Piaggio Fly 125 - 150 4T Workshop Manual.pdf

WORKSHOP MANUAL633225Fly 125 - 150 4T

WORKSHOPMANUALFly 125 - 150 4TThe descriptions and illustrations given in this publication are not binding. While the basic specificationsas described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, atany time and without being required to update this publication beforehand, to make any changes tocomponents, parts or accessories, which it considers necessary to improve the product or which arerequired for manufacturing or construction reasons.Not all versions shown in this publication are available in all countries. The availability of single versionsshould be checked at the official Piaggio sales network."© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publicationin whole or in part is prohibited."PIAGGIO & C. S.p.A. - After-SalesV.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

WORKSHOP MANUALFly 125 - 150 4TThis workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have abasic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any importantchanges made to the vehicles or to specific fixing operations will be promptly reported by updates to thismanual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools areunavailable. It is therefore advisable to read the sections of this manual relating to specific tools, alongwith 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 personalinjury.Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICSCHARACTERISTICSCHARTOOLINGTOOLMAINTENANCEMAINTROUBLESHOOTINGTROUBLELECTRICAL SYSTEMELE SYSENGINE FROM VEHICLEENG VEENGINEENGSUSPENSIONSSUSPBRAKING SYSTEMBRAK SYSCHASSISCHASPRE-DELIVERYPRE DETIMETIME

INDEX OF TOPICSCHARACTERISTICSCHAR

Fly 125 - 150 4TCharacteristicsRulesThis 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. Exhaustfumes are toxic.- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid ishighly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant waterand seek immediate medical attention.- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparksor 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 workingarea, 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 thatyou do not breathe in the dust produced by the wear of the friction material. Even though the lattercontains no asbestos, inhaling dust is harmful.Maintenance rules- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original ornon-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 thework 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 andscrews are not interchangeable with coupling members with English measurement. Using unsuitablecoupling members and tools may damage the scooter.- When carrying out maintenance operations on the vehicle that involve the electrical system, makesure the electric connections have been made properly, particularly the ground and battery connections.CHAR - 7

CharacteristicsFly 125 - 150 4TVehicle identificationVEHICLE IDENTIFICATIONSpecification Desc./QuantityChassis prefix (125) ZAPM42100 ÷ 1001Engine prefix (125) M421M ÷ 1001Chassis prefix (150) ZAPM42200 ÷ 1001Engine prefix (150) M422M ÷ 1001Dimensions and massWEIGHT AND DIMENSIONSSpecificationDesc./QuantityDry weight112 kgOverall height1150 mmSeat height 785Width 735Wheel base 1330Lenght 1870CHAR - 8

Fly 125 - 150 4TCharacteristicsEngineENGINESpecificationDesc./QuantityEngineSingle-cylinder, 4-stroke Piaggio LEADERTiming systemSingle overhead camshaft (SOHC) with 2 valvesValve clearance intake 0.10outlet 0.15Bore x stroke (125)57 x 48.6 mmBore x stroke62,6 x 48.6 mmCubic capacity (125)124 cm³Cubic capacity150,46 cm³Compression ratio (125) 10.6 : 1Compression ratio 10.5: 1CarburettorKEIHIN CVEK26Engine idle speedapprox. 1600 ÷ 1800 rpmStart-upElectricMaximum power to crankshaft (125)10.5 CV at 8000 rpmMax. power11.6 hp at 7750 rpmCoolingForced air circulation.CHAR - 9

CharacteristicsFly 125 - 150 4TTransmissionSpecificationTransmissionTRANSMISSIONDesc./QuantityWith automatic expandable pulley variator with torqueserver, V belt, automatic clutch, gear reductionunit and transmission housing with forced aircirculation cooling.CapacitiesSpecificationEngine oilRear hub oilFuel tank capacityCAPACITYDesc./Quantity61 in³ (1,000 cm³)~ 200 cm³~ 7.2 litres (of which 1.5 l is reserve)Electrical systemELECTRICAL COMPONENTSSpecificationDesc./QuantityStart-upElectricSpark plug (125)Champion RG6YC- NGK CR7EBSpark plugChampion RG6YCFrame and suspensionsBrakesSpecificationChassisFront suspensionRear suspensionFRAME AND SUSPENSIONDesc./QuantitySteel tube chassisØ 32 Hydraulic telescopic fork - travel: 76 mmSingle hydraulic shock-absorber with spring preloadadjustable on 4 positions; 64 mm travel.SpecificationFront brakeRear brakeBRAKEDesc./QuantityDisc brake (Ø 200 mm) with hydraulic control (leveron the far right of the handlebar) and floatingcalliper.Ø 140 mm drum brakeCHAR - 10

Fly 125 - 150 4TCharacteristicsWheels and tyresWHEELS AND TYRESSpecificationDesc./QuantityFront wheel rim Die-cast aluminium alloy; 3.50 x 12"Front tyre Tubeless 120/70-12"Rear wheel rimDie-cast aluminium alloy: 3.00"x12"Rear tyre Tubeless 120/70 - 12"Front tyre pressure1.8 barRear tyre pressure2 barRear wheel pressure (rider and passenger):2.3 barSecondary airIn order to reduce polluting emissions, the vehicleis furnished with a catalytic converter in the muffler.To favour the catalytic process, an extra amountof oxygen is added via a secondary air system(SAS).This system allows more oxygen to be added tothe unburned gases before they reach the converter,thus improving the action of the catalyticconverter.The air enters the exhaust duct from the head, andis purified by a black filter.The system is fitted with a control valve that disablesoperation while decelerating to avoid unwantednoise.To ensure the best functioning of the SAS system,every 12,000 km the scooter should be taken to anAuthorised Piaggio Service Centre to have thefilter cleaned (Scheduled maintenance operationssection).The filter sponge should be cleaned with water andmild soap, then it should be dried with a cloth andslight blows of compressed air.CAUTIONCHAR - 11

CharacteristicsFly 125 - 150 4TCONTACT AN AUTHORISED PIAGGIO SERV-ICE CENTRE TO CARRY OUT THESE OPERA-TIONS.Carburettor125cc VersionKehinCARBURETTOR SETTINGSpecificationDesc./QuantityTypeCVEK26Throttle valve diameter Ø 26.5Diffuser diameter Ø 26.4Setting stamping262AMaximum jet 82Maximum air jet (on the body) 85Tapered pin stampingNELAThrottle valve spring130 ÷ 180 gr.Minimum jet 35Idle air jet (on the body) 150Idle mixture adjustment screw initial opening1 ¾Starter jet 42Starter air jet (on the body) Ø 1.5Starter pin travel 10 mm (at 24°)Starter resistance 20 Ohm (at 24°)150cc VersionKehinCARBURETTOR SETTINGSpecificationDesc./QuantityTypeCVEK26Throttle valve diameter Ø 26.5Diffuser diameter Ø 26.4Setting stamping265AMaximum jet 82Maximum air jet (on the body) 85Tapered pin stampingNELAThrottle valve spring130 ÷ 180 gr.Minimum jet 35Idle air jet (on the body) 150Idle mixture adjustment screw initial opening1 ¾Starter jet 42Starter air jet (on the body) Ø 1.5Starter pin travel 10 mm (at 24°)CHAR - 12

Fly 125 - 150 4TCharacteristicsSpecificationDesc./QuantityStarter resistance 20 Ohm (at 24°)Tightening TorquesLUBRICATIONNameTorque in NmHub oil drainage cap 15 ÷ 17Oil filter 4 ÷ 6Oil pump cover screws 5 - 6Oil pump screws 5 - 6Pump control pulley screw 10 ÷ 14Chain cover screws 4 ÷ 6Oil sump screws 10 ÷ 14Minimum oil pressure sensor 12 ÷ 14Blow-by recovery duct fixing screws 3 - 4HEAD AND CYLINDERNameTorque in NmIgnition spark plug 12 ÷ 14Head cover screws 11 ÷ 13Nuts fixing head to cylinder (*) 28 ÷ 30Head fixing screws (external) 11 ÷ 13Starter ground screw 7 ÷ 8.5Flywheel cover screw 1 ÷ 2Flywheel air manifold screw 3 ÷ 4Pressure reducer counterweight retainer 7 ÷ 8.5Camshaft pulley screw 12 ÷ 14Timing chain tensioner slider screw 10 ÷ 14Starter ground support screw 11 ÷ 15Tensioner screws 11 ÷ 13Timing chain tensioner central screw 5 - 6Camshaft retention plate screw 5 - 6Nut fixing muffler to cylinder head 16 ÷ 18Head intake manifold screw 11 ÷ 13TRANSMISSIONNameTorque in NmDrive pulley nut 75 ÷ 83Transmission cover screw 11 ÷ 13Driven pulley shaft nut 54 ÷ 60Rear hub cap screw 24 ÷ 27Clutch unit nut on driven pulley 45 ÷ 50FLYWHEELNameTorque in NmFlywheel fan screws 3 ÷ 4Stator assembly screws (°) 3 ÷ 4Flywheel nut 52 ÷ 58Pick-up screw 3 ÷ 4(°) Apply LOCTITE 243 threadlockCHAR - 13

CharacteristicsFly 125 - 150 4TCRANKCASE AND CRANKSHAFTNameTorque in NmInternal engine crankcase bulkhead (transmission-side4 ÷ 6half shaft) screwsOil filter on crankcase fitting 27 ÷ 33Rear brake cam tightening screw 11 ÷ 13Engine-crankcase coupling screws 11 ÷ 13Pre-filter cap 24 ÷ 30Starter motor fixing screw 11 ÷ 13Muffler to crankcase fixing screws 24 ÷ 27Engine oil drainage cap 24 ÷ 30STEERING ASSEMBLYNameTorque in NmSteering upper ring nut 35 ÷ 40Steering lower ring nut 8 ÷ 10Handlebar fixing screw 50 ÷ 55FRAMENameTorque in NmEngine arm bolt - frame arm 33 ÷ 41Engine-swinging arm bolt 33 ÷ 41Frame arm-engine arm bolt 60 ÷ 64Centre stand pin 32 ÷ 40Bolts mounting rocker arm silent-block 36 ÷ 44FRONT SUSPENSIONNameTorque in NmLower fork fixing screw 15 ÷ 20Front wheel axle nut 45 - 50FRONT BRAKENameTorque in NmBrake fluid pump - hose fitting16 ÷20 NmBrake fluid tube- calliper fitting 19 ÷ 24Calliper tightening screw 24 ÷ 27Disc tightening screw 8 ÷ 10Oil bleed screw 7 ÷ 10REAR SUSPENSIONNameTorque in NmRear wheel axle 104 ÷ 126Lower shock absorber clamp 33 ÷ 41Shock absorber/frame nut: 20 ÷ 25shock absorber to crankcase clamping bracket 20 - 25Overhaul dataAssembly clearancesCHAR - 14

Fly 125 - 150 4TCharacteristicsCylinder - piston assy.Version 150COUPLING BETWEEN (AXIS-WERKE) PISTON AND CYLINDER (150)Name Initials Cylinder Piston Play on fittingCoupling A 62.580 ÷ 62.587 62.533 ÷ 62.540 0.040 ÷ 0.054Coupling B 62.587 ÷ 62.594 62.540 ÷ 62.547 0.040 ÷ 0.054Coupling C 62.594 ÷ 62.601 62.547 ÷ 62.554 0.040 ÷ 0.054Coupling D 62.601 ÷ 62.608 62.554 ÷ 62.561 0.040 ÷ 0.054Coupling 1st oversizeA1 62.780 ÷ 62.787 62.733 ÷ 62.740 0.040 ÷ 0.054coupling 1st oversizeB1 62.787 ÷ 62.794 62.740 ÷ 62.747 0.040 ÷ 0.054Coupling 1st oversizeC1 62.794 ÷ 62.801 62.747 ÷ 62.754 0.040 ÷ 0.054Coupling 1st oversizeD1 62.801 ÷ 62.808 62.754 ÷ 62.761 0.040 ÷ 0.054Coupling 2nd oversizeA2 62.980 ÷ 62.987 62.933 ÷ 62.940 0.040 ÷ 0.054Coupling 2nd oversizeB2 62.987 ÷ 62.994 62.940 ÷ 62.947 0.040 ÷ 0.054Coupling 2nd oversizeC2 62.994 ÷ 63.001 62.947 ÷ 62.954 0.040 ÷ 0.054Coupling 2nd oversizeD2 63.001 ÷ 63.008 62.954 ÷ 62.961 0.040 ÷ 0.054Coupling 3rd oversizeA3 63.180 ÷ 63.187 63.133 ÷ 63.140 0.040 ÷ 0.054Coupling 3rd oversizeB3 63.187 ÷ 63.194 63.140 ÷ 63.147 0.040 ÷ 0.054Coupling 3rd oversizeC3 63.194 ÷ 63.201 63.147 ÷ 63.154 0.040 ÷ 0.054Coupling 3rd oversizeD3 63.201 ÷ 63.208 63.154 ÷ 63.161 0.040 ÷ 0.054COUPLING BETWEEN (RIGHT WAY) PISTON AND CYLINDER (150)Name Initials Cylinder Piston Play on fittingCoupling A 62.580 ÷ 62.587 62.541 ÷ 62.548 0.032 ÷ 0.046Coupling B 62.587 ÷ 62.594 62.548 ÷ 62.555 0.032 ÷ 0.046Coupling C 62.594 ÷ 62.601 62.555 ÷ 62.562 0.032 ÷ 0.046Coupling D 62.601 ÷ 62.608 62.562 ÷ 62.569 0.032 ÷ 0.046COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER(125)Name Initials Cylinder Piston Play on fittingCoupling A 56.980 ÷ 56.987 56.933 ÷ 56.940 0.040 - 0.054Coupling B 56.987 ÷ 56.994 56.940 ÷ 56.947 0.040 - 0.054Coupling C 56.994 ÷ 57.001 56.947 ÷ 56.954 0.040 - 0.054Coupling D 57.001 ÷ 57.008 56.954 ÷ 56.961 0.040 - 0.054Coupling 1st increaseA1 57.180 ÷ 57.187 57.133 ÷ 57.140 0.040 - 0.054CHAR - 15

CharacteristicsFly 125 - 150 4TName Initials Cylinder Piston Play on fittingCoupling 1st increaseB1 57.187 ÷ 57.194 57.140 ÷ 57.147 0.040 - 0.054Coupling 1st increaseC1 57.194 ÷ 57.201 57.147 ÷ 57.154 0.040 - 0.054Coupling 1st increaseD1 57.201 ÷ 57.208 57.154 ÷ 57.161 0.040 - 0.054Coupling 2nd increaseA2 57.380 ÷ 57.387 57.333 ÷ 57.340 0.040 - 0.054Coupling 2nd increaseB2 57.387 ÷ 57.394 57.340 ÷ 57.347 0.040 - 0.054Coupling 2nd increaseC2 57.394 ÷ 57.401 57.347 ÷ 57.354 0.040 - 0.054Coupling 2nd increaseD2 57.401 ÷ 57.408 57.354 ÷ 57.361 0.040 - 0.054Coupling 3rd oversizeA3 57.580 ÷ 57.587 57.533 ÷ 57.540 0.040 - 0.054Coupling 3rd oversizeB3 57.587 ÷ 57.594 57.540 ÷ 57.547 0.040 - 0.054Coupling 3rd oversizeC3 57.594 ÷ 57.601 57.547 ÷ 57.554 0.040 - 0.054Coupling 3rd oversizeD3 57.601 ÷ 57.608 57.554 ÷ 57.561 0.040 - 0.054PISTON TO CAST IRON CYLINDER COUPLING (125)Name Initials Cylinder Piston Play on fittingCoupling M 56.997 ÷ 57.004 56.944 ÷ 56.951 0.046 ÷ 0.060Coupling N 57.004 ÷ 57.011 56.951 ÷ 56.958 0.046 ÷ 0.060Coupling O 57.011 ÷ 57.018 56.958 ÷ 56.965 0.046 ÷ 0.060Coupling P 57.018 ÷ 57.025 56.965 ÷ 56.972 0.046 ÷ 0.060Coupling 1st oversizeM1 57.197 ÷ 57.204 57.144 ÷ 57.151 0.046 ÷ 0.060Coupling 1st oversizeN1 57.204 ÷ 57.211 57.151 ÷ 57.158 0.046 ÷ 0.060Coupling 1st oversizeO1 57.211 ÷ 57.218 57.158 ÷ 57.165 0.046 ÷ 0.060Coupling 1st oversizeP1 57.218 ÷ 57.225 57.165 ÷ 57.172 0.046 ÷ 0.060Coupling 2nd oversizeM2 57.397 ÷ 57.404 57.344 ÷ 57.351 0.046 ÷ 0.060Coupling 2nd oversizeN2 57.404 ÷ 57.411 57.351 ÷ 57.358 0.046 ÷ 0.060Coupling 2nd oversizeO2 57.411 ÷ 57.418 57.358 ÷ 57.365 0.046 ÷ 0.060Coupling 2nd oversizeP2 57.418 ÷ 57.425 57.365 ÷ 57.372 0.046 ÷ 0.060Coupling 3rd oversizeM3 57.597 ÷ 57.604 57.544 ÷ 57.551 0.046 ÷ 0.060Coupling 3rd oversizeN3 57.604 ÷ 57.611 57.551 ÷ 57.558 0.046 ÷ 0.060Coupling 3rd oversizeO3 57.611 ÷ 57.618 57.558 ÷ 57.565 0.046 ÷ 0.060Coupling 3rd oversizeP3 57.618 ÷ 57.625 57.565 ÷ 57.572 0.046 ÷ 0.060CHAR - 16

Fly 125 - 150 4TCharacteristicsPiston ringsSEALING RINGS (125)Name Description Dimensions Initials QuantityCompression ring 57 x 1 A 0.15 ÷ 0.30Oil scraper ring 57x1 A 0.10 ÷ 0.30Oil scraper ring 57x2.5 A 0.10 ÷ 0.35Compression ring57.2 x 1 A 0.15 ÷ 0.301st oversizeOil scraper ring 1st57.2x1 A 0.10 ÷ 0.30oversizeOil scraper ring 1st57.2x2.5 A 0.10 ÷ 0.35oversizeCompression ring57.4x1 A 0.15 ÷ 0.302nd oversizeOil scraper ring57.4x1 A 0.10 ÷ 0.302nd oversizeOil scraper ring57.4x2.5 A 0.10 ÷ 0.352nd oversizeCompression ring57.6x1 A 0.15 ÷ 0.303rd oversizeOil scraper ring 3rd57.6x1 A 0.10 ÷ 0.30oversizeOil scraper ring 3rdoversize57.6x2.5 A 0.10 ÷ 0.35Maximum clearance after use: 1 mmSEALING RINGS (150)Name Description Dimensions Initials QuantityCompression ring 62.6x1 A 0.15 ÷ 0.30Oil scraper ring 62.6x1 A 0.20 ÷ 0.40Oil scraper ring 62.6x2.5 A 0.20 ÷ 0.40Compression ring62.8x1 A 0.15 ÷ 0.301st oversizeOil scraper ring 1st62.8x1 A 0.20 ÷ 0.40oversizeOil scraper ring 1st62.8x2.5 A 0.20 ÷ 0.40oversizeCompression ring63.0 x 1 A 0.15 ÷ 0.302nd oversizeOil scraper ring63.0 x 1 A 0.20 ÷ 0.402nd oversizeOil scraper ring63.0 x 2.5 A 0.20 ÷ 0.402nd oversizeCompression ring63.2 x 1 A 0.15 ÷ 0.303rd oversizeOil scraper ring 3rd63.2 x 1 A 0.20 ÷ 0.40oversizeOil scraper ring 3rdoversize63.2 x 2.5 A 0.20 ÷ 0.40CHAR - 17

