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WORKSHOP MANUAL
633225
Fly 125 - 150 4T
WORKSHOP
MANUAL
Fly 125 - 150 4T
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions shown in this publication are available in all countries. The availability of single versions
should be checked at the official Piaggio sales network.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
WORKSHOP MANUAL
Fly 125 - 150 4T
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a
basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are
unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along
with the specific tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS
CHAR
TOOLING
TOOL
MAINTENANCE
MAIN
TROUBLESHOOTING
TROUBL
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
ENGINE
ENG
SUSPENSIONS
SUSP
BRAKING SYSTEM
CHASSIS
PRE-DELIVERY
TIME
BRAK SYS
CHAS
PRE DE
TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Fly 125 - 150 4T
Characteristics
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid open flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the
work surfaces except the tapered couplings before refitting.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Fly 125 - 150 4T
Characteristics
Vehicle identification
VEHICLE IDENTIFICATION
Specification
Chassis prefix (125)
Engine prefix (125)
Chassis prefix (150)
Engine prefix (150)
Desc./Quantity
ZAPM42100 ÷ 1001
M421M ÷ 1001
ZAPM42200 ÷ 1001
M422M ÷ 1001
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification
Dry weight
Overall height
Seat height
Width
Wheel base
Lenght
CHAR - 8
Desc./Quantity
112 kg
1150 mm
785
735
1330
1870
Fly 125 - 150 4T
Characteristics
Engine
ENGINE
Specification
Engine
Timing system
Valve clearance
Bore x stroke (125)
Bore x stroke
Cubic capacity (125)
Cubic capacity
Compression ratio (125)
Compression ratio
Carburettor
Engine idle speed
Start-up
Maximum power to crankshaft (125)
Max. power
Cooling
Desc./Quantity
Single-cylinder, 4-stroke Piaggio LEADER
Single overhead camshaft (SOHC) with 2 valves
intake 0.10
outlet 0.15
57 x 48.6 mm
62,6 x 48.6 mm
124 cm³
150,46 cm³
10.6 : 1
10.5: 1
KEIHIN CVEK26
approx. 1600 ÷ 1800 rpm
Electric
10.5 CV at 8000 rpm
11.6 hp at 7750 rpm
Forced air circulation.
CHAR - 9
Fly 125 - 150 4T
Characteristics
Transmission
TRANSMISSION
Specification
Transmission
Desc./Quantity
With automatic expandable pulley variator with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air
circulation cooling.
Capacities
CAPACITY
Specification
Engine oil
Rear hub oil
Fuel tank capacity
Desc./Quantity
61 in³ (1,000 cm³)
~ 200 cm³
~ 7.2 litres (of which 1.5 l is reserve)
Electrical system
ELECTRICAL COMPONENTS
Specification
Start-up
Spark plug (125)
Spark plug
Desc./Quantity
Electric
Champion RG6YC- NGK CR7EB
Champion RG6YC
Frame and suspensions
FRAME AND SUSPENSION
Specification
Chassis
Front suspension
Rear suspension
Desc./Quantity
Steel tube chassis
Ø 32 Hydraulic telescopic fork - travel: 76 mm
Single hydraulic shock-absorber with spring preload adjustable on 4 positions; 64 mm travel.
Brakes
BRAKE
Specification
Front brake
Rear brake
CHAR - 10
Desc./Quantity
Disc brake (Ø 200 mm) with hydraulic control (lever on the far right of the handlebar) and floating
calliper.
Ø 140 mm drum brake
Fly 125 - 150 4T
Characteristics
Wheels and tyres
WHEELS AND TYRES
Specification
Front wheel rim
Front tyre
Rear wheel rim
Rear tyre
Front tyre pressure
Rear tyre pressure
Rear wheel pressure (rider and passenger):
Desc./Quantity
Die-cast aluminium alloy; 3.50 x 12"
Tubeless 120/70-12"
Die-cast aluminium alloy: 3.00"x12"
Tubeless 120/70 - 12"
1.8 bar
2 bar
2.3 bar
Secondary air
In order to reduce polluting emissions, the vehicle
is furnished with a catalytic converter in the muffler.
To favour the catalytic process, an extra amount
of oxygen is added via a secondary air system
(SAS).
This system allows more oxygen to be added to
the unburned gases before they reach the converter, thus improving the action of the catalytic
converter.
The air enters the exhaust duct from the head, and
is purified by a black filter.
The system is fitted with a control valve that disables operation while decelerating to avoid unwanted noise.
To ensure the best functioning of the SAS system,
every 12,000 km the scooter should be taken to an
Authorised Piaggio Service Centre to have the
filter cleaned (Scheduled maintenance operations
section).
The filter sponge should be cleaned with water and
mild soap, then it should be dried with a cloth and
slight blows of compressed air.
CAUTION
CHAR - 11
Fly 125 - 150 4T
Characteristics
CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE TO CARRY OUT THESE OPERATIONS.
Carburettor
125cc Version
Kehin
CARBURETTOR SETTING
Specification
Type
Throttle valve diameter
Diffuser diameter
Setting stamping
Maximum jet
Maximum air jet (on the body)
Tapered pin stamping
Throttle valve spring
Minimum jet
Idle air jet (on the body)
Idle mixture adjustment screw initial opening
Starter jet
Starter air jet (on the body)
Starter pin travel
Starter resistance
Desc./Quantity
CVEK26
Ø 26.5
Ø 26.4
262A
82
85
NELA
130 ÷ 180 gr.
35
150
1¾
42
Ø 1.5
10 mm (at 24°)
20 Ohm (at 24°)
150cc Version
Kehin
CARBURETTOR SETTING
Specification
Type
Throttle valve diameter
Diffuser diameter
Setting stamping
Maximum jet
Maximum air jet (on the body)
Tapered pin stamping
Throttle valve spring
Minimum jet
Idle air jet (on the body)
Idle mixture adjustment screw initial opening
Starter jet
Starter air jet (on the body)
Starter pin travel
CHAR - 12
Desc./Quantity
CVEK26
Ø 26.5
Ø 26.4
265A
82
85
NELA
130 ÷ 180 gr.
35
150
1¾
42
Ø 1.5
10 mm (at 24°)
Fly 125 - 150 4T
Characteristics
Specification
Starter resistance
Desc./Quantity
20 Ohm (at 24°)
Tightening Torques
LUBRICATION
Name
Hub oil drainage cap
Oil filter
Oil pump cover screws
Oil pump screws
Pump control pulley screw
Chain cover screws
Oil sump screws
Minimum oil pressure sensor
Blow-by recovery duct fixing screws
Torque in Nm
15 ÷ 17
4÷6
5-6
5-6
10 ÷ 14
4÷6
10 ÷ 14
12 ÷ 14
3-4
HEAD AND CYLINDER
Name
Ignition spark plug
Head cover screws
Nuts fixing head to cylinder (*)
Head fixing screws (external)
Starter ground screw
Flywheel cover screw
Flywheel air manifold screw
Pressure reducer counterweight retainer
Camshaft pulley screw
Timing chain tensioner slider screw
Starter ground support screw
Tensioner screws
Timing chain tensioner central screw
Camshaft retention plate screw
Nut fixing muffler to cylinder head
Head intake manifold screw
Torque in Nm
12 ÷ 14
11 ÷ 13
28 ÷ 30
11 ÷ 13
7 ÷ 8.5
1÷2
3÷4
7 ÷ 8.5
12 ÷ 14
10 ÷ 14
11 ÷ 15
11 ÷ 13
5-6
5-6
16 ÷ 18
11 ÷ 13
TRANSMISSION
Name
Drive pulley nut
Transmission cover screw
Driven pulley shaft nut
Rear hub cap screw
Clutch unit nut on driven pulley
Torque in Nm
75 ÷ 83
11 ÷ 13
54 ÷ 60
24 ÷ 27
45 ÷ 50
FLYWHEEL
Name
Flywheel fan screws
Stator assembly screws (°)
Flywheel nut
Pick-up screw
Torque in Nm
3÷4
3÷4
52 ÷ 58
3÷4
(°) Apply LOCTITE 243 threadlock
CHAR - 13
Fly 125 - 150 4T
Characteristics
CRANKCASE AND CRANKSHAFT
Name
Internal engine crankcase bulkhead (transmission-side half shaft) screws
Oil filter on crankcase fitting
Rear brake cam tightening screw
Engine-crankcase coupling screws
Pre-filter cap
Starter motor fixing screw
Muffler to crankcase fixing screws
Engine oil drainage cap
Torque in Nm
4÷6
27 ÷ 33
11 ÷ 13
11 ÷ 13
24 ÷ 30
11 ÷ 13
24 ÷ 27
24 ÷ 30
STEERING ASSEMBLY
Name
Steering upper ring nut
Steering lower ring nut
Handlebar fixing screw
Torque in Nm
35 ÷ 40
8 ÷ 10
50 ÷ 55
FRAME
Name
Engine arm bolt - frame arm
Engine-swinging arm bolt
Frame arm-engine arm bolt
Centre stand pin
Bolts mounting rocker arm silent-block
Torque in Nm
33 ÷ 41
33 ÷ 41
60 ÷ 64
32 ÷ 40
36 ÷ 44
FRONT SUSPENSION
Name
Lower fork fixing screw
Front wheel axle nut
Torque in Nm
15 ÷ 20
45 - 50
FRONT BRAKE
Name
Brake fluid pump - hose fitting
Brake fluid tube- calliper fitting
Calliper tightening screw
Disc tightening screw
Oil bleed screw
Torque in Nm
16 ÷20 Nm
19 ÷ 24
24 ÷ 27
8 ÷ 10
7 ÷ 10
REAR SUSPENSION
Name
Rear wheel axle
Lower shock absorber clamp
Shock absorber/frame nut:
shock absorber to crankcase clamping bracket
Overhaul data
Assembly clearances
CHAR - 14
Torque in Nm
104 ÷ 126
33 ÷ 41
20 ÷ 25
20 - 25
Fly 125 - 150 4T
Characteristics
Cylinder - piston assy.
Version 150
COUPLING BETWEEN (AXIS-WERKE) PISTON AND CYLINDER (150)
Name
Coupling
Coupling
Coupling
Coupling
Coupling 1st oversize
coupling 1st oversize
Coupling 1st oversize
Coupling 1st oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Initials
A
B
C
D
A1
Cylinder
62.580 ÷ 62.587
62.587 ÷ 62.594
62.594 ÷ 62.601
62.601 ÷ 62.608
62.780 ÷ 62.787
Piston
62.533 ÷ 62.540
62.540 ÷ 62.547
62.547 ÷ 62.554
62.554 ÷ 62.561
62.733 ÷ 62.740
Play on fitting
0.040 ÷ 0.054
0.040 ÷ 0.054
0.040 ÷ 0.054
0.040 ÷ 0.054
0.040 ÷ 0.054
B1
62.787 ÷ 62.794
62.740 ÷ 62.747
0.040 ÷ 0.054
C1
62.794 ÷ 62.801
62.747 ÷ 62.754
0.040 ÷ 0.054
D1
62.801 ÷ 62.808
62.754 ÷ 62.761
0.040 ÷ 0.054
A2
62.980 ÷ 62.987
62.933 ÷ 62.940
0.040 ÷ 0.054
B2
62.987 ÷ 62.994
62.940 ÷ 62.947
0.040 ÷ 0.054
C2
62.994 ÷ 63.001
62.947 ÷ 62.954
0.040 ÷ 0.054
D2
63.001 ÷ 63.008
62.954 ÷ 62.961
0.040 ÷ 0.054
A3
63.180 ÷ 63.187
63.133 ÷ 63.140
0.040 ÷ 0.054
B3
63.187 ÷ 63.194
63.140 ÷ 63.147
0.040 ÷ 0.054
C3
63.194 ÷ 63.201
63.147 ÷ 63.154
0.040 ÷ 0.054
D3
63.201 ÷ 63.208
63.154 ÷ 63.161
0.040 ÷ 0.054
COUPLING BETWEEN (RIGHT WAY) PISTON AND CYLINDER (150)
Name
Coupling
Coupling
Coupling
Coupling
Initials
A
B
C
D
Cylinder
62.580 ÷ 62.587
62.587 ÷ 62.594
62.594 ÷ 62.601
62.601 ÷ 62.608
Piston
62.541 ÷ 62.548
62.548 ÷ 62.555
62.555 ÷ 62.562
62.562 ÷ 62.569
Play on fitting
0.032 ÷ 0.046
0.032 ÷ 0.046
0.032 ÷ 0.046
0.032 ÷ 0.046
COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER
(125)
Name
Coupling
Coupling
Coupling
Coupling
Coupling 1st increase
Initials
A
B
C
D
A1
Cylinder
56.980 ÷ 56.987
56.987 ÷ 56.994
56.994 ÷ 57.001
57.001 ÷ 57.008
57.180 ÷ 57.187
Piston
56.933 ÷ 56.940
56.940 ÷ 56.947
56.947 ÷ 56.954
56.954 ÷ 56.961
57.133 ÷ 57.140
Play on fitting
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
CHAR - 15
Fly 125 - 150 4T
Characteristics
Name
Coupling 1st increase
Coupling 1st increase
Coupling 1st increase
Coupling 2nd increase
Coupling 2nd increase
Coupling 2nd increase
Coupling 2nd increase
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Initials
B1
Cylinder
57.187 ÷ 57.194
Piston
57.140 ÷ 57.147
Play on fitting
0.040 - 0.054
C1
57.194 ÷ 57.201
57.147 ÷ 57.154
0.040 - 0.054
D1
57.201 ÷ 57.208
57.154 ÷ 57.161
0.040 - 0.054
A2
57.380 ÷ 57.387
57.333 ÷ 57.340
0.040 - 0.054
B2
57.387 ÷ 57.394
57.340 ÷ 57.347
0.040 - 0.054
C2
57.394 ÷ 57.401
57.347 ÷ 57.354
0.040 - 0.054
D2
57.401 ÷ 57.408
57.354 ÷ 57.361
0.040 - 0.054
A3
57.580 ÷ 57.587
57.533 ÷ 57.540
0.040 - 0.054
B3
57.587 ÷ 57.594
57.540 ÷ 57.547
0.040 - 0.054
C3
57.594 ÷ 57.601
57.547 ÷ 57.554
0.040 - 0.054
D3
57.601 ÷ 57.608
57.554 ÷ 57.561
0.040 - 0.054
PISTON TO CAST IRON CYLINDER COUPLING (125)
Name
Coupling
Coupling
Coupling
Coupling
Coupling 1st oversize
Coupling 1st oversize
Coupling 1st oversize
Coupling 1st oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
CHAR - 16
Initials
M
N
O
P
M1
Cylinder
56.997 ÷ 57.004
57.004 ÷ 57.011
57.011 ÷ 57.018
57.018 ÷ 57.025
57.197 ÷ 57.204
Piston
56.944 ÷ 56.951
56.951 ÷ 56.958
56.958 ÷ 56.965
56.965 ÷ 56.972
57.144 ÷ 57.151
Play on fitting
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
N1
57.204 ÷ 57.211
57.151 ÷ 57.158
0.046 ÷ 0.060
O1
57.211 ÷ 57.218
57.158 ÷ 57.165
0.046 ÷ 0.060
P1
57.218 ÷ 57.225
57.165 ÷ 57.172
0.046 ÷ 0.060
M2
57.397 ÷ 57.404
57.344 ÷ 57.351
0.046 ÷ 0.060
N2
57.404 ÷ 57.411
57.351 ÷ 57.358
0.046 ÷ 0.060
O2
57.411 ÷ 57.418
57.358 ÷ 57.365
0.046 ÷ 0.060
P2
57.418 ÷ 57.425
57.365 ÷ 57.372
0.046 ÷ 0.060
M3
57.597 ÷ 57.604
57.544 ÷ 57.551
0.046 ÷ 0.060
N3
57.604 ÷ 57.611
57.551 ÷ 57.558
0.046 ÷ 0.060
O3
57.611 ÷ 57.618
57.558 ÷ 57.565
0.046 ÷ 0.060
P3
57.618 ÷ 57.625
57.565 ÷ 57.572
0.046 ÷ 0.060
Fly 125 - 150 4T
Characteristics
Piston rings
SEALING RINGS (125)
Name
Compression ring
Oil scraper ring
Oil scraper ring
Compression ring
1st oversize
Oil scraper ring 1st
oversize
Oil scraper ring 1st
oversize
Compression ring
2nd oversize
Oil scraper ring
2nd oversize
Oil scraper ring
2nd oversize
Compression ring
3rd oversize
Oil scraper ring 3rd
oversize
Oil scraper ring 3rd
oversize
Description
Dimensions
57 x 1
57x1
57x2.5
57.2 x 1
Initials
A
A
A
A
Quantity
0.15 ÷ 0.30
0.10 ÷ 0.30
0.10 ÷ 0.35
0.15 ÷ 0.30
57.2x1
A
0.10 ÷ 0.30
57.2x2.5
A
0.10 ÷ 0.35
57.4x1
A
0.15 ÷ 0.30
57.4x1
A
0.10 ÷ 0.30
57.4x2.5
A
0.10 ÷ 0.35
57.6x1
A
0.15 ÷ 0.30
57.6x1
A
0.10 ÷ 0.30
57.6x2.5
A
0.10 ÷ 0.35
Dimensions
62.6x1
62.6x1
62.6x2.5
62.8x1
Initials
A
A
A
A
Quantity
0.15 ÷ 0.30
0.20 ÷ 0.40
0.20 ÷ 0.40
0.15 ÷ 0.30
62.8x1
A
0.20 ÷ 0.40
62.8x2.5
A
0.20 ÷ 0.40
63.0 x 1
A
0.15 ÷ 0.30
63.0 x 1
A
0.20 ÷ 0.40
63.0 x 2.5
A
0.20 ÷ 0.40
63.2 x 1
A
0.15 ÷ 0.30
63.2 x 1
A
0.20 ÷ 0.40
63.2 x 2.5
A
0.20 ÷ 0.40
Maximum clearance after use: 1 mm
SEALING RINGS (150)
Name
Compression ring
Oil scraper ring
Oil scraper ring
Compression ring
1st oversize
Oil scraper ring 1st
oversize
Oil scraper ring 1st
oversize
Compression ring
2nd oversize
Oil scraper ring
2nd oversize
Oil scraper ring
2nd oversize
Compression ring
3rd oversize
Oil scraper ring 3rd
oversize
Oil scraper ring 3rd
oversize
Description
CHAR - 17
Fly 125 - 150 4T
Characteristics
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name
Half-shaft, transmission side
Flywheel-side halfshaft
Connecting rod
with PP
Crank pin width
Description
Dimensions
16.6 +0-0.05
Initials
A
Quantity
D = 0.20 - 0.50
16.6 +0-0.05
B
D = 0.20 - 0.50
18 -0.10 -0.15
C
0.20 ÷ 0.50
51.400
E
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS
Name
Crankshaft
Crankshaft
Crankcase
Crankcase
Crankshaft halfbearing
Crankshaft halfbearing
Crankshaft halfbearing
Crankshaft category 1 - Crankcase
category 1
Crankshaft category 1 - Crankcase
category 2
Crankshaft category 2 - Crankcase
category 1
Crankshaft category 2 - Crankcase
category 2
Description
Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40
CHAR - 18
Dimensions
Initials
Category 1
Class 2
Category 1
Category 2
Category B - blue
Quantity
28.998 ÷ 29.004
29.004 ÷ 29.010
32.953 ÷ 32.959
32.959 ÷ 32.965
1.973 ÷ 1.976
Type C - yellow
1.976 ÷ 1.979
Category E - green
1.979 ÷ 1.982
E-E
C-C
C-C
B-B
Fly 125 - 150 4T
Characteristics
Slot packing system
- Provisionally fit the piston into the cylinder, without any base gasket.
