PIAGGIO Fly 150 4T Workshop Manual

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)

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera 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.

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

Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention. - The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it. - Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid open flames or sparks. - Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting. - After refitting, make sure that all the components have been installed correctly and work properly. - For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections. Fly 125 - 150 4T Characteristics CHAR - 7

ZAPM42100 ÷ 1001 Engine prefix (125) M421M ÷ 1001 Chassis prefix (150) ZAPM42200 ÷ 1001 Engine prefix (150) M422M ÷ 1001 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Dry weight 112 kg Overall height 1150 mm Seat height 785 Width 735 Wheel base 1330 Lenght 1870 Characteristics Fly 125 - 150 4T CHAR - 8

Timing system Single overhead camshaft (SOHC) with 2 valves Valve clearance intake 0.10 outlet 0.15 Bore x stroke (125) 57 x 48.6 mm Bore x stroke 62,6 x 48.6 mm Cubic capacity (125) 124 cm³ Cubic capacity 150,46 cm³ Compression ratio (125) 10.6 : 1 Compression ratio 10.5: 1 Carburettor KEIHIN CVEK26 Engine idle speed approx. 1600 ÷ 1800 rpm Start-up Electric Maximum power to crankshaft (125) 10.5 CV at 8000 rpm Max. power 11.6 hp at 7750 rpm Cooling Forced air circulation. Fly 125 - 150 4T Characteristics CHAR - 9

que server, V belt, automatic clutch, gear reduc- tion unit and transmission housing with forced air circulation cooling. Capacities CAPACITY Specification Desc./Quantity Engine oil 61 in³ (1,000 cm³) Rear hub oil ~ 200 cm³ Fuel tank capacity ~ 7.2 litres (of which 1.5 l is reserve) Electrical system ELECTRICAL COMPONENTS Specification Desc./Quantity Start-up Electric Spark plug (125) Champion RG6YC- NGK CR7EB Spark plug Champion RG6YC Frame and suspensions FRAME AND SUSPENSION Specification Desc./Quantity Chassis Steel tube chassis Front suspension Ø 32 Hydraulic telescopic fork - travel: 76 mm Rear suspension Single hydraulic shock-absorber with spring pre- load adjustable on 4 positions; 64 mm travel. Brakes BRAKE Specification Desc./Quantity Front brake Disc brake (Ø 200 mm) with hydraulic control (lev- er on the far right of the handlebar) and floating calliper. Rear brake Ø 140 mm drum brake Characteristics Fly 125 - 150 4T CHAR - 10

WHEELS AND TYRES 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 muf- fler. 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 con- verter, 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 disa- bles operation while decelerating to avoid unwan- ted noise. To ensure the best functioning of the SAS system, every 12,000 km the scooter should be taken to an Authorised Piaggio Service Centre to have the filter cleaned (Scheduled maintenance operations section). The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air. CAUTION Fly 125 - 150 4T Characteristics CHAR - 11

ICE CENTRE TO CARRY OUT THESE OPERA- TIONS. Carburettor 125cc Version Kehin CARBURETTOR SETTING Specification Desc./Quantity Type CVEK26 Throttle valve diameter Ø 26.5 Diffuser diameter Ø 26.4 Setting stamping 262A Maximum jet 82 Maximum air jet (on the body) 85 Tapered pin stamping NELA Throttle valve spring 130 ÷ 180 gr. Minimum jet 35 Idle air jet (on the body) 150 Idle mixture adjustment screw initial opening 1 ¾ Starter jet 42 Starter air jet (on the body) Ø 1.5 Starter pin travel 10 mm (at 24°) Starter resistance 20 Ohm (at 24°) 150cc Version Kehin CARBURETTOR SETTING Specification Desc./Quantity Type CVEK26 Throttle valve diameter Ø 26.5 Diffuser diameter Ø 26.4 Setting stamping 265A Maximum jet 82 Maximum air jet (on the body) 85 Tapered pin stamping NELA Throttle valve spring 130 ÷ 180 gr. Minimum jet 35 Idle air jet (on the body) 150 Idle mixture adjustment screw initial opening 1 ¾ Starter jet 42 Starter air jet (on the body) Ø 1.5 Starter pin travel 10 mm (at 24°) Characteristics Fly 125 - 150 4T CHAR - 12

Tightening Torques LUBRICATION Name Torque in Nm Hub oil drainage cap 15 ÷ 17 Oil filter 4 ÷ 6 Oil pump cover screws 5 - 6 Oil pump screws 5 - 6 Pump control pulley screw 10 ÷ 14 Chain cover screws 4 ÷ 6 Oil sump screws 10 ÷ 14 Minimum oil pressure sensor 12 ÷ 14 Blow-by recovery duct fixing screws 3 - 4 HEAD AND CYLINDER Name Torque in Nm Ignition spark plug 12 ÷ 14 Head cover screws 11 ÷ 13 Nuts fixing head to cylinder (*) 28 ÷ 30 Head fixing screws (external) 11 ÷ 13 Starter ground screw 7 ÷ 8.5 Flywheel cover screw 1 ÷ 2 Flywheel air manifold screw 3 ÷ 4 Pressure reducer counterweight retainer 7 ÷ 8.5 Camshaft pulley screw 12 ÷ 14 Timing chain tensioner slider screw 10 ÷ 14 Starter ground support screw 11 ÷ 15 Tensioner screws 11 ÷ 13 Timing chain tensioner central screw 5 - 6 Camshaft retention plate screw 5 - 6 Nut fixing muffler to cylinder head 16 ÷ 18 Head intake manifold screw 11 ÷ 13 TRANSMISSION Name Torque in Nm Drive pulley nut 75 ÷ 83 Transmission cover screw 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60 Rear hub cap screw 24 ÷ 27 Clutch unit nut on driven pulley 45 ÷ 50 FLYWHEEL Name Torque in Nm Flywheel fan screws 3 ÷ 4 Stator assembly screws (°) 3 ÷ 4 Flywheel nut 52 ÷ 58 Pick-up screw 3 ÷ 4 (°) Apply LOCTITE 243 threadlock Fly 125 - 150 4T Characteristics CHAR - 13

