator bulbs Two, 12V-10W, spherical 16 Stop and tail light bulb Type: Spherical

17 Rear light assembly 18 rear right turn indicator 19 Voltage regulator 20 Mixer oil warning light control 21 Start-up remote control switch 22 Ground lead (-) 23 starter motor wire unit 24 Automatic starter 25 Carburettor heater 26 Chassis wire unit 27 Fuel level transmitter 28 front right turn indicator 29 Key switch 30 Starter button 31 Front brake stop button 32 Headlight 33 Headlight bulb 12V-35/35W 34 Front tail light bulb Type: All glass

35 Left turn indicator warning light 12V - 2W 36 Headlight warning light 12V 1.2W 37 High-beam warning light 12V - 1.2W 38 Instrument panel light bulbs Type: All glass

39 Low fuel warning light 40 Right turn indicator warning light 12V - 2W 41 Low oil warning light 12V - 1.2W 42 Odometer with warning lights and level indicator

Power: 12V 21/5W

Quantity: 1

Power: 12V 5W

Quantity: 1

Power: 12V 1.2W

Quantity: 3

Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black, Ro = Pink, Rs = Red, Ve = Green, Vi = Purple

Conceptual diagrams

ELE SYS - 44

Page 45

Fly Electrical system

Ignition

Specification

1 Electronic control unit 2 Magneto flywheel 3 Pick - up 4 Key switch 5 Spark plug

IGNITION

Desc./Quantity

ELE SYS - 45

Page 46

Electrical system Fly

Headlights and automatic starter section

LIGHTS

Specification

1 Voltage regulator 2 Magneto flywheel 3 Light switch 4 Rear light bulb 12V - 5W 5 Headlight bulb 12V-35/35W 6 High-beam warning light 12V - 1.2W 7 N°3 instrument lighting bulbs 12V - 1.2W 8 Taillight bulb 12V - 5W 9 Headlight warning light 12V - 1.2W 10 Heater control device 11 Key switch contacts 12 Fuse 7,5A 13 Carburettor heater 14 Automatic starter 15 Battery 12V - 4Ah

Desc./Quantity

ELE SYS - 46

Page 47

Fly Electrical system

Battery recharge and starting

BATTERY RECHARGE AND STARTING

Specification

1 Magneto flywheel 2 Voltage regulator 3 Main fuse 7,5A 4 Brake light filament 12V - 21W 5 Front and rear brake light button 6 Start up button 7 Starter motor 8 Remote starter switch 9 Battery 12V - 4Ah

Desc./Quantity

ELE SYS - 47

Page 48

Electrical system Fly

Level indicators and enable signals section

START PERMISSIVE BUTTONS AND LEVEL INDICATORS

Specification

1 Magneto flywheel 2 Voltage regulator 3 Key switch 4 Main fuse 7,5A 5 Brake light filament 12V - 21W 6 Front and rear brake light button 7 Start up button 8 Starter motor 9 Remote starter switch 10 Battery 12V - 4Ah 11 Low oil warning light 12V - 1.2W 12 Oil level sender 13 Low fuel warning light 12V - 1.2W 14 Fuel gauge 15 Fuel level sender

Desc./Quantity

ELE SYS - 48

Page 49

Fly Electrical system

Turn signal lights

TURN INDICATORS AND HORN

Specification

1 Battery 12V - 4Ah 2 Main fuse 7,5A 3 Key switch 4 Magneto flywheel 5 Voltage regulator 6 Horn button 7 Horn 8 Indicators switch 9 Two (2) turn signal warning light bulbs 12V - 2W 10 4 Turn indicator bulbs 12V-10W

Desc./Quantity

Checks and inspections

1) No-load test: the starter motor, when unloaded, must absorb no more than 10A with a supply voltage ≥ 12V and must rotate at ≥ 15,000 rpm.

2) Load test: when the starter motor is so braked that it absorbs 47A with supply voltage ≥ 10V, torque of ≥ 0.2 N•m must be obtained at 10,000 rpm.

3) Static torque test: when the rotor is locked and the supply voltage is <7V, the absorbed current must not exceed 130A and the torque must be at least 0.55 N•m

Specifications

ELE SYS - 49

Page 50

Electrical system Fly

- Rated voltage 12V.

- Rated power 0.25 kW.

- Left-hand rotation view from pinion side.

- Connected to the engine by pinion and crown wheel on crankshaft, transmission side.

- Push-button control.

- Battery used for the test:12V-3,6Ah.

N.B.

THESE VALUES MUST BE MEASURED WITH A CHARGED BATTERY AND AFTER THE STARTER HAS BEEN ROTATING FOR 30" UNDER CONDITIONS OF POINT 1

In case the cause of ignition failure or malfunction cannot be easily identified at sight, first of all replace the control unit by another one in operating conditions. Remember that the engine must be off to disconnect and replace the control unit. If after replacement the vehicle starts properly, the control unit is failing and must be replaced.