- Fit a dial gauge on the specific tool
- Set the dial gauge to zero at a contrast plane with an average precharge, for example 5 mm. Keeping
the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.
- Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation)
- Calculate the difference between the two measurements: use the chart below to identify the thickness
of the cylinder base gasket to be used for refitting. By correctly identifying the cylinder base gasket
thickness, an adequate compression ratio is maintained.
- Remove the specific tool and the cylinder.
Characteristic
Compression ratio (125)
10.6 : 1
Compression ratio
10.5: 1
SHIMMING SYSTEM (125)
Specification
Value measured
Thickness
Value measured
Thickness
Value measured
Thickness
Desc./Quantity
0 ÷ 0.1
0.8 ± 0.05
0.1 ÷ 0.3
0.6 ± 0.05
0.3 - 0.4
0.4 ± 0.05
CHAR - 19
Fly 125 - 150 4T
Characteristics
SHIMMING SYSTEM (150)
Specification
Value measured
Thickness
Value measured
Thickness
Value measured
Thickness
Desc./Quantity
1 ÷ 1.1
0.8 ± 0.05
1.1 ÷ 1.3
0.6 ± 0.05
1.3 ÷ 1.4
0.4 ± 0.05
Products
TABLE OF RECOMMENDED PRODUCTS
Product
AGIP ROTRA 80W-90
AGIP CITY HI TEC 4T
AGIP FILTER OIL
AGIP GP 330
AGIP CITY HI TEC 4T
AGIP GREASE MU3
CHAR - 20
Description
rear oil hub
Specifications
SAE 80W/90 Oil that exceeds the
requirements of API GL3 specifications
Oil to lubricate flexible transmisOil for 4-stroke engines
sions (brakes, throttle control
and odometer)
Oil for air filter sponge
Mineral oil with specific additives
for increased adhesiveness
Grease (brake control levers,
Calcium complex soap-based
throttle grip)
grease with NLGI 2; ISO-LXBCIB2
Engine oil
SAE 5W-40, API SL, ACEA A3,
JASO MA Synthetic oil
Grease for odometer transmis- Soap-based lithium grease with
sion gear case
NLGI 3; ISO-L-XBCHA3, DIN
K3K-20
INDEX OF TOPICS
TOOLING
TOOL
Fly 125 - 150 4T
Tooling
TOOLS
TOOL - 22
Stores code
001330Y
Description
Tool for fitting steering seats
001467Y009
Driver for OD 42 mm bearings
001467Y013
Pliers to extract ø 15-mm bearings
002465Y
Pliers for circlips
005095Y
Engine support
008564Y
Flywheel extractor
Fly 125 - 150 4T
Tooling
Stores code
020004Y
Description
Punch for removing fifth wheels
from headstock
020055Y
Wrench for steering tube ring nut
020074Y
Support base for checking crankshaft alignment
020150Y
Air heater support
020151Y
Air heater
020193Y
Oil pressure gauge
TOOL - 23
Fly 125 - 150 4T
Tooling
TOOL - 24
Stores code
020262Y
Description
Crankcase splitting strip
020263Y
Sheath for driven pulley fitting
020287Y
Clamp to assemble piston on cylinder
020306Y
Punch for assembling valve seal
rings
020329Y
MityVac vacuum-operated pump
020330Y
Stroboscopic light for timing control
Fly 125 - 150 4T
Tooling
Stores code
020331Y
Description
Digital multimeter
020332Y
Digital rev counter
020333Y
Single battery charger
020334Y
Multiple battery charger
TOOL - 25
Fly 125 - 150 4T
Tooling
TOOL - 26
Stores code
020335Y
Description
Magnetic support for dial gauge
020357Y
020359Y
32 x 35 mm adaptor
42x47-mm adaptor
020360Y
Adaptor 52 x 55 mm
020363Y
20 mm guide
020364Y
25-mm guide
Fly 125 - 150 4T
Tooling
Stores code
020368Y
Description
driving pulley lock wrench
020375Y
Adaptor 28 x 30 mm
020376Y
Adaptor handle
020382Y011
adapter for valve removal tool
020409Y
Multimeter adaptor - Peak voltage detection
TOOL - 27
Fly 125 - 150 4T
Tooling
TOOL - 28
Stores code
020412Y
Description
15 mm guide
020414Y
28-mm guide
020423Y
driven pulley lock wrench
020424Y
Driven pulley roller casing fitting
punch
020425Y
Punch for flywheel-side oil seal
020426Y
Piston fitting fork
Fly 125 - 150 4T
Tooling
Stores code
020427Y
Description
Piston fitting band
020428Y
Piston position check support
020430Y
Pin lock fitting tool
020431Y
Valve oil seal extractor
020434Y
Oil pressure control fitting
020444Y
Tool for fitting/ removing the driven pulley clutch
TOOL - 29
Fly 125 - 150 4T
Tooling
TOOL - 30
Stores code
020565Y
Description
Flywheel lock calliper spanner
020622Y
Transmission-side oil guard
punch
494929Y
Exhaust fumes analyser
020625Y
Kit for sampling gas from the exhaust manifold
INDEX OF TOPICS
MAINTENANCE
MAIN
Fly 125 - 150 4T
Maintenance
Maintenance chart
EVERY 2 YEARS
Action
Brake fluid - change
EVERY 3000 KM
Action
Engine oil - level check/ top-up
AFTER 1000 KM
80'
Action
Engine oil - replacement
Hub oil - change
Oil filter (net filter) - clean
Idle speed (*) - adjustment
Throttle lever - adjustment
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - test ride
(*) See instructions in the «Idle speed adjustment» section
AT 6000 KM OR 12 MONTH, 18000 KM, 54000 KM
150'
Action
Engine oil - replacement
Hub oil level - check
Spark plug electrode gap - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Variable speed rollers/pads - check
Driving belt - checking
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - test ride
AT 12000 KM OR 24 MONTHS AND AT 60000 KM
160'
Action
Engine oil - replacement
MAIN - 32
Fly 125 - 150 4T
Maintenance
Action
Hub oil level - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Spark plug - replacement
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Centre stand - lubrication
Secondary air filter - cleaning
Tyre pressure and wear - check
Vehicle and brake test - test ride
(*) See section «Adjusting the idle speed»
AFTER 24000 KM AND AFTER 48000 KM
205'
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
MAIN - 33
Fly 125 - 150 4T
Maintenance
(*) See instructions in «Idle speed adjustment» section
AT 30000 KM, AT 42000 KM AND AT 66000 KM
125'
Action
Engine oil - replacement
Hub oil level - check
Spark plug electrode gap - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Slide pads and variator rollers - check
Driving belt - checking
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - test ride
AFTER 36000 KM
300'
Action
Engine oil - replacement
Hub oil - change
Spark plug - replacement
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Flexible brake tubes - replacement
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Secondary air filter - cleaning
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - test ride
(*) See instructions in «Idle speed adjustment» section
AFTER 72,000 KM
300'
MAIN - 34
Fly 125 - 150 4T
Maintenance
Action
Engine oil - replacement
Hub oil - change
Spark plug - replacement
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Odometer gear - greasing
Steering - adjustment
Cylinder ventilation system - check
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Flexible brake tubes - replacement
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Secondary air filter - cleaning
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - test ride
(*) See instructions in «Idle speed adjustment» section
Checking the spark advance
- To check ignition advance, use the stroboscopic light with induction pincers connected to the spark
plug power wire.
- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the
pincers must be pointing at the spark plug).
- Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines).
- Start the engine and check that the light works properly and the rpm indicator can read also the high
rpm (e.g. 8000 rpm).
- If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive
load on the spark plug power line (10 ÷ 15 KΩ in series to HV wire).
MAIN - 35
Fly 125 - 150 4T
Maintenance
- Operating on the flash bulb phase difference calibrator, make the reference on the flywheel cover
coincide with the fan reference as shown in the
photograph. Read the advance degrees indicated
by the stroboscopic light and compare them with
those specified.
Characteristic
Ignition advance 150 check
10° ± 1° at 2000 rpm - 26° ± 1° at 6000 rpm
Ignition advance 125 check
15° ± 1° at 2000 rpm - 28° ± 1° at 6000 rpm
Spark advance variation
ADVANCE VARIATION
Specification
Operation threshold
Reactivation threshold
Spark elimination
MAIN - 36
Desc./Quantity
First threshold : 9000±50
Second threshold : 9300±50
First threshold : 8900±50
Second threshold : 9200±50
First threshold : 1 spark on 7
Second threshold : 2 sparks on 3
Fly 125 - 150 4T
Maintenance
MAIN - 37
Maintenance
Braking system
Level check
Proceed as follows:
- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;
- Check the level of liquid with the related warning
light «A».
A certain lowering of the level is caused by wear
on the pads.
Proceed as follows:
- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;
- Check the level of liquid with the related warning
light «A».
A certain lowering of the level is caused by wear
on the pads.
Top-up
Proceed as follows:
- Remove the tank cap by loosening the two
screws, remove the gasket and top up using only
the liquid specified without exceeding the maximum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH
YOUR EYES, SKIN, AND CLOTHING. IN CASE
OF ACCIDENTAL CONTACT, WASH WITH WATER.
CAUTION
BRAKE CIRCUIT FLUID IS VERY CORROSIVE;
MAKE SURE THAT IT DOES NOT COME INTO
CONTACT WITH THE PAINTWORK.
CAUTION
MAIN - 38
Fly 125 - 150 4T
Fly 125 - 150 4T
Maintenance
THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS, IT ABSORBS MOISTURE FROM
THE SURROUNDING AIR. IF THE CONTENT OF
MOISTURE IN THE BRAKING FLUID EXCEEDS
A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.
NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS,
THE FLUID MUST BE CHANGED EVERY 20,000
KM OR ANYWAY EVERY TWO YEARS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH
REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE
CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Headlight adjustment
Proceed as follows:
1. Place the vehicle in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10 m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the scooter is perpendicular to the screen;
2. Turn on the headlight and check that the borderline of the projected light beam on the screen
is not lower than 9/10 of the distance from the
ground to the centre of vehicle headlamp and higher than 7/10;
3. If otherwise, adjust the right headlight with screw
«A».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH
THE EUROPEAN STANDARDS REGARDING
MAXIMUM AND MINIMUM HEIGHT OF LIGHT
BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.
MAIN - 39
Maintenance
CO check
- Remove the exhaust gases outlet cap on the exhaust pipe
- Using the supplied washer, install the exhaust
gases collection kit fitting onto the pipe, as shown
in the figure.
- Correctly orientate the components as shown in
the picture
- Shut the gas outlet on the tool
- Start the engine and let it warm up
- Shut the engine down
- Disconnect the SAS check valve vacuum hose
shown in the figure.
- Seal the connection using a conical a cap.
MAIN - 40
Fly 125 - 150 4T
Fly 125 - 150 4T
Maintenance
- Connect the Mitivac vacuum pump to the SAS
control valve.
- Start the vacuum pump up to a pressure of -0.6
÷ -0.8 bar so to close the valve and cut off the SAS
system.
- Remove the exhaust gas collection kit cap and
connect the analyzer adequately pre-heated.
- Check the analyser output and the engine rpm.
- Adjust the CO concentration.
N.B.
CHECK THAT THE RESULT IS OBTAINED
WITH THE VALVE GAS IN CLOSED POSITION.
N.B.
ALSO CHECK THE CARBURETION ADJUSTMENT IS OBTAINED WITH THE FLOW SCREW
OPEN BETWEEN 2 AND 4 TURNS.
N.B.
OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN THE TANK AND THE FUEL CIRCUIT.
N.B.
IN CASE OF UNSTABLE CO, CHECK THAT
THE CARBURETTOR IS CLEAN AND THAT
THE FUEL SUPPLY SYSTEM AND THE DEPRESSION SEALS WORK ADEQUATELY
N.B.
IN CASE OF 1000 PPM UNBURNED HYDROCARBONS (HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYSTEM, THE VALVE
CLEARANCE AND THE EXHAUST VALVE
TIGHTNESS.
Specific tooling
020329Y MityVac vacuum-operated pump
020332Y Digital rev counter
494929Y Exhaust fumes analyser
020625Y Kit for sampling gas from the exhaust
manifold
Characteristic
CO Check
3.8±0.7 to 1650±50 RPM
MAIN - 41
Maintenance
SAS filters inspection and cleaning
- Remove the shock absorber lower retainer from
the engine.
- Remove the retainer clamp indicated in the photograph, the automatic starter cable harness and
the carburettor to frame heater placed under the
helmet compartment cover.
- Lift the vehicle with a jack as shown in the figure
to be able to reach the flywheel cover screws
- Remove the screw fixing the SAS valve to the
flywheel cover, indicated in the photograph.
MAIN - 42
Fly 125 - 150 4T
Fly 125 - 150 4T
Maintenance
- Remove the 4 flywheel cover screws indicated in
the photograph and remove the flywheel cover.
- Remove the filter indicated in the photograph
- Check that the gasket is in good conditions
- Check the SAS filter housing for dents or deformations
- Clean the SAS filter carefully. Replace the filter if
it is damaged or deformed.
To refit, carry out the removal operations but in reverse order.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE
AIR FILTER MUST BE CLEANED MORE OFTEN
THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR FILTER
MAIN - 43
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Fly 125 - 150 4T
Troubleshooting
Engine
Poor performance
POOR PERFORMANCE
Possible Cause
Air filter blocked or dirty.
Operation
Dismantle the sponge, wash with water and shampoo, 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 compressed 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 movement, replace if necessary.
Excessive driving belt wear
Check it and replace, if necessary
Lack of compression: parts, cylinder and valves
Replace the worn parts
worn
Oil level exceeds maximum
Check for causes and fill to reach the correct level
Excess of encrustations in the combustion cham- Descale the cylinder, the piston, the head and the
ber
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, replace the damaged parts and lubricate the driven
pulley moveable guide with Montblanc Molybdenum 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
Idling rpms too high
Clutch fault
Operation
Adjust the engine idle speed and the CO%, if necessary.
Check the springs / clutch masses
TROUBL - 45
Fly 125 - 150 4T
Troubleshooting
Starting difficulties
DIFFICULTY STARTING UP
Possible Cause
Battery flat
Faulty spark plug or incorrect ignition advance
- Engine flooded.
