PIAGGIO FLY 150 4TEMPI USA Full Service & Repair Manual 2005-2011

WORKSHOP MANUAL 633225 Fly 125 - 150 4T

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

WORKSHOP MANUAL Fly 125 - 150 4T This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific tool catalogue. N.B. Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment. Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

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

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 open flames or sparks. - Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting. - After refitting, make sure that all the components have been installed correctly and work properly. - For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections. Fly 125 - 150 4T Characteristics CHAR - 7

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

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

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

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PIAGGIO FLY 150 4TEMPI USA Full Service & Repair Manual 2005-2011

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