If the failure persists, check the generator and the stator components as follows: After visually checking the electrical connections, use a specific tester to measurement the stator winding and the pickup (see table). If any failure is found after checking the loading coil and the pick-up, replace the stator and the dam-

aged parts.

Disconnect the connector on the flywheel cover and measure the resistance between either contact and the earthing.

Specific tooling

020331Y Digital multimeter

PICK-UP CHECK

Specification

1 1) Brown cable and earth ~ 170 Ω

Desc./Quantity

STATOR WINDING CHECK

Specification

1 1) Black cable and earth ~ 1 Ω

ELE SYS - 50

Desc./Quantity

Page 51

Fly Electrical system

Ignition circuit

1) Check the state of the spark plug (clean it with a metallic brush, remove all incrustations, blow it with compressed air, and replace it if necessary).

2) Without removing the stator, perform the checks described below: After a visual inspection of the electrical connections, carry out the measurements on the charging coil and pick-up (see table), and check for continuity using the special tester, 020331Y. If the continuity checks or the inspections on the coil and pick-up are incorrect, proceed by replacing the stator, otherwise replace the ECU. Remember to detach the ECU wirings when the engine is not running.

Specific tooling

020331Y Digital multimeter

PICK - UP CHECK (FIGURE A)

Specification

1 Red cable (1) and White cable (2) 90 ÷ 140 Ohm

Desc./Quantity

RECHARGING COIL CHECK (FIGURE B)

Specification

1 Red cable (3) and Green cable (4) 800 ÷ 1100 Ohm

Desc./Quantity

CONTINUITY CHECK

Specification

1 White cable - Engine Continuity 2 White cable - Frame Continuity

Desc./Quantity

ELE SYS - 51

Page 52

Electrical system Fly

Stator check

- Using a tester, check the resistance between the stator wiring.

N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A

CHECK WITH THE STATOR AT OPERATING TEMPERATURE LEADS TO VALUES HIGHER THAN THOSE STATED.

Electric characteristic

Stator : Grey ÷ Ground

~ 1 ohm

Stator : White ÷ Ground

~ 1 ohm

Stator : Green - Ground

~ 1Kohm

Stator : Blue ÷ Yellow

~ 1 ohm

Pick-Up: Red - ground

~ 170 Ω (Pick-Up)

Voltage regulator check

Voltage regulator

A fault in the voltage regulator can cause the following problems depending on the type of fault:

1) Blow out of the lighting system bulbs.

2) Failure of the lighting system.

3) Excessive battery charging (blowing of main fuse).

4) Battery recharging failure.

5) Failure of the turn indicators.

6) Failure of the oil and petrol check lamp.

Operations FAULT 1:

Make sure that at 5000 rpm with the lights on that the regulation voltage is between 13V and 14.5V. Make sure that at 5000 rpm with the lights off the regulation voltage is ï£ 16V. If the regulation voltage is greater than >16V replace the regulator.

ELE SYS - 52

Page 53

Fly Electrical system

FAULT 2:

a) Make sure the stator is supplying voltage correctly: disconnect the regulator connector and place tester 020331 y between the grey-blue wire (2) and the black wire (6) to measure the alternating voltage and make sure that the voltage supplied at 3000 rpm, is between 25 and 30V (FIG> A). If there are any anomalies, replace the stator. b) If the tests do not reveal any anomalies, replace the regulator. c) If replacement of the regulator does not restore correct operation, check the connections of the electrical system.

FAULT 3

After checking that there are no short circuits in the system towards earthing with the engine off and the regulator connector detached, replace the regulator because it is certainly inefficient, and replace the protection fuse. Following the replacement, measure the current and the recharging voltage on the battery ends (FIG. B). The values detected must be 1.5 ÷ 2 A and 13 V at 3000 rpm.

FAULT 4

a) By positioning tester 020331Y between the yellow wire terminal (8) on the regulator and the black wire (6) (FIG. D), check the generator output voltage is within 26 and 30 V at 3,000 rpm (this measurement must be carried out with the battery detached). In the event of anomalies, replace the stator; otherwise proceed to point b). b) Yellow wire (1) attached to the regulator. Insert an ammeter between the stator's blue wire (2) and the battery, and check, using tester 020331Y, that the current output, at 3,000 rpm and with the battery kept between 12 and 13V, is approx. 1.5 - 2 A (FIG. C).

ELE SYS - 53

Page 54

Electrical system Fly

If the values thus obtained are lower than prescribed, proceed by replacing the regulator. Before carrying out inspections on the regulator and its electrical system, it is always advisable to check for continuity between the black wire and earth.

FAULT 5

(FIG. E) If the turn indicators do not work, proceed as follows:

- Remove the regulator connector, and insert the tester probes between the contact 5 (yellow-red) and the ground lead.