Incorrect valve sealing or valve adjustment
Rpm too low at start-up or engine and start-up
system damaged
Altered fuel characteristics
Vacuum operated cock failure
Failing automatic starter on the carburettor
Start-up enabling buttons failure
Carburettor nozzles clogged or dirty
Air filter obstructed or dirty.
Operation
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
Replace the spark plug or check the ignition circuit
components
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.
Inspect the head and/or restore the correct clearance
Check the starter motor and the kick-starter unit
Drain off the fuel no longer up to standard; then,
refill
Check that fuel is adequately supplied through the
pipe by applying a vacuum to the suction pipe
Check the electrical wiring and mechanical movement, replace if necessary.
Check continuity using an Ohm meter, with the
switch pressed; replace if necessary
Dismantle, wash with solvent and dry with compressed air
Dismantle the sponge, wash with water and shampoo, 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 coupling seal
Worn or broken piston rings or piston rings that Replace the piston cylinder unit or just the piston
have not been fitted properly
rings
TROUBL - 46
Fly 125 - 150 4T
Troubleshooting
Insufficient lubrication pressure
POOR LUBRICATION PRESSURE
Possible Cause
By-Pass remains open
Oil pump with excessive clearance
Oil filter too dirty
Oil level too low
Operation
Check the By-Pass and replace if required. Carefully clean the By-Pass area.
Perform the dimensional checks on the oil pump
components
Replace the cartridge filter
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
Maximum jet clogged
Water or condensate in the carburettor tank
Level in tank too low
Operation
Remove the carburettor, wash with solvent and dry
with compressed air
Remove the tank, wash with solvent and dry with
compressed air
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
Incorrect idle adjustment
Incorrect timing
The starter remains on
Faulty spark plug or incorrect ignition advance
Pressure too low at the end of compression
Minimum nozzle dirty
Operation
Adjust using the rpm indicator
Time the system and check the timing system
components
Check: electric wiring, circuit not interrupted, mechanical movement and power supply; replace if
necessary
Replace the spark plug or check the ignition circuit
components
Check the thermal group seals and replace worn
components
Wash the nozzle with solvent and dry with compressed air
High fuel consumption
EXCESSIVE FUEL CONSUMPTION
Possible Cause
Air filter blocked or dirty.
Starter inefficient
Operation
Clean according to the procedure
Check: electric wiring, circuit continuity, mechanical sliding and power supply
TROUBL - 47
Fly 125 - 150 4T
Troubleshooting
Possible Cause
Loose nozzles
Operation
Check the maximum and minimum nozzles are
adequately fixed in their fittings
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.
Incorrect float level
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause
Slippage or irregular functioning
Operation
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
Worn brake pads or shoes
Operation
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
Rubber gaskets swollen or stuck
Compensation holes on the pump clogged
Brake disc slack or distorted
TROUBL - 48
Operation
Replace gaskets.
Clean carefully and blast with compressed air
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.
Fly 125 - 150 4T
Troubleshooting
Possible Cause
Defective piston sliding
Operation
Check calliper and replace any damaged part.
Electrical system
Battery
BATTERY
Possible Cause
Battery
Operation
The battery is the electrical device in the system
that requires the most frequent inspections and
thorough maintenance. If the vehicle is not used
for some time (1 month or more) the battery needs
to be recharged periodically. The battery runs
down completely in the course of 5 ÷ 6 months. If
the battery is fitted on a motorcycle, be careful not
to invert the connections, keeping in mind that the
black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+. Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the
batteries.
Turn signal lights malfunction
TURN INDICATOR NOT WORKING
Possible Cause
Electronic ignition device failure
Operation
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; otherwise, check the cable harness and the switch.
Steering and suspensions
Heavy steering
STEERING HARDENING
Possible Cause
Steering hardening
Operation
Check the tightening of the top and bottom ring
nuts. If irregularities continue in turning the steering even after making the above adjustments,
check the seats in which the ball bearings rotate:
if they are recessed or if the balls are squashed,
replace them.
TROUBL - 49
Fly 125 - 150 4T
Troubleshooting
Excessive steering play
EXCESSIVE STEERING CLEARANCE
Possible Cause
Excessive steering backlash
Operation
Check the tightening of the top ring nut. If irregularities 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
Noisy suspension
Operation
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 calliper 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
Oil leakage from suspension
TROUBL - 50
Operation
Replace the rear shock absorber or the front fork
cartridge.
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
Legend:
1. Front L.H. turn signal light
2. Immobiliser antenna
3. Electronic ignition device with choke and turn signal controls
4. Horn button
5. Turn signal switch
6. Headlight switch
7. Stop switch on rear brake
8. Double-filament bulb 12V - 55/60W
9. Front sidelight bulb
10. High-beam warning light
11. Engine oil pressure warning light
12. Turn signal warning light (L.H.)
ELE SYS - 52
Fly 125 - 150 4T
Fly 125 - 150 4T
Electrical system
13. Low-fuel warning light
14. Turn signal warning light (R.H.)
15. Dashboard light bulbs
16. Headlamp warning light
17. Odo/speedometer with warning lights and gauges - Red socket light bulbs 2W; black socket light
bulbs 1.2W
18. Headlight
19. 2 fuse holders with 4 fuses (7.5 A)
20. Stop switch on front brake
21. Start button
22. Immobiliser diagnostic outlet
23. Key-switch
24. Front R.H. turn signal light
25. Wire harness
26. Fuel level sender
27. Fuse holder assembly
28. Rear R.H. turn signal light
29. License plate light bulb
30. License plate lamp
31. Battery
32. Starter relay
33. Starter motor
34. Engine oil pressure sensor
35. Pick-up
36. Automatic choke device
37. Carburettor heater
38. H.T. coil
39. Taillight assembly
40. Stop and taillight bulb
41. Voltage regulator
42. Rear L.H. turn signal light
43. 4 amber light bulbs for turn signal lamps
44. Relay
45. Horn Wiring
- Colour coding:
B = White
Bl = Blue
G = Yellow
ELE SYS - 53
Electrical system
Mr = Brown
N = Black
BV = White-Green
GN = Yellow-Black
Gr = Grey
Rs = Pink
R = Red
Vi = Purple
V = Green
VN = Green-Black
BN = White-Black
BBl = White-Blue
GV = Yellow-Green
Ar = Orange
Az = Light Blue
GrBl = Gray-Blue
GrN = Grey-Black
RBl = Red-Blue
GR = Yellow-Red
BlN = Blue-Black
Electrical system installation
ELE SYS - 54
Fly 125 - 150 4T
Fly 125 - 150 4T
Electrical system
Front side
FRONT INSTALLATION 1
1
Specification
Strap
2
3
Zip tie
Fixing
Desc./Quantity
Insert the strap through the hole in the chassis
Fold the chassis strap over the cables
ELE SYS - 55
Fly 125 - 150 4T
Electrical system
FRONT INSTALLATION
1
2
3
4
5
6
7
ELE SYS - 56
Specification
Front R.H. turn signal light
Fuse holder box
Front L.H. turn signal light
Light remote control switch
Ignition key-switch
Control device ignition
Immobiliser diagnostic outlet
Desc./Quantity
Fly 125 - 150 4T
Electrical system
8
9
Specification
Zip tie
Horn
1
Specification
Zip tie
Desc./Quantity
FRONT INSTALLATION 2
Desc./Quantity
ELE SYS - 57
Fly 125 - 150 4T
Electrical system
Back side
REAR INSTALLATION
1
2
3
4
5
6
7
8
Specification
Cable harness fairlead
Breather tube
Heater conductors and automatic choke protective sheath
Voltage regulator
HV coil
Earth node
Starter remote control
License plate light connector
ELE SYS - 58
Desc./Quantity
Fly 125 - 150 4T
Electrical system
REAR INSTALLATION 1
1
2
3
4
5
6
7
Specification
H.T. Cable
Zip tie
To the automatic choke device
To the heater
Rear R.H. turn signal light
Taillight
Rear L.H. turn signal light
Desc./Quantity
ELE SYS - 59
Fly 125 - 150 4T
Electrical system
REAR INSTALLATION 2
1
2
3
4
Specification
Zip tie
Starter motor earth
Starter motor positive outlet
Flywheel connection
Conceptual diagrams
ELE SYS - 60
Desc./Quantity
Fly 125 - 150 4T
Electrical system
Ignition
IGNITION
1
2
3
4
5
6
Specification
electronic control unit
Magneto flywheel
Pick - up
HV coil
Spark plug
Voltage regulator
Desc./Quantity
ELE SYS - 61
Fly 125 - 150 4T
Electrical system
Headlights and automatic starter section
LIGHTS AND AUTOMATIC STARTER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
ELE SYS - 62
Specification
electronic control unit
Carburettor heater
Automatic starter
Key switch
Main fusible
Battery
Headlamp relay
Light switch
High-beam fuse
Low-beam and dashboard lights fuse
Low-beam light bulb
High-beam light bulb
High-beam lamp warning light
Front side-light bulb
Four dashboards illuminating bulbs
Taillight bulb
License plate bulb
Low-beam fuse
Desc./Quantity
15A
12V-9Ah
7,5A
7,5A
12V - 55W
12V-55W
12V - 1.2W
12V - 5W
12V - 1,2W
12V - 5W
12V - 5W
7,5A
Fly 125 - 150 4T
Electrical system
Battery recharge and starting
BATTERY CHARGER AND STARTING
1
2
3
4
5
6
7
8
9
10
11
12
13
Specification
Magneto flywheel
Voltage regulator
Pick - up
Main fusible
Battery
Starter relay
Starter motor
Start up button
Front and rear brake light button
Brake light filament
Fuse
Key switch
electronic control unit
Desc./Quantity
15A
12V-9Ah
12V-21W
7.5 A
ELE SYS - 63
Fly 125 - 150 4T
Electrical system
Level indicators and enable signals section
CONSENSUSES AND LEVEL INDICATORS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
ELE SYS - 64
Specification
electronic control unit
Battery
Main fusible
Key switch
Engine oil pressure sensor
Low oil pressure warning light
Reserve fuel light
Fuel gauge
Fuel level sender
Fuse
Immobilizer aerial
Low engine oil pressure sensor
Immobiliser LED
Front and rear brake light button
Taillight bulb
Starter motor
Starter relay
Start up button
Desc./Quantity
12V-9Ah
15A
12V - 1,2W
12V-1,2W
7.5 A
12V - 5W
Fly 125 - 150 4T
Electrical system
Turn signal lights
TURN INDICATORS AND HORN
1
2
3
4
5
6
7
8
9
10
Specification
electronic control unit
Indicators switch
4 Turn indicator bulbs
Turn signal warning light bulbs
Main fusible
Battery
Horn
Fuse
Key switch
Horn button
Desc./Quantity
12V-10W
12V - 2W
15A
12V-9Ah
7.5 A
ELE SYS - 65
Fly 125 - 150 4T
Electrical system
Instruments and warning lights control board
4 PIN CONNECTOR
Specification
Ground lead (-)
High-beam warning light
Left turn indicator
Engine oil warning light
1
2
3
4
Desc./Quantity
5 PIN CONNECTOR
1
2
3
4
5
Specification
Instrument panel lighting and headlamp
warning light
Right turn indicator
Low-fuel warning light
+ permanent power supply
Fuel gauge
Checks and inspections
ELE SYS - 66
Desc./Quantity
Fly 125 - 150 4T
Electrical system
Immobiliser
The electric ignition system is fed with direct current and is protected by an anti-theft immobilizer
integrated to the control unit.
The ignition system consists of:
- electronic control unit
- immobilizer aerial
- master and service keys with built-in transponder
- HV coil
- diagnosis LED
The diagnosis LED also works as a blinking light
to deter theft. This function is activated every time
the key switch is turned to «OFF», and it remains
active 48 hours so as not to affect the battery
charge.
When the ignition switch is set to «ON», the theft
deterring blinker function is deactivated. Subsequently, a flash confirms the switching to «ON».
The duration of the flash depends on the electronic
control unit program (see figure).
Whenever the LED is off and remains so, even
when switching it to «ON», it is necessary to check
if:
- the battery is charged
- 15A main fuse is working correctly.
Connect the immobilizer tester to the diagnosis
socket (see ET4 125 manual) located behind the
front left fuse box flap.
If the serial LED remains off, check the electronic
control unit supply as follows:
ELE SYS - 67
Electrical system
Detach the connector from the ECU and check the
following:
- Presence of battery potential difference between
terminal 4 (Red/Blue) and earth
- Presence of battery potential difference between
terminals 4 (Red/Blue) and 8 (black), as shown in
the figure.
- Presence of battery potential difference between
terminals 5 and 8 with the key-switch onto «ON».
If no anomalies are found, replace the electronic
control unit.
Virgin circuit
If the ignition system has not been programmed,
the engine can be started but it will run limited to
2000 rpm. When trying to accelerate, some evident loss of power may be felt.
Program the system with the MASTER (Brown)
and SERVICE (Blue) keys as follows:
- Insert the MASTER key, turn it to "ON" and keep
it in that position for 2 seconds (limit values: 1 ÷ 3
seconds).
- Alternatively insert all the available black keys
and turn each one of them to "ON" for 2 seconds.
- Insert the MASTER key again and turn it to "ON"
for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 service keys (blue) can be programmed at one time.
Sequence and times must be strictly observed or
it will be necessary to repeat the procedure from
the start.
ELE SYS - 68
Fly 125 - 150 4T
Fly 125 - 150 4T
Electrical system
Once the control unit has been programmed, the
control unit is inseparably matched with the MASTER key transponder.
This matching allows programming further service
keys in case of loss, replacement, etc. Each new
time new data is programmed the previously stored one is deleted.
If a service key setting is lost, it is essential to
carefully check the efficiency of the high voltage
system:
Shielded cap resistance ~ 5000 Ω.
In any case, it is advisable to use resistive spark
plugs as shown in the figure.
Diagnostic codes
The flash indicating the switching to "ON" (0.7-sec
flash) can be followed by a phase of programmed
failure warnings.
That is, the LED is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-sec flashes.
After the failure code indication, a steadily on LED
signals that ignition is disabled; see the table:
2-FLASH CODE
Example with programmed electronic control unit,
no transponder and/or aerial malfunction
Ignition disabled-Vehicle immobilised
3-FLASH CODE
Example with programmed electronic control unit,
aerial working properly and unknown transponder
code.
Ignition disabled-Vehicle immobilised
Diagnostic code - 2 flashes
When the 2-flash code is detected, carry out the following checks:
- Check if the failure continues even after changing key (including the MASTER key). If the failure
persists with any key, disconnect the aerial connector from the electronic control unit and check the
aerial continuity with the multimeter.
ELE SYS - 69
Electrical system
Fly 125 - 150 4T
If it does not work, replace the aerial.
If no faults are found, replace the control unit.
CAUTION
BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE
CODE IS INDICATED. THIS IS TO AVOID SPOILING A NEW CONTROL UNIT UNNECESSARILY.
Specific tooling
020331Y Digital multimeter
Electric characteristic
Resistance value
~ 7 ÷ 9 Ohm
Diagnostic code - 3 flashes
If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the
key switch.
- If the failure disappears when the MASTER key is used, proceed with coding a new service key (Blue).
- If the failure persists, it means that the MASTER key and the control unit are not linked; in this case,
replace the control unit and then encode the keys.
The immobilizer system is efficient when, after switching over to «ON», only a 0.7-sec flash is detected
(see diagram).
In this case, the engine can be started.
Example with programmed control unit, transponder, programmed key and working aerial. The
ignition is enabled (regular use conditions)
Ignition circuit
All the control operations of the system that entail disconnecting cables (to check connections and the
devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls
might be irretrievably damaged.
The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected
to the Pick-Up by the chassis and the engine ground lead.
ELE SYS - 70
Fly 125 - 150 4T
Electrical system
To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis
ground connection bonding is efficient.
No spark plug
When noticing no spark plug proceded as follows:
- Pick-Up inspection.
Detach the ECU connector and check for continuity between terminals 2 (Green) and 8 (Black).
The inspection must include the pick-up and it's
power cable.
If an open circuit is found, repeat the inspection
between the flywheel connector and earth. If unacceptable values are found, proceed by replacing
the pick-up, otherwise repair the cable.
Electric characteristic
Pick-up resistance value
Pick-up resistance value: 105 ÷ 124 Ohm
- H.T. coil primary circuit inspection
Detach the connector from the ECU and check for
continuity between terminals 3 (purple) and 8
(black) (see figure).
If unacceptable values are found, repeat the inspection directly from the positive and negative
terminals of the H.T. coil primary circuit.
If the values are within the prescribed limit, proceed by repairing the wiring or reattaching all wirings, otherwise replace the H.T. coil.
Electric characteristic
High voltage coil primary resistance value
High voltage coil primary resistance value: 0.4 ÷
0.5 Ohm
- HV coil secondary check
Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable
terminal and the HV coil negative terminal (see figure).