CharacteristicsFly 125 - 150 4TCrankcase - crankshaft - connecting rodAXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING RODName Description Dimensions Initials QuantityHalf-shaft, transmission16.6 +0-0.05 A D = 0.20 - 0.50sideFlywheel-side halfshaft16.6 +0-0.05 B D = 0.20 - 0.50Connecting rod18 -0.10 -0.15 C 0.20 ÷ 0.50with PPCrank pin width 51.400 EAXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGSName Description Dimensions Initials QuantityCrankshaft Category 1 28.998 ÷ 29.004Crankshaft Class 2 29.004 ÷ 29.010Crankcase Category 1 32.953 ÷ 32.959Crankcase Category 2 32.959 ÷ 32.965Crankshaft halfbearingCategory B - blue 1.973 ÷ 1.976Crankshaft halfbearingType C - yellow 1.976 ÷ 1.979Crankshaft halfbearingCategory E - green 1.979 ÷ 1.982Crankshaft categoryE - E1 - Crankcasecategory 1Crankshaft categoryC - C1 - Crankcasecategory 2Crankshaft categoryC - C2 - Crankcasecategory 1Crankshaft category2 - Crankcasecategory 2B - BCrankshaft/crankcase axial clearance: 0.15 ÷ 0.40CHAR - 18

Fly 125 - 150 4TCharacteristicsSlot 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. Keepingthe 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 thicknessof the cylinder base gasket to be used for refitting. By correctly identifying the cylinder base gasketthickness, an adequate compression ratio is maintained.- Remove the specific tool and the cylinder.CharacteristicCompression ratio (125)10.6 : 1Compression ratio10.5: 1SHIMMING SYSTEM (125)SpecificationDesc./QuantityValue measured 0 ÷ 0.1Thickness 0.8 ± 0.05Value measured 0.1 ÷ 0.3Thickness 0.6 ± 0.05Value measured 0.3 - 0.4Thickness 0.4 ± 0.05CHAR - 19

CharacteristicsFly 125 - 150 4TSHIMMING SYSTEM (150)SpecificationDesc./QuantityValue measured 1 ÷ 1.1Thickness 0.8 ± 0.05Value measured 1.1 ÷ 1.3Thickness 0.6 ± 0.05Value measured 1.3 ÷ 1.4Thickness 0.4 ± 0.05ProductsTABLE OF RECOMMENDED PRODUCTSProduct Description SpecificationsAGIP ROTRA 80W-90 rear oil hub SAE 80W/90 Oil that exceeds therequirements of API GL3 specificationsAGIP CITY HI TEC 4T Oil to lubricate flexible transmissionsOil for 4-stroke engines(brakes, throttle controland odometer)AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additivesfor increased adhesivenessAGIP GP 330Grease (brake control levers,throttle grip)Calcium complex soap-basedgrease with NLGI 2; ISO-L-XBCIB2AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,AGIP GREASE MU3Grease for odometer transmissiongear caseJASO MA Synthetic oilSoap-based lithium grease withNLGI 3; ISO-L-XBCHA3, DINK3K-20CHAR - 20

INDEX OF TOPICSTOOLINGTOOL

ToolingFly 125 - 150 4TStores code001330YTOOLSDescriptionTool for fitting steering seats001467Y009Driver for OD 42 mm bearings001467Y013Pliers to extract ø 15-mm bearings002465YPliers for circlips005095YEngine support008564YFlywheel extractorTOOL - 22

Fly 125 - 150 4TToolingStores code020004YDescriptionPunch for removing fifth wheelsfrom headstock020055YWrench for steering tube ring nut020074YSupport base for checking crankshaftalignment020150YAir heater support020151YAir heater020193YOil pressure gaugeTOOL - 23

ToolingFly 125 - 150 4TStores code020262YDescriptionCrankcase splitting strip020263YSheath for driven pulley fitting020287YClamp to assemble piston on cylinder020306YPunch for assembling valve sealrings020329YMityVac vacuum-operated pump020330YStroboscopic light for timing controlTOOL - 24

Fly 125 - 150 4TToolingStores code020331YDescriptionDigital multimeter020332YDigital rev counter020333YSingle battery charger020334YMultiple battery chargerTOOL - 25

ToolingFly 125 - 150 4TStores code020335YDescriptionMagnetic support for dial gauge020357Y020359Y32 x 35 mm adaptor42x47-mm adaptor020360YAdaptor 52 x 55 mm020363Y20 mm guide020364Y25-mm guideTOOL - 26

Fly 125 - 150 4TToolingStores code020368YDescriptiondriving pulley lock wrench020375YAdaptor 28 x 30 mm020376YAdaptor handle020382Y011adapter for valve removal tool020409YMultimeter adaptor - Peak voltagedetectionTOOL - 27

ToolingFly 125 - 150 4TStores code020412YDescription15 mm guide020414Y28-mm guide020423Ydriven pulley lock wrench020424YDriven pulley roller casing fittingpunch020425YPunch for flywheel-side oil seal020426YPiston fitting forkTOOL - 28

Fly 125 - 150 4TToolingStores code020427YDescriptionPiston fitting band020428YPiston position check support020430YPin lock fitting tool020431YValve oil seal extractor020434YOil pressure control fitting020444YTool for fitting/ removing the drivenpulley clutchTOOL - 29

ToolingFly 125 - 150 4TStores code020565YDescriptionFlywheel lock calliper spanner020622YTransmission-side oil guardpunch494929YExhaust fumes analyser020625YKit for sampling gas from the exhaustmanifoldTOOL - 30

INDEX OF TOPICSMAINTENANCEMAIN

MaintenanceFly 125 - 150 4TMaintenance chartBrake fluid - changeEngine oil - level check/ top-upEVERY 2 YEARSActionEVERY 3000 KMAction80'Engine oil - replacementHub oil - changeOil filter (net filter) - cleanIdle speed (*) - adjustmentThrottle lever - adjustmentSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkSafety locks - checkElectrical system and battery - checkTyre pressure and wear - checkVehicle and brake test - test ride(*) See instructions in the «Idle speed adjustment» section150'Engine oil - replacementHub oil level - checkSpark plug electrode gap - checkAir filter - cleanEngine oil - changeOil filter (net filter) - cleanValve clearance - adjustmentVariable speed rollers/pads - checkDriving belt - checkingBrake pads - check condition and wearBrake fluid level - checkElectrical system and battery - checkCentre stand - lubricationTyre pressure and wear - checkVehicle and brake test - test ride160'Engine oil - replacementMAIN - 32AFTER 1000 KMActionAT 6000 KM OR 12 MONTH, 18000 KM, 54000 KMActionAT 12000 KM OR 24 MONTHS AND AT 60000 KMAction

Fly 125 - 150 4TMaintenanceHub oil level - checkAir filter - cleanEngine oil - changeOil filter (net filter) - cleanSpark plug - replacementIdle speed (*) - adjustmentThrottle lever - adjustmentPads and variator rollers - replacementDriving belt - replacementOdometer gear - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentCentre stand - lubricationSecondary air filter - cleaningTyre pressure and wear - checkVehicle and brake test - test ride(*) See section «Adjusting the idle speed»Action205'Engine oil - replacementHub oil - changeAir filter - cleanEngine oil - changeOil filter (net filter) - cleanSpark plug - replacementIdle speed (*) - adjustmentThrottle lever - adjustmentPads and variator rollers - replacementDriving belt - replacementCylinder ventilation system - cleaningOdometer gear - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentTyre pressure and wear - checkSecondary air filter - cleaningCentre stand - lubricationVehicle and brake test - test rideAFTER 24000 KM AND AFTER 48000 KMActionMAIN - 33

MaintenanceFly 125 - 150 4T(*) See instructions in «Idle speed adjustment» section125'Engine oil - replacementHub oil level - checkSpark plug electrode gap - checkAir filter - cleanEngine oil - changeOil filter (net filter) - cleanSlide pads and variator rollers - checkDriving belt - checkingBrake pads - check condition and wearBrake fluid level - checkElectrical system and battery - checkCentre stand - lubricationTyre pressure and wear - checkVehicle and brake test - test ride300'Engine oil - replacementHub oil - changeSpark plug - replacementAir filter - cleanEngine oil - changeOil filter (net filter) - cleanValve clearance - adjustmentIdle speed (*) - adjustmentThrottle lever - adjustmentPads and variator rollers - replacementDriving belt - replacementOdometer gear - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkFlexible brake tubes - replacementTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentSecondary air filter - cleaningCentre stand - lubricationTyre pressure and wear - checkVehicle and brake test - test ride(*) See instructions in «Idle speed adjustment» sectionAT 30000 KM, AT 42000 KM AND AT 66000 KMActionAFTER 36000 KMAction300'AFTER 72,000 KMMAIN - 34

Fly 125 - 150 4TMaintenanceEngine oil - replacementHub oil - changeSpark plug - replacementAir filter - cleanEngine oil - changeOil filter (net filter) - cleanValve clearance - adjustmentIdle speed (*) - adjustmentThrottle lever - adjustmentPads and variator rollers - replacementDriving belt - replacementOdometer gear - greasingSteering - adjustmentCylinder ventilation system - checkBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkFlexible brake tubes - replacementTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentSecondary air filter - cleaningCentre stand - lubricationTyre pressure and wear - checkVehicle and brake test - test ride(*) See instructions in «Idle speed adjustment» sectionActionChecking the spark advance- To check ignition advance, use the stroboscopic light with induction pincers connected to the sparkplug power wire.- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on thepincers 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 highrpm (e.g. 8000 rpm).- If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistiveload on the spark plug power line (10 ÷ 15 KΩ in series to HV wire).MAIN - 35

MaintenanceFly 125 - 150 4T- Operating on the flash bulb phase difference calibrator,make the reference on the flywheel covercoincide with the fan reference as shown in thephotograph. Read the advance degrees indicatedby the stroboscopic light and compare them withthose specified.CharacteristicIgnition advance 150 check10° ± 1° at 2000 rpm - 26° ± 1° at 6000 rpmIgnition advance 125 check15° ± 1° at 2000 rpm - 28° ± 1° at 6000 rpmSpark advance variationADVANCE VARIATIONSpecificationDesc./QuantityOperation threshold First threshold : 9000±50Second threshold : 9300±50Reactivation threshold First threshold : 8900±50Second threshold : 9200±50Spark elimination First threshold : 1 spark on 7Second threshold : 2 sparks on 3MAIN - 36

Fly 125 - 150 4TMaintenanceMAIN - 37

MaintenanceFly 125 - 150 4TBraking systemLevel checkProceed as follows:- Rest the vehicle on its centre stand with the handlebarsperfectly horizontal;- Check the level of liquid with the related warninglight «A».A certain lowering of the level is caused by wearon the pads.Proceed as follows:- Rest the vehicle on its centre stand with the handlebarsperfectly horizontal;- Check the level of liquid with the related warninglight «A».A certain lowering of the level is caused by wearon the pads.Top-upProceed as follows:- Remove the tank cap by loosening the twoscrews, remove the gasket and top up using onlythe liquid specified without exceeding the maximumlevel.CAUTIONONLY USE DOT 4-CLASSIFIED BRAKE FLUID.CAUTIONAVOID CONTACT OF THE BRAKE FLUID WITHYOUR EYES, SKIN, AND CLOTHING. IN CASEOF ACCIDENTAL CONTACT, WASH WITH WA-TER.CAUTIONBRAKE CIRCUIT FLUID IS VERY CORROSIVE;MAKE SURE THAT IT DOES NOT COME INTOCONTACT WITH THE PAINTWORK.CAUTIONMAIN - 38

Fly 125 - 150 4TMaintenanceTHE BRAKE FLUID IS HYGROSCOPIC, IN OTH-ER WORDS, IT ABSORBS MOISTURE FROMTHE SURROUNDING AIR. IF THE CONTENT OFMOISTURE IN THE BRAKING FLUID EXCEEDSA CERTAIN VALUE, BRAKING WILL BE INEF-FICIENT.NEVER USE BRAKE LIQUID IN OPEN OR PAR-TIALLY USED CONTAINERS.UNDER NORMAL CLIMATIC CONDITIONS,THE FLUID MUST BE CHANGED EVERY 20,000KM OR ANYWAY EVERY TWO YEARS.N.B.SEE THE BRAKING SYSTEM CHAPTER WITHREGARD TO THE CHANGING OF BRAKE FLU-ID AND THE BLEEDING OF AIR FROM THECIRCUITS.Recommended productsAGIP BRAKE 4 Brake fluidFMVSS DOT 4 Synthetic fluidHeadlight adjustmentProceed as follows:1. Place the vehicle in running order and with thetyres inflated to the prescribed pressure, on a flatsurface 10 m away from a white screen situated ina shaded area, making sure that the longitudinalaxis of the scooter is perpendicular to the screen;2. Turn on the headlight and check that the borderlineof the projected light beam on the screenis not lower than 9/10 of the distance from theground to the centre of vehicle headlamp and higherthan 7/10;3. If otherwise, adjust the right headlight with screw«A».N.B.THE ABOVE PROCEDURE COMPLIES WITHTHE EUROPEAN STANDARDS REGARDINGMAXIMUM AND MINIMUM HEIGHT OF LIGHTBEAMS. REFER TO THE STATUTORY REGU-LATIONS IN FORCE IN EVERY COUNTRYWHERE THE vehicle IS USED.MAIN - 39

MaintenanceFly 125 - 150 4TCO check- Remove the exhaust gases outlet cap on the exhaustpipe- Using the supplied washer, install the exhaustgases collection kit fitting onto the pipe, as shownin the figure.- Correctly orientate the components as shown inthe 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 hoseshown in the figure.- Seal the connection using a conical a cap.MAIN - 40

Fly 125 - 150 4TMaintenance- Connect the Mitivac vacuum pump to the SAScontrol valve.- Start the vacuum pump up to a pressure of -0.6÷ -0.8 bar so to close the valve and cut off the SASsystem.- Remove the exhaust gas collection kit cap andconnect the analyzer adequately pre-heated.- Check the analyser output and the engine rpm.- Adjust the CO concentration.N.B.CHECK THAT THE RESULT IS OBTAINEDWITH THE VALVE GAS IN CLOSED POSITION.N.B.ALSO CHECK THE CARBURETION ADJUST-MENT IS OBTAINED WITH THE FLOW SCREWOPEN BETWEEN 2 AND 4 TURNS.N.B.OTHERWISE, CHECK THE FUEL LEVEL AD-JUSTMENT IN THE TANK AND THE FUEL CIR-CUIT.N.B.IN CASE OF UNSTABLE CO, CHECK THATTHE CARBURETTOR IS CLEAN AND THATTHE FUEL SUPPLY SYSTEM AND THE DE-PRESSION SEALS WORK ADEQUATELYN.B.IN CASE OF 1000 PPM UNBURNED HYDRO-CARBONS (HC) >, CHECK THE IGNITION SYS-TEM, THE TIMING SYSTEM, THE VALVECLEARANCE AND THE EXHAUST VALVETIGHTNESS.Specific tooling020329Y MityVac vacuum-operated pump020332Y Digital rev counter494929Y Exhaust fumes analyser020625Y Kit for sampling gas from the exhaustmanifoldCharacteristicCO Check3.8±0.7 to 1650±50 RPMMAIN - 41

MaintenanceFly 125 - 150 4TSAS filters inspection and cleaning- Remove the shock absorber lower retainer fromthe engine.- Remove the retainer clamp indicated in the photograph,the automatic starter cable harness andthe carburettor to frame heater placed under thehelmet compartment cover.- Lift the vehicle with a jack as shown in the figureto be able to reach the flywheel cover screws- Remove the screw fixing the SAS valve to theflywheel cover, indicated in the photograph.MAIN - 42

Fly 125 - 150 4TMaintenance- Remove the 4 flywheel cover screws indicated inthe 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 ifit is damaged or deformed.To refit, carry out the removal operations but in reverseorder.CAUTIONWHEN TRAVELLING ON DUSTY ROADS, THEAIR FILTER MUST BE CLEANED MORE OFTENTHAN SHOWN IN THE SCHEDULED MAINTE-NANCE CHART.CAUTIONNEVER RUN THE ENGINE WITHOUT THE SEC-ONDARY AIR FILTERMAIN - 43

INDEX OF TOPICSTROUBLESHOOTINGTROUBL

Fly 125 - 150 4TTroubleshootingEnginePoor performancePOOR PERFORMANCEPossible CauseOperationAir filter blocked or dirty.Dismantle the sponge, wash with water and shampoo,then soak it in a mixture of 50% petrol and50% of specific oil (Selenia Air Filter Oil), thenhand dry without squeezing, allow to drip dry andthen reassemble.Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressedairDirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol andwash the tank, if necessary. Replace the cock asa last resource.Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement,replace if necessary.Excessive driving belt wearCheck it and replace, if necessaryLack of compression: parts, cylinder and valvesReplace the worn partswornOil level exceeds maximumCheck for causes and fill to reach the correct levelExcess of encrustations in the combustion chambervalvesDescale the cylinder, the piston, the head and theIncorrect timing or worn timing system elements Time the system again or replace the worn partsMuffler obstructedReplaceInefficient automatic transmission Check the rollers and the pulley movement, replacethe damaged parts and lubricate the drivenpulley moveable guide with Montblanc MolybdenumGreaseWrong valve adjustmentAdjust the valve clearance properlyOverheated valvesRemove the head and the valves, grind or replacethe valvesValve seat distortedReplace the head assemblyWorn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just thepiston ringsRear wheel spins at idleREAR WHEEL ROTATES WITH ENGINE AT IDLEPossible CauseOperationIdling rpms too highAdjust the engine idle speed and the CO%, if necessary.Clutch faultCheck the springs / clutch massesTROUBL - 45