- Turn the key switch to ON and check that the battery is getting voltage. If no voltage is detected, check the wiring and the contacts on the key switch and on the battery.

(FIG. F) Repeat the procedure now placing the tester probes between contacts 5 (yellow/ red) and 6 (black), and check the presence of the battery voltage with the key switch set to ON. If there is no voltage, check the regulator ground wiring.

(FIG. G) If the above tests have positive results, jump the contacts 5 (yellow/red) and 7 (blue/black) on the connector, set the key switch to ON and shift the turn indicator switch to the right and left to see when the lights are steadily on (as they are powered directly from the battery). If even after this operation the turn indicators fail to turn on, check that the wiring is not damaged and the switch works properly. If these last two tests have a positive result, replace the regulator because it is certainly not functioning properly.

ELE SYS - 54

Page 55

Fly Electrical system

FAULT 6 Oil reserve check warning light not working

(FIG H) - Disconnect the voltage regulator connector.

- Supply 12V to the terminal marked with number 5; with a digital tester check that the terminal number 4 has a similar output (12V) for about 5 seconds.

- If no voltage is detected for terminal number 4, replace the regulator.

- If there is voltage for terminal number 4, check both the installation and the bulb of the oil warning light.

Specific tooling

020331Y Digital multimeter

Sealed battery

INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT

1) Voltage check

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

- If the voltage exceeds 12.60 V, the battery may 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 equal to 14.40÷14.70V

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

-Duration of the charge: 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 nominal capacity of the battery

-Duration of the charge: 5 h

ELE SYS - 55

Page 56

Electrical system Fly

WARNING

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW

12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

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

Dry-charge battery

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

1) Check the level of the electrolyte

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's 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. After charging the battery, check each element electrolyte level and density. 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 earth wire (black) marked (-) must be connected to the - negative terminal while the other two red wires marked (+) must be connected to the terminal marked with the + positive sign. Regular bench charging must be carried out with the specific battery charger, (single) or (multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).

4) Cleaning the battery

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

WARNING

- Before recharging the battery, remove the plugs of each cell. Keep the battery away from naked flames or sparks when charging. Remove the battery from the vehicle removing the negative clamp first.

CAUTION

ELE SYS - 56

Page 57

Fly Electrical system

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

CAUTION

DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BATTERY: USE DISTILLED WATER ONLY.

CAUTION

TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

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.

1)- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries, with a specific gravity of 1.26, corresponding to 30° Bé, at a minimum temperature of 15°C until the upper level is reached.

2) - Leave to rest for at least 2 hours; then, restore the level with sulphuric acid.

3)- Within the following 24 hours, recharge with the specific battery charger (single) or (multiple) at a density of about 1/10 of the battery nominal capacity and until the acid density is about 1.27, corresponding to 31º Bé, and 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 in the vehicle ensuring the connections between the wiring and the battery terminals are correct.

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

ELE SYS - 57

Page 58

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Page 59

Fly Engine from vehicle

Removal of the engine from the vehicle

Remove the engine from the frame

-Disconnect the battery.

-Remove the muffler assembly.

- Remove the rear wheel.

- Remove the mechanical transmission of the rear brake.

-Disconnect the electric terminals.

- Remove the throttle grip and mixer transmissions.

- Disconnect the hoses (petrol-oil-vacuum-operated cock control).

WARNING

Be very careful when handling fuel.

CAUTION

When installing the battery, first attach the positive cable and then the negative cable.

WARNING

Wear safety goggles when using hitting tools.

ENG VE - 59

Page 60

INDEX OF TOPICS

ENGINE ENG

Page 61

Fly Engine

Automatic transmission

Transmission cover

- Loosen the 15 screws and remove the transmission cover with the aid of a mallet.

N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT

FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.

Kickstart

- Remove the seeger ring located on the exterior of the crankshaft.

- Dismantle the dog gear from its seat, slackening the tension that the toothed sector applies to it by means of the spring; to do this, it is necessary to rotate the toothed sector slightly (see the figure).

CAUTION WHILE REMOVING THE TOOTHED SECTOR, BE VERY

CAREFUL OF THE SPRING TENSION: IT COULD CONSTITUTE A HAZARD FOR THE OPERATOR.

- Upon refitting, apply the recommended grease to the bushing, to the spring and along the toothed sector.

- Use the special tool for the charging of the spring, as shown in the figure.

- Refit the seeger ring after checking that it is in good condition.

Specific tooling

020261Y Starter spring fitting

Recommended products

AGIP GREASE MU3 Grease for odometer transmission gear case

ENG - 61

Page 62

Engine Fly

Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20

- Remove the screws shown in the figure and remove the engine starting lever.

- For the assembly, work in reverse and tighten the screws to the prescribed torque..

Locking torques (N*m)

Starter lever replacement 12 to 13 Nm

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

N.B. IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-

AMETER EXTRACTOR CAN BE USED.