If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis,
check the peak voltage with the multimeter adaptor.
Specific tooling
ELE SYS - 71
Electrical system
020409Y Multimeter adaptor - Peak voltage detection
Electric characteristic
High voltage coil secondary resistance value
High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm
- Pick-Up
Detach the ECU connector and connect the positive terminal to connector no. 2 and the negative
terminal to connector no. 8 (see figure).
Crank the engine using the starter motor and
check the tension produced by the pick-up.
If unacceptable values are found, replace the PickUp.
N.B.
THE MULTIMETER MUST BE SELECTED TO
DETECT CONTINUOUS VOLTAGE.
Electric characteristic
Pick-Up voltage value
Pick-Up voltage value: > 2 Volt
- H.V. coil
With the control unit and HV coil connected to the
circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor
and connect the positive terminal to the earth one
and the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
THE POSITIVE TERMINAL OF THE HV COIL
PRIMARY IS BLACK.
Electric characteristic
High voltage coil voltage value
High voltage coil voltage value: > 100 Volt
ELE SYS - 72
Fly 125 - 150 4T
Fly 125 - 150 4T
Electrical system
Battery recharge circuit
The recharge system is provided with a three phase alternator with permanent flywheel.
The alternator is directly connected to the voltage regulator.
In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety
fuse.
This system therefore requires no connection to the key switch.
The three- phase generator provides good recharge power and at low revs a good compromise is
achieved between generated power and idle stability.
For this reason, it is very important that the idle speed is adjusted as prescribed.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
Stator check
Disconnect the connector from the voltage regulator and check there is continuity between any
yellow cable and the other two cables.
Electric characteristic
Ohm value:
0.7 ÷ 0.9 Ohm
Also check that all yellow cables are insulated from
the ground connection.
If non-conforming values are detected, repeat the
checks directly to the stator. In case of further repetitions of incorrect values replace the stator or
repair the wiring.
ELE SYS - 73
Electrical system
Voltage regulator check
With a perfectly charged battery and lights off,
measure voltage at the battery poles with a high
running engine.
The voltage should not exceed 15.2 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
Recharge system voltage check
Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with
engine off, wait for the voltage to set at about 12
V. Start the engine and measure the current generated by the system with lights on and a high
running engine.
In case the generated current value is lower than
8A, repeat the test using a new regulator and/stator alternatively.
Choke Inspection
Refer to the engine section to check the resistance
and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals
receive battery voltage when the engine is on
(see figure).
If no voltage is detected, connect the multimeter
negative terminal to the ground lead and the positive terminal to the automatic starter orange cable;
ELE SYS - 74
Fly 125 - 150 4T
Fly 125 - 150 4T
Electrical system
with the key switch set to "ON" check whether
there is battery voltage; if there is no voltage,
check the wiring connections to the key switch.
If battery potential is found, repeat the inspection
from the connector to the ECU.
After detaching the choke device, start the engine
and, while at idle, check for tension connecting the
positive terminal of the multimetre to terminal 5
(Orange) and the negative to terminal 7 (White/
Black) (see figure).
If no tension is found, replace the ECU; otherwise
check the wiring between the choke device and the
ECU.
Turn signals system check
- If the turn signal lights are faulty, proceed as follows:
- Detach the ECU connector and check for battery
tension between terminal 5 (Orange) and earth,
with the key-switch onto «ON».
- Check the same is present between terminals 5
(Orange) and 8 (Black).
If no tension is measured, check the wiring, otherwise proceed as follows:
- Jumper terminals 1 (Black/Blue) and 5 (Orange),
see figure, and alternately operate the turn signal
switch towards left and right wit the key-switch onto «ON» and check the bulbs go off.
If this happens, replace the ECU, as faulty.
If this does not happen, check the wiring between
the ECU and the turn signal switch, hence repeat
the test.
ELE SYS - 75
Electrical system
Fly 125 - 150 4T
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h
Dry-charge battery
WARNING
- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact
with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about
15 minutes and seek immediate medical attention.
In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg or vegetable oil. Seek immediate medical attention
Batteries produce explosive gases; keep clear of free flames, sparks or cigarettes; ventilate the area
when recharging the battery indoors.
Always protect your eyes when working close to batteries.
Keep out of the reach of children.
ELE SYS - 76
Fly 125 - 150 4T
Electrical system
Commissioning dry-charged batteries :
1) - Remove the short closed tube and the caps,
then pour sulphuric acid into the cells using the
type specified for batteries with a specific gravity
of 1.26, corresponding to 30 Be at a minimum temperature of 15°C until the upper level is reached.
2) - Leave to rest for at least 2 hours; then, restore
the level with sulphuric acid.
3) - Within the following 24 hours, recharge using
the specific battery charger (single) or (multiple) at
a density of about 1/10 of the battery nominal capacity until fully charged; check that the acid density is about 27, corresponding to 31 Be, and that
these values are stabilised.
4) - Once the charge is over, level the acid (by
adding distilled water). Close and clean carefully.
5) Once the above operations have been performed, install the battery on the vehicle ensuring
that it is wired up properly.
1 Hold the vertical tube
2 Look at the level
3 The float must be freed
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED
IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED
END) NEAR THE + POSITIVE TERMINAL WITH
THE CORRESPONDING LONG TUBE (WITH
OPEN END), THAT YOU FIND FITTED TO THE
VEHICLE, TO ENSURE THAT THE GASES
THAT FORM CAN ESCAPE PROPERLY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
Battery maintenance
The battery is an electrical device which requires careful monitoring and careful maintenance. The
maintenance rules are:
1) Electrolyte level check
ELE SYS - 77
Electrical system
Fly 125 - 150 4T
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level. If it is necessary to add water too frequently, check the vehicle electrical
system: the battery works overcharged and is subject to quick wear.
2)Load status check
After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure).
When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific
weight of 1.26 to 1.28 at a temperature of no lower than 15° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
The battery runs down completely in the course of three months. If it is necessary to refit the battery in
the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked
(-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign.
3) Recharging the battery
Remove the battery from the vehicle removing the negative clamp first.
Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),
setting the battery charger selector to the type of battery to be recharged. Connections to the power
supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).
4) Battery cleaning
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS
AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT
IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
ELE SYS - 78
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Engine from vehicle
Exhaust assy. Removal
- Remove the 2 fixing nuts from the manifold to the
head
- Unscrew the 2 screws fixing the muffler to the
housing; then remove the whole muffler paying attention to the interference between its supporting
bracket and the cooling cover.
Removal of the engine from the vehicle
- Remove the left side fairing
- Remove the helmet compartment door
- Remove the full muffler assembly.
- Remove the 3 rear brake transmission fixing
screws indicated in the photograph
- Remove the throttle control cable from the carburettor, indicated in the photograph
ENG VE - 80
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine from vehicle
- Remove the fuel supply pipe from the carburettor
- Remove the fuel valve low-pressure pipe from the
manifold as shown in the photograph
- Remove the flywheel wiring connector, the earth
terminal and the starter motor positive cable indicated in the figure
- Remove the clamp retaining the starter wiring
and the heater indicated in the figure
ENG VE - 81
Engine from vehicle
- Remove the protection sheath indicated in the
figure and disconnect the automatic starter and
carburettor heater connections
- Unscrew the engine pin-swinging arm nut on the
right-hand side of the vehicle and slide off the pin
on the left hand side
- Support the vehicle adequately (with a jack) and
remove the shock absorber lower clamping. The
engine is now free.
See also
Exhaust assy. Removal
ENG VE - 82
Fly 125 - 150 4T
INDEX OF TOPICS
ENGINE
ENG
Engine
Fly 125 - 150 4T
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- To remove the transmission cover it is necessary
to remove the rear plastic cover first by inserting a
screwdriver in the corresponding slotted holes.
Using the clutch bell lock wrench, remove the driven pulley axle locking nut and recover the washer.
- Remove the cap/dipstick from the engine oil filling
hole.
- Remove the 10 screws and the earth cable fastened under one of them.
- Remove the transmission cover. If this operation
is performed directly on the vehicle, it is necessary
to remove the cooling air coupling and the three air
filter housing retainers.
Specific tooling
020423Y driven pulley lock wrench
CAUTION
Maybe a first batch of vehicles features an air
manifold bulkhead with the tail highlighted in the
figure. While removing the transmission cover,
take care not to deform this tongue with the fixed
driving half-pulley.
ENG - 84
Fly 125 - 150 4T
Engine
Air duct
- Unscrew the Torx screws fixing the air manifold
bulkhead and remove the bulkhead.
- Remove the 3 screws, then take out the manifold
as well as the filter.
Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.
- Use the specific tools to remove the bearing from
the crankcase.
CAUTION
USE AN APPROPRIATE REST SURFACE TO
AVOID DAMAGING THE COVER PAINT.
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
ENG - 85
Engine
Refitting the driven pulley shaft bearing
- Heat up the crankcase inside with the hot air gun.
- Insert the bearing in its housing, refit the Seeger
ring.
N.B.
ALWAYS REPLACE THE BEARING WITH A
NEW ONE UPON REFITTING.
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
Removing the driven pulley
- Remove the spacer, the clutch bell and the whole
driven pulley unit.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE
DRIVING PULLEY MOUNTED.
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.
- Measure the clutch bell inside diameter.
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
Clutch bell standard value
Standard value: Ø 134 - 134.2 mm
ENG - 86
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Checking the bell working surface eccentricity
- Install the bell on a driven pulley shaft using 2
bearings (inner diameter 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft assembly on the support to
check the crankshaft alignment.
- Using a feeler pin gauge and the magnetic base,
measure the bell eccentricity.
- Repeat the measurement in 3 positions (Central,
internal, external).
- If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft
alignment
020335Y Magnetic support for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
Removing the clutch
- Prepare the locking tool for the driven pulley with
the pins half-screwed in the tool set to «C».
ENG - 87
Engine
Fly 125 - 150 4T
- Fit the driven pulley unit in the tool so as the bolt
get into the masses clutch support holes. Afterwards make the support screw make contact with
a minimum force.
- Using the specific wrench, inserted 46 mm from
the side, remove the clutch central locking nut.
- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE
TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE
SPECIFIC TOOL.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch
020444Y009 46x55 Wrench
Inspecting the clutch
- Check the thickness of the clutch mass friction
material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS
TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
ENG - 88
Fly 125 - 150 4T
Engine
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
- Remove the 3 guide pins and the movable halfpulley.
Removing the driven half-pulley bearing
- Remove the retaining ring using two flat blade
screwdrivers.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
- Remove the roller bearing using the specific extractor.
N.B.
REST THE HALF-PULLEY ON A WOOD SURFACE TO AVOID DAMAGING THE THREADED
RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT.
Specific tooling
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020439Y 17 mm guide
ENG - 89
Engine
Inspecting the driven fixed half-pulley
- Measure the external diameter of the pulley bushing.
Characteristic
Minimum diameter permitted
Ø 40.96 mm
Standard diameter
Ø 40.965 mm
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two Orings.
- Measure the inside diameter of the mobile halfpulley bushing.
Characteristic
Minimum admissible diameter
Ø 41.08 mm
Standard diameter
Ø 41.035 mm
Refitting the driven half-pulley bearing
- Assemble a new roller case using the specific
punch, fit the bearing with the label facing outward
and insert it completely up to the punch on the halfpulley.
N.B.
REST THE HALF-PULLEY ON A WOOD SURFACE TO AVOID DAMAGING THE THREADED
RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT.
Specific tooling
020424Y Driven pulley roller casing fitting
punch
ENG - 90
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- To assemble the new ball bearing insert it completely down in its housing with the specific punch
and finally assemble the Seeger ring.
Specific tooling
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020439Y 17 mm guide
Refitting the driven pulley
- Check that the faying surfaces between the 2
half-pulleys and the belt do not show any signs of
wear, scoring and grease.
- Insert the new oil seals and O-rings on the movable half-pulley.
- Assemble the half-pulley on the ringlet with the
appropriate protection sheath.
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Use a greaser with a curved spout to lubricate the
driven pulley unit with around 6 g of grease. This
operation must be done through one of the holes
inside the bushing until grease comes out of the
opposite hole. This operation is necessary to avoid
the presence of grease beyond the O-rings.
Specific tooling
020263Y Sheath for driven pulley fitting
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
ENG - 91
Engine
Inspecting the clutch spring
- Measure the unloaded length of the spring of the
movable driven half-pulley.
Characteristic
Standard length:
106 mm
Refitting the clutch
- Check the thickness of the clutch mass friction
material.
-The masses must not show traces of lubricants;
otherwise, check the driven pulley unit.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE
THE CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS
SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Minimum thickness permitted:
1 mm
- Support the driven pulley spring compressor appropriate tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring 11 with the chamfering
facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the servo-system closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
ENG - 92
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- Insert the driving belt into the pulley unit according to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
- Apply the clutch fixing nut and tighten it to the
prescribed torque using the special 46x55 wrench.
- Loosen the tool clamp and insert the belt according to its direction of rotation.
- Lock the driven pulley again using the specific
tool.
- Preload the clutch return spring with a traction/
rotation combined action and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.
N.B.
DURING THE SPRING PRELOADING PHASE,
BE CAREFUL NOT TO DAMAGE THE PLASTIC
SPRING STOP AND THE BUSHING THREADING.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE
SHOULD BE MOUNTED IN CONTACT WITH
THE CLUTCH.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 46x55 Wrench
Locking torques (N*m)
Nut locking clutch unit on pulley 55 ÷ 60 Nm
ENG - 93
Fly 125 - 150 4T
Engine
Refitting the driven pulley
- Reassemble the clutch bell and spacer.
Drive-belt
During the wear checks foreseen in the scheduled
maintenance services at 6,000 km; 18,000 km;
etc., check that the rim bottom of the toothing does
not show signs of incisions or cracking (see figure):
The rim bottom of the tooth must not have incisions
or cracking; if it does, change the belt.
- Check that the driving belt is not damaged.
- Check the width of the belt.
BELT SIZE
Specification
Minimum width
Standard width
ENG - 94
Desc./Quantity
21.5 mm
22.5 ± 0.2 mm
Fly 125 - 150 4T
Engine
Removing the driving pulley
- Lock the driving pulley with the specific tool as
shown in the figure. - Disassemble the central nut
and the Belleville washer, remove the drive and
the 2 washers. - Remove the stationary half pulley
and the steel washer.
Specific tooling
020368Y driving pulley lock wrench
- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative
guide pads.
Inspecting the rollers case
- Check that the internal bushing is not abnormally worn and measure inner diameter.
N.B.
DO NOT LUBRICATE OR CLEAN THE BUSHING.
BUSHING ROLLER CONTAINER
Specification
Maximum allowable diameter
Standard diameter
Desc./Quantity
Ø 26.121 mm
Ø 26+0 +0.021 mm
BUSH SLIDE PULLEY
Specification
Minimum diameter permitted
Standard diameter
Desc./Quantity
Ø 25.950 mm
Ø 26-0.020 -0.041 mm
VARIABLE SPEED ROLLERS
Specification
Minimum diameter permitted
Standard diameter
Desc./Quantity
Ø 18.5 mm
Ø 26±0.1 mm
ENG - 95
Engine
- Check the guide shoes for the variator back-plate
are not worn.
- Check there is no wear in the roller housing, and
the surfaces in contact with the belt on either of the
pulley halves.
Refitting the driving pulley
- Reassemble the parts of the unit (internal lining,
fixed half-pulley, external lining, drive and nut),
spread threadlock on the thread and screw the nut
to the prescribed torque.
-Avoid the half-pulley rotation using a calliper
spanner
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
Specific tooling
020368Y driving pulley lock wrench
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Locking torque 75 ÷ 83
ENG - 96
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Refitting the transmission cover
- Check the presence of the 2 centring dowels and
the correct installation of the sealing gasket for the
oil sump on the transmission cover.
- Replace the cover tightening the 10 screws at the
specified torque.
- Refit the oil loading cap/bar.
- refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Replace the plastic cover.
Specific tooling
020423Y driven pulley lock wrench
Locking torques (N*m)
Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60
End gear
Removing the hub cover
- Empty the rear hub through the oil drainage tap
located inside the hub cover
- Remove the brake shoe and relevant spring
- Remove the 7 flanged screws as shown in the
figure.
- Remove the rubber cover and the brake pad lever
sliding unscrewing the relevant retaining screw to
reach the rear of the cover
- Take off the hub cover and relevant gaskets
ENG - 97
Engine
Removing the wheel axle
Remove the intermediate gear and the complete
hub cover.
Removing the hub bearings
- Check the state of the bearings being examined
(wear, clearance and noisiness). If faults are detected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
001467Y009 Driver for OD 42 mm bearings
001467Y013 Pliers to extract ø 15-mm bearings
Removing the wheel axle bearings
- Take out the clip on the outside of the gearbox
cover.
- Remove the bearing with the adequate tools adequately supporting the hub cover, as shown in the
figure.