TroubleshootingFly 125 - 150 4TStarting difficultiesDIFFICULTY STARTING UPPossible CauseOperationBattery flatCheck the state of the battery. If it shows signs ofsulphation replace it and bring the new battery intoservice charging it for eight hours at a current of1/10 of the capacity of the battery itselfFaulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuitcomponents- Engine flooded. Try starting-up with the throttle fully open. If theengine fails to start, remove the spark plug, dry itand before refitting, make the motor turn so as toexpel the fuel excess taking care to connect thecap to the spark plug, and this in turn to the ground.If the fuel tank is empty, refuel and start up.Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearanceRpm too low at start-up or engine and start-up Check the starter motor and the kick-starter unitsystem damagedAltered fuel characteristicsDrain off the fuel no longer up to standard; then,refillVacuum operated cock failure Check that fuel is adequately supplied through thepipe by applying a vacuum to the suction pipeFailing automatic starter on the carburettor Check the electrical wiring and mechanical movement,replace if necessary.Start-up enabling buttons failure Check continuity using an Ohm meter, with theswitch pressed; replace if necessaryCarburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressedairAir filter obstructed or dirty.Dismantle the sponge, wash with water and shampoo,then soak it in a mixture of 50% petrol and50% of specific oil (Selenia Air Filter Oil), thenhand dry without squeezing, allow to drip dry andthen reassemble.Excessive oil consumption/Exhaust smokeEXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUSTPossible CauseWorn valve guidesWorn valve oil guardOil leaks from the couplings or from the gasketsWorn or broken piston rings or piston rings thathave not been fitted properlyOperationCheck and replace the head unit if requiredReplace the valve oil guardCheck and replace the gaskets or restore the couplingsealReplace the piston cylinder unit or just the pistonringsTROUBL - 46

Fly 125 - 150 4TTroubleshootingInsufficient lubrication pressurePossible CauseBy-Pass remains openOil pump with excessive clearanceOil filter too dirtyOil level too lowPOOR LUBRICATION PRESSUREEngine tends to cut-off at full throttleOperationCheck the By-Pass and replace if required. Carefullyclean the By-Pass area.Perform the dimensional checks on the oil pumpcomponentsReplace the cartridge filterRestore the level using the recommended oil type(Selenia HI Scooter 4 Tech)THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLEPossible CauseMaximum jet cloggedWater or condensate in the carburettor tankLevel in tank too lowEngine tends to cut-off at idleOperationRemove the carburettor, wash with solvent and drywith compressed airRemove the tank, wash with solvent and dry withcompressed airRestore the level in the tank by bending on the floatthe thrusting reed of the petrol inlet rod so as tohave the float parallel to the tank level with thecarburettor inverted.THE ENGINE TENDS TO STOP AT IDLE SPEEDPossible CauseIncorrect idle adjustmentIncorrect timingThe starter remains onFaulty spark plug or incorrect ignition advancePressure too low at the end of compressionMinimum nozzle dirtyHigh fuel consumptionOperationAdjust using the rpm indicatorTime the system and check the timing systemcomponentsCheck: electric wiring, circuit not interrupted, mechanicalmovement and power supply; replace ifnecessaryReplace the spark plug or check the ignition circuitcomponentsCheck the thermal group seals and replace worncomponentsWash the nozzle with solvent and dry with compressedairPossible CauseAir filter blocked or dirty.Starter inefficientEXCESSIVE FUEL CONSUMPTIONOperationClean according to the procedureCheck: electric wiring, circuit continuity, mechanicalsliding and power supplyTROUBL - 47

TroubleshootingFly 125 - 150 4TPossible CauseLoose nozzlesIncorrect float levelOperationCheck the maximum and minimum nozzles areadequately fixed in their fittingsRestore the level in the tank by bending on the floatthe thrusting reed of the petrol inlet rod so as tohave the float parallel to the tank level with thecarburettor inverted.Transmission and brakesClutch grabbing or performing inadequatelyIRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible CauseSlippage or irregular functioningInsufficient brakingOperationCheck that there is no grease on the masses.Check that the faying surface between the clutchmasses and the clutch bell is mainly in the middleand with equivalent specifications on the threemasses.Check that the clutch bell is not scored or wornabnormallyNever run the engine without the clutch bellPossible CauseWorn brake pads or shoesFront brake disk loose or deformedAir bubbles inside the hydraulic braking systemFluid leakage in hydraulic braking systemINEFFICIENT OR NOISY BRAKINGOperationReplace the brake pads or shoes and check forbrake disk or drum wear conditions.Check the brake disc screws are locked; use a dialgauge and a wheel mounted on the vehicle tomeasure the axial shift of the disc.Carefully bleed the hydraulic braking system,(there must be no flexible movement of the brakelever).Failing elastic fittings, plunger or brake pumpseals, replaceExcessive backlash in the rear brake control cable Adjust the backlash with the appropriate adjusterlocated on the back part of the crankcase.Brakes overheatingPossible CauseRubber gaskets swollen or stuckCompensation holes on the pump cloggedBrake disc slack or distortedBRAKES OVERHEATINGOperationReplace gaskets.Clean carefully and blast with compressed airCheck the brake disc screws are locked; use a dialgauge and a wheel mounted on the vehicle tomeasure the axial shift of the disc.TROUBL - 48

Fly 125 - 150 4TTroubleshootingPossible CauseDefective piston slidingOperationCheck calliper and replace any damaged part.Electrical systemBatteryPossible CauseBatteryBATTERYOperationThe battery is the electrical device in the systemthat requires the most frequent inspections andthorough maintenance. If the vehicle is not usedfor some time (1 month or more) the battery needsto be recharged periodically. The battery runsdown completely in the course of 5 ÷ 6 months. Ifthe battery is fitted on a motorcycle, be careful notto invert the connections, keeping in mind that theblack ground wire is connected to the negative terminalwhile the red wire is connected to the terminalmarked+. Follow the instructions in the ELEC-TRICAL SYSTEM chapter for the recharging of thebatteries.Turn signal lights malfunctionPossible CauseElectronic ignition device failureSteering and suspensionsTURN INDICATOR NOT WORKINGOperationWith the key switch set to "ON" jump the contacts1 (Blue-Black) and 5 (Orange) on the control unitconnector.If by operating the turn indicator control the lightsare not steadily on, replace the control unit; otherwise,check the cable harness and the switch.Heavy steeringPossible CauseSteering hardeningSTEERING HARDENINGOperationCheck the tightening of the top and bottom ringnuts. If irregularities continue in turning the steeringeven 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

TroubleshootingFly 125 - 150 4TExcessive steering playPossible CauseExcessive steering backlashNoisy suspensionEXCESSIVE STEERING CLEARANCEOperationCheck the tightening of the top ring nut. If irregularitiescontinue in turning the steering even aftermaking the above adjustments, check the seats inwhich the ball bearings rotate: replace if they arerecessed.Possible CauseNoisy suspensionNOISY SUSPENSIONOperationIf the front suspension is noisy, check: that thefront shock absorber works properly and the ballbearings are good condition. Finally, check thelocking torque of the wheel axle nut, the brake calliperand the disc. Check that the swinging armconnecting the engine to the chassis and the rearshock absorber work properly.Suspension oil leakagePossible CauseOil leakage from suspensionOIL LEAKAGE FROM SUSPENSIONOperationReplace the rear shock absorber or the front forkcartridge.TROUBL - 50

INDEX OF TOPICSELECTRICAL SYSTEMELE SYS

Electrical systemFly 125 - 150 4TLegend:1. Front L.H. turn signal light2. Immobiliser antenna3. Electronic ignition device with choke and turn signal controls4. Horn button5. Turn signal switch6. Headlight switch7. Stop switch on rear brake8. Double-filament bulb 12V - 55/60W9. Front sidelight bulb10. High-beam warning light11. Engine oil pressure warning light12. Turn signal warning light (L.H.)ELE SYS - 52

Fly 125 - 150 4TElectrical system13. Low-fuel warning light14. Turn signal warning light (R.H.)15. Dashboard light bulbs16. Headlamp warning light17. Odo/speedometer with warning lights and gauges - Red socket light bulbs 2W; black socket lightbulbs 1.2W18. Headlight19. 2 fuse holders with 4 fuses (7.5 A)20. Stop switch on front brake21. Start button22. Immobiliser diagnostic outlet23. Key-switch24. Front R.H. turn signal light25. Wire harness26. Fuel level sender27. Fuse holder assembly28. Rear R.H. turn signal light29. License plate light bulb30. License plate lamp31. Battery32. Starter relay33. Starter motor34. Engine oil pressure sensor35. Pick-up36. Automatic choke device37. Carburettor heater38. H.T. coil39. Taillight assembly40. Stop and taillight bulb41. Voltage regulator42. Rear L.H. turn signal light43. 4 amber light bulbs for turn signal lamps44. Relay45. Horn Wiring- Colour coding:B = WhiteBl = BlueG = YellowELE SYS - 53

Electrical systemFly 125 - 150 4TMr = BrownN = BlackBV = White-GreenGN = Yellow-BlackGr = GreyRs = PinkR = RedVi = PurpleV = GreenVN = Green-BlackBN = White-BlackBBl = White-BlueGV = Yellow-GreenAr = OrangeAz = Light BlueGrBl = Gray-BlueGrN = Grey-BlackRBl = Red-BlueGR = Yellow-RedBlN = Blue-BlackElectrical system installationELE SYS - 54

Fly 125 - 150 4TElectrical systemFront sideFRONT INSTALLATION 1SpecificationDesc./Quantity1 Strap Insert the strap through the hole in the chassis2 Zip tie3 Fixing Fold the chassis strap over the cablesELE SYS - 55

Electrical systemFly 125 - 150 4TSpecification1 Front R.H. turn signal light2 Fuse holder box3 Front L.H. turn signal light4 Light remote control switch5 Ignition key-switch6 Control device ignition7 Immobiliser diagnostic outletFRONT INSTALLATIONDesc./QuantityELE SYS - 56

Fly 125 - 150 4TElectrical systemSpecification8 Zip tie9 HornDesc./QuantitySpecification1 Zip tieFRONT INSTALLATION 2Desc./QuantityELE SYS - 57

Electrical systemFly 125 - 150 4TBack sideREAR INSTALLATIONSpecification1 Cable harness fairlead2 Breather tube3 Heater conductors and automatic choke protectivesheath4 Voltage regulator5 HV coil6 Earth node7 Starter remote control8 License plate light connectorDesc./QuantityELE SYS - 58

Fly 125 - 150 4TElectrical systemSpecification1 H.T. Cable2 Zip tie3 To the automatic choke device4 To the heater5 Rear R.H. turn signal light6 Taillight7 Rear L.H. turn signal lightREAR INSTALLATION 1Desc./QuantityELE SYS - 59

Electrical systemFly 125 - 150 4TSpecification1 Zip tie2 Starter motor earth3 Starter motor positive outlet4 Flywheel connectionREAR INSTALLATION 2Desc./QuantityConceptual diagramsELE SYS - 60

Fly 125 - 150 4TElectrical systemIgnitionSpecification1 electronic control unit2 Magneto flywheel3 Pick - up4 HV coil5 Spark plug6 Voltage regulatorIGNITIONDesc./QuantityELE SYS - 61

Electrical systemFly 125 - 150 4THeadlights and automatic starter sectionLIGHTS AND AUTOMATIC STARTERSpecificationDesc./Quantity1 electronic control unit2 Carburettor heater3 Automatic starter4 Key switch5 Main fusible 15A6 Battery 12V-9Ah7 Headlamp relay8 Light switch9 High-beam fuse 7,5A10 Low-beam and dashboard lights fuse 7,5A11 Low-beam light bulb 12V - 55W12 High-beam light bulb 12V-55W13 High-beam lamp warning light 12V - 1.2W14 Front side-light bulb 12V - 5W15 Four dashboards illuminating bulbs 12V - 1,2W16 Taillight bulb 12V - 5W17 License plate bulb 12V - 5W18 Low-beam fuse 7,5AELE SYS - 62

Fly 125 - 150 4TElectrical systemBattery recharge and startingBATTERY CHARGER AND STARTINGSpecificationDesc./Quantity1 Magneto flywheel2 Voltage regulator3 Pick - up4 Main fusible 15A5 Battery 12V-9Ah6 Starter relay7 Starter motor8 Start up button9 Front and rear brake light button10 Brake light filament 12V-21W11 Fuse 7.5 A12 Key switch13 electronic control unitELE SYS - 63

Electrical systemFly 125 - 150 4TLevel indicators and enable signals sectionCONSENSUSES AND LEVEL INDICATORSSpecificationDesc./Quantity1 electronic control unit2 Battery 12V-9Ah3 Main fusible 15A4 Key switch5 Engine oil pressure sensor6 Low oil pressure warning light 12V - 1,2W7 Reserve fuel light 12V-1,2W8 Fuel gauge9 Fuel level sender10 Fuse 7.5 A11 Immobilizer aerial12 Low engine oil pressure sensor13 Immobiliser LED14 Front and rear brake light button15 Taillight bulb 12V - 5W16 Starter motor17 Starter relay18 Start up buttonELE SYS - 64

Fly 125 - 150 4TElectrical systemTurn signal lightsTURN INDICATORS AND HORNSpecificationDesc./Quantity1 electronic control unit2 Indicators switch3 4 Turn indicator bulbs 12V-10W4 Turn signal warning light bulbs 12V - 2W5 Main fusible 15A6 Battery 12V-9Ah7 Horn8 Fuse 7.5 A9 Key switch10 Horn buttonELE SYS - 65

Electrical systemFly 125 - 150 4TInstruments and warning lights control boardSpecification1 Ground lead (-)2 High-beam warning light3 Left turn indicator4 Engine oil warning light4 PIN CONNECTOR5 PIN CONNECTORSpecification1 Instrument panel lighting and headlampwarning light2 Right turn indicator3 Low-fuel warning light4 + permanent power supply5 Fuel gaugeDesc./QuantityDesc./QuantityChecks and inspectionsELE SYS - 66

Fly 125 - 150 4TElectrical systemImmobiliserThe electric ignition system is fed with direct currentand is protected by an anti-theft immobilizerintegrated 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 LEDThe diagnosis LED also works as a blinking lightto deter theft. This function is activated every timethe key switch is turned to «OFF», and it remainsactive 48 hours so as not to affect the batterycharge.When the ignition switch is set to «ON», the theftdeterring blinker function is deactivated. Subsequently,a flash confirms the switching to «ON».The duration of the flash depends on the electroniccontrol unit program (see figure).Whenever the LED is off and remains so, evenwhen switching it to «ON», it is necessary to checkif:- the battery is charged- 15A main fuse is working correctly.Connect the immobilizer tester to the diagnosissocket (see ET4 125 manual) located behind thefront left fuse box flap.If the serial LED remains off, check the electroniccontrol unit supply as follows:ELE SYS - 67

Electrical systemFly 125 - 150 4TDetach the connector from the ECU and check thefollowing:- Presence of battery potential difference betweenterminal 4 (Red/Blue) and earth- Presence of battery potential difference betweenterminals 4 (Red/Blue) and 8 (black), as shown inthe figure.- Presence of battery potential difference betweenterminals 5 and 8 with the key-switch onto «ON».If no anomalies are found, replace the electroniccontrol unit.Virgin circuitIf the ignition system has not been programmed,the engine can be started but it will run limited to2000 rpm. When trying to accelerate, some evidentloss 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 keepit in that position for 2 seconds (limit values: 1 ÷ 3seconds).- Alternatively insert all the available black keysand 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 programmedat one time.Sequence and times must be strictly observed orit will be necessary to repeat the procedure fromthe start.ELE SYS - 68

Fly 125 - 150 4TElectrical systemOnce the control unit has been programmed, thecontrol unit is inseparably matched with the MAS-TER key transponder.This matching allows programming further servicekeys in case of loss, replacement, etc. Each newtime new data is programmed the previously storedone is deleted.If a service key setting is lost, it is essential tocarefully check the efficiency of the high voltagesystem:Shielded cap resistance ~ 5000 Ω.In any case, it is advisable to use resistive sparkplugs as shown in the figure.Diagnostic codesThe flash indicating the switching to "ON" (0.7-secflash) can be followed by a phase of programmedfailure warnings.That is, the LED is off for 2 seconds, and then diagnosiscodes are transmitted with 0.5-sec flashes.After the failure code indication, a steadily on LEDsignals that ignition is disabled; see the table:2-FLASH CODEExample with programmed electronic control unit,no transponder and/or aerial malfunctionIgnition disabled-Vehicle immobilised3-FLASH CODEExample with programmed electronic control unit,aerial working properly and unknown transpondercode.Ignition disabled-Vehicle immobilisedDiagnostic code - 2 flashesWhen 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 failurepersists with any key, disconnect the aerial connector from the electronic control unit and check theaerial continuity with the multimeter.ELE SYS - 69

Electrical systemFly 125 - 150 4TIf it does not work, replace the aerial.If no faults are found, replace the control unit.CAUTIONBEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURECODE IS INDICATED. THIS IS TO AVOID SPOILING A NEW CONTROL UNIT UNNECESSARILY.Specific tooling020331Y Digital multimeterElectric characteristicResistance value~ 7 ÷ 9 OhmDiagnostic code - 3 flashesIf the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into thekey 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. Theignition is enabled (regular use conditions)Ignition circuitAll the control operations of the system that entail disconnecting cables (to check connections and thedevices making up the ignition circuit) must be done with the engine off: if this is not done, the controlsmight be irretrievably damaged.The battery provides the basic power supply. The system is adjusted so that the start-up system immediatelydetects an eventual battery voltage drop, and this is practically irrelevant for the ignitionsystem.The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connectedto the Pick-Up by the chassis and the engine ground lead.ELE SYS - 70

Fly 125 - 150 4TElectrical systemTo avoid disturbances in the ignition system during start-up, it is very important that the engine-chassisground connection bonding is efficient.No spark plugWhen noticing no spark plug proceded as follows:- Pick-Up inspection.Detach the ECU connector and check for continuitybetween terminals 2 (Green) and 8 (Black).The inspection must include the pick-up and it'spower cable.If an open circuit is found, repeat the inspectionbetween the flywheel connector and earth. If unacceptablevalues are found, proceed by replacingthe pick-up, otherwise repair the cable.Electric characteristicPick-up resistance valuePick-up resistance value: 105 ÷ 124 Ohm- H.T. coil primary circuit inspectionDetach the connector from the ECU and check forcontinuity between terminals 3 (purple) and 8(black) (see figure).If unacceptable values are found, repeat the inspectiondirectly from the positive and negativeterminals of the H.T. coil primary circuit.If the values are within the prescribed limit, proceedby repairing the wiring or reattaching all wirings,otherwise replace the H.T. coil.Electric characteristicHigh voltage coil primary resistance valueHigh voltage coil primary resistance value: 0.4 ÷0.5 Ohm- HV coil secondary checkDisconnect the spark plug cap from the HV cable and measure the resistance between the HV cableterminal 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 toolingELE SYS - 71

Electrical systemFly 125 - 150 4T020409Y Multimeter adaptor - Peak voltage detectionElectric characteristicHigh voltage coil secondary resistance valueHigh voltage coil secondary resistance value: ~ 3000 ± 300 Ohm- Pick-UpDetach the ECU connector and connect the positiveterminal to connector no. 2 and the negativeterminal to connector no. 8 (see figure).Crank the engine using the starter motor andcheck the tension produced by the pick-up.If unacceptable values are found, replace the Pick-Up.N.B.THE MULTIMETER MUST BE SELECTED TODETECT CONTINUOUS VOLTAGE.Electric characteristicPick-Up voltage valuePick-Up voltage value: > 2 Volt- H.V. coilWith the control unit and HV coil connected to thecircuit, measure the voltage of the coil primary duringthe start-up test with the voltage peak adaptorand connect the positive terminal to the earth oneand the negative to the coil positive connector.If non-conforming values are measured, replacethe control unit.THE POSITIVE TERMINAL OF THE HV COILPRIMARY IS BLACK.Electric characteristicHigh voltage coil voltage valueHigh voltage coil voltage value: > 100 VoltELE SYS - 72