Name Torque in Nm Internal engine crankcase bulkhead (transmis- sion-side half shaft) screws 4 ÷ 6 Oil filter on crankcase fitting 27 ÷ 33 Rear brake cam tightening screw 11 ÷ 13 Engine-crankcase coupling screws 11 ÷ 13 Pre-filter cap 24 ÷ 30 Starter motor fixing screw 11 ÷ 13 Muffler to crankcase fixing screws 24 ÷ 27 Engine oil drainage cap 24 ÷ 30 STEERING ASSEMBLY Name Torque in Nm Steering upper ring nut 35 ÷ 40 Steering lower ring nut 8 ÷ 10 Handlebar fixing screw 50 ÷ 55 FRAME Name Torque in Nm Engine arm bolt - frame arm 33 ÷ 41 Engine-swinging arm bolt 33 ÷ 41 Frame arm-engine arm bolt 60 ÷ 64 Centre stand pin 32 ÷ 40 Bolts mounting rocker arm silent-block 36 ÷ 44 FRONT SUSPENSION Name Torque in Nm Lower fork fixing screw 15 ÷ 20 Front wheel axle nut 45 - 50 FRONT BRAKE Name Torque in Nm Brake fluid pump - hose fitting 16 ÷20 Nm Brake fluid tube- calliper fitting 19 ÷ 24 Calliper tightening screw 24 ÷ 27 Disc tightening screw 8 ÷ 10 Oil bleed screw 7 ÷ 10 REAR SUSPENSION Name Torque in Nm Rear wheel axle 104 ÷ 126 Lower shock absorber clamp 33 ÷ 41 Shock absorber/frame nut: 20 ÷ 25 shock absorber to crankcase clamping bracket 20 - 25 Overhaul data Assembly clearances Characteristics Fly 125 - 150 4T CHAR - 14

Version 150 COUPLING BETWEEN (AXIS-WERKE) PISTON AND CYLINDER (150) Name Initials Cylinder Piston Play on fitting Coupling A 62.580 ÷ 62.587 62.533 ÷ 62.540 0.040 ÷ 0.054 Coupling B 62.587 ÷ 62.594 62.540 ÷ 62.547 0.040 ÷ 0.054 Coupling C 62.594 ÷ 62.601 62.547 ÷ 62.554 0.040 ÷ 0.054 Coupling D 62.601 ÷ 62.608 62.554 ÷ 62.561 0.040 ÷ 0.054 Coupling 1st over- size A1 62.780 ÷ 62.787 62.733 ÷ 62.740 0.040 ÷ 0.054 coupling 1st over- size B1 62.787 ÷ 62.794 62.740 ÷ 62.747 0.040 ÷ 0.054 Coupling 1st over- size C1 62.794 ÷ 62.801 62.747 ÷ 62.754 0.040 ÷ 0.054 Coupling 1st over- size D1 62.801 ÷ 62.808 62.754 ÷ 62.761 0.040 ÷ 0.054 Coupling 2nd over- size A2 62.980 ÷ 62.987 62.933 ÷ 62.940 0.040 ÷ 0.054 Coupling 2nd over- size B2 62.987 ÷ 62.994 62.940 ÷ 62.947 0.040 ÷ 0.054 Coupling 2nd over- size C2 62.994 ÷ 63.001 62.947 ÷ 62.954 0.040 ÷ 0.054 Coupling 2nd over- size D2 63.001 ÷ 63.008 62.954 ÷ 62.961 0.040 ÷ 0.054 Coupling 3rd over- size A3 63.180 ÷ 63.187 63.133 ÷ 63.140 0.040 ÷ 0.054 Coupling 3rd over- size B3 63.187 ÷ 63.194 63.140 ÷ 63.147 0.040 ÷ 0.054 Coupling 3rd over- size C3 63.194 ÷ 63.201 63.147 ÷ 63.154 0.040 ÷ 0.054 Coupling 3rd over- size D3 63.201 ÷ 63.208 63.154 ÷ 63.161 0.040 ÷ 0.054 COUPLING BETWEEN (RIGHT WAY) PISTON AND CYLINDER (150) Name Initials Cylinder Piston Play on fitting Coupling A 62.580 ÷ 62.587 62.541 ÷ 62.548 0.032 ÷ 0.046 Coupling B 62.587 ÷ 62.594 62.548 ÷ 62.555 0.032 ÷ 0.046 Coupling C 62.594 ÷ 62.601 62.555 ÷ 62.562 0.032 ÷ 0.046 Coupling D 62.601 ÷ 62.608 62.562 ÷ 62.569 0.032 ÷ 0.046 COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER (125) Name Initials Cylinder Piston Play on fitting Coupling A 56.980 ÷ 56.987 56.933 ÷ 56.940 0.040 - 0.054 Coupling B 56.987 ÷ 56.994 56.940 ÷ 56.947 0.040 - 0.054 Coupling C 56.994 ÷ 57.001 56.947 ÷ 56.954 0.040 - 0.054 Coupling D 57.001 ÷ 57.008 56.954 ÷ 56.961 0.040 - 0.054 Coupling 1st in- crease A1 57.180 ÷ 57.187 57.133 ÷ 57.140 0.040 - 0.054 Fly 125 - 150 4T Characteristics CHAR - 15