Specific tooling
020376Y Adaptor handle
020364Y 25-mm guide
ENG - 98
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
With the appropriate tools, remove the oil seal as
shown in the figure.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
Removing the driven pulley shaft bearing
If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven
pulley.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, working from inside the bearing and being careful not to
damage the housing, make it come out of the belt transmission side.
- Remove the seeger ring shown in the figure
With the sectional punch, remove the driven pulley
shaft bearing.
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020363Y 20 mm guide
See also
Removing the driven pulley
Inspecting the hub shaft
- Check the three shafts for wear or distortion of
the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of anomalies, replace the damaged components.
ENG - 99
Engine
Fly 125 - 150 4T
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and the
brake camshaft. - If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing
- Heat up the parts using the specific heat gun
Specific tooling
020150Y Air heater support
020151Y Air heater
- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of
the hub cover using the adequate tools
Specific tooling
020376Y Adaptor handle
- Refit the Seeger ring with the opening facing the
bearing as shown in the figure and fit a new oil
guard flush with the crankcase.
Refitting the wheel axle bearing
- Heat up the parts using the specific heat gun
Specific tooling
020151Y Air heater
020150Y Air heater support
-The wheel axle bearing on the cover, should be assembled with the specific tools
Specific tooling
020364Y 25-mm guide
020360Y Adaptor 52 x 55 mm
020376Y Adaptor handle
ENG - 100
Fly 125 - 150 4T
•
Assemble the Seeger ring.
•
Assemble the oil seal flush with the in-
Engine
ternal surface as shown in the figure to
the hub using the adequate tools and
with the seal lip towards the inside of
the hub.
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
Refitting the hub cover bearings
- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the
specific heat gun.
Specific tooling
020150Y Air heater support
020151Y Air heater
- The three 15 mm bearings must be fitted using
the appropriate tools.
Refitting the hub bearings
- Insert the cover prepared in the crankcase taking
care of inserting the gear of the pulley shaft on the
intermediary gear.
ENG - 101
Engine
Refitting the ub cover
- Fit a new gasket together with the centring dowels.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Screw the 7 screws to the specified torque, positioning the support plate of the pipe in the position shown in the figure.
- Remove the control pin of the shoe taking care
so as the long tooth coincides with the groove on
the control lever.
Locking torques (N*m)
Locking torque 24 ÷ 27
Flywheel cover
Cooling hood
-Remove the housing acting on the 4 retaining
screws.
CAUTION
DURING REMOVAL SLIDE THE HOUSING
CONNECTOR ON THE HOUSING.
- Loosen the clamp and remove the carburettor
from the manifold.
-Remove the complete manifold acting on the 2
retainers as shown in the figure.
- Remove the 2 self threading screws, left and right
and the lateral base retaining screw on the crankcase base.
- Take off the housings.
- Remove the gasket seal of the housing on the
head.
N.B.
ENG - 102
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
IF THE FLYWHEEL HOUSING IS NOT REMOVED, IT IS ALSO NECESSARY TO REMOVE
THE TWO KNOB SCREWS.
On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggest
to intervene on the vacuum socket inserting on the inlet manifold widening the hole from 0.4 mm to 1.5
mm. Remember that such operation must have performed on a disassembled manifold which must be
cleaned afterwards.
Cooling fan
- Refit the parts in reverse order of the removal
operation.
- Make sure that there are spacers with the two
rear retainers of the housing.
- The long spacers should be in a high position.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE
FLYWHEEL CONNECTOR.
- Remove the cooling fan by acting on the three
fixings indicated in the figure.
Removing the stator
- Remove the electric terminal of the minimum oil
pressure switch.
- Remove the two Pick-Up screws and the one for
the wiring harness bracket as well as the two stator
fixing screws shown in the figure.
- Remove the stator and its wiring.
ENG - 103
Engine
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
- Place the cable harness as shown in the figure.
N.B.
THE PICK-UP WIRE SHOULD BE POSITIONED
BETWEEN THE UPPER SCREW AND THE REFERENCE PIN AS SHOWN IN THE DETAIL
DRAWING.
Locking torques (N*m)
Stator screw 3 ÷ 4
Flywheel and starting
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
Specific tooling
020565Y Flywheel lock calliper spanner
- Extract the flywheel with the extractor.
Specific tooling
008564Y Flywheel extractor
ENG - 104
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Inspecting the flywheel components
- Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key
properly.
- Lock the flywheel nut to the prescribed torque
- Check that the Pick-Up air gap is between 0.34
÷ 0.76 mm.
The air gap cannot be modified when assembling
the Pick-Up.
Different values result from deformations visible
on the Pick-Up support.
N.B.
A VARIATION IN THE AIR GAP DISTANCE
MODIFIES THE IGNITION SYSTEM IDLE
SPEED
Locking torques (N*m)
Flywheel nut 52 ÷ 58
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 motor screws 11 ÷ 13
Cylinder assy. and timing system
ENG - 105
Engine
Removing the timing system drive
- Remove the parts listed below first: transmission
cover, belt driving pulley, oil pump pulley cover and
pinion separator washer.
- Remove the tappet cover.
- Remove the central screw fastener and the automatic valve-lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve
lifter assembly and the automatic valve lifter assembly and its end of stroke washer.
- Loosen the central screw on the tensioner first.
- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.
- Remove the internal hex screw and the counterweight shown in the figure.
- Remove the camshaft command pulley and its
washer.
- Remove the command sprocket wheel and the
timing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner pad.
The chain tensioning pad must be removed from
the transmission side. As regards the lower chain
guide pad, it may only be removed after the head
has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
See also
Transmission cover
Removing the driving pulley
Removal
ENG - 106
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Removing the cam shaft
- Remove the two screws and the cam shaft retainer shown in the diagram.
- Remove the cam shaft.
- Remove the pin of the rocking levers from the
flywheel side holes.
- Remove the rocking levers and the elastic washer.
N.B.
MARK THE ROCKING LEVERS ASSEMBLE
POSITION, SO AS TO AVOID THE INVERSION
OF INLET WITH THE OUTLET.
Removing the cylinder head
- Remove the spark plug.
- Remove the 2 side fixings shown in the figure.
- Loosen the 4 head-cylinder fastening nuts in two
or three stages and in criss-cross fashion.
- Remove the head, the two centring dowels and
the gasket.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REENG - 107
Engine
MOVING THE CHAIN AND THE DRIVING
SHAFT CHAIN TIGHTENER.
Removing the valves
- Using the specific tool fitted with the element
shown in the figure, remove the cotters, the plates
and the spring between the valves.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
- Remove the oil seals with the appropriate tool.
- Remove the lower spring supports.
Specific tooling
020431Y Valve oil seal extractor
Removing the cylinder - piston assy.
- Remove the chain guide pad.
- Remove the cylinder base gasket.
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER.
ENG - 108
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- Remove the two stop rings, the wrist pin and the
piston.
- Remove the 3 piston rings from the piston.
N.B.
BE CAREFUL NOT TO DAMAGE THE PISTON
RINGS DURING REMOVAL.
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 check-up: Maximum diameter
15.030 mm
Rod small end check-up: Standard diameter
15 +0.015+0.025 mm
Inspecting the wrist pin
- Check the outer diameter of the gudgeon pin.
Characteristic
Standard pin diameter
14.996 ÷ 15 mm
Minimum diameter permitted
Ø 14.994 mm
ENG - 109
Engine
- Calculate the piston pin coupling clearance.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION
CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED
OUT ACCORDING TO THE AXIS OF THE PISTON.
Characteristic
Piston pin bore - standard diameter
Ø 15+0.001 +0.006
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis.
- Measure 36.5 mm from the piston crown's shown
in the figure.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION
CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED
OUT ACCORDING TO THE AXIS OF THE PISTON.
- Using a bore meter, measure the inner cylinder
diameter at three different points according to the
directions shown in the figure.
- Check that the coupling surface with the head is
not worn or misshapen.
- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out:
0.05 mm
- The cylinder rectifying operation should be carried out with a surfacing that respects the original
angle.
- The cylinder surface roughness should be 0.9
micron.
- This is indispensable for a good seating of the
sealing rings, which in turn minimises oil consumption and guarantees optimum performance.
ENG - 110
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- The pistons are oversized due to cylinder rectification and are subdivided into three categories
1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They
are also classified into 4 categories A-A, B-B, CC, D-D.
Inspecting the piston
- Carefully clean the seal housings.
- Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as
shown in the diagram.
- If the clearance is greater than that indicated in the table, replace the piston.
STANDARD COUPLING CLEARANCE
Name
Top piston ring
Middle piston ring
oil scraper
Description
Dimensions
0.025 ÷ 0.070
0.015 ÷ 0.060
0.015 ÷ 0.060
Initials
Quantity
MAXIMUM ADMITTED CLEARANCE AFTER USE
Name
Top piston ring
Middle piston ring
oil scraper
Description
Dimensions
0.080 mm
0.070 mm
0.070 mm
Initials
Quantity
Removing the piston
- Install piston and wrist pin onto the connecting
rod, aligning the piston arrow the arrow facing towards the exhaust.
- Fit the pin stop ring onto the appropriate tool.
Specific tooling
020430Y Pin lock fitting tool
ENG - 111
Engine
- With the opening in position indicated on the tool,
take stop ring in the closed position using the
punch.
- Fit the wrist pin stop using the plug as shown in
the figure
N.B.
THE TOOL FOR INSTALLING THE STOP
RINGS MUST BE USED MANUALLY.
CAUTION
USING A HAMMER TO POSITION THE RINGS
CAN DAMAGE THE LOCKING HOUSING.
Refitting the piston rings
- Place the oil scraper spring on the piston.
- Refit the oil scraper ring with the join of spring
ends on the opposite side from the ring gap and
the word 'TOP' towards the crown of the piston.
The tapered side of the middle piston ring should
always be facing away from the crown of the piston.
- Fit the middle piston ring with the identification
letter facing the crown of the piston. In any case,
the step must be facing opposite the piston top.
- Fit the top piston ring with the word 'top' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
N.B.
SO AS TO OBTAIN THE BEST CONFIGURATION THE 2 SEALING RINGS ARE MADE WITH
A CONTACT CONICAL CYLINDER SECTION.
ENG - 112
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Refitting the cylinder
- Insert the cylinder base gasket with the thickness
determined above.
- Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND
OIL THE CYLINDER BARREL.
Specific tooling
020426Y Piston fitting fork
020427Y Piston fitting band
Inspecting the cylinder head
- Using a trued bar check that the cylinder head
surface is not worn or distorted.
- Check that the camshaft and rocking lever pin
bearings show no signs of wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
Maximum admitted unevenness: Head check
0.05 mm
STANDARD DIAMETER
Specification
Standard diameter
Standard diameter
Standard diameter
Desc./Quantity
A Ø 32.5 ÷ 32.525
B Ø 20 ÷ 20.021
C Ø 12 ÷ 12.018
ENG - 113
Fly 125 - 150 4T
Engine
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Ensure that the camshaft drive pulley, the chain
assembly and the sprocket wheel are not worn.
- If sings of wear are found, replace the parts. if the
chain, pinion or pulley are worn, replace the whole
assembly.
- Remove the central screw and the tensioner
spring. Check that the one-way mechanism is not
worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
Inspecting the valve sealings
- Measure the width of the sealing surface on the valve seats.
VALVE SEAL SURFACE
Specification
Inlet valve - seal surface
Outlet valve - seal surface
Desc./Quantity
2.4 ÷ 2.8 mm
2.2 ÷ 2.6 mm
Inspecting the valve housings
- Remove any carbon formation from the valve guides.
- Measure the inside diameter of each valve guide.
- Take the measurement at three different heights in the rocker arm push direction.
ENG - 114
Fly 125 - 150 4T
Engine
Characteristic
Standard drainage guide diameter
5.012 mm
Standard inlet guide diameter
5.012 mm
- If the width of the impression on the valve seat or
the diameter of the valve guide exceed the specified limits, replace the cylinder head.
- Check width of the impression on the valve seat
«V»
Characteristic
Wear limits:
Max. 1.6 mm.
Inspecting the valves
- Measure the diameter of the valve stems in the
three positions indicated in the diagram.
- Calculate the clearance between valve and valve
guide.
Characteristic
Minimum diameter admitted - Inlet:
4.96 mm
Minimum diameter admitted - Outlet:
4.95 mm
Standard clearance - Inlet:
0.013 ÷ 0.040 mm
Standard clearance - Outlet:
0.025 ÷ 0.052 mm
Maximum clearance admitted- Inlet:
0.062 mm
Maximum clearance admitted - Outlet:
0.072 mm
ENG - 115
Engine
- Check that there are no signs of wear on the
contact surface with the articulated register terminal.
- If the sealing surface on the valves is wider than
the specified limit, damaged in one or more points
or curved, replace the valve with a new one.
Characteristic
Standard valve length - Inlet:
80.6 mm
Valve standard length: drainage
79.6 mm
- If the checks above give no failures, you can use
the same valves. For best sealing results, it is advisable to grind the valves. Grind the valves gently
with a fine-grained lapping compound. During
grinding, keep the cylinder head in a horizontal
position. This will prevent the lapping compound
residues from penetrating between the valve stem/
guide coupling.
CAUTION
TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE
WHEN NO LAPPING COMPOUND IS LEFT.
CAREFULLY WASH THE CYLINDER HEAD
AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND
BEING USED.
- Insert the valves into the cylinder head.
- Test the 2 valves alternatively.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
ENG - 116
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter
halves show no signs of abnormal wear.
- Check the length clearance of the springs.
Characteristic
Valve spring length
33.9 ÷ 34.4 mm
Refitting the valves
- Lubricate the valve guides with engine oil.
- Place the lower plates of the valve spring on the
head.
- Use the punch to fit the 2 sealing rings one at a
time.
Specific tooling
020306Y Punch for assembling valve seal
rings
- Fit the valves, the springs and the spring retaining
caps. Using the appropriate tool with adapter 11,
compress the springs and insert the cotters in their
seats.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear
on the cams.
Characteristic
Standard diameter Bearing A
Ø: 32.5 mm -0.025 -0.050 mm
Standard diameter Bearing B
20 -0.020 -0.041 mm
ENG - 117
Engine
Minimum admitted diameter bearing A
Ø: 32.440 mm
Minimum admitted diameter bearing B
Ø: 19.950 mm
Inlet cam height
27.512 mm
Outlet cam height
27.212 mm
- Check there is no wear on the cam shaft retaining
plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
Characteristic
Maximum axial clearance admitted
0.42 mm
- Check there are no signs of wear on the automatic valve-lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check there are no signs of scoring or wear on
the rocking lever bolt.
Check there are no signs of wear on the pad from
contact with the cam and on the jointed adjustment
plate.
- Measure the internal diameter of each rocking
lever.
-Check that the elastic washer dedicated to the
axle clearance of the rocking levers is not worn. -
ENG - 118
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
In case of anomalies, replace the damaged components.
Characteristic
Minimum diameter permitted
Ø 11.970 mm
Maximum diameter admitted
Ø 12.030 mm
Refitting the head and timing system components
- Fit the timing chain guide pad.
- Insert the head and cylinder centring dowels, fit the head gasket and the head on the cylinder.
-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.
Locking torques (N*m)
Locking torque 28 ÷ 30
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE
SURE THAT THE LUBRICATION CHANNEL IS
CLEAN USING A COMPRESSED AIR JET.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Fit the timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the tensioner pad by the cylinder head.
- Fit the spacer and the screw fastener.
- Fit the pin, the outlet rocking lever, the spring
washer and the inlet rocking lever.
- Lubricate the 2 rocking levers through the holes
at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams opposing the
rocking levers.
ENG - 119
Engine
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed torque.
Locking torques (N*m)
Locking torque 4 ÷ 6
- Refit the spacer on the cam shaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- While doing so, fit the chain onto the control camshaft pulley and keep the reference 2V in correspondence with the reference mark on the head.
- Fit the pulley onto the camshaft.
- Assemble the counterweight with the corresponding fixing screw and tighten to the specified
torque.
Locking torques (N*m)
Locking torque 7 ÷ 8.5
-Fit the end-stop ring on the automatic valve-lifter
cam and fit the automatic valve-lifter cam to the
cam shaft.
- Fit the automatic valve-lifter return spring.
- During this operation the spring must be loaded
approximately 180°.
N.B.
GREASE THE END STOP RING TO PREVENT
IT COMING OUT AND FALLING INTO THE ENGINE.
ENG - 120
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- Fit the automatic valve-lifter retaining dish, using
the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed torque.
Locking torques (N*m)
Locking torque 12 - 14
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed
torque.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed
torque.
Locking torques (N*m)
Locking torque 5 - 6
- Adjust the valve clearance.
- Fit the spark plug
Electric characteristic
Recommended spark plug:
CHAMPION RG4HC
Electrode gap
0.8 mm
Locking torques (N*m)
Locking torque 12 - 14
- Assemble the casing sealing gasket on the head.
