PIAGGIO FLY 125 FLY 150 Scooter Workshop Service Manual

SERVICE STATION MANUAL 677566 (EN) Fly 125 i.e - 150 i.e Leader (2011)

SERVICE STATION MANUAL Fly 125 i.e - 150 i.e Leader (2011) The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, Piaggio Việt Nam reserves the right, at any time and without being required, to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of single models should be checked at the official Piaggio sales network. "© Copyright 2011 - PIAGGIO VIỆT NAM. All rights reserved. Reproduction of this publication in whole or in part is prohibited." PIAGGIO VIỆT NAM- After Sales LOT M - BINH XUYEN INDUSTRIAL ZONE - VINCH PHUC - VIET NAM CUSTOMER SERVICE CENTRE Please contact with us following: Hot line: 1800 5555 85 Email: customer.service@piaggio.com.vn Website: www.piaggio.com.vn

SERVICE STATION MANUAL Fly 125 i.e - 150 i.e Leader (2011) This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue. N.B. Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment. Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE-DELIVERY PRE DE

INDEX OF TOPICS CHARACTERISTICS CHAR

Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention. - The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it. - Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks. - Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. The non original or non-compliant spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections. Fly 125 i.e - 150 i.e Leader (2011) Characteristics CHAR - 7

Vehicle identification The chassis prefix is stamped on the right strut. The engine prefix is stamped on the rear wall of the transmission crankcase. VEHICLE IDENTIFICATION (125) Specification Desc./Quantity Chassis prefix M77200 Engine prefix M772M VEHICLE IDENTIFICATION (150) Specification Desc./Quantity Chassis prefix M77600 Engine prefix M776M Characteristics Fly 125 i.e - 150 i.e Leader (2011) CHAR - 8

Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity dry weight 123 kg Wheelbase 1330 mm Length 1,870 mm Width (handlebar) 695 mm Height (without mirrors) 1140 mm Engine SPECIFICATIONS - 125 ENGINES Specification Desc./Quantity Type Single-cylinder, 4-stroke Engine capacity 124 cm³ Bore x stroke 57.0 x 48.6 mm Compression ratio 10.6 ± 0.5: 1 Engine idle speed 1700 ± 100 rpm Timing system 2 valves, single overhead camshaft, chain-driven. Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm MAX. Power 7.6 kW at 8,250 rpm MAX. torque 9.2 Nm at 6,500 rpm Transmission Automatic expandable pulley variator with torque server, V- belt, self-ventilating dry automatic centrifugal clutch and transmission housing with forced-circulation air cooling. Final reduction gear Gear reduction unit in oil bath. Lubrication Engine lubrication with lobe pump (inside crankcase), chain- driven, with double filter: mesh and paper. Cooling Forced-air circulation cooling. Electric Electric starter Ignition Capacitive discharge ignition, with variable advance and sep- arate HV coil. Ignition advance Three-dimensional map managed by control unit Spark plug NGK CR8EB - DENSO U24ESR-NB Fly 125 i.e - 150 i.e Leader (2011) Characteristics CHAR - 9

Specification Desc./Quantity Fuel system Electronic injection with Ø 28 mm throttle body, single injector Fuel Unleaded petrol Exhaust silencer Absorption-type exhaust muffler with catalytic converter. Emissions compliance EURO 3 SPECIFICATIONS - 150 ENGINES Specification Desc./Quantity Type Single-cylinder, 4-stroke Engine capacity 149.5 cm³ Bore x stroke 62.6 x 48.6 mm Compression ratio 10.6 ± 0.5 : 1 Engine idle speed 1,650±100 rpm Timing system 2 valves, single overhead camshaft, chain-driven. Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm MAX. Power 8.6 kW at 8,000 rpm MAX. torque 11.2 Nm at 6,250 rpm Transmission Automatic expandable pulley variator with torque server, V- belt, self-ventilating dry automatic centrifugal clutch and transmission housing with forced-circulation air cooling. Final reduction gear Gear reduction unit in oil bath. Lubrication Engine lubrication with lobe pump (inside crankcase), chain- driven, with double filter: mesh and paper. Cooling Forced-air circulation cooling. Electric Electric starter Ignition Capacitive discharge ignition, with variable advance and sep- arate HV coil. Ignition advance Three-dimensional map managed by control unit Spark plug NGK CR7EB - DENSO U22ESR-NB Fuel system Electronic injection with Ø 28 mm throttle body, single injector Fuel Unleaded petrol Exhaust silencer Absorption-type exhaust muffler with catalytic converter. Emissions compliance EURO 3 Transmission TRANSMISSION Specification Desc./Quantity Primary drive Automatic expandable pulley variator with torque server, V- belt, automatic self-ventilating centrifugal dry clutch Final reduction gear Gear reduction unit in oil bath. Capacities CAPACITIES Specification Desc./Quantity Engine oil 1.10 l Transmission oil 200 cm3 Fuel tank capacity approx. 7 litres (of which 1.5 l reserve) Electrical system E LECTRICAL COMPONENTS Specification Desc./Quantity Spark plug (125 cc) NGK CR8EB - DENSO U24ESR-NB Spark plug (150 cc) NGK CR7EB - DENSO U22ESR-NB Battery Sealed, 12 V / 6 Ah Fuses 1 30A fuse - 1 5A fuse - 1 10A fuse - 4 7.5A fuses Characteristics Fly 125 i.e - 150 i.e Leader (2011) CHAR - 10

PIAGGIO FLY 125 FLY 150 Scooter Workshop Service Manual

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