Fly 125 - 150 4TElectrical systemBattery recharge circuitThe 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 safetyfuse.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 isachieved between generated power and idle stability.For this reason, it is very important that the idle speed is adjusted as prescribed.Specific tooling020333Y Single battery charger020334Y Multiple battery chargerStator checkDisconnect the connector from the voltage regulatorand check there is continuity between anyyellow cable and the other two cables.Electric characteristicOhm value:0.7 ÷ 0.9 OhmAlso check that all yellow cables are insulated fromthe ground connection.If non-conforming values are detected, repeat thechecks directly to the stator. In case of further repetitionsof incorrect values replace the stator orrepair the wiring.ELE SYS - 73

Electrical systemFly 125 - 150 4TVoltage regulator checkWith a perfectly charged battery and lights off,measure voltage at the battery poles with a highrunning engine.The voltage should not exceed 15.2 Volt.In case higher voltages are detected, replace theregulator.In case of voltage values lower than 14 Volt, checkthe stator and the corresponding cable harness.Recharge system voltage checkConnect an ammeter induction clamp to the voltageregulator positive terminal, measure the batteryvoltage and turning on the vehicles lights withengine off, wait for the voltage to set at about 12V. Start the engine and measure the current generatedby the system with lights on and a highrunning engine.In case the generated current value is lower than8A, repeat the test using a new regulator and/statoralternatively.Choke InspectionRefer to the engine section to check the resistanceand operating conditions of the component. As regardsvoltage supply, keep the connector connectedto the system and check that the two terminalsreceive battery voltage when the engine is on(see figure).If no voltage is detected, connect the multimeternegative terminal to the ground lead and the positiveterminal to the automatic starter orange cable;ELE SYS - 74

Fly 125 - 150 4TElectrical systemwith the key switch set to "ON" check whetherthere is battery voltage; if there is no voltage,check the wiring connections to the key switch.If battery potential is found, repeat the inspectionfrom the connector to the ECU.After detaching the choke device, start the engineand, while at idle, check for tension connecting thepositive 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; otherwisecheck the wiring between the choke device and theECU.Turn signals system check- If the turn signal lights are faulty, proceed as follows:- Detach the ECU connector and check for batterytension 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, otherwiseproceed as follows:- Jumper terminals 1 (Black/Blue) and 5 (Orange),see figure, and alternately operate the turn signalswitch 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 betweenthe ECU and the turn signal switch, hence repeatthe test.ELE SYS - 75

Electrical systemFly 125 - 150 4TSealed batteryIf the vehicle is provided with a sealed battery, the only maintenance required is the check of its chargeand recharging, if necessary.These operations should be carried out before delivering the vehicle, and on a six-month basis whilethe vehicle is stored in open circuit.Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, ifrequired, before storing the vehicle and, afterwards, every six months.INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE1) Voltage check upBefore 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 recommendedMinimum 6 hMaximum 24 h3) Constant current battery charge mode- Charge current equal to 1/10 of the battery rated capacity- Charge time: Maximum 5 hDry-charge batteryWARNING- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contactwith eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about15 minutes and seek immediate medical attention.In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Followwith milk of magnesia, beaten egg or vegetable oil. Seek immediate medical attentionBatteries produce explosive gases; keep clear of free flames, sparks or cigarettes; ventilate the areawhen 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 4TElectrical systemCommissioning dry-charged batteries :1) - Remove the short closed tube and the caps,then pour sulphuric acid into the cells using thetype specified for batteries with a specific gravityof 1.26, corresponding to 30 Be at a minimum temperatureof 15°C until the upper level is reached.2) - Leave to rest for at least 2 hours; then, restorethe level with sulphuric acid.3) - Within the following 24 hours, recharge usingthe specific battery charger (single) or (multiple) ata density of about 1/10 of the battery nominal capacityuntil fully charged; check that the acid densityis about 27, corresponding to 31 Be, and thatthese values are stabilised.4) - Once the charge is over, level the acid (byadding distilled water). Close and clean carefully.5) Once the above operations have been performed,install the battery on the vehicle ensuringthat it is wired up properly.1 Hold the vertical tube2 Look at the level3 The float must be freedWARNING- ONCE THE BATTERY HAS BEEN INSTALLEDIN THE VEHICLE IT IS NECESSARY TO RE-PLACE THE SHORT TUBE (WITH CLOSEDEND) NEAR THE + POSITIVE TERMINAL WITHTHE CORRESPONDING LONG TUBE (WITHOPEN END), THAT YOU FIND FITTED TO THEVEHICLE, TO ENSURE THAT THE GASESTHAT FORM CAN ESCAPE PROPERLY.Specific tooling020333Y Single battery charger020334Y Multiple battery chargerBattery maintenanceThe battery is an electrical device which requires careful monitoring and careful maintenance. Themaintenance rules are:1) Electrolyte level checkELE SYS - 77

Electrical systemFly 125 - 150 4TThe electrolyte level must be checked frequently and must reach the upper level. Only use distilledwater, to restore this level. If it is necessary to add water too frequently, check the vehicle electricalsystem: the battery works overcharged and is subject to quick wear.2)Load status checkAfter 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 specificweight 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 thereforebe recharged.If the scooter is not used for a given time (1 month or more) it will be necessary to periodically rechargethe battery.The battery runs down completely in the course of three months. If it is necessary to refit the battery inthe 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 connectedto the clamp marked with the +positive sign.3) Recharging the batteryRemove 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 powersupply source must be implemented by connecting the corresponding poles (+ to+ and - to -).4) Battery cleaningThe battery should always be kept clean, especially on its top side, and the terminals should be coatedwith Vaseline.WARNINGBEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKSAND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.CAUTIONNEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USINGA FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSEA FIRE.CAUTIONORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FORTHE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.CAUTIONTO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE ITIS FIRST USED SHORTENS THE LIFE OF THE BATTERY.Specific tooling020333Y Single battery charger020334Y Multiple battery chargerELE SYS - 78

INDEX OF TOPICSENGINE FROM VEHICLEENG VE

Engine from vehicleFly 125 - 150 4TExhaust assy. Removal- Remove the 2 fixing nuts from the manifold to thehead- Unscrew the 2 screws fixing the muffler to thehousing; then remove the whole muffler paying attentionto the interference between its supportingbracket 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 fixingscrews indicated in the photograph- Remove the throttle control cable from the carburettor,indicated in the photographENG VE - 80

Fly 125 - 150 4TEngine from vehicle- Remove the fuel supply pipe from the carburettor- Remove the fuel valve low-pressure pipe from themanifold as shown in the photograph- Remove the flywheel wiring connector, the earthterminal and the starter motor positive cable indicatedin the figure- Remove the clamp retaining the starter wiringand the heater indicated in the figureENG VE - 81

Engine from vehicleFly 125 - 150 4T- Remove the protection sheath indicated in thefigure and disconnect the automatic starter andcarburettor heater connections- Unscrew the engine pin-swinging arm nut on theright-hand side of the vehicle and slide off the pinon the left hand side- Support the vehicle adequately (with a jack) andremove the shock absorber lower clamping. Theengine is now free.See alsoExhaust assy. RemovalENG VE - 82

INDEX OF TOPICSENGINEENG

EngineFly 125 - 150 4TThis section describes the operations to be carried out on the engine and the tools to be used.Automatic transmissionTransmission cover- To remove the transmission cover it is necessaryto remove the rear plastic cover first by inserting ascrewdriver in the corresponding slotted holes.Using the clutch bell lock wrench, remove the drivenpulley axle locking nut and recover the washer.- Remove the cap/dipstick from the engine oil fillinghole.- Remove the 10 screws and the earth cable fastenedunder one of them.- Remove the transmission cover. If this operationis performed directly on the vehicle, it is necessaryto remove the cooling air coupling and the three airfilter housing retainers.Specific tooling020423Y driven pulley lock wrenchCAUTIONMaybe a first batch of vehicles features an airmanifold bulkhead with the tail highlighted in thefigure. While removing the transmission cover,take care not to deform this tongue with the fixeddriving half-pulley.ENG - 84

Fly 125 - 150 4TEngineAir duct- Unscrew the Torx screws fixing the air manifoldbulkhead and remove the bulkhead.- Remove the 3 screws, then take out the manifoldas 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 fromthe crankcase.CAUTIONUSE AN APPROPRIATE REST SURFACE TOAVOID DAMAGING THE COVER PAINT.Specific tooling020376Y Adaptor handle020375Y Adaptor 28 x 30 mmENG - 85

EngineFly 125 - 150 4TRefitting the driven pulley shaft bearing- Heat up the crankcase inside with the hot air gun.- Insert the bearing in its housing, refit the Seegerring.N.B.ALWAYS REPLACE THE BEARING WITH ANEW ONE UPON REFITTING.Specific tooling020151Y Air heater020376Y Adaptor handle020357Y 32 x 35 mm adaptor020412Y 15 mm guideRemoving the driven pulley- Remove the spacer, the clutch bell and the wholedriven pulley unit.N.B.THE UNIT CAN ALSO BE REMOVED WITH THEDRIVING PULLEY MOUNTED.Inspecting the clutch drum- Check that the clutch bell is not worn or damaged.- Measure the clutch bell inside diameter.CharacteristicMax. value clutch bellMax. value: Ø 134.5 mmClutch bell standard valueStandard value: Ø 134 - 134.2 mmENG - 86

Fly 125 - 150 4TEngineChecking the bell working surface eccentricity- Install the bell on a driven pulley shaft using 2bearings (inner diameter 15 and 17 mm).- Lock with the original spacer and nut.- Place the bell/shaft assembly on the support tocheck 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 tooling020074Y Support base for checking crankshaftalignment020335Y Magnetic support for dial gaugeCharacteristicclutch bell inspection: Limit eccentricity.Admissible limit eccentricity: 0.15 mmRemoving the clutch- Prepare the locking tool for the driven pulley withthe pins half-screwed in the tool set to «C».ENG - 87

EngineFly 125 - 150 4T- Fit the driven pulley unit in the tool so as the boltget into the masses clutch support holes. Afterwardsmake the support screw make contact witha minimum force.- Using the specific wrench, inserted 46 mm fromthe side, remove the clutch central locking nut.- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).CAUTIONTHE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BETIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THESPECIFIC TOOL.Specific tooling020444Y Tool for fitting/ removing the driven pulley clutch020444Y009 46x55 WrenchInspecting the clutch- Check the thickness of the clutch mass frictionmaterial.- The masses must not show traces of lubricants;otherwise, check the driven pulley unit seals.N.B.UPON RUNNING-IN, THE MASSES MUST EX-HIBIT A CENTRAL CONTACT SURFACE ANDMUST NOT BE DIFFERENT FROM ONE AN-OTHER.VARIOUS CONDITIONS CAN CAUSE THECLUTCH TO TEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLSTO PREVENT A VARIATION IN THE RETURNSPRING LOAD.CharacteristicCheck minimum thickness1 mmENG - 88

Fly 125 - 150 4TEnginePin 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 bladescrewdrivers.- Using a hammer and pin, knock the ball bearingout as shown in the figure.- Remove the roller bearing using the specific extractor.N.B.REST THE HALF-PULLEY ON A WOOD SUR-FACE TO AVOID DAMAGING THE THREADEDRINGLET OF THE DRIVEN PULLEY UPON RE-MOVING IT.Specific tooling020375Y Adaptor 28 x 30 mm020376Y Adaptor handle020439Y 17 mm guideENG - 89

EngineFly 125 - 150 4TInspecting the driven fixed half-pulley- Measure the external diameter of the pulley bushing.CharacteristicMinimum diameter permittedØ 40.96 mmStandard diameterØ 40.965 mmInspecting the driven sliding half-pulley- Remove the 2 inner sealing rings and the two O-rings.- Measure the inside diameter of the mobile halfpulleybushing.CharacteristicMinimum admissible diameterØ 41.08 mmStandard diameterØ 41.035 mmRefitting the driven half-pulley bearing- Assemble a new roller case using the specificpunch, fit the bearing with the label facing outwardand insert it completely up to the punch on the halfpulley.N.B.REST THE HALF-PULLEY ON A WOOD SUR-FACE TO AVOID DAMAGING THE THREADEDRINGLET OF THE DRIVEN PULLEY UPON RE-MOVING IT.Specific tooling020424Y Driven pulley roller casing fittingpunchENG - 90

Fly 125 - 150 4TEngine- To assemble the new ball bearing insert it completelydown in its housing with the specific punchand finally assemble the Seeger ring.Specific tooling020375Y Adaptor 28 x 30 mm020376Y Adaptor handle020439Y 17 mm guideRefitting the driven pulley- Check that the faying surfaces between the 2half-pulleys and the belt do not show any signs ofwear, scoring and grease.- Insert the new oil seals and O-rings on the movablehalf-pulley.- Assemble the half-pulley on the ringlet with theappropriate protection sheath.- Make sure the pins and collar are not worn, reassemblethe pins and collar.- Use a greaser with a curved spout to lubricate thedriven pulley unit with around 6 g of grease. Thisoperation must be done through one of the holesinside the bushing until grease comes out of theopposite hole. This operation is necessary to avoidthe presence of grease beyond the O-rings.Specific tooling020263Y Sheath for driven pulley fittingRecommended productsAGIP GREASE SM 2 Grease for the tone wheelrevolving ringSoap-based lithium grease containing NLGI 2 Molybdenumdisulphide; ISO-L-XBCHB2, DINKF2K-20ENG - 91

EngineFly 125 - 150 4TInspecting the clutch spring- Measure the unloaded length of the spring of themovable driven half-pulley.CharacteristicStandard length:106 mmRefitting the clutch- Check the thickness of the clutch mass frictionmaterial.-The masses must not show traces of lubricants;otherwise, check the driven pulley unit.N.B.UPON RUNNING-IN, THE MASSES MUST EX-HIBIT A CENTRAL CONTACT SURFACE ANDMUST NOT BE DIFFERENT FROM ONE AN-OTHER. VARIOUS CONDITIONS CAN CAUSETHE CLUTCH TO TEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLSSO AS TO PREVENT A VARIATION IN THE RE-TURN SPRING LOAD.CharacteristicMinimum thickness permitted:1 mm- Support the driven pulley spring compressor appropriatetool with the control screw in vertical axis.- Arrange the tool with the medium length pinsscrewed in position "C" on the inside.- Introduce the adapter ring 11 with the chamferingfacing upwards.- Insert the clutch on the adapter ring.- Lubricate the end of the spring that abuts againstthe servo-system closing collar.- Insert the spring with its plastic holder in contactwith the clutch.ENG - 92

Fly 125 - 150 4TEngine- Insert the driving belt into the pulley unit accordingto 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 intothe adapter ring before proceeding to tighten theclutch nut.- Place the tool in the clamp with the control screwon the horizontal axis.- Fully preload the spring.- Apply the clutch fixing nut and tighten it to theprescribed torque using the special 46x55 wrench.- Loosen the tool clamp and insert the belt accordingto its direction of rotation.- Lock the driven pulley again using the specifictool.- Preload the clutch return spring with a traction/rotation combined action and place the belt in thesmaller 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 PLASTICSPRING STOP AND THE BUSHING THREAD-ING.N.B.FOR DESIGN REASONS, THE NUT IS SLIGHT-LY ASYMMETRIC; THE FLATTEST SURFACESHOULD BE MOUNTED IN CONTACT WITHTHE CLUTCH.Specific tooling020444Y Tool for fitting/ removing the drivenpulley clutch020444Y011 adapter ring020444Y009 46x55 WrenchLocking torques (N*m)Nut locking clutch unit on pulley 55 ÷ 60 NmENG - 93

EngineFly 125 - 150 4TRefitting the driven pulley- Reassemble the clutch bell and spacer.Drive-beltDuring the wear checks foreseen in the scheduledmaintenance services at 6,000 km; 18,000 km;etc., check that the rim bottom of the toothing doesnot show signs of incisions or cracking (see figure):The rim bottom of the tooth must not have incisionsor cracking; if it does, change the belt.- Check that the driving belt is not damaged.- Check the width of the belt.SpecificationMinimum widthStandard widthBELT SIZEDesc./Quantity21.5 mm22.5 ± 0.2 mmENG - 94

Fly 125 - 150 4TEngineRemoving the driving pulley- Lock the driving pulley with the specific tool asshown in the figure. - Disassemble the central nutand the Belleville washer, remove the drive andthe 2 washers. - Remove the stationary half pulleyand the steel washer.Specific tooling020368Y driving pulley lock wrench- Remove the belt and slide the movable half-pulleywith the relevant bush, taking care of the fallingfree assembled rollers.- Remove the return rollers plate with the relativeguide 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 CONTAINERSpecificationDesc./QuantityMaximum allowable diameterØ 26.121 mmStandard diameterØ 26+0 +0.021 mmBUSH SLIDE PULLEYSpecificationMinimum diameter permittedStandard diameterDesc./QuantityØ 25.950 mmØ 26-0.020 -0.041 mmVARIABLE SPEED ROLLERSSpecificationDesc./QuantityMinimum diameter permittedØ 18.5 mmStandard diameterØ 26±0.1 mmENG - 95

EngineFly 125 - 150 4T- Check the guide shoes for the variator back-plateare not worn.- Check there is no wear in the roller housing, andthe surfaces in contact with the belt on either of thepulley 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 nutto the prescribed torque.-Avoid the half-pulley rotation using a calliperspannerN.B.REPLACE THE NUT WITH A NEW ONE AT EV-ERY REFITSpecific tooling020368Y driving pulley lock wrenchRecommended productsLoctite 243 Medium strength threadlockLoctite 243 medium-strength threadlockLocking torques (N*m)Locking torque 75 ÷ 83ENG - 96

Fly 125 - 150 4TEngineRefitting the transmission cover- Check the presence of the 2 centring dowels andthe correct installation of the sealing gasket for theoil sump on the transmission cover.- Replace the cover tightening the 10 screws at thespecified torque.- Refit the oil loading cap/bar.- refit the steel washer and the driven pulley nut.- Tighten the nut to the prescribed torque using thelock wrench and the torque wrench tools.- Replace the plastic cover.Specific tooling020423Y driven pulley lock wrenchLocking torques (N*m)Transmission cover screws 11 ÷ 13 Driven pulleyshaft nut 54 ÷ 60End gearRemoving the hub cover- Empty the rear hub through the oil drainage taplocated inside the hub cover- Remove the brake shoe and relevant spring- Remove the 7 flanged screws as shown in thefigure.- Remove the rubber cover and the brake pad leversliding unscrewing the relevant retaining screw toreach the rear of the cover- Take off the hub cover and relevant gasketsENG - 97