On the fitting direction, use the supplements on the
timing side as reference.
- Assemble the screw fixing the housing to the
crankcase to the specified torque and the 2 selfthreading screws joining the half-shells.
- Take care that the gasket is well inserted in its
housing during the assembly stage.
- Place the spark plug access cap.
Locking torques (N*m)
ENG - 121
Engine
Locking torque 3 ÷ 4
- Fit the inlet manifold and lock the 2 screws to the
specified torque.
- Fit the carburettor onto the inlet manifold and lock
the clamp
N.B.
FIT THE CARBURETTOR THROUGH THE SUPPLEMENT ON THE MANIFOLD.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Refit the cylinder head cover, tightening the 4
clamping screws to the prescribed torque.
- Refit the fan and the housing.
- Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as
described in the lubrication chapter.
- Reassemble the driving pulley, the belt and the
transmission cover as described in the transmission chapter.
Locking torques (N*m)
Locking torque 11 ÷ 13
Crankcase - crankshaft
- Precautionary remove the following units:
transmission cover, driving pulley, driven pulley
and belt, rear hub cover, gears, bearings and oil
seals as described in the transmission chapter.
- Remove the oil sump, the by-pass, the chain
compartment cover and the oil pump as in the lubrication chapter.
- Remove the flywheel cover, the fan, the flywheel
and the stator as described in the magneto flywheel chapter.
- Remove the oil filter and the oil pressure bulb.
- Remove the cylinder-piston-head unit as described in the cylinder head timing system chapter.
- Remove the 2 retainers indicated in the figure
and the starter motor.
ENG - 122
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- Before opening the crankcase, it is advisable to
check the axial clearance of the crankshaft. To do
this, use a plate and a support with specific tool
dial gauge.
Specific tooling
020262Y Crankcase splitting strip
020335Y Magnetic support for dial gauge
Characteristic
Standard clearance
0.15 ÷ 0.40 mm
Splitting the crankcase halves
Remove the 11 coupling screws to the crankcase.
- Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase.
Remove the crankshaft.
CAUTION
IF YOU FAIL TO DO THIS, THE CRANKSHAFT
MIGHT ACCIDENTALLY FALL.
- Remove the coupling gasket of the crankcase
halves.
- Remove the two screws and the internal cover
shown in the diagram.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING THE DRIVING SHAFT, CHECK THAT
THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE
TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS.
ENG - 123
Engine
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram
- Check the axial clearance on the connecting rod.
Characteristic
Standard clearance
0.20 ÷ 0.50 mm
- Check the radial clearance on the connecting rod.
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crankshaft between these surfaces, as shown in the
diagram.
CAUTION
BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH
THE CRANKSHAFT ENDS.
Characteristic
Standard clearance
0.036 ÷ 0.054 mm
- If the axial clearance between crankshaft and
crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN
THE WIDTH IS WITHIN THE STANDARD VALUES AND THE SURFACES SHOW NO SIGNS
OF SCORING.
Characteristic
ENG - 124
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Distance between the shoulders
55.67 ÷ 55.85 mm
- Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces
shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart
below.
STANDARD DIAMETER
Specification
Class 1
Class 2
Desc./Quantity
28.998 ÷ 29.004
28.004 ÷ 29.010
Inspecting the crankshaft alignment
To install the drive shaft on the support and to
measure the misalignment in the 4 points indicated
in figure.
- Check that the driving shaft cone, the tab seat,
the oil seal capacity, the toothed gear and the
threaded tangs are in good working order.
- In case of failures, replace the crankshaft.
The connecting rod head bushings cannot be replaced. For the same reason, the connecting rod
may not be replaced and, when cleaning the
crankshaft, be very careful that no impurities get in
through the shaft's lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
ENG - 125
Engine
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
N.B.
THE MAIN BEARINGS ARE NOT GRINDABLE
Specific tooling
020074Y Support base for checking crankshaft
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
Inspecting the crankcase halves
- Before proceeding to check the crankcase
halves, thoroughly clean the all surfaces and oil
ducts.
- On the transmission side crankcase half, take
particular care cleaning the housing and oil ducts
for the following components: the oil pump, the oil
by-pass valve, the main bushings and the cooling
jet on the transmission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the valve, which regulates the oil pressure.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE PISTON TOP COOLING.
CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE
INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING
AND CONNECTING ROD LUBRICATION PRESSURE.
ENG - 126
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the flywheel side oil seal.
N.B.
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A
"LOW PRESSURE" HEAD LUBRICATION; THIS
CHOICE WAS MADE TO REDUCE THE OIL
TEMPERATURE IN THE SUMP. THE JET
CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET
FAILURE CAUSES A DECREASE OF THE MAIN
BUSHING AND CONNECTING ROD LUBRICATION PRESSURE.
- Inspect the mating surfaces on the crankcase
halves for scratches or deformation, taking particular with the surfaces that mate with the cylinder
and the mating surfaces between the crankcase
halves.
- Defects in the crankcase coupling gasket or the
surfaces indicated in the figure can cause a drop
in the oil pressure and affect the lubricating pressure for the main bushings and the connecting rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and dimensions.
ENG - 127
Fly 125 - 150 4T
Engine
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two halfbearings, one containing holes and channels for
lubrication and the other solid.
- The solid half-bearing is intended to stand the
thrusts caused by combustion, and for this reason
it is arranged opposed the cylinder.
- To prevent shutters in the oil feeding channels,
the matching surface of the two half-bearings must
be perfectly orthogonal to the cylinder axis, as
shown in the figure.
- The oil supply channel section is also affected by
the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP THIS POSITION OF THE BUSHINGS
ON THE CRANKCASE, FITTING IS FORCED ON
STEEL RINGS INSERTED IN THE CASTING OF
BOTH CRANKCASE HALVES.
Characteristic
Standard driving depth
1.35 ÷ 1.6
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- The standard bushing diameter after driving is variable on the basis of a coupling selection.
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
3 - The main bushings are subdivided into 3 thickness categories; see the table below:
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE
THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
MAIN BEARINGS
Specification
B
ENG - 128
Desc./Quantity
Blue
Fly 125 - 150 4T
Specification
C
E
Engine
Desc./Quantity
Yellow
Green
Refitting the crankcase halves
- Fit the internal bulkhead by locking the two
screws to the prescribed torque.
Locking torques (N*m)
Locking torque 4 ÷ 6
- Fit the oil filter joint and tighten it to the prescribed
torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, together with the locating dowels.
Locking torques (N*m)
Locking torque 27 ÷ 33
- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half.
- Reassemble the two crankcase halves.
- Fit the 11 screws and tighten them to the prescribed torque.
N.B.
WHEN FITTING THE HALF CASING AND THE
CRANKSHAFT, TAKE CARE NO TO DAMAGE
THE SHAFT THREADED TANGS.
ENG - 129
Engine
Locking torques (N*m)
Locking torque 11 ÷ 13
- Lubricate the flywheel oil seal.
- Use the appropriate tool to assemble the oil seal.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the pre-filter on the engine with its corresponding cover to the specific torque.
N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER
PLANE, TO ENSURE BETTER SEALING PERFORMANCE.
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN
RESULT IN AN INCORRECT DEPTH POSITION
AND AS A CONSEQUENCE IN INADEQUATE
OIL SEALING.
Specific tooling
020425Y Punch for flywheel-side oil seal
Locking torques (N*m)
Locking torque 24 ÷ 30
Lubrication
ENG - 130
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Conceptual diagrams
ENG - 131
Engine
Oil pressure check
- After removing the cover protections as described in the "Flywheel" chapter, disconnect the electrical connexion of the minimum oil pressure
switch and then remove the switch.
- With the engine idling at 1650 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 0.5 ÷ 1.2 atm.
- With the engine idling at 6000 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 3.2 ÷ 4.2 atm.
- Remove the appropriate tools once the measurement is complete, refit the oil pressure switch
and washer, tightening it to the prescribed torque
and fit the fan cover.
- If the oil pressure is outside the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH
OIL AT THE CORRECT LEVEL AND WITH AN
OIL FILTER IN GOOD CONDITION.
Characteristic
Minimum pressure admitted
3.2 atm.
Locking torques (N*m)
Locking torque 12 ÷ 14 (also valid for the control connector).
Crankshaft oil seals
ENG - 132
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Removal
- First remove the transmission cover and the complete driving pulley
- Install the base of the appropriate tool on the oil
guard using the screws provided.
- Screw the threaded bar onto the base of the tool
and extract the oil guard.
Specific tooling
020622Y Transmission-side oil guard punch
Refitting
- Prepare the new oil guard, lubricating the sealing
lip. Warning: do not lubricate the surface for keying
onto the engine crankcase.
CAUTION
DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO THE ENGINE CRANKCASE.
ENG - 133
Engine
- Preassemble the oil seal with the appropriate
tool, positioning the screws
- Place the sheath over the crankshaft
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase
CAUTION
ORIENT THE OIL GUARD BY POSITIONING
THE CHAIN HOUSING CHANNEL FACING
DOWNWARDS. WHEN THE POSITION IS
REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS
RULE CAN CAUSE A WRONG POSITIONING
OF THE OIL GUARD SHEATH.
- Orientate the oil guard by inserting the bracket
which is part of the specific tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
ENG - 134
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- Use the nut to move the base of the tool until you
can see end of the oil seal driving stroke
- Remove all of the tool components following the procedure in reverse order
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE
ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.
Assemble a new oil seal on the flywheel side using
the specific tool as shown in the photograph
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN
RESULT IN AN INCORRECT DEPTH POSITION
AND AS A CONSEQUENCE IN INADEQUATE
OIL SEALING.
Specific tooling
020425Y Punch for flywheel-side oil seal
Oil pump
Removal
- Remove the cover of the pump control pulley using the two retainers, as shown in the figure.
- Block the rotation of the oil pump control pulley
using a screwdriver inserted through one of its two
holes.
ENG - 135
Engine
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the pulley.
- Remove the crankshaft control pinion.
- Remove the oil pump acting on the 2 retainers as
shown in the figure.
- Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.
- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the
clip.
- Using a thickness gauge, check the distance between the rotors in the position shown in the figure.
Characteristic
Maximum clearance admitted
0.12 mm
ENG - 136
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Measure the distance between the outer rotor and
the pump body; see figure.
Characteristic
Admissible limit clearance:
0.20 mm
Check the axial clearance of the rotors with a trued
bar as reference, as shown in the figure.
Characteristic
Limit values admitted:
0.09 mm
Refitting
- Check there are no signs of wear on the oil pump
shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the assembly.
- Fit the pulley to the pump, the central screw to
the specified torque and the belleville washer.
-Fit the oil pump cover, by tightening the two
screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS
OUTER (CURVED) RIM TOUCHES THE PULLEY.
Locking torques (N*m)
Central screw 12 ÷ 14 Nm Cover screws 0.7 ÷
0.9 Nm
ENG - 137
Engine
Removing the oil sump
- Remove the oil filler plug, the transmission cover,
the complete drive pulley assembly with belt and
the sprocket wheel, as described in the Transmission chapter.
- Drain the oil from the sump as described above.
- Remove the 7 screws indicated in the figure and
the 2 rear brake transmission fixing brackets.
- Remove the spring, the by-pass piston and the
gasket shown in the second image.
Inspecting the by-pass valve
- Check the unloaded spring length.
- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defective parts.
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 138
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Refitting the oil sump
- Refit the by-pass valve plunger in its housing.
- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the sump, taking care to locate the spring in
the appropriate recess machined into the inside of
the sump.
- Refit the rear brake transmission support brackets and the screws in the reverse order from which
they were removed.
- Tighten the screws to the prescribed torque.
- Refit the drive pulley assembly, the drive belt, the
sprocket wheel and the transmission cover, as described in the "Transmissions" chapter.
- When testing the lubrication system, refer to
the "Crankcase and Crankshaft" chapter, regarding lubrication of the crankshaft and connecting rod
Locking torques (N*m)
Locking torque 11 ÷ 13
Fuel supply
- 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 MITIVAC 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.
ENG - 139
Engine
N.B.
THE MEASUREMENT MAY BE FALSIFIED BY
THE INCORRECT 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 MityVac vacuum-operated pump
Characteristic
Minimum flow rate
20 cc
- Completely empty the gas tank.
- Remove the petrol delivery tube and the suction
tube.
- Loosen the clip and remove the tap.
- Clean the tank and the filter of the tap with a specific solvent.
- Refit the tap making sure that there is an O-Ring.
- Turn the tap 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.
Removing the carburettor
- To detach the carburettor from the engine, it is
necessary to move the air filter and remove the
throttle control transmission, the automatic starter
connection, the clamps anchoring the carburettor
to the filter housing and to the inlet manifold, the
air delivery pipe to the diaphragm, the heater and
the intake fitting.
ENG - 140
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- Remove the protection, the bracket and the starter acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with
the gasket.
- Remove the clamp and cover with the airing filter
of the diaphragm chamber.
- Remove the 4 fixing screws shown in the figure
and the vacuum chamber cover.
WARNING
DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO
RELEASE THE SPRING ACCIDENTALLY.
ENG - 141
Engine
- Remove the vacuum valve together with the diaphragm.
- Unscrew the bayonet joint 1/8 of a turn and remove, take out the spring and vacuum valve needle
- Remove the 4 screws indicated in the figure.
ENG - 142
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- Remove the chamber with the accelerating
pump, its control and gasket.
- Remove the oil pump seal.
- Remove the intake and outlet valves of the intake
pump from the tank
N.B.
CAUTION, THE ACCELERATION PUMP
VALVES ARE MADE UP OF NOZZLES, SPRING
AND BALL.
N.B.
AVOID REMOVING THE PISTON OF THE PUMP
AND ITS CONTROL.
Adequately support the carburettor and using a
rod and hammer remove the float pin acting from
the throttle control side.
- Remove the float and the plunger.
- Remove the maximum nozzle
ENG - 143
Engine
-Remove the maximum nozzle.
-Remove diffuser.
ENG - 144
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
- Remove the sprayer.
N.B.
WHEN CLEANING THE CARBURETTOR BODY
REMOVE THE SPRAYER TO AVOID LOSING
PARTS. IF THE SPRAYER IS FORCED IN ITS
HOUSING DO NOT ATTEMPT TO REMOVE IT
AS THIS WILL ONLY DAMAGE IT.
-Remove the minimum nozzle.
- Remove the minimum flow set screw and the
spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH
AS: FUEL SUPPLY PIPE, PLUNGER HOUSING,
STARTER NOZZLE, PIT COVER FOR PROGRESSIONS AND INLET NOZZLE, MINIMUM
AND MAXIMUM AIR GAUGE, THROTTLE
VALVE CONTROL SHAFT. DO NOT REMOVE
THROTTLE-SHAFT CONNECTION SCREWS.
THE FIXING SCREWS ARE CAULKED AFTER
ASSEMBLY AND THEIR REMOVAL DAMAGES
THE SHAFT.
ENG - 145
Engine
Fly 125 - 150 4T
Refitting the carburettor
- Before refitting, wash the carburettor body accurately with petrol and compressed air.
- Pay special attention to the fuel supply pipe and
the plunger seat.
- For maximum circuit, check the air adjustment is
correct as shown in the figure.
- For the minimum circuit, make sure the following
points are properly cleaned: air gauging, outlet
section controlled by flow screw, progression
holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the
nozzle support hides other inaccessible internal calibrations.
- Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE
THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAYING.
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
ENG - 146
Fly 125 - 150 4T
Engine
- Check that the coupling surfaces, the tank and the diaphragm are not dented.
-Check that the depression valve housing pipe is not scratched.
- Check that the throttle valve and the shaft do not show abnormal wear.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
- Wash and blow the minimum nozzle properly and
reassemble it.
- Properly wash and blow the components of the
sprayer maximum circuit, the diffuser and the nozzle.
- Introduce the sprayer in the carburettor body with
the shortest cylindrical part directed to the diffuser.
- Assemble the diffuser making sure the sprayer is
being adequately inserted and lock it.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs
of wear on the sealing surfaces of the shock absorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that
there are no fuel infiltration.
- Replace it in case of anomalies.
ENG - 147
Fly 125 - 150 4T
Engine
- Introduce the float with the rod on the fuel feeding tube side.
N.B.
INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
- Remove the drainage screw from the tank, wash
and blow it properly and make sure the acceleration pump pipes are clean.
- Operate the acceleration pump piston repeatedly
and blow with compressed air.
- Reassemble the acceleration pump valves following this order:
INTAKE VALVE (A)
•
Spring
•
Ball
•
Nozzle
IN VALVE (M)
•
Ball
•
Spring
•
Nozzle
N.B.
THE IN VALVE NOZZLE, CORRESPONDING
TO THE ACCELERATION PUMP, IS MILLED.
-Check the screw tightness introducing a small
amount of fuel in the tank.
- Assemble a new gasket on the tank.
- Assemble the tank on the carburettor body fastening the 4 screws.
- Check that the control roller is free to rotate in its
own seat.