Coupling 1st in- crease B1 57.187 ÷ 57.194 57.140 ÷ 57.147 0.040 - 0.054 Coupling 1st in- crease C1 57.194 ÷ 57.201 57.147 ÷ 57.154 0.040 - 0.054 Coupling 1st in- crease D1 57.201 ÷ 57.208 57.154 ÷ 57.161 0.040 - 0.054 Coupling 2nd in- crease A2 57.380 ÷ 57.387 57.333 ÷ 57.340 0.040 - 0.054 Coupling 2nd in- crease B2 57.387 ÷ 57.394 57.340 ÷ 57.347 0.040 - 0.054 Coupling 2nd in- crease C2 57.394 ÷ 57.401 57.347 ÷ 57.354 0.040 - 0.054 Coupling 2nd in- crease D2 57.401 ÷ 57.408 57.354 ÷ 57.361 0.040 - 0.054 Coupling 3rd over- size A3 57.580 ÷ 57.587 57.533 ÷ 57.540 0.040 - 0.054 Coupling 3rd over- size B3 57.587 ÷ 57.594 57.540 ÷ 57.547 0.040 - 0.054 Coupling 3rd over- size C3 57.594 ÷ 57.601 57.547 ÷ 57.554 0.040 - 0.054 Coupling 3rd over- size D3 57.601 ÷ 57.608 57.554 ÷ 57.561 0.040 - 0.054 PISTON TO CAST IRON CYLINDER COUPLING (125) Name Initials Cylinder Piston Play on fitting Coupling M 56.997 ÷ 57.004 56.944 ÷ 56.951 0.046 ÷ 0.060 Coupling N 57.004 ÷ 57.011 56.951 ÷ 56.958 0.046 ÷ 0.060 Coupling O 57.011 ÷ 57.018 56.958 ÷ 56.965 0.046 ÷ 0.060 Coupling P 57.018 ÷ 57.025 56.965 ÷ 56.972 0.046 ÷ 0.060 Coupling 1st over- size M1 57.197 ÷ 57.204 57.144 ÷ 57.151 0.046 ÷ 0.060 Coupling 1st over- size N1 57.204 ÷ 57.211 57.151 ÷ 57.158 0.046 ÷ 0.060 Coupling 1st over- size O1 57.211 ÷ 57.218 57.158 ÷ 57.165 0.046 ÷ 0.060 Coupling 1st over- size P1 57.218 ÷ 57.225 57.165 ÷ 57.172 0.046 ÷ 0.060 Coupling 2nd over- size M2 57.397 ÷ 57.404 57.344 ÷ 57.351 0.046 ÷ 0.060 Coupling 2nd over- size N2 57.404 ÷ 57.411 57.351 ÷ 57.358 0.046 ÷ 0.060 Coupling 2nd over- size O2 57.411 ÷ 57.418 57.358 ÷ 57.365 0.046 ÷ 0.060 Coupling 2nd over- size P2 57.418 ÷ 57.425 57.365 ÷ 57.372 0.046 ÷ 0.060 Coupling 3rd over- size M3 57.597 ÷ 57.604 57.544 ÷ 57.551 0.046 ÷ 0.060 Coupling 3rd over- size N3 57.604 ÷ 57.611 57.551 ÷ 57.558 0.046 ÷ 0.060 Coupling 3rd over- size O3 57.611 ÷ 57.618 57.558 ÷ 57.565 0.046 ÷ 0.060 Coupling 3rd over- size P3 57.618 ÷ 57.625 57.565 ÷ 57.572 0.046 ÷ 0.060 Characteristics Fly 125 - 150 4T CHAR - 16

Name Description Dimensions Initials Quantity Compression ring 57 x 1 A 0.15 ÷ 0.30 Oil scraper ring 57x1 A 0.10 ÷ 0.30 Oil scraper ring 57x2.5 A 0.10 ÷ 0.35 Compression ring 1st oversize 57.2 x 1 A 0.15 ÷ 0.30 Oil scraper ring 1st oversize 57.2x1 A 0.10 ÷ 0.30 Oil scraper ring 1st oversize 57.2x2.5 A 0.10 ÷ 0.35 Compression ring 2nd oversize 57.4x1 A 0.15 ÷ 0.30 Oil scraper ring 2nd oversize 57.4x1 A 0.10 ÷ 0.30 Oil scraper ring 2nd oversize 57.4x2.5 A 0.10 ÷ 0.35 Compression ring 3rd oversize 57.6x1 A 0.15 ÷ 0.30 Oil scraper ring 3rd oversize 57.6x1 A 0.10 ÷ 0.30 Oil scraper ring 3rd oversize 57.6x2.5 A 0.10 ÷ 0.35 Maximum clearance after use: 1 mm SEALING RINGS (150) Name Description Dimensions Initials Quantity Compression ring 62.6x1 A 0.15 ÷ 0.30 Oil scraper ring 62.6x1 A 0.20 ÷ 0.40 Oil scraper ring 62.6x2.5 A 0.20 ÷ 0.40 Compression ring 1st oversize 62.8x1 A 0.15 ÷ 0.30 Oil scraper ring 1st oversize 62.8x1 A 0.20 ÷ 0.40 Oil scraper ring 1st oversize 62.8x2.5 A 0.20 ÷ 0.40 Compression ring 2nd oversize 63.0 x 1 A 0.15 ÷ 0.30 Oil scraper ring 2nd oversize 63.0 x 1 A 0.20 ÷ 0.40 Oil scraper ring 2nd oversize 63.0 x 2.5 A 0.20 ÷ 0.40 Compression ring 3rd oversize 63.2 x 1 A 0.15 ÷ 0.30 Oil scraper ring 3rd oversize 63.2 x 1 A 0.20 ÷ 0.40 Oil scraper ring 3rd oversize 63.2 x 2.5 A 0.20 ÷ 0.40 Fly 125 - 150 4T Characteristics CHAR - 17