EngineFly 125 - 150 4TRemoving the wheel axleRemove the intermediate gear and the completehub 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 thethree 15 mm bearings (2 in the crankcase and 1 inthe hub cover).Specific tooling001467Y009 Driver for OD 42 mm bearings001467Y013 Pliers to extract ø 15-mm bearingsRemoving the wheel axle bearings- Take out the clip on the outside of the gearboxcover.- Remove the bearing with the adequate tools adequatelysupporting the hub cover, as shown in thefigure.Specific tooling020376Y Adaptor handle020364Y 25-mm guideENG - 98

Fly 125 - 150 4TEngineWith the appropriate tools, remove the oil seal asshown in the figure.Specific tooling020376Y Adaptor handle020359Y 42x47-mm adaptorRemoving the driven pulley shaft bearingIf it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove drivenpulley.- Extract the driven pulley shaft from its bearing.- Remove the oil guard using a screwdriver, working from inside the bearing and being careful not todamage the housing, make it come out of the belt transmission side.- Remove the seeger ring shown in the figureWith the sectional punch, remove the driven pulleyshaft bearing.Specific tooling020376Y Adaptor handle020375Y Adaptor 28 x 30 mm020363Y 20 mm guideSee alsoRemoving the driven pulleyInspecting the hub shaft- Check the three shafts for wear or distortion ofthe toothed surfaces, the bearing housings, andthe oil seal housings.- In case of anomalies, replace the damaged components.ENG - 99

EngineFly 125 - 150 4TInspecting the hub cover- Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and thebrake camshaft. - If faults are found, replace the hub cover.Refitting the driven pulley shaft bearing- Heat up the parts using the specific heat gunSpecific tooling020150Y Air heater support020151Y Air heater- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside ofthe hub cover using the adequate toolsSpecific tooling020376Y Adaptor handle- Refit the Seeger ring with the opening facing thebearing as shown in the figure and fit a new oilguard flush with the crankcase.Refitting the wheel axle bearing- Heat up the parts using the specific heat gunSpecific tooling020151Y Air heater020150Y Air heater support-The wheel axle bearing on the cover, should be assembled with the specific toolsSpecific tooling020364Y 25-mm guide020360Y Adaptor 52 x 55 mm020376Y Adaptor handleENG - 100

Fly 125 - 150 4TEngine• Assemble the Seeger ring.• Assemble the oil seal flush with the internalsurface as shown in the figure tothe hub using the adequate tools andwith the seal lip towards the inside ofthe hub.Specific tooling020376Y Adaptor handle020360Y Adaptor 52 x 55 mmRefitting the hub cover bearings- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with thespecific heat gun.Specific tooling020150Y Air heater support020151Y Air heater- The three 15 mm bearings must be fitted usingthe appropriate tools.Refitting the hub bearings- Insert the cover prepared in the crankcase takingcare of inserting the gear of the pulley shaft on theintermediary gear.ENG - 101

EngineFly 125 - 150 4TRefitting the ub cover- Fit a new gasket together with the centring dowels.- Fit the gearbox cover, making sure the breatherpipe is in the correct position.- Screw the 7 screws to the specified torque, positioningthe support plate of the pipe in the positionshown in the figure.- Remove the control pin of the shoe taking careso as the long tooth coincides with the groove onthe control lever.Locking torques (N*m)Locking torque 24 ÷ 27Flywheel coverCooling hood-Remove the housing acting on the 4 retainingscrews.CAUTIONDURING REMOVAL SLIDE THE HOUSINGCONNECTOR ON THE HOUSING.- Loosen the clamp and remove the carburettorfrom the manifold.-Remove the complete manifold acting on the 2retainers as shown in the figure.- Remove the 2 self threading screws, left and rightand the lateral base retaining screw on the crankcasebase.- Take off the housings.- Remove the gasket seal of the housing on thehead.N.B.ENG - 102

Fly 125 - 150 4TEngineIF THE FLYWHEEL HOUSING IS NOT RE-MOVED, IT IS ALSO NECESSARY TO REMOVETHE TWO KNOB SCREWS.On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggestto intervene on the vacuum socket inserting on the inlet manifold widening the hole from 0.4 mm to 1.5mm. Remember that such operation must have performed on a disassembled manifold which must becleaned afterwards.Cooling fan- Refit the parts in reverse order of the removaloperation.- Make sure that there are spacers with the tworear retainers of the housing.- The long spacers should be in a high position.CAUTIONTAKE CARE TO CORRECTLY POSITION THEFLYWHEEL CONNECTOR.- Remove the cooling fan by acting on the threefixings indicated in the figure.Removing the stator- Remove the electric terminal of the minimum oilpressure switch.- Remove the two Pick-Up screws and the one forthe wiring harness bracket as well as the two statorfixing screws shown in the figure.- Remove the stator and its wiring.ENG - 103

EngineFly 125 - 150 4TRefitting the stator- Refit the stator and flywheel carrying out the removalprocedure in reverse, tightening the retainersto the specified torque.- Place the cable harness as shown in the figure.N.B.THE PICK-UP WIRE SHOULD BE POSITIONEDBETWEEN THE UPPER SCREW AND THE REF-ERENCE PIN AS SHOWN IN THE DETAILDRAWING.Locking torques (N*m)Stator screw 3 ÷ 4Flywheel and startingRemoving the flywheel magneto- Lock the rotation of the flywheel using the calliperspanner.- Remove the nut.CAUTIONTHE USE OF A CALLIPER SPANNER OTHERTHAN THE ONE SUPPLIED COULD DAMAGETHE STATOR COILSSpecific tooling020565Y Flywheel lock calliper spanner- Extract the flywheel with the extractor.Specific tooling008564Y Flywheel extractorENG - 104

Fly 125 - 150 4TEngineInspecting 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 keyproperly.- 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 assemblingthe Pick-Up.Different values result from deformations visibleon the Pick-Up support.N.B.A VARIATION IN THE AIR GAP DISTANCEMODIFIES THE IGNITION SYSTEM IDLESPEEDLocking torques (N*m)Flywheel nut 52 ÷ 58Refitting the starter motor- Fit a new O-ring on the starter and lubricate it.- Fit the starter on the crankcase, locking the twoscrews to the prescribed torque.N.B.REFIT THE REMAINING PARTS AS DESCRI-BED IN THE CYLINDER HEAD, TIMING, LUBRI-CATION, FLYWHEEL AND TRANSMISSIONCHAPTERS.Locking torques (N*m)Starter motor screws 11 ÷ 13Cylinder assy. and timing systemENG - 105

EngineFly 125 - 150 4TRemoving the timing system drive- Remove the parts listed below first: transmissioncover, belt driving pulley, oil pump pulley cover andpinion separator washer.- Remove the tappet cover.- Remove the central screw fastener and the automaticvalve-lifter retaining cover, as shown in thefigure.- Remove the return spring of the automatic valvelifter assembly and the automatic valve lifter assemblyand 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 counterweightshown in the figure.- Remove the camshaft command pulley and itswasher.- Remove the command sprocket wheel and thetiming chain.- Remove the screws indicated in the figure, thespacer bar and the tensioner pad.The chain tensioning pad must be removed fromthe transmission side. As regards the lower chainguide pad, it may only be removed after the headhas been removed.N.B.IT IS ADVISABLE TO MARK THE CHAIN IN OR-DER TO ENSURE THAT THE INITIAL DIREC-TION OF ROTATION IS MAINTAINED.See alsoTransmission coverRemoving the driving pulleyRemovalENG - 106

Fly 125 - 150 4TEngineRemoving the cam shaft- Remove the two screws and the cam shaft retainershown in the diagram.- Remove the cam shaft.- Remove the pin of the rocking levers from theflywheel side holes.- Remove the rocking levers and the elastic washer.N.B.MARK THE ROCKING LEVERS ASSEMBLEPOSITION, SO AS TO AVOID THE INVERSIONOF 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 twoor three stages and in criss-cross fashion.- Remove the head, the two centring dowels andthe gasket.N.B.IN CASE OF NEED, THE HEAD MAY BE RE-MOVED WITH THE CAMSHAFT, PINS, ROCK-ING LEVERS AND FIXING BRACKET. THEHEAD CAN ALSO BE REMOVED WITHOUT RE-ENG - 107

EngineFly 125 - 150 4TMOVING THE CHAIN AND THE DRIVINGSHAFT CHAIN TIGHTENER.Removing the valves- Using the specific tool fitted with the elementshown in the figure, remove the cotters, the platesand the spring between the valves.Specific tooling020382Y Valve cotters equipped with part 012removal tool020382Y011 adapter for valve removal tool- Remove the oil seals with the appropriate tool.- Remove the lower spring supports.Specific tooling020431Y Valve oil seal extractorRemoving the cylinder - piston assy.- Remove the chain guide pad.- Remove the cylinder base gasket.CAUTIONTO AVOID DAMAGING THE PISTON, SUP-PORT IT WHILE REMOVING THE CYLINDER.ENG - 108

Fly 125 - 150 4TEngine- Remove the two stop rings, the wrist pin and thepiston.- Remove the 3 piston rings from the piston.N.B.BE CAREFUL NOT TO DAMAGE THE PISTONRINGS DURING REMOVAL.Inspecting the small end- Measure the internal diameter of the small endusing an internal micrometer.N.B.IF THE DIAMETER OF THE ROD SMALL ENDEXCEEDS THE MAXIMUM DIAMETER AL-LOWED, SHOWS SIGNS OF WEAR OR OVER-HEATING REPLACE THE CRANKSHAFT ASDESCRIBED IN THE "CRANKCASE ANDCRANKSHAFT" CHAPTER".CharacteristicRod small end check-up: Maximum diameter15.030 mmRod small end check-up: Standard diameter15 +0.015+0.025 mmInspecting the wrist pin- Check the outer diameter of the gudgeon pin.CharacteristicStandard pin diameter14.996 ÷ 15 mmMinimum diameter permittedØ 14.994 mmENG - 109

EngineFly 125 - 150 4T- Calculate the piston pin coupling clearance.N.B.THE PIN HOUSINGS HAVE 2 LUBRICATIONCHANNELS. FOR THIS REASON MEASURE-MENT OF THE DIAMETER MUST BE CARRIEDOUT ACCORDING TO THE AXIS OF THE PIS-TON.CharacteristicPiston pin bore - standard diameterØ 15+0.001 +0.006- Measure the outside diameter of the piston, perpendicularto the gudgeon pin axis.- Measure 36.5 mm from the piston crown's shownin the figure.N.B.THE PIN HOUSINGS HAVE 2 LUBRICATIONCHANNELS. FOR THIS REASON MEASURE-MENT OF THE DIAMETER MUST BE CARRIEDOUT ACCORDING TO THE AXIS OF THE PIS-TON.- Using a bore meter, measure the inner cylinderdiameter at three different points according to thedirections shown in the figure.- Check that the coupling surface with the head isnot worn or misshapen.- Pistons and cylinders are classified into categoriesbased on their diameter. The coupling is carriedout in pairs (A-A, B-B, C-C, D-D).CharacteristicMaximum allowable run-out:0.05 mm- The cylinder rectifying operation should be carriedout with a surfacing that respects the originalangle.- The cylinder surface roughness should be 0.9micron.- This is indispensable for a good seating of thesealing rings, which in turn minimises oil consumptionand guarantees optimum performance.ENG - 110

Fly 125 - 150 4TEngine- The pistons are oversized due to cylinder rectificationand are subdivided into three categories1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. Theyare also classified into 4 categories A-A, B-B, C-C, D-D.Inspecting the piston- Carefully clean the seal housings.- Measure the coupling clearance between the seal rings and the grooves using suitable sensors, asshown in the diagram.- If the clearance is greater than that indicated in the table, replace the piston.STANDARD COUPLING CLEARANCEName Description Dimensions Initials QuantityTop piston ring 0.025 ÷ 0.070Middle piston ring 0.015 ÷ 0.060oil scraper 0.015 ÷ 0.060MAXIMUM ADMITTED CLEARANCE AFTER USEName Description Dimensions Initials QuantityTop piston ring0.080 mmMiddle piston ring0.070 mmoil scraper0.070 mmRemoving the piston- Install piston and wrist pin onto the connectingrod, aligning the piston arrow the arrow facing towardsthe exhaust.- Fit the pin stop ring onto the appropriate tool.Specific tooling020430Y Pin lock fitting toolENG - 111

EngineFly 125 - 150 4T- With the opening in position indicated on the tool,take stop ring in the closed position using thepunch.- Fit the wrist pin stop using the plug as shown inthe figureN.B.THE TOOL FOR INSTALLING THE STOPRINGS MUST BE USED MANUALLY.CAUTIONUSING A HAMMER TO POSITION THE RINGSCAN 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 springends on the opposite side from the ring gap andthe word 'TOP' towards the crown of the piston.The tapered side of the middle piston ring shouldalways be facing away from the crown of the piston.- Fit the middle piston ring with the identificationletter 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 thereference mark facing the crown of the piston.- Offset the piston ring gaps on the three rings by120° to each other as shown in the figure.- Lubricate the components with engine oil.N.B.SO AS TO OBTAIN THE BEST CONFIGURA-TION THE 2 SEALING RINGS ARE MADE WITHA CONTACT CONICAL CYLINDER SECTION.ENG - 112

Fly 125 - 150 4TEngineRefitting the cylinder- Insert the cylinder base gasket with the thicknessdetermined above.- Using the fork support and the piston ring retainingband, refit the cylinder as shown in the figure.N.B.BEFORE FITTING THE CYLINDER, CAREFUL-LY BLOW OUT THE LUBRICATION DUCT ANDOIL THE CYLINDER BARREL.Specific tooling020426Y Piston fitting fork020427Y Piston fitting bandInspecting the cylinder head- Using a trued bar check that the cylinder headsurface is not worn or distorted.- Check that the camshaft and rocking lever pinbearings show no signs of wear.- Check that the cylinder head cover surface, theintake manifold and the exhaust manifold are notworn.CharacteristicMaximum admitted unevenness: Head check0.05 mmSTANDARD DIAMETERSpecificationDesc./QuantityStandard diameter A Ø 32.5 ÷ 32.525Standard diameter B Ø 20 ÷ 20.021Standard diameter C Ø 12 ÷ 12.018ENG - 113

EngineFly 125 - 150 4TInspecting the timing system components- Check that the guide shoe and the tensioner shoeare not worn out.- Ensure that the camshaft drive pulley, the chainassembly and the sprocket wheel are not worn.- If sings of wear are found, replace the parts. if thechain, pinion or pulley are worn, replace the wholeassembly.- Remove the central screw and the tensionerspring. Check that the one-way mechanism is notworn.- Check the condition of the tensioner spring.- If examples of wear are found, replace the wholeassembly.Inspecting the valve sealings- Measure the width of the sealing surface on the valve seats.VALVE SEAL SURFACESpecificationInlet valve - seal surfaceOutlet valve - seal surfaceDesc./Quantity2.4 ÷ 2.8 mm2.2 ÷ 2.6 mmInspecting 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 4TEngineCharacteristicStandard drainage guide diameter5.012 mmStandard inlet guide diameter5.012 mm- If the width of the impression on the valve seat orthe diameter of the valve guide exceed the specifiedlimits, replace the cylinder head.- Check width of the impression on the valve seat«V»CharacteristicWear limits:Max. 1.6 mm.Inspecting the valves- Measure the diameter of the valve stems in thethree positions indicated in the diagram.- Calculate the clearance between valve and valveguide.CharacteristicMinimum diameter admitted - Inlet:4.96 mmMinimum diameter admitted - Outlet:4.95 mmStandard clearance - Inlet:0.013 ÷ 0.040 mmStandard clearance - Outlet:0.025 ÷ 0.052 mmMaximum clearance admitted- Inlet:0.062 mmMaximum clearance admitted - Outlet:0.072 mmENG - 115

EngineFly 125 - 150 4T- Check that there are no signs of wear on thecontact surface with the articulated register terminal.- If the sealing surface on the valves is wider thanthe specified limit, damaged in one or more pointsor curved, replace the valve with a new one.CharacteristicStandard valve length - Inlet:80.6 mmValve standard length: drainage79.6 mm- If the checks above give no failures, you can usethe same valves. For best sealing results, it is advisableto grind the valves. Grind the valves gentlywith a fine-grained lapping compound. Duringgrinding, keep the cylinder head in a horizontalposition. This will prevent the lapping compoundresidues from penetrating between the valve stem/guide coupling.CAUTIONTO AVOID SCORING THE CONTACT SUR-FACE, DO NOT KEEP ROTATING THE VALVEWHEN NO LAPPING COMPOUND IS LEFT.CAREFULLY WASH THE CYLINDER HEADAND THE VALVES WITH A SUITABLE PROD-UCT FOR THE TYPE OF LAPPING COMPOUNDBEING USED.- Insert the valves into the cylinder head.- Test the 2 valves alternatively.- The test is carried out by filling the manifold withpetrol and checking that the head does not oozethrough the valves when these are just pressedwith the fingers.ENG - 116

Fly 125 - 150 4TEngineInspecting the springs and half-cones- Check that the upper spring caps and the cotterhalves show no signs of abnormal wear.- Check the length clearance of the springs.CharacteristicValve spring length33.9 ÷ 34.4 mmRefitting the valves- Lubricate the valve guides with engine oil.- Place the lower plates of the valve spring on thehead.- Use the punch to fit the 2 sealing rings one at atime.Specific tooling020306Y Punch for assembling valve sealrings- Fit the valves, the springs and the spring retainingcaps. Using the appropriate tool with adapter 11,compress the springs and insert the cotters in theirseats.Specific tooling020382Y Valve cotters equipped with part 012removal tool020382Y011 adapter for valve removal toolInspecting the cam shaft- Inspect the cam shaft for signs of abnormal wearon the cams.CharacteristicStandard diameter Bearing AØ: 32.5 mm -0.025 -0.050 mmStandard diameter Bearing B20 -0.020 -0.041 mmENG - 117

EngineFly 125 - 150 4TMinimum admitted diameter bearing AØ: 32.440 mmMinimum admitted diameter bearing BØ: 19.950 mmInlet cam height27.512 mmOutlet cam height27.212 mm- Check there is no wear on the cam shaft retainingplate and its associated groove on the cam shaft.- If any of the above dimensions are outside thespecified limits, or there are signs of excessivewear, replace the defective components with newones.CharacteristicMaximum axial clearance admitted0.42 mm- Check there are no signs of wear on the automaticvalve-lifter cam, or the end-of stroke roller,or the rubber buffer on the automatic valve-lifterretaining 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 onthe rocking lever bolt.Check there are no signs of wear on the pad fromcontact with the cam and on the jointed adjustmentplate.- Measure the internal diameter of each rockinglever.-Check that the elastic washer dedicated to theaxle clearance of the rocking levers is not worn. -ENG - 118