N.B.
MAKE SURE THE TANK GASKET IS CORRECTLY INTRODUCED
N.B.
AVOID DEFORMING THE ACCELERATION
PUMP CONTROL ROCKING LEVER.
ENG - 148
Fly 125 - 150 4T
Engine
- Wash and blow the flow screw properly.
- Check that screw is not deformed and/or rusty.
- Assemble the spring on the screw.
- Screw the flow screw on the carburettor body.
- The screw final position should be determined by an exhaust fume analysis.
- Adjust the carburettor by turning the screw twice from the close position.
Level check
- Place the carburettor inclined as shown in the
figure.
- Check that the float reference is parallel to the tank coupling surface
- If different positions are detected, change the plunger control metal plate direction to obtain the position
described above.
ENG - 149
Fly 125 - 150 4T
Engine
•
Insert a transparent rubber pipe to the bleeding intake of the fuel tank.
•
Keep the pipe up so that the ends are higher than the venturi pipe.
•
Unscrew the bleed screw and stabilise the petrol level, then measure as shown in the diagram.
ENG - 150
Fly 125 - 150 4T
Engine
Inspecting the valve and needle
- Check that the tapered pin of the vacuum valve
does not show wear.
- Check that the depression valve does not show
threads on the external surfaces.
- Check that the vacuum intake hole is not clogged.
- Check that the diaphragm is not damaged or has
hardened, otherwise replacement the whole valve.
- Insert the tapered pin into the vacuum valve
housing.
- Reassemble the vacuum valve on the carburettor
body taking care that the tapered pin is inserted
into the sprayer.
N.B.
THE VALVE CAN BE INSERTED IN ONLY ONE
POSSIBLE POSITION.
- Reassemble the spring with the pin lock.
- Remove the cover of the vacuum chamber being
careful to correctly insert the spring in its place on
the cover.
- Tighten the screws.
ENG - 151
Engine
- Wash and blow dry the filter sponge of the ambient pressure intake.
- Reassemble the filter with its clamp.
- Wash and blow dry the starter support.
Assemble a new gasket on the carburettor body
and tighten the 2 fixing screws.
ENG - 152
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
Inspecting the automatic choke device
- Check that the automatic starter piston is not deformed or rusty.
- Check that the piston slides freely from the seat
to the support.
- Check that the piston sealing gasket is not deformed.
- The starter must be more or less functional depending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the ambient temperature.
- The starter should disconnect progressively by
means of electrical heating.
- Check the starter resistance when adjusted to the
ambient temperature.
With a 12V battery power the automatic starter and
check that the piston protrudes as much as possible.
- The correct warm up time depends on the ambient temperature.
- If protrusion, resistance or timing values are different from the ones prescribed, replace the starter.
- Assemble the starter to the carburettor being
careful to position the O-Ring correctly, insert the
plate with the machined side contacting the starter,
tighten the fixing screws.
- Position the starter as shown in the figure.
- Assemble the protection casing.
N.B.
TO CARRY OUT THIS CHECK PAY SPECIAL
ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNECTED TO THE
STARTER.
Characteristic
ENG - 153
Engine
Check the automatic starter: Kehin: Protrusion
value
XX ÷ XX mm at approx. 20°C
Check the automatic starter: Kehin maximum
protrusion
XXX ÷ XXX mm
Check the automatic starter: Keihin maximum
time
5 min
Adjusting the idle
- The engine does not require frequent adjustment
of the idle, however it is important that this adjustment be made in complete compliance with a few
rules.
- Before adjusting the carburettor make sure that
the following conditions are met: good lubrication,
valve play and distribution timing conform, spark
plug in excellent conditions, air filter clean and
sealed, exhaust system completely sealed. Warm up the engine for at least 5 minutes at
around 50 Km/h.
- Connect the vehicle to an exhaust analyser inserting the analyser probe into a extension hose
fitted airtight to the outlet of the silencer.
- Connect the thermometer of the multimeter
(020331y) to the sump, using the oil cap specifically made for insertion of the probe.
- Start the engine before adjusting the idle speed,
making sure the oil temperature is between 70 - 80
°C.
- Using the analyser revolution counter or a separate one (020332y), adjust the idle until obtaining
a speed of 1600 - 1700 rpm.
- Adjust the flow screw until obtaining a percentage
of carbon monoxide (CO) of 3.1
ENG - 154
Fly 125 - 150 4T
Fly 125 - 150 4T
Engine
â 4.5%, by loosening the screw the CO value increases (rich mixture) by tightening the CO value
decreases (thin mixture).
- If correction of the flow screw position leads to an
increase in speed, adjust the revolutions again and
if necessary the flow screw until stabilised values
are achieved.
- Idle carburetion is considered correct when the
values of oil temperature, number of revolutions
and percentage of carbon monoxide are correct.
Additional information can be obtained from the
analyser:
- the percentage of carbon dioxide (CO2), the percentage of carbon dioxide has a reverse trend
compared to the percentage of (CO), values above
12.5% are considered correct. Values out of this
range are considered as an indication of a nonairtight condition on the exhaust system.
- Unburnt hydrocarbons (HC) are measured in
parts per million (PPM), the value of the HC decreases with increased rpm, with the engine idling
it is normal to measure 200
â 400 PPM, these exhaust values are considered
normal for an engine with motorcycle distribution
diagram. Much higher values can be caused by
engine misfiring due to a too thin mixture (low CO),
ignition defects or incorrect distribution timing or a
stuck or non-airtight exhaust valve.
- If the CO is difficult to adjust, carefully check:
- Cleaning of the carburettor
- Correct working order of the automatic starter
- Correct working order of the tapered pin-seat
- Bowl level
N.B.
THE EXTENSION TUBE IS INDISPENSABLE
SO AS NOT TO SEND POLLUTED EXHAUST
FUMES TO THE AMBIENT OXYGEN. IT IS INDISPENSABLE TO USE AN EXHAUST FUMES
ANALYSER PREVIOUSLY HEATED AND PREPARED TO GUARANTEE THE RESET OF THE
ENG - 155
Engine
READING OF GASES AND THE CORRECT
GAS CAPACITY. FAILURE TO RESPECT
THESE REGULATIONS RESULTS IN INACCURATE READINGS.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS
MAY NOT BE ACCURATE IF INADEQUATE
RPM INDICATORS ARE USED. CORRECT
COUPLING OF THE RPM INDICATOR WILL BE
INDICATED WHEN IT CAN READ RPM OVER
6000 ÷ 8000
Characteristic
Idle adjustment: Pipe sizes
Ø 40 mm
Idle adjustment: length
500 ÷- 600 mm
ENG - 156
Fly 125 - 150 4T
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
Fly 125 - 150 4T
Sospensioni anteriore
This section is devoted to operations that can be carried out on the suspension.
Front
Removing the front wheel
- Remove the wheel axle locking 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
Cuscinetti a sfere sul mozzo ruota
- 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 disk side; insert handle on the side the rpm indicator detects movement, as shown in the photo
SUSP - 158
Fly 125 - 150 4T
Suspensions
- Check that the bearings do not show flaws or
jamming. If there is, replace it.
- Check that the internal spacer does not show abnormal wear. If there is, 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 disk side
- Insert the spacer bushing on the brake disk 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 disk side, as shown in the photo
- Use an appropriate tool to insert the bearing on
the rpm indicator movement detector side
Specific tooling
001467Y009 Driver for OD 42 mm bearings
001467Y014 Pliers to extract ø 15-mm bearings
020357Y 32 x 35 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 put the odometer movement sensor out of phase at 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 - 159
Suspensions
Handlebar
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 operations in the reverse order to the
removal, observing the prescribed tightening torque.
Locking torques (N*m)
Handlebar fixing screw 50 ÷ 55
Front fork
Overhaul
Replacement of seal ring rod disassembly
- 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).
SUSP - 160
Fly 125 - 150 4T
Fly 125 - 150 4T
Suspensions
- 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
Refitting
When fitting the fork, lubricate with the steering
bearing tracks with the recommended grease.
Tighten the lower ring nut "A" and the upper ring
nut "B" to the specified torque
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 C
and +120 C; NLGI 2; ISO-L-XBCIB2.
Locking torques (N*m)
Steering lower ring nut 8 ÷ 10 Steering upper
ring nut 35 ÷ 40
SUSP - 161
Fly 125 - 150 4T
Suspensions
Steering column
Refitting
Upper and lower seat on chassis
Lower and upper seating on the chassis
LOWER AND UPPER SEATING ON THE CHASSIS
Titolo
Durata/
Valore
Testo
Indirizzo
Breve (< Immagine
4000 car.)
Lower and
upper
seating on
the chassis
Steering bearing
Steering bearing upper seat
Removal
Lower and upper races from frame
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
Lower and upper seating from the chassis
Washer and upper bearing upper seat
After removing the upper seating, tilt the vehicle to
a side and take out the steering tube making sure
mudflaps have been removed and the calliper disconnected.
SUSP - 162
Testo Breve (< 4000
car.)
Indirizzo Immagine
Fly 125 - 150 4T
Suspensions
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.
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 battery access flap to reach and remove the shock
absorber/ frame anchoring nut. Then remove the
shock absorber/engine anchorage nut.
- When refitting, tighten the shock absorber/frame
anchoring nut and the shock absorber/engine pin
to the specified torque.
Locking torques (N*m)
SUSP - 163
Suspensions
Shock absorber/engine pin torque 33 to 41
N·m Shock absorber/frame nut torque 20 to 25
Nm
Centre-stand
Complete centre stand replacement
- Undo the screw marked in the figure.
- When refitting, secure to the prescribed torque.
Locking torques (N*m)
Centre stand screw 32 ÷ 40
SUSP - 164
Fly 125 - 150 4T
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
Front brake calliper
Removal
- Inspect the condition of the hoses, packing and
joint. In the event of fluid leaks from the calliper,
this must be replaced.
- Detach the oil brake pipe from the calliper; pour
the fluid inside a container.
- Remove the clamps shown in the figure.
Overhaul
Proceed as follows:
1) remove the two male hexagonal screws (1) and
take out the two pads (10);
2) remove the two male hexagonal screws (2) and
remove the reaction plate (3);
3) take out the fixed plate (4) from the guide;
4) remove the internal elements from the floating
body (5) with the help of short blows of compressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
- that the cylinder and the floating body of the calliper do not show signs of scratches or erosion,
otherwise replace the entire calliper;
- that the guides of the fixed plate are not scratched
or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.
Reassembly
1) insert the pistons (6) and the sealing rings (7) in
the body;
BRAK SYS - 166
Fly 125 - 150 4T
Fly 125 - 150 4T
Braking system
2) place the guide rubbers (8) and refit the fixed
plate (4);
3) assemble the reaction plate (3) tightening the
screws (2), insert the brake pad check spring (9)
and then the pads, fixing them with the corresponding screws (1);
5) place the calliper on the disc and lock it to the
strut by tightening the fixing screws;
6) fix the pipe joint on the calliper at the prescribed
torque.
Functioning
This is a floating type calliper.
It takes advantage of the action and reaction principle to obtain the thrust for both pads.
The body and the reaction plate body work integrally and can move axially with respect of the
fixed plate that is integral to the strut.
The pistons, forced by pressure to push the pad to
the disk, cause the reaction plate to push in turn
the other pad towards the disc.
The brake pad lock spring
1. Pad fixing screws
2. Reaction plate fixing screws
3. Reaction plate
4. Fixed plate
5. Floating body
6. Piston
7. Piston sealing rings
8. Guide protection rubbers
9. Brake pad check spring
10. Pads
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE CALLIPER IS
SERVICED.
Locking torques (N*m)
Calliper tightening screw 24 ÷ 27 Brake fluid
tube- calliper fitting 19 ÷ 24
BRAK SYS - 167
Braking system
Fly 125 - 150 4T
Refitting
- When refitting, tighten the nuts to the prescribed torque.
- Bleed the system.
N.B.
WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS.
Locking torques (N*m)
Oil bleed screw 7 ÷ 10 Calliper tightening screw 24 ÷ 27 Brake fluid tube- calliper fitting 19 ÷ 24
See also
Front
Front brake disc
Removal
- Remove the front wheel undoing the axle clamping.
- Undo the five disc clamps.
Locking torques (N*m)
Disc tightening screw 8 ÷ 10
Refitting
-When refitting, position the disc correctly making sure that it rotates in the right direction.
Locking torques (N*m)
Disc tightening screw 8 - 12
BRAK SYS - 168
Fly 125 - 150 4T
Braking system
Disc Inspection
- Remove the wheel and check for unevenness of
the disc.
Maximum permissible out of true is 0.1 mm. If the
value measured is greater, fit a new disc and repeat the check.
- If the problem persists, check and replace the
wheel rim if necessary.
Specific tooling
020335Y Magnetic support for dial gauge
Front brake pads
Removal
Proceed as follows:
- Remove the front calliper.
- Loosen the two pins shown in the figure that lock
the two pads.
- Remove the pads, being careful of the pads'
spring clamp.
- Check the thickness of the pads.
Characteristic
Minimum value
1.5 mm
See also
Front brake calliper
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
BRAK SYS - 169
Braking system
Fly 125 - 150 4T
Locking torques (N*m)
Screw tightening calliper to the support 20 ÷ 25 Pad fastening pin 19.6 ÷ 24.5
Fill
Front
-Once the bleed valve is closed, fill the system with
brake liquid to the maximum level.
-Undo the bleed screw.
-Apply the tube of the special tool to the bleed
screws.
When bleeding it is necessary to fill the oil tank in
continuation while working with a MITYVAC pump
on the bleed screws until no more air comes out of
the system.
The operation is finished when just oil comes out
of the bleed screws.
-Do up the bleed screw.
-When the operation is over, tighten up the oil
bleed screw to the prescribed torque.
N.B.
IF AIR CONTINUES TO COME OUT DURING
PURGING, EXAMINE ALL THE FITTINGS:
IF SAID FITTINGS DO NOT SHOW SIGNS OF
BEING FAULTY, LOOK FOR THE AIR INPUT
AMONG THE VARIOUS SEALS ON THE PUMP
AND CALLIPER PISTONS.
CAUTION
- DURING THE OPERATIONS, THE VEHICLE
MUST BE ON THE STAND AND LEVEL.
N.B.
DURING PURGING FREQUENTLY CHECK THE
LEVEL TO PREVENT AIR GETTING INTO THE
SYSTEM THROUGH THE PUMP.
WARNING
- BRAKING CIRCUIT FLUID IS HYGROSCOPIC.
IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR.
IF THE LEVEL OF HUMIDITY IN THE BRAKING
FLUID EXCEEDS A GIVEN VALUE, BRAKING
EFFICIENCY WILL BE REDUCED.
THEREFORE, ALWAYS USE FLUID FROM
SEALED CONTAINERS.
BRAK SYS - 170
Fly 125 - 150 4T
Braking system
UNDER NORMAL DRIVING AND CLIMATIC
CONDITIONS YOU SHOULD CHANGE THIS
LIQUID EVERY TWO YEARS.
IF THE BRAKES ARE USED INTENSELY AND/
OR IN HARSH CONDITIONS, CHANGE THE
FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION,
BRAKE FLUID MAY LEAK FROM BETWEEN
THE BLEED SCREW AND ITS SEAT ON THE
CALLIPER.
CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE OIL
ON IT.
Specific tooling
020329Y MityVac vacuum-operated pump
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Locking torques (N*m)
Oil bleed screw 7 ÷ 10
Front brake pump
-After removing the front and rear handlebar covers, act on the two stand fixing points (see the figure).
- Disconnect the tube, collecting the brake oil in a container.
- On refitting, perform the operation in reverse.
- Tighten the hydraulic line to the prescribed torque
and bleed the system.
Locking torques (N*m)
Brake fluid pump - hose fitting 16 ÷20 Nm
BRAK SYS - 171
Braking system
Removal
- Bleed the circuit and drain the brake fluid through
the bleeding screw located on the calliper and actuate the brake lever until no more fluid flows out.
-Remove the oil pump from the handlebar; remove
the brake lever and then remove the wheel cylinder.
1 - Tank cap screw.
2. Tank cover.
3. Diaphragm.
4. Bellows.
5. Sealing ring.
6. Piston.
7. Gasket.
8 - Spring
CAUTION
- THE PRESENCE OF BRAKE FLUID ON THE
DISC OR BRAKE PADS REDUCES THE BRAKING EFFICIENCY.
IN THIS CASE, REPLACE THE PADS AND
CLEAN THE DISC WITH A HIGH-QUALITY SOLVENT.
CONTACT WITH BRAKE FLUID WILL DAMAGE
PAINTED SURFACES.
RUBBER PARTS SHOULD NEVER BE LEFT IN
ALCOHOL FOR LONGER THAN 20 SECONDS.
AFTER WASHING, THE PIECES MUST BE
DRIED WITH A BLAST OF COMPRESSED AIR
AND A CLEAN CLOTH.
THE SEALING RINGS MUST BE IMMERSED IN
THE OPERATING LIQUID.