Refitting the driven pulley shaft bearing

-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside.

N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.

CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED SURFACE.

ENG - 62

Page 63

Fly Engine

Removing the driven pulley

- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the whole of the driven pulley assembly.

N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING

PULLEY MOUNTED.

Specific tooling

020565Y Flywheel lock calliper spanner

Inspecting the clutch drum

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

- Measure the inner diameter of the clutch bell.

Characteristic

Clutch bell diameter/standard value

Ø 107+0.2 +0 mm

Clutch bell diameter/max. value allowed after use

Ø 107.5 mm

Eccentricity measured /max.

0.20 mm

Removing the clutch

- Equip the tool with long pins screwed into position «A» from the outside, insert the entire driven pulley in the tool and put the central screw under stress.

CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW

IS TIGHTENED UP TOO FAR.

ENG - 63

Page 64

Engine Fly

- Using a 34 mm socket wrench remove the clutch locking nut.

- Loosen the central screw thereby undoing the driven pulley unit

- Separate the components.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

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 CEN-

TRAL FAYING 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

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

ENG - 64

Page 65

Fly Engine

- Remove the three guide pins and the mobile half pulley.

Removing the driven half-pulley bearing

- Remove the roller bearing with the special extractor inserted from the bottom of the fixed halfpulley.

CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI-

ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.

Specific tooling

001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch housing by means of the special tool.

N.B. PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO

DEFORM THE SLIDING SURFACE OF THE DRIVING BELT

Specific tooling

020376Y Adaptor handle 020363Y 20-mm guide

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work surface of the belt. If there are, replace the halfpulley..

- Make sure the bearings do not show signs of unusual wear.

- Measure the external diameter of the pulley bushing.

Characteristic

ENG - 65

Page 66

Engine Fly

Stationary driven half-pulley/Standard diameter

Ø 33.965 to 33.985 mm

Stationary driven half-pulley / Minimum diameter admitted after use

Ø 33.96 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

Mobile driven half-pulley/ Maximum diameter allowed

Ø 34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile half-pulley.

- Fitting the half-pulley on the bushing.

Recommended products

AGIP GREASE SM 2 Grease for the C-ring of the tone wheel

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

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

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

Recommended products

AGIP GREASE SM 2 Grease for the C-ring of the tone wheel

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

ENG - 66

Page 67

Fly Engine

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible from the outside.

CAUTION PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT

DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED.

Specific tooling

020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley does not show signs of deformation

- Measure the free length of the spring

Characteristic

Standard length

118 mm

Minimum length allowed after use

XXXX

Refitting the clutch

- Preassemble the driven pulley group with spring, sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded bar.

ENG - 67

Page 68

Engine Fly

- Reassemble the nut securing the clutch and tighten to the prescribed torque.

CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK-

ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE

NUT IN CONTACT WITH THE CLUTCH

Locking torques (N*m)

Nut locking clutch unit on pulley 55 ÷ 60 Nm

Refitting the driven pulley

-Refit the driven pulley assembly, the clutch bell and the nut, using the specific tool.

Specific tooling

020565Y Flywheel lock calliper spanner

Locking torques (N*m)

Driven pulley shaft nut 40 to 44 Nm

Drive-belt

- Make sure the driving belt is not damaged and does not have cracks in the toothed grooves.

- Check the width of the belt.

Characteristic

Transmission belt/Minimum width

17.5 mm

ENG - 68

Page 69

Fly Engine

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer, then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.

Specific tooling

020451Y Starting ring gear lock

Mixer gears and belt

- Remove gear and belt.

CAUTION PAY PARTICULAR ATTENTION TO NOT TOUCHING OR

BENDING THE BELT BECAUSE THIS COULD BREAK SUDDENLY DURING OPERATION.

CAUTION ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET

INTO THE INNER BUSHING OF THE MIXER CONTROL GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON THE CRANKCASE PIN.

N.B. REPLACE THE BELT EVERY 20000 KM.

Inspecting the rollers case

1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation.

2) Check the roller running tracks on the contact pulley; there must not be signs of wear and check the condition of the contact surface of the belt on the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of marked facetting on the sliding surface and that the metallic insert does not come out of the plastic shell borders.

ENG - 69

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Engine Fly

4) Check the integrity of the sliding blocks of the contact plate.

- Check that the internal bushing shown in the figure is not abnormally worn and measure inside diameter «A».

- Measure outside diameter «B» of the pulley sliding bushing shown in the figure.

CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING.

Characteristic

Driving pulley / Maximum diameter:

20.12 mm

Driving pulley/ Standard diameter:

20.021 mm

Driving pulley bushing/ Diameter maximum:

XXX mm

Driving pulley bushing/ Standard diameter:

20 -0.020/-0.041mm

Refitting the driving pulley

- Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.