Fly 125 - 150 4TEngineIn case of anomalies, replace the damaged components.CharacteristicMinimum diameter permittedØ 11.970 mmMaximum diameter admittedØ 12.030 mmRefitting 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 timingchain side and tighten them to the specified torque.N.B.BEFORE INSTALLING THE HEAD, MAKESURE THAT THE LUBRICATION CHANNEL ISCLEAN 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 thecrankshaft.- Fit the tensioner pad by the cylinder head.- Fit the spacer and the screw fastener.- Fit the pin, the outlet rocking lever, the springwasher and the inlet rocking lever.- Lubricate the 2 rocking levers through the holesat the top.- Lubricate the 2 bearings and insert the camshaftin the cylinder head with the cams opposing therocking levers.ENG - 119

EngineFly 125 - 150 4T- Insert the retention plate and tighten the twoscrews 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 deadcentre, using the reference marks on the flywheeland the crankcase.- While doing so, fit the chain onto the control camshaftpulley and keep the reference 2V in correspondencewith the reference mark on the head.- Fit the pulley onto the camshaft.- Assemble the counterweight with the correspondingfixing screw and tighten to the specifiedtorque.Locking torques (N*m)Locking torque 7 ÷ 8.5-Fit the end-stop ring on the automatic valve-liftercam and fit the automatic valve-lifter cam to thecam shaft.- Fit the automatic valve-lifter return spring.- During this operation the spring must be loadedapproximately 180°.N.B.GREASE THE END STOP RING TO PREVENTIT COMING OUT AND FALLING INTO THE EN-GINE.ENG - 120

Fly 125 - 150 4TEngine- Fit the automatic valve-lifter retaining dish, usingthe 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 prescribedtorque.Locking torques (N*m)Locking torque 11 ÷ 13- Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribedtorque.Locking torques (N*m)Locking torque 5 - 6- Adjust the valve clearance.- Fit the spark plugElectric characteristicRecommended spark plug:CHAMPION RG4HCElectrode gap0.8 mmLocking torques (N*m)Locking torque 12 - 14- Assemble the casing sealing gasket on the head.On the fitting direction, use the supplements on thetiming side as reference.- Assemble the screw fixing the housing to thecrankcase to the specified torque and the 2 selfthreadingscrews joining the half-shells.- Take care that the gasket is well inserted in itshousing during the assembly stage.- Place the spark plug access cap.Locking torques (N*m)ENG - 121

EngineFly 125 - 150 4TLocking torque 3 ÷ 4- Fit the inlet manifold and lock the 2 screws to thespecified torque.- Fit the carburettor onto the inlet manifold and lockthe clampN.B.FIT THE CARBURETTOR THROUGH THE SUP-PLEMENT ON THE MANIFOLD.Locking torques (N*m)Locking torque 11 ÷ 13- Refit the cylinder head cover, tightening the 4clamping screws to the prescribed torque.- Refit the fan and the housing.- Reassemble the oil pump control, the chain compartmentcover, the by-pass and the oil sump asdescribed in the lubrication chapter.- Reassemble the driving pulley, the belt and thetransmission cover as described in the transmissionchapter.Locking torques (N*m)Locking torque 11 ÷ 13Crankcase - crankshaft- Precautionary remove the following units:transmission cover, driving pulley, driven pulleyand belt, rear hub cover, gears, bearings and oilseals as described in the transmission chapter.- Remove the oil sump, the by-pass, the chaincompartment cover and the oil pump as in the lubricationchapter.- Remove the flywheel cover, the fan, the flywheeland the stator as described in the magneto flywheelchapter.- Remove the oil filter and the oil pressure bulb.- Remove the cylinder-piston-head unit as describedin the cylinder head timing system chapter.- Remove the 2 retainers indicated in the figureand the starter motor.ENG - 122

Fly 125 - 150 4TEngine- Before opening the crankcase, it is advisable tocheck the axial clearance of the crankshaft. To dothis, use a plate and a support with specific tooldial gauge.Specific tooling020262Y Crankcase splitting strip020335Y Magnetic support for dial gaugeCharacteristicStandard clearance0.15 ÷ 0.40 mmSplitting the crankcase halvesRemove the 11 coupling screws to the crankcase.- Separate the crankcase while keeping the crankshaftin one of the two halves of the crankcase.Remove the crankshaft.CAUTIONIF YOU FAIL TO DO THIS, THE CRANKSHAFTMIGHT ACCIDENTALLY FALL.- Remove the coupling gasket of the crankcasehalves.- Remove the two screws and the internal covershown in the diagram.CAUTIONWHILE OPENING THE CRANKCASES AND RE-MOVING THE DRIVING SHAFT, CHECK THATTHE THREADED SHAFT ENDS DO NOT INTER-FERE WITH THE MAIN BUSHINGS. FAILURETO OBSERVE THIS PRECAUTION CAN DAM-AGE THE MAIN BUSHINGS.ENG - 123

EngineFly 125 - 150 4T- 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.CharacteristicStandard clearance0.20 ÷ 0.50 mm- Check the radial clearance on the connecting rod.-Check the surfaces that limit the axial free-playare not scored and measure the width of the crankshaftbetween these surfaces, as shown in thediagram.CAUTIONBE CAREFUL NOT TO LET THE MEASURE-MENT BE AFFECTED BY THE UNIONS WITHTHE CRANKSHAFT ENDS.CharacteristicStandard clearance0.036 ÷ 0.054 mm- If the axial clearance between crankshaft andcrankcase is exceeding and the crankshaft doesnot have any defect, the problem must be due toeither excessive wear or wrong machining on thecrankcase.CAUTIONTHE CRANKSHAFT CAN BE REUSED WHENTHE WIDTH IS WITHIN THE STANDARD VAL-UES AND THE SURFACES SHOW NO SIGNSOF SCORING.CharacteristicENG - 124

Fly 125 - 150 4TEngineDistance between the shoulders55.67 ÷ 55.85 mm- Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfacesshown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chartbelow.STANDARD DIAMETERSpecificationDesc./QuantityClass 1 28.998 ÷ 29.004Class 2 28.004 ÷ 29.010Inspecting the crankshaft alignmentTo install the drive shaft on the support and tomeasure the misalignment in the 4 points indicatedin figure.- Check that the driving shaft cone, the tab seat,the oil seal capacity, the toothed gear and thethreaded 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 rodmay not be replaced and, when cleaning thecrankshaft, be very careful that no impurities get inthrough the shaft's lubrication holes.In order to prevent damaging the connecting rodbushings, do not attempt cleaning the lubricationduct with compressed air.- Make sure that the 2 caps on the crankpin areproperly fitted.ENG - 125

EngineFly 125 - 150 4T- A wrong installation of a cap can seriously affectthe bushing lubrication pressure.N.B.THE MAIN BEARINGS ARE NOT GRINDABLESpecific tooling020074Y Support base for checking crankshaftalignmentCharacteristicOff-line maximum admittedA = 0.15 mmB = 0.01 mmC = 0.01 mmD = 0.10 mmInspecting the crankcase halves- Before proceeding to check the crankcasehalves, thoroughly clean the all surfaces and oilducts.- On the transmission side crankcase half, takeparticular care cleaning the housing and oil ductsfor the following components: the oil pump, the oilby-pass valve, the main bushings and the coolingjet on the transmission side (see diagram).- Take particular care, also, that there are no signswear in the oil by-pass valve housing (see ChapterLubrication), as this could prevent a good seal inthe valve, which regulates the oil pressure.N.B.THE JET IS FED THROUGH THE MAIN BUSH-INGS. PROPER OPERATION OF THIS COMPO-NENT IMPROVES THE PISTON TOP COOLING.CLOGGING HAS EFFECTS THAT ARE DIFFI-CULT TO DETECT (PISTON TEMPERATUREINCREASE). FAILURE OR LEAK CAN CONSID-ERABLY DECREASE THE MAIN BUSHINGAND CONNECTING ROD LUBRICATION PRES-SURE.ENG - 126

Fly 125 - 150 4TEngine- On the flywheel side crankcase half, take particularcare cleaning the oil ducts for the main bushings,the oil duct for the jet that lubricates thecylinder head and the oil drainage duct at the flywheelside oil seal.N.B.THE HEAD LUBRICATION CHANNEL IS PRO-VIDED WITH A SHUTTER JET; THIS GIVES A"LOW PRESSURE" HEAD LUBRICATION; THISCHOICE WAS MADE TO REDUCE THE OILTEMPERATURE IN THE SUMP. THE JETCLOGGING IMPAIRS THE HEAD LUBRICA-TION AND THE TIMING MECHANISMS. A JETFAILURE CAUSES A DECREASE OF THE MAINBUSHING AND CONNECTING ROD LUBRICA-TION PRESSURE.- Inspect the mating surfaces on the crankcasehalves for scratches or deformation, taking particularwith the surfaces that mate with the cylinderand the mating surfaces between the crankcasehalves.- Defects in the crankcase coupling gasket or thesurfaces indicated in the figure can cause a dropin the oil pressure and affect the lubricating pressurefor the main bushings and the connecting rod.- Check the main bearing seats that limit axialclearance in the crankshaft show no signs of wear.The dimension between these seats is measuredby way of the procedure described previously formeasuring the crankshaft axial clearance and dimensions.ENG - 127

EngineFly 125 - 150 4TInspecting the crankshaft plain bearings- To obtain a good bushing lubrication it is necessaryto have both an optimal lubricating pressure(4 bar) and a good oil flow rate; the bushings mustbe correctly positioned so as not to obstruct the oilsupply channels.- The main bushings are comprised of two halfbearings,one containing holes and channels forlubrication and the other solid.- The solid half-bearing is intended to stand thethrusts caused by combustion, and for this reasonit is arranged opposed the cylinder.- To prevent shutters in the oil feeding channels,the matching surface of the two half-bearings mustbe perfectly orthogonal to the cylinder axis, asshown in the figure.- The oil supply channel section is also affected bythe bushings driving depth compared with thecrankshaft axial clearance of the limiting surface.N.B.TO KEEP THIS POSITION OF THE BUSHINGSON THE CRANKCASE, FITTING IS FORCED ONSTEEL RINGS INSERTED IN THE CASTING OFBOTH CRANKCASE HALVES.CharacteristicStandard driving depth1.35 ÷ 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 likethose 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 SINCETHE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.SpecificationBMAIN BEARINGSDesc./QuantityBlueENG - 128

Fly 125 - 150 4TEngineSpecificationCEDesc./QuantityYellowGreenRefitting the crankcase halves- Fit the internal bulkhead by locking the twoscrews to the prescribed torque.Locking torques (N*m)Locking torque 4 ÷ 6- Fit the oil filter joint and tighten it to the prescribedtorque.- Place a new gasket on one of the crankcasehalves, preferably on the transmission side, togetherwith the locating dowels.Locking torques (N*m)Locking torque 27 ÷ 33- Lubricate the main bushings and insert the crankshaftin the transmission side crankcase half.- Reassemble the two crankcase halves.- Fit the 11 screws and tighten them to the prescribedtorque.N.B.WHEN FITTING THE HALF CASING AND THECRANKSHAFT, TAKE CARE NO TO DAMAGETHE SHAFT THREADED TANGS.ENG - 129

EngineFly 125 - 150 4TLocking 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 correspondingcover to the specific torque.N.B.REMOVE ANY EXCESS FROM THE CRANK-CASE COUPLING GASKET ON THE CYLINDERPLANE, TO ENSURE BETTER SEALING PER-FORMANCE.N.B.FAILURE TO USE THE SPECIFIC TOOL CANRESULT IN AN INCORRECT DEPTH POSITIONAND AS A CONSEQUENCE IN INADEQUATEOIL SEALING.Specific tooling020425Y Punch for flywheel-side oil sealLocking torques (N*m)Locking torque 24 ÷ 30LubricationENG - 130

Fly 125 - 150 4TEngineConceptual diagramsENG - 131

EngineFly 125 - 150 4TOil pressure check- After removing the cover protections as describedin the "Flywheel" chapter, disconnect the electricalconnexion of the minimum oil pressureswitch and then remove the switch.- With the engine idling at 1650 rpm and the oiltemperature at ~90°C, check that the oil pressureis between 0.5 ÷ 1.2 atm.- With the engine idling at 6000 rpm and the oiltemperature at ~90°C, check that the oil pressureis between 3.2 ÷ 4.2 atm.- Remove the appropriate tools once the measurementis complete, refit the oil pressure switchand washer, tightening it to the prescribed torqueand fit the fan cover.- If the oil pressure is outside the specified limits,in the following order, check: the oil filter, the oilby-pass valve, the oil pump and the crankshaftseals.N.B.THE CHECK MUST BE CARRIED OUT WITHOIL AT THE CORRECT LEVEL AND WITH ANOIL FILTER IN GOOD CONDITION.CharacteristicMinimum pressure admitted3.2 atm.Locking torques (N*m)Locking torque 12 ÷ 14 (also valid for the controlconnector).Crankshaft oil sealsENG - 132

Fly 125 - 150 4TEngineRemoval- First remove the transmission cover and the completedriving pulley- Install the base of the appropriate tool on the oilguard using the screws provided.- Screw the threaded bar onto the base of the tooland extract the oil guard.Specific tooling020622Y Transmission-side oil guard punchRefitting- Prepare the new oil guard, lubricating the sealinglip. Warning: do not lubricate the surface for keyingonto the engine crankcase.CAUTIONDO NOT LUBRICATE THE SURFACE FOR KEY-ING ONTO THE ENGINE CRANKCASE.ENG - 133

EngineFly 125 - 150 4T- Preassemble the oil seal with the appropriatetool, positioning the screws- Place the sheath over the crankshaft- Insert the tool with the oil seal on the crankshaftuntil it comes into contact with the crankcaseCAUTIONORIENT THE OIL GUARD BY POSITIONINGTHE CHAIN HOUSING CHANNEL FACINGDOWNWARDS. WHEN THE POSITION ISREACHED, DO NOT RETRACT THE OILGUARD. FAILURE TO COMPLY WITH THISRULE CAN CAUSE A WRONG POSITIONINGOF THE OIL GUARD SHEATH.- Orientate the oil guard by inserting the bracketwhich is part of the specific tool.- Tighten the threaded bar onto the crankshaft asfar as it will go.ENG - 134

Fly 125 - 150 4TEngine- Use the nut to move the base of the tool until youcan see end of the oil seal driving stroke- Remove all of the tool components following the procedure in reverse orderCAUTIONFAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THEENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.Assemble a new oil seal on the flywheel side usingthe specific tool as shown in the photographN.B.FAILURE TO USE THE SPECIFIC TOOL CANRESULT IN AN INCORRECT DEPTH POSITIONAND AS A CONSEQUENCE IN INADEQUATEOIL SEALING.Specific tooling020425Y Punch for flywheel-side oil sealOil pumpRemoval- Remove the cover of the pump control pulley usingthe two retainers, as shown in the figure.- Block the rotation of the oil pump control pulleyusing a screwdriver inserted through one of its twoholes.ENG - 135

EngineFly 125 - 150 4T- 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 asshown in the figure.- Remove the oil pump seal.IT IS ADVISABLE TO MARK THE CHAIN IN OR-DER TO ENSURE THAT THE INITIAL DIREC-TION 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 petroland compressed air.- Reassemble the rotors in the pump body, keepingthe two reference marks visible Replace theclip.- Using a thickness gauge, check the distance betweenthe rotors in the position shown in the figure.CharacteristicMaximum clearance admitted0.12 mmENG - 136

Fly 125 - 150 4TEngineMeasure the distance between the outer rotor andthe pump body; see figure.CharacteristicAdmissible limit clearance:0.20 mmCheck the axial clearance of the rotors with a truedbar as reference, as shown in the figure.CharacteristicLimit values admitted:0.09 mmRefitting- Check there are no signs of wear on the oil pumpshaft or body.- Check there are no signs of scoring or wear onthe oil pump cover.- If you detect non-conforming measurements orscoring, replace the faulty parts or the assembly.- Fit the pulley to the pump, the central screw tothe specified torque and the belleville washer.-Fit the oil pump cover, by tightening the twoscrews to the prescribed torque.N.B.FIT THE BELLEVILLE WASHER SO THAT ITSOUTER (CURVED) RIM TOUCHES THE PUL-LEY.Locking torques (N*m)Central screw 12 ÷ 14 Nm Cover screws 0.7 ÷0.9 NmENG - 137

EngineFly 125 - 150 4TRemoving the oil sump- Remove the oil filler plug, the transmission cover,the complete drive pulley assembly with belt andthe sprocket wheel, as described in the Transmissionchapter.- Drain the oil from the sump as described above.- Remove the 7 screws indicated in the figure andthe 2 rear brake transmission fixing brackets.- Remove the spring, the by-pass piston and thegasket 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 andthat it guarantees a good seal.- If not, eliminate any impurities or replace defectiveparts.CharacteristicBy-pass check up: Standard length54.2 mmENG - 138

Fly 125 - 150 4TEngineRefitting 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 inthe appropriate recess machined into the inside ofthe sump.- Refit the rear brake transmission support bracketsand the screws in the reverse order from whichthey were removed.- Tighten the screws to the prescribed torque.- Refit the drive pulley assembly, the drive belt, thesprocket wheel and the transmission cover, as describedin the "Transmissions" chapter.- When testing the lubrication system, refer tothe "Crankcase and Crankshaft" chapter, regardinglubrication of the crankshaft and connectingrodLocking torques (N*m)Locking torque 11 ÷ 13Fuel supply- Disconnect the fuel supply and the suction takingpipe from the carburettor.- Check that there are no fuel leaks between thetwo tubes.- Close the fuel outlet pipe.- By means of the MITIVAC pump apply 0.1 bar ofsuction to the tap.- Make sure that the suction is kept stable and thatand that there are no fuel leaks.- Reconnect the suction pipe to the manifold.- Position the fuel pipe with the outlet at the pointof the tap.- Turn the engine by using the starter for five secondswith the carburettor at minimum.- Take up the fuel by means of a graded burette.ENG - 139

EngineFly 125 - 150 4TN.B.THE MEASUREMENT MAY BE FALSIFIED BYTHE INCORRECT NUMBER OF REVS OR BYTHE WRONG POSITION OF THE TUBE.. INTHIS CASE, THE TENDENCY IS TO OBTAIN AREDUCED FUEL FLOW RATE. THE SUCTIONOUTLET ON THE MANIFOLD HAS A SECTIONINTENTIONALLY REDUCED FOR THE PUR-POSE OF ENHANCING THE SUCTION PULSA-TION AND THEREBY GUARANTEE A CON-STANT TAP FLOW RATE.Specific tooling020329Y MityVac vacuum-operated pumpCharacteristicMinimum flow rate20 cc- Completely empty the gas tank.- Remove the petrol delivery tube and the suctiontube.- Loosen the clip and remove the tap.- Clean the tank and the filter of the tap with a specificsolvent.- Refit the tap making sure that there is an O-Ring.- Turn the tap to the direction it had before it wasremoved and block the clip.N.B.THE FILTER CAN BE UNSCREWED FROM THECOCK TO FACILITATE CLEANING.Removing the carburettor- To detach the carburettor from the engine, it isnecessary to move the air filter and remove thethrottle control transmission, the automatic starterconnection, the clamps anchoring the carburettorto the filter housing and to the inlet manifold, theair delivery pipe to the diaphragm, the heater andthe intake fitting.ENG - 140