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, trans- mission side 16.6 +0-0.05 A D = 0.20 - 0.50 Flywheel-side half- shaft 16.6 +0-0.05 B D = 0.20 - 0.50 Connecting rod with PP 18 -0.10 -0.15 C 0.20 ÷ 0.50 Crank pin width 51.400 E AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS Name Description Dimensions Initials Quantity Crankshaft Category 1 28.998 ÷ 29.004 Crankshaft Class 2 29.004 ÷ 29.010 Crankcase Category 1 32.953 ÷ 32.959 Crankcase Category 2 32.959 ÷ 32.965 Crankshaft half- bearing Category B - blue 1.973 ÷ 1.976 Crankshaft half- bearing Type C - yellow 1.976 ÷ 1.979 Crankshaft half- bearing Category E - green 1.979 ÷ 1.982 Crankshaft catego- ry 1 - Crankcase category 1 E - E Crankshaft catego- ry 1 - Crankcase category 2 C - C Crankshaft catego- ry 2 - Crankcase category 1 C - C Crankshaft catego- ry 2 - Crankcase category 2 B - B Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40 Characteristics Fly 125 - 150 4T CHAR - 18

- Provisionally fit the piston into the cylinder, without any base gasket. - Fit a dial gauge on the specific tool - Set the dial gauge to zero at a contrast plane with an average precharge, for example 5 mm. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure. - Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation) - Calculate the difference between the two measurements: use the chart below to identify the thickness of the cylinder base gasket to be used for refitting. By correctly identifying the cylinder base gasket thickness, an adequate compression ratio is maintained. - Remove the specific tool and the cylinder. Characteristic Compression ratio (125) 10.6 : 1 Compression ratio 10.5: 1 SHIMMING SYSTEM (125) Specification Desc./Quantity Value measured 0 ÷ 0.1 Thickness 0.8 ± 0.05 Value measured 0.1 ÷ 0.3 Thickness 0.6 ± 0.05 Value measured 0.3 - 0.4 Thickness 0.4 ± 0.05 Fly 125 - 150 4T Characteristics CHAR - 19

Specification Desc./Quantity Value measured 1 ÷ 1.1 Thickness 0.8 ± 0.05 Value measured 1.1 ÷ 1.3 Thickness 0.6 ± 0.05 Value measured 1.3 ÷ 1.4 Thickness 0.4 ± 0.05 Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 rear oil hub SAE 80W/90 Oil that exceeds the requirements of API GL3 specifi- cations AGIP CITY HI TEC 4T Oil to lubricate flexible transmis- sions (brakes, throttle control and odometer) Oil for 4-stroke engines AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness AGIP GP 330 Grease (brake control levers, throttle grip) Calcium complex soap-based grease with NLGI 2; ISO-L- XBCIB2 AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil AGIP GREASE MU3 Grease for odometer transmis- sion gear case Soap-based lithium grease with NLGI 3; ISO-L-XBCHA3, DIN K3K-20 Characteristics Fly 125 - 150 4T CHAR - 20

001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15-mm bear- ings 002465Y Pliers for circlips 005095Y Engine support 008564Y Flywheel extractor Tooling Fly 125 - 150 4T TOOL - 22

from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank- shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge Fly 125 - 150 4T Tooling TOOL - 23

020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cyl- inder 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol Tooling Fly 125 - 150 4T TOOL - 24

020333Y Single battery charger 020334Y Multiple battery charger Fly 125 - 150 4T Tooling TOOL - 25

020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25-mm guide Tooling Fly 125 - 150 4T TOOL - 26

020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y011 adapter for valve removal tool 020409Y Multimeter adaptor - Peak volt- age detection Fly 125 - 150 4T Tooling TOOL - 27

020414Y 28-mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel-side oil seal 020426Y Piston fitting fork Tooling Fly 125 - 150 4T TOOL - 28

020428Y Piston position check support 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driv- en pulley clutch Fly 125 - 150 4T Tooling TOOL - 29

020622Y Transmission-side oil guard punch 494929Y Exhaust fumes analyser 020625Y Kit for sampling gas from the ex- haust manifold Tooling Fly 125 - 150 4T TOOL - 30

Action Brake fluid - change EVERY 3000 KM Action Engine oil - level check/ top-up AFTER 1000 KM 80' Action Engine oil - replacement Hub oil - change Oil filter (net filter) - clean Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - test ride (*) See instructions in the «Idle speed adjustment» section AT 6000 KM OR 12 MONTH, 18000 KM, 54000 KM 150' Action Engine oil - replacement Hub oil level - check Spark plug electrode gap - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Variable speed rollers/pads - check Driving belt - checking Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - test ride AT 12000 KM OR 24 MONTHS AND AT 60000 KM 160' Action Engine oil - replacement Maintenance Fly 125 - 150 4T MAIN - 32

Air filter - clean Engine oil - change Oil filter (net filter) - clean Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Centre stand - lubrication Secondary air filter - cleaning Tyre pressure and wear - check Vehicle and brake test - test ride (*) See section «Adjusting the idle speed» AFTER 24000 KM AND AFTER 48000 KM 205' Action Engine oil - replacement Hub oil - change Air filter - clean Engine oil - change Oil filter (net filter) - clean Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Cylinder ventilation system - cleaning Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Secondary air filter - cleaning Centre stand - lubrication Vehicle and brake test - test ride Fly 125 - 150 4T Maintenance MAIN - 33