N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO

THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE.

- Refit the components of the assembly (roller container assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive, washer and nut).

- With the specific tool, tighten the lock nut to 20 Nm and then perform a final 90° locking in order to prevent the rotation of the driving pulley.

N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UTMOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN

ENG - 70

Page 71

Fly Engine

ORDER TO AVOID WRONG TIGHTENING AND CONSEQUENTLY DAMAGING THE CRANKSHAFT KNURLING.

Specific tooling

020451Y Starting ring gear lock

Locking torques (N*m)

Crankshaft pulley nut 18 to 20 + 90° Nm

For 25 km/h engine type versions, the limit washer is 5.5 mm thick

End gear

Removing the hub cover

- Drain the rear hub oil

- Remove driven pulley

- Remove the rear brake shoes

- Remove the 5 screws fixing the cover to the crankcase

- Remove the cover with the wheel axle and pull it out

- Remove the intermediate gear with the appropriate shim washers

Removing the wheel axle bearings

- Remove the oil seal and the seeger ring.

- Fix the hub cover properly to avoid damaging the sealing surface with the housing

- Remove the wheel axle bearing using the specific tool

Specific tooling

020363Y 20-mm guide 020376Y Adaptor handle

ENG - 71

Page 72

Engine Fly

020477Y 37 mm adaptor

Removing the driven pulley shaft bearing

- Remove the seeger ring

- Heat the engine crankcase but do not direct the hot air towards the bearing

- Extract the driven pulley shaft together with the bearing with a few mallet blows

ENG - 72

Page 73

Fly Engine

- Remove the bearing off the driven pulley shaft using the specific tool and a press

N.B. USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALL-

ER INTERNAL DIAMETER

Specific tooling

020452Y Tube for removing and refitting the driven pulley shaft

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.

- Check capacity ( A ) of the transmission gear (wear, deformations, etc.)

- Check the pulley shaft seating: Superficial wear ( B ) may indicate irregularities in the crankcase seatings or in the pulley shaft capacities

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.

ENG - 73

Page 74

Engine Fly

Refitting the driven pulley shaft bearing

- Support the inner track of the bearing from the outside of the hub cover with the specific tool positioned under the press and insert the driven pulley axle.

- Refit the oil seal flush with the cover.

Specific tooling

020452Y Tube for removing and refitting the driven pulley shaft

- Slightly heat the hub cover and then fit the bearing with the specific drift.

- Fit the circlip with the concave or radial part facing the bearing.

N.B. FIT THE BALL BEARING WITH THE SHIELD FACING THE

OIL SEAL.

Specific tooling

020151Y Air heater 020376Y Adaptor handle 020439Y 17-mm guide 020358Y 37x40-mm Adaptor

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface

- Heat up the hub cover using the thermal gun.

- Preassemble the bearing on the specific punch using grease and then insert the bearing in its seating

- Refit the seeger ring and the oil seal using the 42 x 47 mm adaptor

N.B. POSITION THE OIL SEAL WITH THE SEALING LIP FACING

THE HUB INTERNAL SIDE

Specific tooling

020150Y Air heater mounting 020151Y Air heater 020376Y Adaptor handle

ENG - 74

Page 75

Fly Engine

020363Y 20-mm guide 020359Y 42x47-mm Adaptor

Refitting the hub bearings

- Remove the wheel axle on the cover and pay attention not to damage the sealing lip of the oil seal

- Apply a thin layer of grease on the two shim washers of the intermediate gear and fit one on the cap so that it does not interfere with the wheel axle gear when placing the transmission shaft

Refitting the ub cover

- Apply product recommended for surfaces on the hub cap and refit cap on the crankcase

- Fit the 5 screws and tighten them to the specified torque.

N.B. CLEAN THE CONTACT SURFACES OF THE HUB COVER

AND THE HALF CRANKCASE OF RESIDUE FROM PREVIOUS GASKETS BEFORE APPLYING A NEW ONE.

Recommended products

Loctite 510 Liquid sealant

ENG - 75

Page 76

Engine Fly

Gasket

Locking torques (N*m)

hub cap screws 24 - 26

Flywheel cover

Cooling hood

- Remove the four fixings shown in the figure.

- Remove the fan cover

- Remove the oil piping retention band from the hood

- Remove the 2 screws shown in the figure

Cooling fan

- Remove the cooling fan by acting on the three fixings indicated in the figure.

ENG - 76

Page 77

Fly Engine

Removing the stator

- Remove the three stator fixings shown in the photo

- Remove the two pick-up fixings shown in the photo

- Remove the stator with the wiring

Refitting the stator

- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.

N.B.

THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEMBLY.

Locking torques (N*m)

Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4

Flywheel and starting

Removing the starter motor

Remove the two clamps shown in the figure

ENG - 77

Page 78

Engine Fly

Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper spanner.

- Remove the nut.

CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE

ONE SUPPLIED COULD DAMAGE THE STATOR COILS

- Extract the flywheel with the extractor.

Specific tooling

020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor

Inspecting the flywheel components

- Check the condition of the flywheel and any distortions that might cause rubbing on the stator and on the Pick-Up.

Refitting the flywheel magneto

- Fit the flywheel being careful to insert the key properly.

- Lock the flywheel nut at the prescribed torque

- Check the Pick-Up air gap.

- The air gap may not be modified in the fitting of the Pick-Up.

- Other values derive from deformations visible on the Pick-Up support.

ENG - 78

Page 79

Fly Engine

N.B. A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO

A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING, KNOCKING ETC.

Locking torques (N*m)

Flywheel nut 40 to 44 N.m

Refitting the starter motor

- Fit a new O-ring on the starter and lubricate it.

- Fit the starter on the crankcase, locking the two screws to the prescribed torque.

N.B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE

CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS.

Locking torques (N*m)

Starter screws 11 ÷ 13

Cylinder assy. and timing system

Removing the intake manifold

Use an anti-tampering TORX spanner to remove the two clamping screws of the intake manifold

Removing the cylinder head

Remove the 4 screws shown in the figure

ENG - 79

Page 80

Engine Fly

Removing the cylinder - piston assy.

Remove the cylinder very carefully

Remove the snap rings and remove the pin

CAUTION AFTER EACH REMOVAL OPERATION REPLACE THE PIN

RETENTION SNAP RINGS

Inspecting the small end

- Measure the internal diameter of the small end using an internal micrometer.

N.B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS

THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER".

Characteristic

Rod small end: standard diameter

17 +0.011-0.001

Rod small end: maximum allowable diameter

17,060 mm

ENG - 80

Page 81

Fly Engine

Inspecting the wrist pin

- Check the wrist pin external diameter using a micrometer

Characteristic

Wrist pin: standard diameter

12 +0.005 +0.001 mm

Inspecting the piston

- Measure the bearings on the piston using a bore meter

- Calculate the piston-pin coupling clearance.

Characteristic

Wrist pin housing: standard diameter

12 +0.007 +0.012

Wrist pin housing: standard clearance

0.002 ÷ 0.011 mm

- Measure the outer diameter of the piston, perpendicular to the pin axis.

- Take the measurement in the position shown in the figure To classify the cylinder-piston fitting, check the appropriate table

Recommended products

AGIP CITY TEC 2T Oil

Recommended oil

ENG - 83

Page 84

Engine Fly

Inspecting the timing system components

CAUTION CHECK THE CORRECT REED UNIT SEAL; NO LIGHT

MUST PASS BETWEEN THE SUPPORT AND LAMELLA.

Crankcase - crankshaft

Splitting the crankcase halves

Remove the eight crankcase union fasteners.

Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side

Specific tooling

020163Y Crankcase splitting plate

ENG - 84

Page 85

Fly Engine

Removing the crankshaft

- Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length.

- Remove the crankshaft from the transmission side half crankcase

Specific tooling

020163Y Crankcase splitting plate

Removing the crankshaft bearings

The bearings can stay on either the half crankcase or the crankshaft indifferently

- Using the special tool, remove any bearings that have been left on the crankshaft

N.B.

The half rings must be inserted on the bearings with a few mallet blows.

Specific tooling

004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring 004499Y002 Bearing extractor screw 004499Y007 Half rings

- Using the specific tool remove any bearings left on the half crankcase

Specific tooling

001467Y007 Driver for OD 54 mm bearing 001467Y006 Pliers to extract 20 mm bearings

ENG - 85

Page 86

Engine Fly

Refitting the crankshaft bearings

Heat the bearings in an oil bath at around 150°C and fit them on the crankshaft, if necessary using a section of tube that acts on the bearing's inner track

Specific tooling

020265Y Bearing fitting base

Inspecting the crankshaft alignment

With the specific tool shown check that the eccentricity of the surfaces of diam. «A»-«B»-« C» are within 0.03 mm. (reading limit on the dial gauge); in addition, check the eccentricity of diam. «D», for which a maximum reading of 0.02 mm is permitted. In the case where eccentricity is not much above prescribed levels, straighten the shaft by acting on the counterweights with a shim or tighten them in a clamp (with an aluminium bushing) as required..

Specific tooling

020335Y Magnetic mounting for dial gauge 020074Y Mounting base for checking crank-

shaft alignment

Refitting the crankshaft

- Position the transmission side half crankcase on two wooden supports

- Using a thermal gun, heat the bearing seat to about 120°

ENG - 86

Page 87

Fly Engine

- Firmly insert the crankshaft until the bearing reaches the end-of-stroke stop

- Let the temperature of the half crankcase settle at the temperature of the crankshaft.

- Again install the special crankcase separation plate NOT installing the crankshaft protection

- During the assembly phase keep the central thrust screw loose.