Fly 125 - 150 4TEngine- Remove the protection, the bracket and the starteracting on the screw shown in the figure.- Remove the 2 screws and the starter support withthe gasket.- Remove the clamp and cover with the airing filterof the diaphragm chamber.- Remove the 4 fixing screws shown in the figureand the vacuum chamber cover.WARNINGDURING THE REMOVAL OF THE CARBURET-TOR COVER TAKE SPECIAL CARE NOT TORELEASE THE SPRING ACCIDENTALLY.ENG - 141

EngineFly 125 - 150 4T- 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 4TEngine- Remove the chamber with the acceleratingpump, its control and gasket.- Remove the oil pump seal.- Remove the intake and outlet valves of the intakepump from the tankN.B.CAUTION, THE ACCELERATION PUMPVALVES ARE MADE UP OF NOZZLES, SPRINGAND BALL.N.B.AVOID REMOVING THE PISTON OF THE PUMPAND ITS CONTROL.Adequately support the carburettor and using arod and hammer remove the float pin acting fromthe throttle control side.- Remove the float and the plunger.- Remove the maximum nozzleENG - 143

EngineFly 125 - 150 4T-Remove the maximum nozzle.-Remove diffuser.ENG - 144

Fly 125 - 150 4TEngine- Remove the sprayer.N.B.WHEN CLEANING THE CARBURETTOR BODYREMOVE THE SPRAYER TO AVOID LOSINGPARTS. IF THE SPRAYER IS FORCED IN ITSHOUSING DO NOT ATTEMPT TO REMOVE ITAS THIS WILL ONLY DAMAGE IT.-Remove the minimum nozzle.- Remove the minimum flow set screw and thespring.CAUTIONDO NOT ATTEMPT REMOVING PARTS EM-BEDDED IN THE CARBURETTOR BODY SUCHAS: FUEL SUPPLY PIPE, PLUNGER HOUSING,STARTER NOZZLE, PIT COVER FOR PRO-GRESSIONS AND INLET NOZZLE, MINIMUMAND MAXIMUM AIR GAUGE, THROTTLEVALVE CONTROL SHAFT. DO NOT REMOVETHROTTLE-SHAFT CONNECTION SCREWS.THE FIXING SCREWS ARE CAULKED AFTERASSEMBLY AND THEIR REMOVAL DAMAGESTHE SHAFT.ENG - 145

EngineFly 125 - 150 4TRefitting the carburettor- Before refitting, wash the carburettor body accuratelywith petrol and compressed air.- Pay special attention to the fuel supply pipe andthe plunger seat.- For maximum circuit, check the air adjustment iscorrect as shown in the figure.- For the minimum circuit, make sure the followingpoints are properly cleaned: air gauging, outletsection controlled by flow screw, progressionholes near the throttle valve.- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because thenozzle support hides other inaccessible internal calibrations.- Blow the intake nozzle properly.N.B.THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THETHROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAY-ING.- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.ENG - 146

Fly 125 - 150 4TEngine- 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 andreassemble it.- Properly wash and blow the components of thesprayer maximum circuit, the diffuser and the nozzle.- Introduce the sprayer in the carburettor body withthe shortest cylindrical part directed to the diffuser.- Assemble the diffuser making sure the sprayer isbeing adequately inserted and lock it.-Assemble the maximum nozzle.- Check that the tapered pin does not show signsof wear on the sealing surfaces of the shock absorberpin 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 thatthere are no fuel infiltration.- Replace it in case of anomalies.ENG - 147

EngineFly 125 - 150 4T- 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, washand blow it properly and make sure the accelerationpump pipes are clean.- Operate the acceleration pump piston repeatedlyand blow with compressed air.- Reassemble the acceleration pump valves followingthis order:INTAKE VALVE (A)• Spring• Ball• NozzleIN VALVE (M)N.B.• Ball• Spring• NozzleTHE IN VALVE NOZZLE, CORRESPONDINGTO THE ACCELERATION PUMP, IS MILLED.-Check the screw tightness introducing a smallamount of fuel in the tank.- Assemble a new gasket on the tank.- Assemble the tank on the carburettor body fasteningthe 4 screws.- Check that the control roller is free to rotate in itsown seat.N.B.MAKE SURE THE TANK GASKET IS COR-RECTLY INTRODUCEDN.B.AVOID DEFORMING THE ACCELERATIONPUMP CONTROL ROCKING LEVER.ENG - 148

Fly 125 - 150 4TEngine- 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 thefigure.- 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 positiondescribed above.ENG - 149

EngineFly 125 - 150 4T• 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 4TEngineInspecting the valve and needle- Check that the tapered pin of the vacuum valvedoes not show wear.- Check that the depression valve does not showthreads on the external surfaces.- Check that the vacuum intake hole is not clogged.- Check that the diaphragm is not damaged or hashardened, otherwise replacement the whole valve.- Insert the tapered pin into the vacuum valvehousing.- Reassemble the vacuum valve on the carburettorbody taking care that the tapered pin is insertedinto the sprayer.N.B.THE VALVE CAN BE INSERTED IN ONLY ONEPOSSIBLE POSITION.- Reassemble the spring with the pin lock.- Remove the cover of the vacuum chamber beingcareful to correctly insert the spring in its place onthe cover.- Tighten the screws.ENG - 151

EngineFly 125 - 150 4T- Wash and blow dry the filter sponge of the ambientpressure intake.- Reassemble the filter with its clamp.- Wash and blow dry the starter support.Assemble a new gasket on the carburettor bodyand tighten the 2 fixing screws.ENG - 152

Fly 125 - 150 4TEngineInspecting the automatic choke device- Check that the automatic starter piston is not deformedor rusty.- Check that the piston slides freely from the seatto the support.- Check that the piston sealing gasket is not deformed.- The starter must be more or less functional dependingon the ambient temperature.- Measure the protrusion of the piston as shown inthe figure and check its corresponding value.- Make sure that the starter is adjusted for the ambienttemperature.- The starter should disconnect progressively bymeans of electrical heating.- Check the starter resistance when adjusted to theambient temperature.With a 12V battery power the automatic starter andcheck that the piston protrudes as much as possible.- The correct warm up time depends on the ambienttemperature.- If protrusion, resistance or timing values are differentfrom the ones prescribed, replace the starter.- Assemble the starter to the carburettor beingcareful to position the O-Ring correctly, insert theplate 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 SPECIALATTENTION NOT TO GENERATE SHORT CIR-CUITS USE A CABLE SECTION WITH A TER-MINAL SUITABLE TO BE CONNECTED TO THESTARTER.CharacteristicENG - 153

EngineFly 125 - 150 4TCheck the automatic starter: Kehin: ProtrusionvalueXX ÷ XX mm at approx. 20°CCheck the automatic starter: Kehin maximumprotrusionXXX ÷ XXX mmCheck the automatic starter: Keihin maximumtime5 minAdjusting the idle- The engine does not require frequent adjustmentof the idle, however it is important that this adjustmentbe made in complete compliance with a fewrules.- Before adjusting the carburettor make sure thatthe following conditions are met: good lubrication,valve play and distribution timing conform, sparkplug in excellent conditions, air filter clean andsealed, exhaust system completely sealed. -Warm up the engine for at least 5 minutes ataround 50 Km/h.- Connect the vehicle to an exhaust analyser insertingthe analyser probe into a extension hosefitted airtight to the outlet of the silencer.- Connect the thermometer of the multimeter(020331y) to the sump, using the oil cap specificallymade 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 separateone (020332y), adjust the idle until obtaininga speed of 1600 - 1700 rpm.- Adjust the flow screw until obtaining a percentageof carbon monoxide (CO) of 3.1ENG - 154

Fly 125 - 150 4TEngineâ 4.5%, by loosening the screw the CO value increases(rich mixture) by tightening the CO valuedecreases (thin mixture).- If correction of the flow screw position leads to anincrease in speed, adjust the revolutions again andif necessary the flow screw until stabilised valuesare achieved.- Idle carburetion is considered correct when thevalues of oil temperature, number of revolutionsand percentage of carbon monoxide are correct.Additional information can be obtained from theanalyser:- the percentage of carbon dioxide (CO2), the percentageof carbon dioxide has a reverse trendcompared to the percentage of (CO), values above12.5% are considered correct. Values out of thisrange are considered as an indication of a nonairtightcondition on the exhaust system.- Unburnt hydrocarbons (HC) are measured inparts per million (PPM), the value of the HC decreaseswith increased rpm, with the engine idlingit is normal to measure 200â 400 PPM, these exhaust values are considerednormal for an engine with motorcycle distributiondiagram. Much higher values can be caused byengine misfiring due to a too thin mixture (low CO),ignition defects or incorrect distribution timing or astuck 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 levelN.B.THE EXTENSION TUBE IS INDISPENSABLESO AS NOT TO SEND POLLUTED EXHAUSTFUMES TO THE AMBIENT OXYGEN. IT IS IN-DISPENSABLE TO USE AN EXHAUST FUMESANALYSER PREVIOUSLY HEATED AND PRE-PARED TO GUARANTEE THE RESET OF THEENG - 155

EngineFly 125 - 150 4TREADING OF GASES AND THE CORRECTGAS CAPACITY. FAILURE TO RESPECTTHESE REGULATIONS RESULTS IN INACCU-RATE READINGS.N.B.THE WASTED SPARK IGNITION SYSTEM OF-FERS REMARKABLE POWER. READINGSMAY NOT BE ACCURATE IF INADEQUATERPM INDICATORS ARE USED. CORRECTCOUPLING OF THE RPM INDICATOR WILL BEINDICATED WHEN IT CAN READ RPM OVER6000 ÷ 8000CharacteristicIdle adjustment: Pipe sizesØ 40 mmIdle adjustment: length500 ÷- 600 mmENG - 156

INDEX OF TOPICSSUSPENSIONSSUSP

SuspensionsFly 125 - 150 4TSospensioni anterioreThis section is devoted to operations that can be carried out on the suspension.FrontRemoving the front wheel- Remove the wheel axle locking nut.- Remove the wheel axle and the wheel.- Upon removal take care not to damage the sensorthat detects movement in the odometer.Front wheel hub overhaulCuscinetti a sfere sul mozzo ruota- Remove the front wheel- Keep the wheel level by means of two woodenwedges- With the appropriate pliers and tool remove thewheel bearing on the side the rpm indicator detectsmovement, as shown in the photograph- Remove the internal spacer- Use appropriate handle, adaptor and guide andhit with a mallet to extract the bearing and thespacer bushing on the brake disk side; insert handleon the side the rpm indicator detects movement,as shown in the photoSUSP - 158

Fly 125 - 150 4TSuspensions- Check that the bearings do not show flaws orjamming. If there is, replace it.- Check that the internal spacer does not show abnormalwear. If there is, replace it.- With a hot air gun heat the seat of the bearing onthe brake calliper side- With an appropriate tool remove the bearing onthe brake disk side- Insert the spacer bushing on the brake disk side- With a hot air gun heat the seat of the bearing onthe side the rpm indicator detects movement- Insert the internal spacer with the centring ringfacing to the brake disk side, as shown in the photo- Use an appropriate tool to insert the bearing onthe rpm indicator movement detector sideSpecific tooling001467Y009 Driver for OD 42 mm bearings001467Y014 Pliers to extract ø 15-mm bearings020357Y 32 x 35 mm adaptor020376Y Adaptor handle020412Y 15 mm guide020456Y Ø 24 mm adaptorRefitting the front wheel- Follow the same procedure as per removal but in reverse order, tighten to the specified torque, rememberto put the odometer movement sensor out of phase at 90° compared with its own seating onthe wheel so as to avoid damages.Locking torques (N*m)Front wheel axle nut 45 - 50SUSP - 159

SuspensionsFly 125 - 150 4THandlebarRemovalRemove the handlebar cover before carrying outthis operation,.- After removing the transmissions and disconnectingthe electrical terminals, remove the terminalfixing the handlebar to the steering.- Check all components and replace faulty parts.N.B.IF THE HANDLEBAR IS BEING REMOVED TOREMOVE THE STEERING, TILT THE HANDLE-BAR FORWARD TO AVOIDING DAMAGINGTHE TRANSMISSIONS.RefittingCarry out the operations in the reverse order to theremoval, observing the prescribed tightening torque.Locking torques (N*m)Handlebar fixing screw 50 ÷ 55Front forkOverhaulReplacement 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 lubricatingtheir seatings.- Refit the stem and the lower screw (1).SUSP - 160

Fly 125 - 150 4TSuspensions- Remove the upper screw (2).- Add 30 cc ±1 "Fork PG" oil (SAE 20W oil forforks).- Refit all components.Locking torques (N*m)Upper screw tightening torque 20 to 25 NmLower screw tightening torque: 20 to 25 NmRefittingWhen fitting the fork, lubricate with the steeringbearing tracks with the recommended grease.Tighten the lower ring nut "A" and the upper ringnut "B" to the specified torqueRecommended productsAGIP GREASE PV2 Grease for the steeringbearings, pin seats and swinging armWhite anhydrous-calcium based grease to protectroller bearings; temperature range between -20 Cand +120 C; NLGI 2; ISO-L-XBCIB2.Locking torques (N*m)Steering lower ring nut 8 ÷ 10 Steering upperring nut 35 ÷ 40SUSP - 161

SuspensionsFly 125 - 150 4TSteering columnRefittingUpper and lower seat on chassisLower and upper seating on the chassisLOWER AND UPPER SEATING ON THE CHASSISTitoloLower andupperseating onthe chassisDurata/ValoreTestoBreve (

Fly 125 - 150 4TSuspensionsRearRemoving the rear wheel- Use a screwdriver as a lever between the drumand the cover.-Straighten the split pin and remove the cap.-Remove the wheel acting on the central fixingpoint.WARNING-ALWAYS USE NEW SPLIT PINS FOR REFIT-TING.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 ASSHOWN IN ORDER TO AVOID BACKSLASHBETWEEN THE CAP AND THE WHEEL AXLE.Locking torques (N*m)Rear wheel axle 104 ÷ 126Shock absorbersRemoval- To replace the shock absorber remove the batteryaccess flap to reach and remove the shockabsorber/ frame anchoring nut. Then remove theshock absorber/engine anchorage nut.- When refitting, tighten the shock absorber/frameanchoring nut and the shock absorber/engine pinto the specified torque.Locking torques (N*m)SUSP - 163

SuspensionsFly 125 - 150 4TShock absorber/engine pin torque 33 to 41N·m Shock absorber/frame nut torque 20 to 25NmCentre-standComplete 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 ÷ 40SUSP - 164

INDEX OF TOPICSBRAKING SYSTEMBRAK SYS

Braking systemFly 125 - 150 4TFront brake calliperRemoval- Inspect the condition of the hoses, packing andjoint. In the event of fluid leaks from the calliper,this must be replaced.- Detach the oil brake pipe from the calliper; pourthe fluid inside a container.- Remove the clamps shown in the figure.OverhaulProceed as follows:1) remove the two male hexagonal screws (1) andtake out the two pads (10);2) remove the two male hexagonal screws (2) andremove the reaction plate (3);3) take out the fixed plate (4) from the guide;4) remove the internal elements from the floatingbody (5) with the help of short blows of compressedair through the brake fluid pipe in order tofacilitate the expulsion of pistons (6).5) Check:- that the plates and the body are whole and ingood condition;- that the cylinder and the floating body of the calliperdo not show signs of scratches or erosion,otherwise replace the entire calliper;- that the guides of the fixed plate are not scratchedor eroded, otherwise replace the entire plate;- that the brake pad check spring works properly.Reassembly1) insert the pistons (6) and the sealing rings (7) inthe body;BRAK SYS - 166

Fly 125 - 150 4TBraking system2) place the guide rubbers (8) and refit the fixedplate (4);3) assemble the reaction plate (3) tightening thescrews (2), insert the brake pad check spring (9)and then the pads, fixing them with the correspondingscrews (1);5) place the calliper on the disc and lock it to thestrut by tightening the fixing screws;6) fix the pipe joint on the calliper at the prescribedtorque.FunctioningThis is a floating type calliper.It takes advantage of the action and reaction principleto obtain the thrust for both pads.The body and the reaction plate body work integrallyand can move axially with respect of thefixed plate that is integral to the strut.The pistons, forced by pressure to push the pad tothe disk, cause the reaction plate to push in turnthe other pad towards the disc.The brake pad lock spring1. Pad fixing screws2. Reaction plate fixing screws3. Reaction plate4. Fixed plate5. Floating body6. Piston7. Piston sealing rings8. Guide protection rubbers9. Brake pad check spring10. PadsCAUTIONALL THE SEALS AND GASKETS MUST BE RE-PLACED EVERY TIME THE CALLIPER ISSERVICED.Locking torques (N*m)Calliper tightening screw 24 ÷ 27 Brake fluidtube- calliper fitting 19 ÷ 24BRAK SYS - 167

Braking systemFly 125 - 150 4TRefitting- 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 ÷ 24See alsoFrontFront brake discRemoval- Remove the front wheel undoing the axle clamping.- Undo the five disc clamps.Locking torques (N*m)Disc tightening screw 8 ÷ 10Refitting-When refitting, position the disc correctly making sure that it rotates in the right direction.Locking torques (N*m)Disc tightening screw 8 - 12BRAK SYS - 168

Fly 125 - 150 4TBraking systemDisc Inspection- Remove the wheel and check for unevenness ofthe disc.Maximum permissible out of true is 0.1 mm. If thevalue measured is greater, fit a new disc and repeatthe check.- If the problem persists, check and replace thewheel rim if necessary.Specific tooling020335Y Magnetic support for dial gaugeFront brake padsRemovalProceed as follows:- Remove the front calliper.- Loosen the two pins shown in the figure that lockthe two pads.- Remove the pads, being careful of the pads'spring clamp.- Check the thickness of the pads.CharacteristicMinimum value1.5 mmSee alsoFront brake calliperRefittingTo 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 FIT-TING, GENTLY EXPAND THE PADS.Recommended productsLoctite 243 Medium strength threadlockLoctite 243 medium-strength threadlockBRAK SYS - 169

Braking systemFly 125 - 150 4TLocking torques (N*m)Screw tightening calliper to the support 20 ÷ 25 Pad fastening pin 19.6 ÷ 24.5FillFront-Once the bleed valve is closed, fill the system withbrake liquid to the maximum level.-Undo the bleed screw.-Apply the tube of the special tool to the bleedscrews.When bleeding it is necessary to fill the oil tank incontinuation while working with a MITYVAC pumpon the bleed screws until no more air comes out ofthe system.The operation is finished when just oil comes outof the bleed screws.-Do up the bleed screw.-When the operation is over, tighten up the oilbleed screw to the prescribed torque.N.B.IF AIR CONTINUES TO COME OUT DURINGPURGING, EXAMINE ALL THE FITTINGS:IF SAID FITTINGS DO NOT SHOW SIGNS OFBEING FAULTY, LOOK FOR THE AIR INPUTAMONG THE VARIOUS SEALS ON THE PUMPAND CALLIPER PISTONS.CAUTION- DURING THE OPERATIONS, THE VEHICLEMUST BE ON THE STAND AND LEVEL.N.B.DURING PURGING FREQUENTLY CHECK THELEVEL TO PREVENT AIR GETTING INTO THESYSTEM THROUGH THE PUMP.WARNING- BRAKING CIRCUIT FLUID IS HYGROSCOPIC.IT ABSORBS HUMIDITY FROM THE SUR-ROUNDING AIR.IF THE LEVEL OF HUMIDITY IN THE BRAKINGFLUID EXCEEDS A GIVEN VALUE, BRAKINGEFFICIENCY WILL BE REDUCED.THEREFORE, ALWAYS USE FLUID FROMSEALED CONTAINERS.BRAK SYS - 170