AT 30000 KM, AT 42000 KM AND AT 66000 KM 125' Action Engine oil - replacement Hub oil level - check Spark plug electrode gap - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Slide pads and variator rollers - check Driving belt - checking Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - test ride AFTER 36000 KM 300' Action Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Flexible brake tubes - replacement Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Secondary air filter - cleaning Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - test ride (*) See instructions in «Idle speed adjustment» section AFTER 72,000 KM 300' Maintenance Fly 125 - 150 4T MAIN - 34

Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment Cylinder ventilation system - check Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Flexible brake tubes - replacement Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Secondary air filter - cleaning Centre stand - lubrication Tyre pressure and wear - check Vehicle and brake test - test ride (*) See instructions in «Idle speed adjustment» section Checking the spark advance - To check ignition advance, use the stroboscopic light with induction pincers connected to the spark plug power wire. - Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug). - Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines). - Start the engine and check that the light works properly and the rpm indicator can read also the high rpm (e.g. 8000 rpm). - If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive load on the spark plug power line (10 ÷ 15 KΩ in series to HV wire). Fly 125 - 150 4T Maintenance MAIN - 35

ibrator, make the reference on the flywheel cover coincide with the fan reference as shown in the photograph. Read the advance degrees indicated by the stroboscopic light and compare them with those specified. Characteristic Ignition advance 150 check 10° ± 1° at 2000 rpm - 26° ± 1° at 6000 rpm Ignition advance 125 check 15° ± 1° at 2000 rpm - 28° ± 1° at 6000 rpm Spark advance variation ADVANCE VARIATION Specification Desc./Quantity Operation threshold First threshold : 9000±50 Second threshold : 9300±50 Reactivation threshold First threshold : 8900±50 Second threshold : 9200±50 Spark elimination First threshold : 1 spark on 7 Second threshold : 2 sparks on 3 Maintenance Fly 125 - 150 4T MAIN - 36

- Rest the vehicle on its centre stand with the han- dlebars 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 han- dlebars 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 maxi- mum 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 WA- TER. CAUTION BRAKE CIRCUIT FLUID IS VERY CORROSIVE; MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK. CAUTION Maintenance Fly 125 - 150 4T MAIN - 38

ER WORDS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEF- FICIENT. NEVER USE BRAKE LIQUID IN OPEN OR PAR- TIALLY 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 FLU- ID 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 bor- derline 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 high- er 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 REGU- LATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED. Fly 125 - 150 4T Maintenance MAIN - 39

haust pipe - Using the supplied washer, install the exhaust gases collection kit fitting onto the pipe, as shown in the figure. - Correctly orientate the components as shown in the picture - Shut the gas outlet on the tool - Start the engine and let it warm up - Shut the engine down - Disconnect the SAS check valve vacuum hose shown in the figure. - Seal the connection using a conical a cap. Maintenance Fly 125 - 150 4T MAIN - 40

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 ADJUST- MENT IS OBTAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS. N.B. OTHERWISE, CHECK THE FUEL LEVEL AD- JUSTMENT IN THE TANK AND THE FUEL CIR- CUIT. N.B. IN CASE OF UNSTABLE CO, CHECK THAT THE CARBURETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYSTEM AND THE DE- PRESSION SEALS WORK ADEQUATELY N.B. IN CASE OF 1000 PPM UNBURNED HYDRO- CARBONS (HC) >, CHECK THE IGNITION SYS- TEM, THE TIMING SYSTEM, THE VALVE CLEARANCE AND THE EXHAUST VALVE TIGHTNESS. Specific tooling 020329Y MityVac vacuum-operated pump 020332Y Digital rev counter 494929Y Exhaust fumes analyser 020625Y Kit for sampling gas from the exhaust manifold Characteristic CO Check 3.8±0.7 to 1650±50 RPM Fly 125 - 150 4T Maintenance MAIN - 41

- Remove the shock absorber lower retainer from the engine. - Remove the retainer clamp indicated in the pho- tograph, the automatic starter cable harness and the carburettor to frame heater placed under the helmet compartment cover. - Lift the vehicle with a jack as shown in the figure to be able to reach the flywheel cover screws - Remove the screw fixing the SAS valve to the flywheel cover, indicated in the photograph. Maintenance Fly 125 - 150 4T MAIN - 42

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 defor- mations - Clean the SAS filter carefully. Replace the filter if it is damaged or deformed. To refit, carry out the removal operations but in re- verse order. CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTE- NANCE CHART. CAUTION NEVER RUN THE ENGINE WITHOUT THE SEC- ONDARY AIR FILTER Fly 125 - 150 4T Maintenance MAIN - 43

Dismantle the sponge, wash with water and sham- poo, then soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with com- pressed air Dirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol and wash the tank, if necessary. Replace the cock as a last resource. Failing automatic starter on the carburettor Check the electrical wiring and mechanical move- ment, replace if necessary. Excessive driving belt wear Check it and replace, if necessary Lack of compression: parts, cylinder and valves worn Replace the worn parts Oil level exceeds maximum Check for causes and fill to reach the correct level Excess of encrustations in the combustion cham- ber Descale the cylinder, the piston, the head and the valves Incorrect timing or worn timing system elements Time the system again or replace the worn parts Muffler obstructed Replace Inefficient automatic transmission Check the rollers and the pulley movement, re- place the damaged parts and lubricate the driven pulley moveable guide with Montblanc Molybde- num Grease Wrong valve adjustment Adjust the valve clearance properly Overheated valves Remove the head and the valves, grind or replace the valves Valve seat distorted Replace the head assembly Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings Rear wheel spins at idle REAR WHEEL ROTATES WITH ENGINE AT IDLE Possible Cause Operation Idling rpms too high Adjust the engine idle speed and the CO%, if nec- essary. Clutch fault Check the springs / clutch masses Fly 125 - 150 4T Troubleshooting TROUBL - 45