Refitting
Before fitting, the parts must be perfectly clean and
free of traces of oil, diesel fuel, grease, etc.. They
should be washed thoroughly in denatured alcohol
before proceeding.
- Reinstall the individual parts in the reverse order
to the removal, paying attention to the correct positioning of the rubber parts in order to ensure leak
tightness.
1 - Tank cap screw.
BRAK SYS - 172
Fly 125 - 150 4T
Fly 125 - 150 4T
Braking system
2. Tank cover.
3. Diaphragm.
4. Bellows.
5. Sealing ring.
6. Piston.
7. Gasket.
8. Spring.
Rear drum brake
Once the muffler and the wheel have been removed, follow these steps:
1.Remove the shoe spring using the specific spanner.
2. Remove the shoe with the aid of a lever.
3. Refit the new shoes giving a few taps with the
mallet.
4. Attach the spring using the specific pliers.
Specific tooling
020325Y Brake-shoe spring calliper
BRAK SYS - 173
INDEX OF TOPICS
CHASSIS
CHAS
Fly 125 - 150 4T
Chassis
Removing the ignition key-switch when on *off*
• Remove the shield back plate
• Push the lock body until the stop spring does not
show grooves.
• Keep the lock body blocked with a screwdriver
and remove the spring with a pair of pliers.
• Take out the lock block.
Removing the ignition key-switch when on *lock*
Remove the shield.
- Remove the switch of the key switch.
- Make a hole on the block using a drill as shown
in the figure.
- Insert the wheel cylinder with the key and with the
anchoring tab facing down halfway on the lock
body taking care that the insertion phase of the key
is oriented matching "ON" (the only position that
enables the cylinder to get into the lock body); now
turn the key leftwards to "OFF" and at the same
time press until the cylinder is completely in.
Footrest
- Remove the side fairings
- Remove the shield back plate
- Remove the 6 screws shown in the photograph
CHAS - 175
Chassis
Air filter
• Unscrew the 7 cover screws and remove the
cover to reach the filter sponge.
• To disassemble the filter housing, unscrew the 2
bottom screws and disconnect the manifold connections, the carburettor and the external air intake.
Rear mudguard
- Remove the side fairings
- Remove the 4 screws shown in the photograph
CHAS - 176
Fly 125 - 150 4T
Fly 125 - 150 4T
Chassis
Helmet bay
- Remove the side fairings
- Remove the helmet compartment by undoing the
4 screws indicated in the figure
Fuel tank
- Remove the side fairings
- Remove the rear mudguard
- Remove the crews shown in the photograph
- Remove the shock absorber upper clamping in
order to create the necessary space to take out the
tank.
CHAS - 177
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Fly 125 - 150 4T
Pre-delivery
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
Lock check
- Safety locks
- clamping screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
Electrical system
- Main switch
- Headlamps: high beam, low beam, position and parking lights and the respective warning lights
- Adjusting the headlights according to the regulations currently in force
- Tail light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument lighting
- Instrument panel: fuel gauge
- Instrument panel warning lights
- Horn
- Starter
PRE DE - 179
Pre-delivery
Fly 125 - 150 4T
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
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, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
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.
Levels check
Level check:
- Hydraulic brake system fluid level.
- Rear hub oil level
- Engine oil level
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
PRE DE - 180
Fly 125 - 150 4T
Pre-delivery
Static test
Static control after the test ride:
- Starting when warm
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional check up:
Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 181
INDEX OF TOPICS
TIME
TIME
Fly 125 - 150 4T
Time
Engine
ENGINE
1
Code
001001
Action
engine from frame - removal
and refitting
Duration
TIME - 183
Fly 125 - 150 4T
Time
Crankcase
CRANKCASE
1
Code
001133
2
001153
3
002031
TIME - 184
Action
Engine crankcase - Replacement
Half crankcase gasket - Replacement
Rear wheel hub bearings Replacement
Duration
Fly 125 - 150 4T
Time
Crankshaft
CRANKSHAFT
1
2
Code
001117
001099
Action
Crankshaft - Replacement
Oil seal, flywheel side - Replacement
Duration
TIME - 185
Fly 125 - 150 4T
Time
Cylinder assy.
CYLINDER GROUP
1
Code
001002
2
001107
TIME - 186
Action
Cylinder-Piston - Replacement
Cylinder / piston - Inspection /
cleaning
Duration
Fly 125 - 150 4T
Time
Cylinder head assy.
HEAD UNIT
1
2
3
Code
001045
001056
001126
Action
Valves - Replacement
Head gasket - change
Head - Replacement
Duration
TIME - 187
Fly 125 - 150 4T
Time
Rocker arms support assy.
ROCKING LEVER SUPPORT UNIT
1
2
Code
001044
001148
3
001049
TIME - 188
Action
Camshaft - Replacement
Rocking lever valve - Replacement
Valves - Adjustments
Duration
Fly 125 - 150 4T
Time
Cylinder head cover
HEAD COVER
1
2
Code
001089
001088
3
001159
4
5
6
7
001093
001097
001091
001074
Action
Head cover - Replacement
Head cover gasket - Replacement
Oil vapour recovery tank Service
Spark plug - Replacement
Cooling hood - Replacement
Head cover sealing ring
Oil vapour recovery pipe - Replacement
Duration
TIME - 189
Fly 125 - 150 4T
Time
Chain tensioner
CHAIN TIGHTENER
1
Code
001129
2
001124
TIME - 190
Action
Chain tensioner - Service and
Replacement
By pass lubrication - Replacement
Duration
Fly 125 - 150 4T
Time
Oil filter
OIL FILTER
1
2
Code
001123
001160
3
4
003064
001102
Action
Oil filter - Replacement
Oil pressure sensor - Replacement
Engine oil - Change
Mesh oil filter - Replacement /
Cleaning
Duration
TIME - 191
Fly 125 - 150 4T
Time
Flywheel cover
FLYWHEEL COVER
1
Code
001087
2
001163
3
001161
4
5
001174
001164
TIME - 192
Action
Flywheel cover - Replacement
Muffler secondary air connection - Replacement
Secondary air filter - Replacement / Cleaning
SAS valve - Replacement
Crankcase secondary air
connection - Replacement
Duration
Fly 125 - 150 4T
Time
Driven pulley
DRIVEN PULLEY
1
Code
001155
2
3
4
001022
001012
001110
Action
Clutch bell housing - Replacement
Clutch - Replacement
Driven pulley - Overhaul
Driven pulley - Replacement
Duration
TIME - 193
Fly 125 - 150 4T
Time
Oil pump
OIL PUMP
1
2
Code
001051
001125
3
4
5
6
001042
001112
001130
001100
7
001122
TIME - 194
Action
Belt/Timing chain - Change
Chain guide pads - Replacement
Oil pump - Service
Oil pump - change
Oil sump - Replacement
Oil seal, clutch side - Replacement
Oil pump chain - Replacement
Duration
Fly 125 - 150 4T
Time
Final gear assy.
FINAL REDUCTION GEAR ASSEMBLY
1
Code
004125
2
001156
3
4
003065
001010
Action
Rear wheel axle - Replacement
Gear reduction unit cover Replacement
Gear box oil - Replacement
Gear reduction unit - Inspection
Duration
TIME - 195
Fly 125 - 150 4T
Time
Driving pulley
DRIVING PULLEY
1
Code
001066
2
001086
3
001177
4
001011
TIME - 196
Action
Drive pulley - Removal and
refitting
Driving half-pulley - Replacement
Variator rollers / shoes - Replacement
Driving belt - Replacement
Duration
Fly 125 - 150 4T
Time
Transmission cover
TRANSMISSION COVER
1
Code
001096
2
001135
3
001065
Action
Transmission crankcase cover - Replacement
Transmission cover bearing Replacement
Transmission cover - Removal and Refit
Duration
TIME - 197
Fly 125 - 150 4T
Time
Starter motor
STARTER MOTOR
1
2
TIME - 198
Code
001020
001017
Action
Starter motor - Replacement
Starter sprocket wheel - Replacement
Duration
Fly 125 - 150 4T
Time
Flywheel magneto
Belt cooling duct
TIME - 199
Fly 125 - 150 4T
Time
BELT COOLING PIPE
1
2
Code
001170
001132
3
001131
Action
Air manifold - replacement
Transmission air inlet pipe Replacement
Transmission air intake - Replacement
Duration
Carburettor
CARBURETTOR
1
Code
001082
2
3
001013
004122
4
001081
5
6
001008
001063
TIME - 200
Action
Carburettor heating resistor Replacement
Intake manifold - change
Air cleaner carburettor fitting Replacement
Automatic choke - Replacement
Carburettor - Inspection
Carburettor - Replacement
Duration
Fly 125 - 150 4T
Time
Exhaust pipe
MUFFLER
1
2
Code
001009
001136
3
001095
Action
Muffler - Replacement
Exhaust emissions - Adjustment
Muffler guard - Replacement
Duration
TIME - 201
Fly 125 - 150 4T
Time
Air cleaner
AIR CLEANER
1
Code
001014
2
001015
TIME - 202
Action
Air filter - Replacement/
Cleaning
Air filter box - Replacement
Duration
Fly 125 - 150 4T
Time
Frame
FRAME
1
2
3
Code
004001
004004
001053
Action
Frame - replace
Stand - Replacement
Stand bolt - Replacement
Duration
TIME - 203
Fly 125 - 150 4T
Time
Legshield spoiler
FRONT SHIELD SPOILER
1
Code
004159
2
004149
3
004064
4
004015
5
004053
TIME - 204
Action
Plates / Stickers - Replacement
Shield central cover - Replacement
Front shield, front part - Removal and refitting
Footrest - Removal and Refitting
Spoiler - Replacement
Duration
Fly 125 - 150 4T
Time
Rear cover
REAR SHIELD
1
2
Code
004174
004065
3
004081
Action
Trunk levers - Replacement
Front shield, rear part - Removal and refitting
Glove box door - Replacement
Duration
TIME - 205
Fly 125 - 150 4T
Time
Central cover
CENTRAL COVER
1
Code
004059
2
004106
3
4
004085
004105
5
004131
TIME - 206
Action
Spark plug inspection flap Replacement
Under-saddle band - Replacement
Fairing (1) - Replacement
Right side clamp - Replacement
Luggage rack support - Replacement
Duration
Fly 125 - 150 4T
Time
Underseat compartment
UNDERSEAT COMPARTMENT
1
2
Code
005046
004016
3
001027
Action
Battery cover - Replacement
Helmet compartment - Removal and Refitting
Body / air cleaner union - Replacement
Duration
TIME - 207
Fly 125 - 150 4T
Time
Plate holder
LICENCE PLATE HOLDER
1
Code
004136
2
005048
TIME - 208
Action
License plate support - replace
Licence plate holder - Replacement
Duration
Fly 125 - 150 4T
Time
Mudguard
MUDGUARDS
1
Code
004002
2
004009
Action
Front mudguard - Replacement
Rear mudguard - Replacement
Duration
TIME - 209
Fly 125 - 150 4T
Time
Fuel tank
FUEL TANK
1
2
3
Code
004168
005010
004112
4
5
6
004005
004007
004109
TIME - 210
Action
Fuel tank cap - Replacement
Tank float - Replacement
Cock-carburettor hose - Replacement
Fuel tank - Replacement
Fuel valve - Replacement
Fuel tank breather - Replacement
Duration
Fly 125 - 150 4T
Time
Rear shock-absorber
REAR SHOCK ABSORBER
1
Code
003007
Action
Rear shock absorber - Removal and Refitting
Duration
TIME - 211
Fly 125 - 150 4T
Time
Steering column bearings
STEERING COLUMN BEARINGS
1
Code
003002
2
003073
TIME - 212
Action
Steering fifth wheel - Replacement
Steering clearance - Adjustment
Duration
Fly 125 - 150 4T
Time
Handlebar covers
HANDLEBAR COVERS
1
Code
004019
2
004018
3
005078
4
5
6
005076
005014
005038
Action
Handlebar rear section - Replacement
Handlebar front section - Replacement
Odometer glass - Replacement
Clock / Cell - Replacement
Odometer - Replacement
Instrument panel warning
light bulbs - Replacement
Duration
TIME - 213
Fly 125 - 150 4T
Time
Handlebar components
HANDLEBAR COMPONENTS
1
Code
004066
2
002037
3
4
002071
003001
5
6
005017
002024
7
003061
8
002060
9
004162
10
002059
11
002063
TIME - 214
Action
Rear-view mirror - Replacement
Brake or clutch lever - Replacement
Left hand grip - Replacement
Handlebar - Removal and refitting
Stop switch - Replacement
Front brake pump - Removal
and Refitting
Accelerator transmission Adjustment
Complete throttle control Replacement
Mirror support and/or brake
pump fitting U-bolt - Replacement
Right hand grip - Replacement
Throttle control transmission
- Replacement
Duration
Fly 125 - 150 4T
Time
Swing-arm
SWINGING ARM
1
Code
001072
2
003080
Action
Engine / frame swinging arm
fitting - Replacement
Swinging arm on frame - Replacement
Duration
TIME - 215
Fly 125 - 150 4T
Time
Brake hoses
BRAKE HOSES
1
Code
002007
2
002039
3
002021
4
002047
TIME - 216
Action
Front brake shoes/pads - Remov. and Refitt
Front brake line - Replacement
Front brake hose - Remov.
and Refitt.
Front brake fluid and system
bleeding plug - Change
Duration
Fly 125 - 150 4T
Time
Seat
SADDLE
1
2
Code
004003
004068
Action
Saddle - Replacement
Passenger handgrip - Replacement
Duration
TIME - 217
Fly 125 - 150 4T
Time
Turn signal lights
TURN SIGNAL LIGHTS
1
2
Code
005002
005012
3
005067
4
005008
5
6
005005
005066
7
005022
8
005068
TIME - 218
Action
Front headlamp - change
Front turn indicator - Replacement
Front turn indicator bulb - Replacement
Front headlamp bulbs - Replacement
Taillight - Replacement
Rear light bulbs - Replacement
Rear turn indicators - Replacement
Rear turn indicator bulb - Replacement
Duration
Fly 125 - 150 4T
9
Code
005131
10
005031
11
005032
Time
Action
Licence plate light support Replacement
Licence plate light bulb - Replacement
Licence plate light glass - Replacement
Duration
Front wheel
FRONT WHEEL
1
Code
003038
2
002011
3
003040
4
5
003047
003037
6
7
004123
002041
Action
Front wheel axle - Replacement
Odometer drive- Replacement
Front wheel bearings - Replacement
Front tyre - Replacement
Front wheel rim - Removal
and Refitting
Front wheel - Replacement
Brake disc - Replacement
Duration
TIME - 219
Time
Grease tone wheel or drive
Please take note that the code has been introduced:
900001 - Tone wheel / drive greasing - 15'.
Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated
components. The grease recommended is TUTELA MRM 2 (soap-based lithium grease with Molybdenum disulphide).
In the following points we indicate with an arrow
the area to be greased (1 - Drive, 2 - Tone wheel)
Rear wheel
TIME - 220
Fly 125 - 150 4T
Fly 125 - 150 4T
Time
REAR WHEEL
1
Code
002002
2
004126
3
4
001016
001071
Action
Rear brake pads/shoes - Replacement
Rear wheel tyre - Replacement
Rear wheel - Replacement
Rear wheel rim - Removal
and Refit
Duration
Electric devices
ELECTRICAL DEVICES
1
2
Code
001023
005035
3
005001
4
001094
5
6
7
001069
005052
005025
8
005009
9
005011
Action
Control unit - Replacement
Headlight remote control Replacement
Electric system - Removal
and reassembly
Spark plug cap - Replacement
HV coil - Replacement
Fuse - Replacement
Battery fuse box - Replacement
Voltage regulator - Replacement
Start-up remote control
switch - change
Duration
TIME - 221
Fly 125 - 150 4T
Time
10
11
Code
005007
005114
Action
Battery - Replacement
Electrical system - Service
Duration
Electronic controls
ELECTRIC CONTROLS
1
Code
005039
2
005006
3
4
5
6
7
8
005040
005003
005041
005016
004096
005072
Action
Headlight switch - Replacement
Light switch or turn indicators
- Replacement
Horn button - Replacement
Horn - Replacement
Starter button - Replacement
Key switch - Replacement
Lock series - Replacement
Immobilizer aerial - Replacement
Duration
Transmissions
TRANSMISSIONS
1
Code
002051
2
002049
3
002053
TIME - 222
Action
Odometer transmission assembly - Replacement
Odometer cable - Replacement
Rear brake transmission
complete - replacement
Duration
Fly 125 - 150 4T
Time
Front suspension
FRONT SUSPENSION
1
2
3
4
5
6
Code
003010
003048
003076
003079
003051
003069
Action
Front suspension - Service
Fork oil seal - Replacement
Fork leg - Replacement
Fork stem - Replacement
Complete fork - replace
Front fork oil - Replacement
Duration
TIME - 223
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