Fly 125 - 150 4TBraking systemUNDER NORMAL DRIVING AND CLIMATICCONDITIONS YOU SHOULD CHANGE THISLIQUID EVERY TWO YEARS.IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE THEFLUID MORE FREQUENTLY.CAUTIONWHEN CARRYING OUT THE OPERATION,BRAKE FLUID MAY LEAK FROM BETWEENTHE BLEED SCREW AND ITS SEAT ON THECALLIPER.CAREFULLY DRY THE CALLIPER AND DE-GREASE THE DISC SHOULD THERE BE OILON IT.Specific tooling020329Y MityVac vacuum-operated pumpRecommended productsAGIP BRAKE 4 Brake fluidFMVSS DOT 4 Synthetic fluidLocking torques (N*m)Oil bleed screw 7 ÷ 10Front 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 torqueand bleed the system.Locking torques (N*m)Brake fluid pump - hose fitting 16 ÷20 NmBRAK SYS - 171

Braking systemFly 125 - 150 4TRemoval- Bleed the circuit and drain the brake fluid throughthe bleeding screw located on the calliper and actuatethe brake lever until no more fluid flows out.-Remove the oil pump from the handlebar; removethe 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 - SpringCAUTION- THE PRESENCE OF BRAKE FLUID ON THEDISC OR BRAKE PADS REDUCES THE BRAK-ING EFFICIENCY.IN THIS CASE, REPLACE THE PADS ANDCLEAN THE DISC WITH A HIGH-QUALITY SOL-VENT.CONTACT WITH BRAKE FLUID WILL DAMAGEPAINTED SURFACES.RUBBER PARTS SHOULD NEVER BE LEFT INALCOHOL FOR LONGER THAN 20 SECONDS.AFTER WASHING, THE PIECES MUST BEDRIED WITH A BLAST OF COMPRESSED AIRAND A CLEAN CLOTH.THE SEALING RINGS MUST BE IMMERSED INTHE OPERATING LIQUID.RefittingBefore fitting, the parts must be perfectly clean andfree of traces of oil, diesel fuel, grease, etc.. Theyshould be washed thoroughly in denatured alcoholbefore proceeding.- Reinstall the individual parts in the reverse orderto the removal, paying attention to the correct positioningof the rubber parts in order to ensure leaktightness.1 - Tank cap screw.BRAK SYS - 172

Fly 125 - 150 4TBraking system2. Tank cover.3. Diaphragm.4. Bellows.5. Sealing ring.6. Piston.7. Gasket.8. Spring.Rear drum brakeOnce 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 themallet.4. Attach the spring using the specific pliers.Specific tooling020325Y Brake-shoe spring calliperBRAK SYS - 173

INDEX OF TOPICSCHASSISCHAS

Fly 125 - 150 4TChassisRemoving the ignition key-switch when on *off*• Remove the shield back plate• Push the lock body until the stop spring does notshow grooves.• Keep the lock body blocked with a screwdriverand 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 shownin the figure.- Insert the wheel cylinder with the key and with theanchoring tab facing down halfway on the lockbody taking care that the insertion phase of the keyis oriented matching "ON" (the only position thatenables the cylinder to get into the lock body); nowturn the key leftwards to "OFF" and at the sametime press until the cylinder is completely in.Footrest- Remove the side fairings- Remove the shield back plate- Remove the 6 screws shown in the photographCHAS - 175

ChassisFly 125 - 150 4TAir filter• Unscrew the 7 cover screws and remove thecover to reach the filter sponge.• To disassemble the filter housing, unscrew the 2bottom 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 photographCHAS - 176

Fly 125 - 150 4TChassisHelmet bay- Remove the side fairings- Remove the helmet compartment by undoing the4 screws indicated in the figureFuel tank- Remove the side fairings- Remove the rear mudguard- Remove the crews shown in the photograph- Remove the shock absorber upper clamping inorder to create the necessary space to take out thetank.CHAS - 177

INDEX OF TOPICSPRE-DELIVERYPRE DE

Fly 125 - 150 4TPre-deliveryAesthetic inspectionAppearance check:- Paintwork- Fitting of plastics- Scratches- DirtTightening torques inspectionLock check- Safety locks- clamping screwsSafety locksRear shock absorber upper fixingRear shock absorber lower fixingFront wheel axle nutWheel hub nutFrame - swinging arm bolt *Swinging arm bolt - EngineEngine arm pin - Frame armHandlebar lock nutSteering lower ring nutUpper steering ring nutElectrical systemElectrical 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- StarterPRE DE - 179

Pre-deliveryFly 125 - 150 4TCAUTIONTO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFOREIT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.WARNINGBEFORE 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 TERMINALFIRST.CAUTIONWHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-ATIVE LEAD.WARNINGBATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLEOIL. 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 CARETO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKINGCLOSE TO BATTERIES.KEEP OUT OF THE REACH OF CHILDRENCAUTIONNEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USINGA FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSEA FIRE.Levels checkLevel check:- Hydraulic brake system fluid level.- Rear hub oil level- Engine oil levelRoad testTest 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 noisePRE DE - 180

Fly 125 - 150 4TPre-deliveryStatic testStatic control after the test ride:- Starting when warm- Starter operation- Minimum hold (turning the handlebar)- Uniform turning of the steering- Possible leaksCAUTIONCHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.CAUTIONNEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.Functional inspectionFunctional check up:Braking system (hydraulic)- Lever travelBraking system (mechanical)- Lever travelClutch- Proper functioning checkEngine- Throttle travel checkOthers- Check documentation- Check the frame and engine numbers- Tool kit- License plate fitting- Check locks- Check tyre pressures- Installation of mirrors and any accessoriesPRE DE - 181

INDEX OF TOPICSTIMETIME

Fly 125 - 150 4TTimeEngineENGINECode Action Duration1 001001 engine from frame - removaland refittingTIME - 183

TimeFly 125 - 150 4TCrankcaseCRANKCASECode Action Duration1 001133 Engine crankcase - Replacement2 001153 Half crankcase gasket - Replacement3 002031 Rear wheel hub bearings -ReplacementTIME - 184

Fly 125 - 150 4TTimeCrankshaftCRANKSHAFTCode Action Duration1 001117 Crankshaft - Replacement2 001099 Oil seal, flywheel side - ReplacementTIME - 185

TimeFly 125 - 150 4TCylinder assy.CYLINDER GROUPCode Action Duration1 001002 Cylinder-Piston - Replacement2 001107 Cylinder / piston - Inspection /cleaningTIME - 186

Fly 125 - 150 4TTimeCylinder head assy.HEAD UNITCode Action Duration1 001045 Valves - Replacement2 001056 Head gasket - change3 001126 Head - ReplacementTIME - 187

TimeFly 125 - 150 4TRocker arms support assy.ROCKING LEVER SUPPORT UNITCode Action Duration1 001044 Camshaft - Replacement2 001148 Rocking lever valve - Replacement3 001049 Valves - AdjustmentsTIME - 188

Fly 125 - 150 4TTimeCylinder head coverHEAD COVERCode Action Duration1 001089 Head cover - Replacement2 001088 Head cover gasket - Replacement3 001159 Oil vapour recovery tank -Service4 001093 Spark plug - Replacement5 001097 Cooling hood - Replacement6 001091 Head cover sealing ring7 001074 Oil vapour recovery pipe - ReplacementTIME - 189

TimeFly 125 - 150 4TChain tensionerCHAIN TIGHTENERCode Action Duration1 001129 Chain tensioner - Service andReplacement2 001124 By pass lubrication - ReplacementTIME - 190

Fly 125 - 150 4TTimeOil filterOIL FILTERCode Action Duration1 001123 Oil filter - Replacement2 001160 Oil pressure sensor - Replacement3 003064 Engine oil - Change4 001102 Mesh oil filter - Replacement /CleaningTIME - 191

TimeFly 125 - 150 4TFlywheel coverFLYWHEEL COVERCode Action Duration1 001087 Flywheel cover - Replacement2 001163 Muffler secondary air connection- Replacement3 001161 Secondary air filter - Replacement/ Cleaning4 001174 SAS valve - Replacement5 001164 Crankcase secondary airconnection - ReplacementTIME - 192

Fly 125 - 150 4TTimeDriven pulleyDRIVEN PULLEYCode Action Duration1 001155 Clutch bell housing - Replacement2 001022 Clutch - Replacement3 001012 Driven pulley - Overhaul4 001110 Driven pulley - ReplacementTIME - 193

TimeFly 125 - 150 4TOil pumpOIL PUMPCode Action Duration1 001051 Belt/Timing chain - Change2 001125 Chain guide pads - Replacement3 001042 Oil pump - Service4 001112 Oil pump - change5 001130 Oil sump - Replacement6 001100 Oil seal, clutch side - Replacement7 001122 Oil pump chain - ReplacementTIME - 194

Fly 125 - 150 4TTimeFinal gear assy.FINAL REDUCTION GEAR ASSEMBLYCode Action Duration1 004125 Rear wheel axle - Replacement2 001156 Gear reduction unit cover -Replacement3 003065 Gear box oil - Replacement4 001010 Gear reduction unit - InspectionTIME - 195

TimeFly 125 - 150 4TDriving pulleyDRIVING PULLEYCode Action Duration1 001066 Drive pulley - Removal andrefitting2 001086 Driving half-pulley - Replacement3 001177 Variator rollers / shoes - Replacement4 001011 Driving belt - ReplacementTIME - 196

Fly 125 - 150 4TTimeTransmission coverTRANSMISSION COVERCode Action Duration1 001096 Transmission crankcase cover- Replacement2 001135 Transmission cover bearing -Replacement3 001065 Transmission cover - Removaland RefitTIME - 197

TimeFly 125 - 150 4TStarter motorSTARTER MOTORCode Action Duration1 001020 Starter motor - Replacement2 001017 Starter sprocket wheel - ReplacementTIME - 198

Fly 125 - 150 4TTimeFlywheel magnetoBelt cooling ductTIME - 199

TimeFly 125 - 150 4TBELT COOLING PIPECode Action Duration1 001170 Air manifold - replacement2 001132 Transmission air inlet pipe -Replacement3 001131 Transmission air intake - ReplacementCarburettorCARBURETTORCode Action Duration1 001082 Carburettor heating resistor -Replacement2 001013 Intake manifold - change3 004122 Air cleaner carburettor fitting -Replacement4 001081 Automatic choke - Replacement5 001008 Carburettor - Inspection6 001063 Carburettor - ReplacementTIME - 200

Fly 125 - 150 4TTimeExhaust pipeMUFFLERCode Action Duration1 001009 Muffler - Replacement2 001136 Exhaust emissions - Adjustment3 001095 Muffler guard - ReplacementTIME - 201

TimeFly 125 - 150 4TAir cleanerAIR CLEANERCode Action Duration1 001014 Air filter - Replacement/Cleaning2 001015 Air filter box - ReplacementTIME - 202

Fly 125 - 150 4TTimeFrameFRAMECode Action Duration1 004001 Frame - replace2 004004 Stand - Replacement3 001053 Stand bolt - ReplacementTIME - 203

TimeFly 125 - 150 4TLegshield spoilerFRONT SHIELD SPOILERCode Action Duration1 004159 Plates / Stickers - Replacement2 004149 Shield central cover - Replacement3 004064 Front shield, front part - Removaland refitting4 004015 Footrest - Removal and Refitting5 004053 Spoiler - ReplacementTIME - 204

Fly 125 - 150 4TTimeRear coverREAR SHIELDCode Action Duration1 004174 Trunk levers - Replacement2 004065 Front shield, rear part - Removaland refitting3 004081 Glove box door - ReplacementTIME - 205

TimeFly 125 - 150 4TCentral coverCENTRAL COVERCode Action Duration1 004059 Spark plug inspection flap -Replacement2 004106 Under-saddle band - Replacement3 004085 Fairing (1) - Replacement4 004105 Right side clamp - Replacement5 004131 Luggage rack support - ReplacementTIME - 206

Fly 125 - 150 4TTimeUnderseat compartmentUNDERSEAT COMPARTMENTCode Action Duration1 005046 Battery cover - Replacement2 004016 Helmet compartment - Removaland Refitting3 001027 Body / air cleaner union - ReplacementTIME - 207

TimeFly 125 - 150 4TPlate holderLICENCE PLATE HOLDERCode Action Duration1 004136 License plate support - replace2 005048 Licence plate holder - ReplacementTIME - 208

Fly 125 - 150 4TTimeMudguardMUDGUARDSCode Action Duration1 004002 Front mudguard - Replacement2 004009 Rear mudguard - ReplacementTIME - 209

TimeFly 125 - 150 4TFuel tankFUEL TANKCode Action Duration1 004168 Fuel tank cap - Replacement2 005010 Tank float - Replacement3 004112 Cock-carburettor hose - Replacement4 004005 Fuel tank - Replacement5 004007 Fuel valve - Replacement6 004109 Fuel tank breather - ReplacementTIME - 210

Fly 125 - 150 4TTimeRear shock-absorberREAR SHOCK ABSORBERCode Action Duration1 003007 Rear shock absorber - Removaland RefittingTIME - 211

TimeFly 125 - 150 4TSteering column bearingsSTEERING COLUMN BEARINGSCode Action Duration1 003002 Steering fifth wheel - Replacement2 003073 Steering clearance - AdjustmentTIME - 212

Fly 125 - 150 4TTimeHandlebar coversHANDLEBAR COVERSCode Action Duration1 004019 Handlebar rear section - Replacement2 004018 Handlebar front section - Replacement3 005078 Odometer glass - Replacement4 005076 Clock / Cell - Replacement5 005014 Odometer - Replacement6 005038 Instrument panel warninglight bulbs - ReplacementTIME - 213

TimeFly 125 - 150 4THandlebar componentsHANDLEBAR COMPONENTSCode Action Duration1 004066 Rear-view mirror - Replacement2 002037 Brake or clutch lever - Replacement3 002071 Left hand grip - Replacement4 003001 Handlebar - Removal and refitting5 005017 Stop switch - Replacement6 002024 Front brake pump - Removaland Refitting7 003061 Accelerator transmission -Adjustment8 002060 Complete throttle control -Replacement9 004162 Mirror support and/or brakepump fitting U-bolt - Replacement10 002059 Right hand grip - Replacement11 002063 Throttle control transmission- ReplacementTIME - 214

Fly 125 - 150 4TTimeSwing-armSWINGING ARMCode Action Duration1 001072 Engine / frame swinging armfitting - Replacement2 003080 Swinging arm on frame - ReplacementTIME - 215

TimeFly 125 - 150 4TBrake hosesBRAKE HOSESCode Action Duration1 002007 Front brake shoes/pads - Remov.and Refitt2 002039 Front brake line - Replacement3 002021 Front brake hose - Remov.and Refitt.4 002047 Front brake fluid and systembleeding plug - ChangeTIME - 216

Fly 125 - 150 4TTimeSeatSADDLECode Action Duration1 004003 Saddle - Replacement2 004068 Passenger handgrip - ReplacementTIME - 217

TimeFly 125 - 150 4TTurn signal lightsTURN SIGNAL LIGHTSCode Action Duration1 005002 Front headlamp - change2 005012 Front turn indicator - Replacement3 005067 Front turn indicator bulb - Replacement4 005008 Front headlamp bulbs - Replacement5 005005 Taillight - Replacement6 005066 Rear light bulbs - Replacement7 005022 Rear turn indicators - Replacement8 005068 Rear turn indicator bulb - ReplacementTIME - 218

Fly 125 - 150 4TTimeCode Action Duration9 005131 Licence plate light support -Replacement10 005031 Licence plate light bulb - Replacement11 005032 Licence plate light glass - ReplacementFront wheelFRONT WHEELCode Action Duration1 003038 Front wheel axle - Replacement2 002011 Odometer drive- Replacement3 003040 Front wheel bearings - Replacement4 003047 Front tyre - Replacement5 003037 Front wheel rim - Removaland Refitting6 004123 Front wheel - Replacement7 002041 Brake disc - ReplacementTIME - 219

TimeFly 125 - 150 4TGrease tone wheel or drivePlease take note that the code has been introduced:900001 - Tone wheel / drive greasing - 15'.Never mistake the codes 002011 (movement sensorreplacement) and 005089 (tone wheel replacement)in the event of noise of the indicatedcomponents. The grease recommended is TUTE-LA MRM 2 (soap-based lithium grease with Molybdenumdisulphide).In the following points we indicate with an arrowthe area to be greased (1 - Drive, 2 - Tone wheel)Rear wheelTIME - 220

Fly 125 - 150 4TTimeREAR WHEELCode Action Duration1 002002 Rear brake pads/shoes - Replacement2 004126 Rear wheel tyre - Replacement3 001016 Rear wheel - Replacement4 001071 Rear wheel rim - Removaland RefitElectric devicesELECTRICAL DEVICESCode Action Duration1 001023 Control unit - Replacement2 005035 Headlight remote control -Replacement3 005001 Electric system - Removaland reassembly4 001094 Spark plug cap - Replacement5 001069 HV coil - Replacement6 005052 Fuse - Replacement7 005025 Battery fuse box - Replacement8 005009 Voltage regulator - Replacement9 005011 Start-up remote controlswitch - changeTIME - 221

TimeFly 125 - 150 4TCode Action Duration10 005007 Battery - Replacement11 005114 Electrical system - ServiceElectronic controlsELECTRIC CONTROLSCode Action Duration1 005039 Headlight switch - Replacement2 005006 Light switch or turn indicators- Replacement3 005040 Horn button - Replacement4 005003 Horn - Replacement5 005041 Starter button - Replacement6 005016 Key switch - Replacement7 004096 Lock series - Replacement8 005072 Immobilizer aerial - ReplacementTransmissionsTRANSMISSIONSCode Action Duration1 002051 Odometer transmission assembly- Replacement2 002049 Odometer cable - Replacement3 002053 Rear brake transmissioncomplete - replacementTIME - 222

Fly 125 - 150 4TTimeFront suspensionFRONT SUSPENSIONCode Action Duration1 003010 Front suspension - Service2 003048 Fork oil seal - Replacement3 003076 Fork leg - Replacement4 003079 Fork stem - Replacement5 003051 Complete fork - replace6 003069 Front fork oil - ReplacementTIME - 223