Possible Cause Operation Battery flat Check the state of the battery. If it shows signs of sulphation replace it and bring the new battery into service charging it for eight hours at a current of 1/10 of the capacity of the battery itself Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components - Engine flooded. Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it and before refitting, make the motor turn so as to expel the fuel excess taking care to connect the cap to the spark plug, and this in turn to the ground. If the fuel tank is empty, refuel and start up. Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clear- ance Rpm too low at start-up or engine and start-up system damaged Check the starter motor and the kick-starter unit Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill Vacuum operated cock failure Check that fuel is adequately supplied through the pipe by applying a vacuum to the suction pipe Failing automatic starter on the carburettor Check the electrical wiring and mechanical move- ment, replace if necessary. Start-up enabling buttons failure Check continuity using an Ohm meter, with the switch pressed; replace if necessary Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with com- pressed air Air filter obstructed or dirty. Dismantle the sponge, wash with water and sham- poo, then soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. Excessive oil consumption/Exhaust smoke EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST Possible Cause Operation Worn valve guides Check and replace the head unit if required Worn valve oil guard Replace the valve oil guard Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the cou- pling seal Worn or broken piston rings or piston rings that have not been fitted properly Replace the piston cylinder unit or just the piston rings Troubleshooting Fly 125 - 150 4T TROUBL - 46

POOR LUBRICATION PRESSURE Possible Cause Operation By-Pass remains open Check the By-Pass and replace if required. Care- fully clean the By-Pass area. Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level using the recommended oil type (Selenia HI Scooter 4 Tech) Engine tends to cut-off at full throttle THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE Possible Cause Operation Maximum jet clogged Remove the carburettor, wash with solvent and dry with compressed air Water or condensate in the carburettor tank Remove the tank, wash with solvent and dry with compressed air Level in tank too low Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted. Engine tends to cut-off at idle THE ENGINE TENDS TO STOP AT IDLE SPEED Possible Cause Operation Incorrect idle adjustment Adjust using the rpm indicator Incorrect timing Time the system and check the timing system components The starter remains on Check: electric wiring, circuit not interrupted, me- chanical movement and power supply; replace if necessary Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components Pressure too low at the end of compression Check the thermal group seals and replace worn components Minimum nozzle dirty Wash the nozzle with solvent and dry with com- pressed air High fuel consumption EXCESSIVE FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty. Clean according to the procedure Starter inefficient Check: electric wiring, circuit continuity, mechani- cal sliding and power supply Fly 125 - 150 4T Troubleshooting TROUBL - 47

adequately fixed in their fittings Incorrect float level Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted. Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operation Slippage or irregular functioning Check that there is no grease on the masses. Check that the faying surface between the clutch masses and the clutch bell is mainly in the middle and with equivalent specifications on the three masses. Check that the clutch bell is not scored or worn abnormally Never run the engine without the clutch bell Insufficient braking INEFFICIENT OR NOISY BRAKING Possible Cause Operation Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk or drum wear conditions. Front brake disk loose or deformed Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be no flexible movement of the brake lever). Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace Excessive backlash in the rear brake control cable Adjust the backlash with the appropriate adjuster located on the back part of the crankcase. Brakes overheating BRAKES OVERHEATING Possible Cause Operation Rubber gaskets swollen or stuck Replace gaskets. Compensation holes on the pump clogged Clean carefully and blast with compressed air Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Troubleshooting Fly 125 - 150 4T TROUBL - 48

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 ter- minal while the red wire is connected to the termi- nal marked+. Follow the instructions in the ELEC- TRICAL SYSTEM chapter for the recharging of the batteries. Turn signal lights malfunction TURN INDICATOR NOT WORKING Possible Cause Operation Electronic ignition device failure With the key switch set to "ON" jump the contacts 1 (Blue-Black) and 5 (Orange) on the control unit connector. If by operating the turn indicator control the lights are not steadily on, replace the control unit; other- wise, check the cable harness and the switch. Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steer- ing even after making the above adjustments, check the seats in which the ball bearings rotate: if they are recessed or if the balls are squashed, replace them. Fly 125 - 150 4T Troubleshooting TROUBL - 49

EXCESSIVE STEERING CLEARANCE Possible Cause Operation Excessive steering backlash Check the tightening of the top ring nut. If irregu- larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed. Noisy suspension NOISY SUSPENSION Possible Cause Operation Noisy suspension If the front suspension is noisy, check: that the front shock absorber works properly and the ball bearings are good condition. Finally, check the locking torque of the wheel axle nut, the brake cal- liper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly. Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the rear shock absorber or the front fork cartridge. Troubleshooting Fly 125 - 150 4T TROUBL - 50

2. Immobiliser antenna 3. Electronic ignition device with choke and turn signal controls 4. Horn button 5. Turn signal switch 6. Headlight switch 7. Stop switch on rear brake 8. Double-filament bulb 12V - 55/60W 9. Front sidelight bulb 10. High-beam warning light 11. Engine oil pressure warning light 12. Turn signal warning light (L.H.) Electrical system Fly 125 - 150 4T ELE SYS - 52