- Take the four clamping screws to the end of the

stroke and loosen them again with the same angle

(e.g. 90°)

- When the temperature has settled, preload the

thrust screw of the tool manually until the ball bear-

ing clearance is cancelled out.

Specific tooling

020163Y Crankcase splitting plate

Refitting the crankcase halves

- Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the surface using a suitable solvent (e.g. trichloroethylene)

- Heat the flywheel-side half crankcase with a thermal gun.

Recommended products

Loctite 510 Liquid sealant

Gasket

ENG - 87

Page 88

Engine Fly

- Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement

- Insert at least three clamping screws and tighten up rapidly

- Insert the other 5 screws and tighten them to the specified torque.

Locking torques (N*m)

crankcase coupling screws 11 - 13

- Move the crankcase separation plate in a position back from the one indicated in the figure

- Install the special magnetic support with dial gauge at the end of the crankshaft

- Check the axial clearance of the crankcase If this is not within the maximum limit allowed, repeat the crankcase coupling procedure

Specific tooling

020335Y Magnetic mounting for dial gauge

Characteristic

Axial clearance with warm crankcase

0.10 ÷ 0.12 mm

Axial clearance with cold crankcase

0.06 to 0.08 mm

Limit value with cold crankcase

0.02 ÷ 0.03 mm

Lubrication

Crankshaft oil seals

ENG - 88

Page 89

Fly Engine

Refitting

- Install a new flywheel-side oil seal only with the special tool's punch The flywheel-side oil seal is recognised by its smaller diameter

N.B. THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE

WITH THE FITTED WRENCH

Specific tooling

020340Y Flywheel and transmission oil seals fitting punch

- Install a new transmission side oil seal using the special tool with adapter ring. The transmission-side oil seal is recognised by the larger diameter

Specific tooling

020340Y Flywheel and transmission oil seals fitting punch

Oil pump

Removal

- Remove the 2 screws shown in the figure

ENG - 89

Page 90

Engine Fly

Remove the tube passage seal from the crankcase shown in the figure

Refitting

To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure

Fuel supply

- Completely empty the fuel tank.

- Remove the petrol delivery pipe and the lowpressure pipe.

- Loosen the clip and remove the cock.

- Clean the tank and the filter of the cock with a specific solvent.

- Refit the cock making sure that there is an ORing.

- Turn the cock to the direction it had before it was removed and block the clip.

N.B. THE FILTER CAN BE UNSCREWED FROM THE COCK TO

FACILITATE CLEANING.

ENG - 90

Page 91

Fly Engine

- Disconnect the fuel supply and the suction taking pipe from the carburettor.

- Check that there are no fuel leaks between the two tubes.

- Close the fuel outlet pipe.

- By means of the MITYVAC pump apply 0.1 bar of suction to the tap.

- Make sure that the suction is kept stable and that and that there are no fuel leaks.

- Reconnect the suction pipe to the manifold.

- Position the fuel pipe with the outlet at the point of the tap.

- Turn the engine by using the starter for five seconds with the carburettor at minimum.

- Take up the fuel by means of a graded burette.

N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-

RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUTLET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUCTION PULSATION AND THEREBY GUARANTEE A CONSTANT TAP FLOW RATE.

Specific tooling

020329Y Mity-Vac vacuum-operated pump

Characteristic

Minimum flow rate

20 cc

ENG - 91

Page 92

INDEX OF TOPICS

SUSPENSIONS SUSP

Page 93

Fly Suspensions

This section is devoted to operations that can be carried out on the suspensions.

Front

Removing the front wheel

- Remove the wheel axle lock nut.

- Remove the wheel axle and the wheel.

- Upon removal take care not to damage the sensor that detects movement in the odometer.

Front wheel hub overhaul

Ball bearings on wheel hub

- Remove the front wheel

- Keep the wheel level by means of two wooden wedges

- With the appropriate pliers and tool remove the wheel bearing on the side the rpm indicator detects movement, as shown in the photograph

- Remove the internal spacer

- Use appropriate handle, adaptor and guide and hit with a mallet to extract the bearing and the spacer bushing on the brake disc side; insert handle on the side the rpm indicator detects movement, as shown in the photo

SUSP - 93

Page 94

Suspensions Fly

- Check that the bearings do not show flaws or jamming. Otherwise, replace them.

- Check that the internal spacer does not show abnormal wear. Otherwise, replace it.