14. Turn signal warning light (R.H.) 15. Dashboard light bulbs 16. Headlamp warning light 17. Odo/speedometer with warning lights and gauges - Red socket light bulbs 2W; black socket light bulbs 1.2W 18. Headlight 19. 2 fuse holders with 4 fuses (7.5 A) 20. Stop switch on front brake 21. Start button 22. Immobiliser diagnostic outlet 23. Key-switch 24. Front R.H. turn signal light 25. Wire harness 26. Fuel level sender 27. Fuse holder assembly 28. Rear R.H. turn signal light 29. License plate light bulb 30. License plate lamp 31. Battery 32. Starter relay 33. Starter motor 34. Engine oil pressure sensor 35. Pick-up 36. Automatic choke device 37. Carburettor heater 38. H.T. coil 39. Taillight assembly 40. Stop and taillight bulb 41. Voltage regulator 42. Rear L.H. turn signal light 43. 4 amber light bulbs for turn signal lamps 44. Relay 45. Horn Wiring - Colour coding: B = White Bl = Blue G = Yellow Fly 125 - 150 4T Electrical system ELE SYS - 53

N = Black BV = White-Green GN = Yellow-Black Gr = Grey Rs = Pink R = Red Vi = Purple V = Green VN = Green-Black BN = White-Black BBl = White-Blue GV = Yellow-Green Ar = Orange Az = Light Blue GrBl = Gray-Blue GrN = Grey-Black RBl = Red-Blue GR = Yellow-Red BlN = Blue-Black Electrical system installation Electrical system Fly 125 - 150 4T ELE SYS - 54

Specification Desc./Quantity 1 Strap Insert the strap through the hole in the chas- sis 2 Zip tie 3 Fixing Fold the chassis strap over the cables Fly 125 - 150 4T Electrical system ELE SYS - 55

2 Fuse holder box 3 Front L.H. turn signal light 4 Light remote control switch 5 Ignition key-switch 6 Control device ignition 7 Immobiliser diagnostic outlet Electrical system Fly 125 - 150 4T ELE SYS - 56

Specification Desc./Quantity 1 Zip tie Fly 125 - 150 4T Electrical system ELE SYS - 57

2 Breather tube 3 Heater conductors and automatic choke pro- tective sheath 4 Voltage regulator 5 HV coil 6 Earth node 7 Starter remote control 8 License plate light connector Electrical system Fly 125 - 150 4T ELE SYS - 58

Specification Desc./Quantity 1 H.T. Cable 2 Zip tie 3 To the automatic choke device 4 To the heater 5 Rear R.H. turn signal light 6 Taillight 7 Rear L.H. turn signal light Fly 125 - 150 4T Electrical system ELE SYS - 59

Specification Desc./Quantity 1 Zip tie 2 Starter motor earth 3 Starter motor positive outlet 4 Flywheel connection Conceptual diagrams Electrical system Fly 125 - 150 4T ELE SYS - 60

2 Magneto flywheel 3 Pick - up 4 HV coil 5 Spark plug 6 Voltage regulator Fly 125 - 150 4T Electrical system ELE SYS - 61

LIGHTS AND AUTOMATIC STARTER Specification Desc./Quantity 1 electronic control unit 2 Carburettor heater 3 Automatic starter 4 Key switch 5 Main fusible 15A 6 Battery 12V-9Ah 7 Headlamp relay 8 Light switch 9 High-beam fuse 7,5A 10 Low-beam and dashboard lights fuse 7,5A 11 Low-beam light bulb 12V - 55W 12 High-beam light bulb 12V-55W 13 High-beam lamp warning light 12V - 1.2W 14 Front side-light bulb 12V - 5W 15 Four dashboards illuminating bulbs 12V - 1,2W 16 Taillight bulb 12V - 5W 17 License plate bulb 12V - 5W 18 Low-beam fuse 7,5A Electrical system Fly 125 - 150 4T ELE SYS - 62

BATTERY CHARGER AND STARTING Specification Desc./Quantity 1 Magneto flywheel 2 Voltage regulator 3 Pick - up 4 Main fusible 15A 5 Battery 12V-9Ah 6 Starter relay 7 Starter motor 8 Start up button 9 Front and rear brake light button 10 Brake light filament 12V-21W 11 Fuse 7.5 A 12 Key switch 13 electronic control unit Fly 125 - 150 4T Electrical system ELE SYS - 63

CONSENSUSES AND LEVEL INDICATORS Specification Desc./Quantity 1 electronic control unit 2 Battery 12V-9Ah 3 Main fusible 15A 4 Key switch 5 Engine oil pressure sensor 6 Low oil pressure warning light 12V - 1,2W 7 Reserve fuel light 12V-1,2W 8 Fuel gauge 9 Fuel level sender 10 Fuse 7.5 A 11 Immobilizer aerial 12 Low engine oil pressure sensor 13 Immobiliser LED 14 Front and rear brake light button 15 Taillight bulb 12V - 5W 16 Starter motor 17 Starter relay 18 Start up button Electrical system Fly 125 - 150 4T ELE SYS - 64

TURN INDICATORS AND HORN Specification Desc./Quantity 1 electronic control unit 2 Indicators switch 3 4 Turn indicator bulbs 12V-10W 4 Turn signal warning light bulbs 12V - 2W 5 Main fusible 15A 6 Battery 12V-9Ah 7 Horn 8 Fuse 7.5 A 9 Key switch 10 Horn button Fly 125 - 150 4T Electrical system ELE SYS - 65

4 PIN CONNECTOR Specification Desc./Quantity 1 Ground lead (-) 2 High-beam warning light 3 Left turn indicator 4 Engine oil warning light 5 PIN CONNECTOR Specification Desc./Quantity 1 Instrument panel lighting and headlamp warning light 2 Right turn indicator 3 Low-fuel warning light 4 + permanent power supply 5 Fuel gauge Checks and inspections Electrical system Fly 125 - 150 4T ELE SYS - 66

rent 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. Subse- quently, a flash confirms the switching to «ON». The duration of the flash depends on the electronic control unit program (see figure). Whenever the LED is off and remains so, even when switching it to «ON», it is necessary to check if: - the battery is charged - 15A main fuse is working correctly. Connect the immobilizer tester to the diagnosis socket (see ET4 125 manual) located behind the front left fuse box flap. If the serial LED remains off, check the electronic control unit supply as follows: Fly 125 - 150 4T Electrical system ELE SYS - 67

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 evi- dent 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 pro- grammed at one time. Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start. Electrical system Fly 125 - 150 4T ELE SYS - 68

control unit is inseparably matched with the MAS- TER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stor- ed 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 di- agnosis codes are transmitted with 0.5-sec flash- es. 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. Fly 125 - 150 4T Electrical system ELE SYS - 69

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, trans- ponder, 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 im- mediately 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. Electrical system Fly 125 - 150 4T ELE SYS - 70

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 continu- ity 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 un- acceptable 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 in- spection directly from the positive and negative terminals of the H.T. coil primary circuit. If the values are within the prescribed limit, pro- ceed by repairing the wiring or reattaching all wir- ings, 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 Fly 125 - 150 4T Electrical system ELE SYS - 71

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 posi- tive 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 Pick- Up. 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 dur- ing 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 Electrical system Fly 125 - 150 4T ELE SYS - 72

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 regu- lator 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 rep- etitions of incorrect values replace the stator or repair the wiring. Fly 125 - 150 4T Electrical system ELE SYS - 73

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 volt- age regulator positive terminal, measure the bat- tery 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 gen- erated 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/sta- tor alternatively. Choke Inspection Refer to the engine section to check the resistance and operating conditions of the component. As re- gards voltage supply, keep the connector connec- ted 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 pos- itive terminal to the automatic starter orange cable; Electrical system Fly 125 - 150 4T ELE SYS - 74

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 fol- lows: - 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, other- wise 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 on- to «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. Fly 125 - 150 4T Electrical system ELE SYS - 75

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. Electrical system Fly 125 - 150 4T ELE SYS - 76

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 tem- perature 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 ca- pacity until fully charged; check that the acid den- sity 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 per- formed, 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 RE- PLACE 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 Fly 125 - 150 4T Electrical system ELE SYS - 77

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 con- nected 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 Electrical system Fly 125 - 150 4T ELE SYS - 78

- 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 at- tention 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 car- burettor, indicated in the photograph Engine from vehicle Fly 125 - 150 4T ENG VE - 80

- 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 indi- cated in the figure - Remove the clamp retaining the starter wiring and the heater indicated in the figure Fly 125 - 150 4T Engine from vehicle ENG VE - 81

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 Engine from vehicle Fly 125 - 150 4T ENG VE - 82

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 driv- en 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 fas- tened 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. Engine Fly 125 - 150 4T ENG - 84

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 Fly 125 - 150 4T Engine ENG - 85

- 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 Engine Fly 125 - 150 4T ENG - 86

- 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». Fly 125 - 150 4T Engine ENG - 87

get into the masses clutch support holes. After- wards 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 EX- HIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE AN- OTHER. 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 Engine Fly 125 - 150 4T ENG - 88

- Remove the collar with the aid of 2 screwdrivers. - Remove the 3 guide pins and the movable half- pulley. 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 ex- tractor. N.B. REST THE HALF-PULLEY ON A WOOD SUR- FACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON RE- MOVING IT. Specific tooling 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020439Y 17 mm guide Fly 125 - 150 4T Engine ENG - 89

- Measure the external diameter of the pulley bush- ing. 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 O- rings. - Measure the inside diameter of the mobile half- pulley 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 half- pulley. N.B. REST THE HALF-PULLEY ON A WOOD SUR- FACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON RE- MOVING IT. Specific tooling 020424Y Driven pulley roller casing fitting punch Engine Fly 125 - 150 4T ENG - 90

pletely 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 mov- able half-pulley. - Assemble the half-pulley on the ringlet with the appropriate protection sheath. - Make sure the pins and collar are not worn, re- assemble 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 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Fly 125 - 150 4T Engine ENG - 91

- 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 EX- HIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE AN- OTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RE- TURN SPRING LOAD. Characteristic Minimum thickness permitted: 1 mm - Support the driven pulley spring compressor ap- propriate 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. Engine Fly 125 - 150 4T ENG - 92

ing 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 accord- ing 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 THREAD- ING. N.B. FOR DESIGN REASONS, THE NUT IS SLIGHT- LY 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 Fly 125 - 150 4T Engine ENG - 93

- 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 Engine Fly 125 - 150 4T ENG - 94

- 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-pul- ley 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 Fly 125 - 150 4T Engine ENG - 95

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 EV- ERY 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 Engine Fly 125 - 150 4T ENG - 96

- 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 pul- ley 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 Fly 125 - 150 4T Engine ENG - 97

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 de- tected, 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 ad- equately supporting the hub cover, as shown in the figure. Specific tooling 020376Y Adaptor handle 020364Y 25-mm guide Engine Fly 125 - 150 4T ENG - 98

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 com- ponents. Fly 125 - 150 4T Engine ENG - 99

- 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 Engine Fly 125 - 150 4T ENG - 100