- With a hot air gun heat the seat of the bearing on the brake calliper side

- With an appropriate tool remove the bearing on the brake disc side

- Insert the spacer bushing on the brake disc side

- With a hot air gun heat the seat of the bearing on the side the rpm indicator detects movement

- Insert the internal spacer with the centring ring facing to the brake disc side, as shown in the photo

- Use an appropriate tool to insert the bearing on the side the rpm indicator detects movement

Specific tooling

001467Y009 Driver for OD 42-mm bearings 001467Y014 Pliers to extract ø 15-mm bearings 020357Y 32x35-mm Adaptor 020376Y Adaptor handle 020412Y 15-mm guide 020456Y Ø 24 mm adaptor

Refitting the front wheel

- Follow the same procedure as per removal but in reverse order, tighten to the specified torque, remember to offset the odometer movement sensor by 90° compared with its own seating on the wheel so as to avoid damages.

Locking torques (N*m)

Front wheel axle nut 45 - 50

SUSP - 94

Page 95

Fly Suspensions

Handlebar

Removal

Handlebars removal

Remove the handlebar cover before carrying out this operation,.

- After removing the transmissions and disconnecting the electrical terminals, remove the terminal fixing the handlebar to the steering.

- Check all components and replace faulty parts.

N.B. IF THE HANDLEBAR IS BEING REMOVED TO REMOVE

THE STEERING, TILT THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS.

Refitting

Carry out the removal operations but in the reverse order, observing the prescribed tightening torque.

Locking torques (N*m)

Handlebar fixing screw 50 ÷ 55

Front fork

Overhaul

Seal replacement and stanchion removal

- Remove the wheel axle.

- Remove the lower screw (1).

- Discharge the oil in the suspension.

- Remove the stem.

- Replace the sealing rings (3-4) with new ones.

- Insert the new sealing rings only after lubricating their seatings.

- Refit the stem and the lower screw (1).

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Page 96

Suspensions Fly

- Remove the upper screw (2).

- Add 30 cc ±1 "Fork PG" oil (SAE 20W oil for forks).

- Refit all components.

Locking torques (N*m)

Upper screw tightening torque 20 to 25 Nm Lower screw tightening torque: 20 to 25 Nm

Steering column

Refitting

Lower and upper bearing races to frame

Lower and upper seating on the chassis

LOWER AND UPPER SEATING ON THE CHASSIS

Titolo Durata/

Valore

Lower and

upper seating

on the chas-

sis

Testo Breve

(< 4000 car.)

Steering bearing

Steering locking ring nut

Steering lock ring nut

Top washer and upper bearing housing

- Lubricate race and balls with Z2 grease.

Indirizzo

Immagine

- Tighten to the specified torque and then rotate the tool through 80° - 90° in an anticlockwise direction.

Removal

Lower and upper races from frame

SUSP - 96

Page 97

Fly Suspensions

To remove the bearing seats from the chassis, use the appropriate tool as shown in the figure.

N.B.

To remove the lower seating of the lower bearing just use a screwdriver as a lever between the seating and the shell.

LOWER AND UPPER SEATING FROM THE CHASSIS

Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine

Lower and upper seating from

Top washer and upper bearing housing

After removing the upper seating, tilt the vehicle to

the chassis

a side and take out the steering tube making sure mudflaps have been removed and the calliper disconnected.

Rear

Removing the rear wheel

- Use a screwdriver as a lever between the drum and the cover.

-Straighten the split pin and remove the cap.

-Remove the wheel acting on the central fixing point.

WARNING

-ALWAYS USE NEW SPLIT PINS FOR REFITTING.

SUSP - 97

Page 98

Suspensions Fly

Refitting the rear wheel

-Refit the parts in the reverse order as for removal, lock the wheel nut to the specified torque.

WARNING

- FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN ORDER TO AVOID BACKSLASH BETWEEN THE CAP AND THE WHEEL AXLE.

Locking torques (N*m)

Rear wheel axle 104 ÷ 126

Shock absorbers

Removal

- To replace the shock absorber remove the rear cover and battery access flap to get and remove the shock absorber/ chassis anchoring nut. Then remove the shock absorber/engine anchorage nut.

- When refitting, tighten the shock absorber/chassis anchoring nut and the shock absorber/engine pin to the prescribed torque.

Locking torques (N*m)

Shock absorber/engine pin torque 33 to 41 N·m Shock absorber/frame nut torque 20 to 25 Nm

Centre-stand

Centre-stand bolt refitting and caulking to mounting bracket

- Caulk the end of the pin «P» between the two punches shown in the figure.

- After caulking it must be possible for the stand to turn freely.

N.B. UPON REFITTING USE NEW O-RING AND PIN, GREASE

THE SPRING ATTACHMENTS AND THE PIN.

Centre-stand assy. removal

SUSP - 98

Page 99

Fly Suspensions

- Work on the screws shown in the figure.

- When refitting, secure to the prescribed torque.

Locking torques (N*m)

Stand screw torque 18.5 to 19 Nm

Centre-stand bolt removal from mounting bracket

- Remove the stand support bracket from the engine.

- Drill a 5 mm hole in the bracket so that the pin «P» can come out.

SUSP - 99

Page 100

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Piaggio Vespa WORKSHOP Fly 50 2T Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual