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677586 EN
Fly 50 4t 4v
WORKSHOP MANUAL
Fly 50 4t 4v
The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. 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 each model should be checked at the official PIAGGIO sales network. Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy www.piaggio.com
WORKSHOP MANUAL
Fly 50 4t 4v
This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggio dealers and sub-agents. It is assumed that the person utilizing this manual for servicing or repairing Piaggio vehicles has knowledge of the principles of mechanics and standard procedures required for general vehicle repair. Any relevant changes concerning the vehicle characteristics or specific repair operations will be divulged in the form of updates to this manual. Satisfactory repair or service cannot be achieved without the necessary equipment and tools. Refer to the pages of this manual concerning specific tools and equipment and the special tools 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 TOOLING MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE SUSPENSIONS BRAKING SYSTEM CHASSIS PRE-DELIVERY
CHAR TOOL MAIN TROUBL ELE SYS ENG VE ENG SUSP BRAK SYS CHAS PRE DE
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Fly 50 4t 4v
Characteristics
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are 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. 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 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.
CHAR - 7
Characteristics
Fly 50 4t 4v
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
Specification Chassis prefix Engine prefix Desc./Quantity RP8C52 C522M
CHAR - 8
Fly 50 4t 4v
Characteristics
Engine
ENGINE
Specification Type Bore Stroke Engine capacity Max. power MAX. torque Compression ratio Timing system Engine idle speed Air filter Starting system LUBRICATION Fuel system Valve clearance (cold engine) CARBURETTOR Cooling Desc./Quantity single-cylinder, four-stroke and four-valve, air-cooled engine 39 mm 41.8 mm 49.93 cm 3.2 kW at 8250 rpm 3.8 Nm at 7,750 rpm 12.00.5 single overhead camshaft, chain-driven, on the left-hand side, three-arm rocking levers set up with threaded set screw 1900 to 2000 rpm Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and 50% unleaded petrol). electric starter/kick starter engine lubrication with lobe pump (in the crankcase), chaindriven. Mesh pre-filter and centrifugal filter on the crankshaft Gravity feed, with unleaded petrol (with a minimum octane rating of 95) with carburettor. intake 0.10 mm discharge 0.15 mm depression type, KEIHIN NCV 20 forced air circulation
OIL PUMP
Specification Type Distance between the rotors Axial rotor clearance Distance between the outer rotor and the pump body Levelness Desc./Quantity Trochoidal Admissible limit clearance: 0.15 mm Limit values admitted: 0.09 mm Admissible limit clearance: 0.20 mm 0.1 mm
OIL FILTER
Specification Type Desc./Quantity mesh, plastic and centrifugal filter, before the oil pump and coaxially mounted onto the crankshaft keyed on the right crank
Transmission
TRANSMISSION
Specification Transmission Desc./Quantity With automatic expandable pulley variator, torque server, Vbelt, automatic clutch, gear reduction unit.
CHAR - 9
Characteristics
Fly 50 4t 4v
Capacities
CAPACITY
Specification Fuel tank Rear hub Engine oil Desc./Quantity 70.5 lt 85 cm ~ 850 cc
Electrical system
When the advance check is carried out with a stroboscopic gun, add 10 flywheel keying to the table below.
ELECTRICAL COMPONENTS
1 2 3 4 5 Specification Ignition advance Spark plug Battery Fuses Generator Desc./Quantity reference in table NGK ER9EH-N 12V - 9Ah 1 15A - 1 10A - 1 7.5A single-phase alternating current
CHECKING REMOTE CONTROLS A OPERATING AS CIRCUIT BREAKERS 1) Check that, given regular conditions, there is no continuity between terminals 30 and 87. 2) Apply 12V voltage to power terminals 85 and 86 of the remote control. 3) With the remote control powered, check that there is continuity between terminals 30 and 87. 4) If these conditions are not fulfilled, the remote control is damaged and must be replaced. CHAR - 10
Fly 50 4t 4v
Characteristics
IGNITION KEY
LIGHT SWITCH
STARTER BUTTON
CHAR - 11
Characteristics
Fly 50 4t 4v
HORN BUTTON
STOP BUTTON
Resistance between green cable and ground connection: approx. 170 Ohm
- Primary resistance: 0.5 to 0.6 Ohm - Resistance between primary and ground connection: infinite - Resistance between primary and HV output: 3 to 3.6 kOhm - Shielded cap: 5000 Ohm
CHAR - 12
Fly 50 4t 4v
Characteristics
- Power: 120 W - resistance between BLUE cable and GROUND CONNECTION: 1 Ohm
Brakes
BRAKES
Specification Front brake Rear brake Desc./Quantity Disc brake ( 220 mm) with hydraulic control (lever on the far right of the handlebar) and floating calliper. 140-mm drum brake with mechanical control activated by the handlebar left-side lever.
Tightening Torques
ENGINE ASSEMBLY
Name Ignition spark plug: Floating head cover screws Head-cylinder stud bolt nuts Screws fixing head and cylinder to crankcase Chain tensioner pad screw Timing chain tensioner central screw Torque in Nm 10 to 15 Nm 6 to 7 6 to 7 + 90 + 90 * 8 - 10 5 to 7 Nm 5-6
CHAR - 13
Characteristics
Fly 50 4t 4v
Name Camshaft pulley screw Rocking lever axle and camshaft bearing screw Rocking levers adjusting nuts: Engine oil pre-filter cover: Engine oil drainage cap Flywheel nut Stator screws Pick-up screws Oil pump bulkhead screw Timing chain/oil pump compartment cover screws Oil decantation labyrinth sheet screws Oil pump sprocket gear screw Screws fixing oil pump to the crankcase Oil sump screws Inlet manifold screw Carburettor/manifold clamp screw Screws fixing cables to starter motor Starter motor screws Transmission cover screws Start-up lever screw Crankcase cooling cover screw Clutch assembly nut Crankshaft pulley nut Driven pulley shaft nut Hub oil drainage screw Rear hub cap screws Crankcase half union screw
Torque in Nm 12 - 14 3 to 4 Nm 7 to 9 Nm 25 - 28 Nm 25 - 28 40 to 44 N.m 3 to 4 3-4 4-5 4 to 5 7 to 8 8 - 10 5-6 8 - 10 Nm 7-9 1.2 to 1.5 1.5 - 2.5 11 - 13 11 13 11 to 13 2 to 2.5 55 to 60 18 to 20 + 90 Nm 40 to 44 Nm 3 - 5 Nm 11 to 13 8 - 10
STEERING ASSEMBLY
Name Steering upper ring nut Steering lower ring nut Handlebar fixing screw Torque in Nm 35 to 40 8 10 50 to 55
CHASSIS ASSEMBLY
Name Engine arm bolt - frame arm Engine-swinging arm bolt Frame-swinging arm bolt Silent-block swinging arm retaining bolts Side stand bolt Centre stand pin Torque in Nm 40 to 45 40 to 45 50 to 55 36 to 44 12 - 16 40 to 45
FRONT SUSPENSION
Name Fork bottom screw Front wheel axle Wheel axle clamp screws Front mudguard to plate fixing screw Torque in Nm 20 25 45 50 6 - 7 Nm 4.5 to 7
REAR SUSPENSION
Name Rear wheel axle Lower shock absorber clamp Shock absorber/Chassis nut: Shock absorber to crankcase bracket fastener Torque in Nm 104 126 40 to 45 20 25 20 25
CHAR - 14
Fly 50 4t 4v
Characteristics
Name Disc tightening screw (Apply LOCTITE 243 medium-strength threadlock) Oil bleeding valve Rear brake adjustment nut
Torque in Nm 8 - 12 Nm 8 - 12 5
Overhaul data
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS. CHAR - 15
Characteristics
Fly 50 4t 4v
Characteristic
Pin outside diameter 13 +0 -0.004 mm Minimum admissible diameter gudgeon pin 12.990 mm
Characteristic
Pin seat diameter 13 +0.005 + 0.010 mm
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS
Characteristic
Standard clearance 0.005 to 0.014 mm - Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
N.B. MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE SECOND SEAL RING SIDE.
Fitting clearance
Top piston ring - standard coupling clearance 0.03 to 0.065 mm Top piston ring - maximum clearance allowed after use 0.07 mm Middle piston ring - standard coupling clearance 0.02 to 0.055 mm Middle piston ring - maximum clearance allowed after use 0.06 mm oil scraper ring - standard coupling clearance 0.04 to 0.16 mm oil scraper
CHAR - 16
Fly 50 4t 4v
Characteristics
- Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out: 0.001 over 0.05 mm
Piston rings
- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis. - Measure the opening, see figure, of the sealing rings using a thickness gauge. - If any measurements are greater than specified, replace the piston rings.
N.B. BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
CHAR - 17
Characteristics
Fly 50 4t 4v
SEALING RINGS
Name 1st Compression ring 2nd Compression ring Oil scraper ring 1st Compression ring 1st Oversize 2nd Compression ring 1st Oversize Oil scraper ring 1st Oversize 1st Compression ring 2nd Oversize 2nd Compression ring 2nd Oversize Oil scraper ring 2nd Oversize 1st Compression ring 3rd Oversize 2nd Compression ring 3rd Oversize Oil scraper ring 3rd Oversize Description Dimensions 39 x 1 39 x 1 39 x 2 39.2 x 1 39.2 x 1 39.2 x 2 39.4 x 1 39.4 x 1 39.4 x 2 39.6 x 1 39.6 x 1 39.6 x 2 Initials A A A A A A A A A A A A Quantity 0.08 to 0.20 0.05 to 0.20 0.20 to 0.70 0.08 to 0.20 0.05 to 0.20 0.20 to 0.70 0.08 to 0.20 0.05 to 0.20 0.20 to 0.70 0.08 to 0.20 0.05 to 0.20 0.20 to 0.70
CHAR - 18
Fly 50 4t 4v
Characteristics
Characteristic
Clearance between crankshaft and connecting rod A = 0.15 to 0.30 mm
CHAR - 19
Characteristics
Fly 50 4t 4v
Characteristic
Crankshaft bearing, transmission side 20 -0.012 -0.025 mm Crankshaft bearing, flywheel side 17 +0.007 0 mm
- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order. - In case of failures, replace the crankshaft.
Specific tooling
020074Y Support base for checking crankshaft alignment
CHAR - 20
Fly 50 4t 4v
Characteristics
To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure.
N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE DETECTED, TRY STRAIGHTENING THE CRANKSHAFT BY INSERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEEDED. IF EVEN AFTER THIS OPERATION THE VALUES ARE NOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.
Characteristic
Off-line maximum admitted - A 0.15 mm Off-line maximum admitted - B 0.02 mm Off-line maximum admitted - C 0.02 mm Off-line maximum admitted - D 0.10 mm - Using a bore gauge, measure the connecting rod small end diameter.
N.B. IF THE CONNECTING ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Characteristic
Rod small end diameter 13 +0.015 + 0.025 mm Max. diameter admitted: check the small end 13.030 mm Calculate the coupling clearance between pin and rod small end
Characteristic
Pin - connecting rod clearance 0.015 - 0.029 mm
Cylinder Head
Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of the springs and the valves so as not to change the original position during refitting
CHAR - 21
Characteristics
Fly 50 4t 4v
- Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn. - It is advisable to replace the head if any failure is found.
Characteristic
Maximum allowable run-out: 0.1 mm - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
Measure the camshaft bearing seats and rocking lever support pins with a bore meter
HEAD CHECK
Specification Standard diameter (mm) A Standard diameter (mm) B Standard diameter (mm) C Desc./Quantity 32.015 to 32.025 16.0 to 16.018 11.0 to 11.018
CHAR - 22
Fly 50 4t 4v
Characteristics
Measure the unloaded spring length. Standard length: 31.3 mm Limit allowed after use: 29.3
- Remove any carbon deposits from the valve seats. - Check the width of the mark on the valve seat V with Prussian blue.
Characteristic
Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45 milling cutter and then grind. - In case of excessive wear or damage, replace the head.
CHAR - 23
Characteristics
Fly 50 4t 4v
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
STANDARD DIAMETER
Specification Intake Exhaust Desc./Quantity 3.970 to 3.985 mm 3.960 to 3.975 mm
- Calculate the clearance between valve and valve guide. - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the V shaped support.
Characteristic
Admissible limit: 0.03 mm
- Check the deviation of the valve stem by resting it on a V shaped support and measuring the extent of the deformation using a dial gauge.
Characteristic
Limit values admitted: 0.1 mm
CHAR - 24
Fly 50 4t 4v
Characteristics
- After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem.
INTAKE
Specification Standard clearance Admissible limit Desc./Quantity 0.015 to 0.042 mm 0.06 mm
EXHAUST
Specification Standard clearance Admissible limit Desc./Quantity 0.025 - 0.052 mm 0.07 mm
- If no faults are found during the above checks, you can use the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently with a fine-grained lapping compound. During the grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the lapping compound residues from penetrating between the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
CHAR - 25
Characteristics
Fly 50 4t 4v
Characteristic
Standard diameter - Bearing A: 12 +0.002 +0.010
mm Standard
diameter - Bearing B:
16-0.015 -0.023 mm Minimum diameter allowed - Bearing A: 11.98 mm Minimum diameter allowed - Bearing B: 15.96 mm - Using a gauge, measure the height of the cams. Check the axial clearance of the camshaft - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
N.B. A BALL BEARING IS FITTED ON BEARING A; CONSEQUENTLY, BEARING B IS THE MOST IMPORTANT AS IT WORKS DIRECTLY ON THE HEAD ALUMINIUM
Characteristic
Standard height - Inlet 24.397 mm Standard height - Outlet 23.996 mm
Fitting clearance
Maximum admissible axial clearance: 0.5 mm
- Measure the outside diameter of the rocking lever pins - Check the rocking lever pins do not show signs of wear or scoring. - Measure the internal diameter of each rocker. - Check that the pad in contact with the cam is not worn.
CHAR - 26
Fly 50 4t 4v
Characteristics
Products
RECOMMENDED PRODUCTS TABLE
Product AGIP GEAR SAE 80W-90 AGIP BRAKE 4 Description Lubricant for gearboxes and transmissions. Brake fluid. Specifications API GL-4 Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4 JASO MA, MA2 - API SL - ACEA A3 ISO L-X-BCHA 3 - DIN 51 825 K3K -20 R.I.D./A.D.R. 2 10b) 2 R.I.Na. 2.42 I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Page 9022 EM 25-89
eni i-Ride PG 5W-40 AGIP FILTER OIL AGIP GREASE MU3 AGIP GP 330
Synthetic based lubricant for high-performance four-stroke engines. Special product for the treatment of foam filters. Yellow-brown, lithium-base, medium-fibre multipurpose grease. Water repellent stringy calcium spray grease.
CHAR - 27
INDEX OF TOPICS
TOOLING
TOOL
Fly 50 4t 4v
Tooling
SPECIFIC TOOLS
Stores code 001330Y Description Tool for fitting steering seats
001467Y008
001467Y029
002465Y
004499Y
Bearing extractor. Fitted with: 1 Bell, 2 Sleeve, 3 Screw, 6 Ring, 7 Half rings, 27 Half rings, 34 Half rings
005095Y
Engine support
006029Y
TOOL - 29
Tooling
Fly 50 4t 4v
020004Y
020055Y
020150Y
020151Y
Air heater
020162Y
Flywheel extractor
020171Y
TOOL - 30
Fly 50 4t 4v
Tooling
020265Y
020271Y
020288Y
020291Y
020306Y
TOOL - 31
Tooling
Fly 50 4t 4v
020330Y
020331Y
Digital multimeter
020332Y
020334Y
TOOL - 32
Fly 50 4t 4v
Tooling
020340Y
020359Y
42x47-mm Adaptor
020360Y
52x55-mm Adaptor
020363Y
20-mm guide
TOOL - 33
Tooling
Fly 50 4t 4v
020376Y
Adaptor handle
020431Y
020432Y
020439Y
17-mm guide
020444Y
TOOL - 34
Fly 50 4t 4v
Tooling
020449Y
020450Y
020451Y
020452Y
020456Y
24-mm adaptor
TOOL - 35
Tooling
Fly 50 4t 4v
020565Y
020683Y
TOOL - 36
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
Fly 50 4t 4v
Maintenance chart
SCHEDULED MAINTENANCE TABLE
I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R:REPLACE, A: ADJUST, L:LUBRICATE * Replace every 2 years Km x 1000 1 3 6 9 Safety fasteners I Spark plug R Drive belt I Throttle control A Tyre condition and wear Air filter Oil filter (mesh) C Solenoid filter C Valve clearance I Electrical system I I and battery Cylinder ventilation system Brake levers L Brake oil level (*) I I Hub oil level R I Engine oil R I R I Brake Pads/Shoes I I Tyre pressure I I Headlight Vehicle road test I I Idle speed A Odometer gear CVT rollers I Suspension Steering A Transmission Operation time 90' 10' 60' 10' 12 I R R A I C C C I I 15 18 R I 21 24 I R R A I C C C I I I L I R R I I A I A L R I A L 13 0' L I R R I I A I A L R I A L 18 0' L I R R I I A I A L R I A L 16 5' 27 30 R I 33 36 I R R A I C C C I I 39 42 R I 45 48 I R R A I C C C I I I L I R R I I A I A L R I A L 18 0' L I R R I I A I A L R I A L 13 0' 51 54 R I 57 60 I R R A I C C C I I
C C I
C C I
C C I
C C I
I I R I I I
I I R I I I
I I R I I I
I I R I I I
Carburettor
The carburettor features a solenoid valve "A" that, via an ECU, manages an extra flow of air. It is connected to the carburettor via flexible pipes as shown in the figure. The valve is positioned under the helmet compartment. The piping is joined to a filter positioned inside the body. The solenoid filter should be cleaned according to the kilometres travelled as instructed in the scheduled maintenance chart.
MAIN - 38
Fly 50 4t 4v
Maintenance
- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condition. -The throttle valve should move freely in the chamber. Replace valve in case of wear due to excessive clearance. - If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it is new), replace the carburettor. - It is advisable to replace the gaskets at every refit.
WARNING PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
1. Needle valve - 2. Idle adjustment screw - 3. Max jet - 4. Accelerating pump - 5. Tapered pin - 6. Jet holder - 7. Float - 8. Reservoir - 9. Starter device - 10. Depression valve - 11. Cover - 12. Minimum jet.
Spark plug
- Position the vehicle on the stand - Remove the external engine inspection panel, unscrewing the indicated screws.
- Disconnect the spark plug H.V. cable cap. - Slide the internal cover upwards.
MAIN - 39
Maintenance
Fly 50 4t 4v
- Check the conditions of the spark plug, make sure the insulation is intact, that the electrodes are not excessively worn or sooty, the conditions of the washer, and measure the distance between the electrodes using the appropriate feeler gauge. -Adjust the distance, if necessary, by bending the side electrode very carefully. In case of anomaly (as described before), replace the spark plug with another of the recommended type.
- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it. - Refit the cover. - Place the cap fully over the spark plug, and tie down the cable to the bracket. - Carry out refit operations.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD.THE SPARK PLUG MUST BE REPLACED EVERY 20,000 KM. THE USE OF NON CONFORMING ELECTRONIC IGNITION CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Electrode gap MAIN - 40
Fly 50 4t 4v
Maintenance
- Remove the dipstick/cover and check that the oil level is between MIN and MAX. - If the level is below the MIN value, restore the proper amount of oil in the hub. - Screw the oil dipstick back and check it is locked.
Replacement
- Remove the oil dipstick/cover.
MAIN - 41
Maintenance
Fly 50 4t 4v
- Remove the rear wheel. - Prepare an adequately sized container. - Unscrew the oil drainage plug and drain out all the oil.
See also
Removing the rear wheel - Screw in the drainage cap again and fill the hub with the prescribed oil.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions. API GL-4
Characteristic
Rear hub oil Quantity: approx. 85 cc
Air filter
- Remove the l.h.s. fairing. - Remove the air-box cover after removing the 6 fixing screws shown in the figure, and then extract the filtering element. Cleaning: - Clean with water and neuter soap; - Dry with a clean cloth, without squeezing, and with light jets of air; - Immerge in a 50% oil-petrol mixture; - Let it drip and then compress it with your hands, without squeezing. - Refit all components in the reverse order.
CAUTION IF THE VEHICLE IS MOSTLY USED ON DUSTY ROADS, THE AIR FILTER NEEDS TO BE CLEANED AT SHORTER INTERVALS THAN INDICATED IN THE SCHEDULED MAINTENANCE TABLE.
MAIN - 42
Fly 50 4t 4v
Maintenance
DO NOT RUN THE ENGINE WITH THE AIR FILTER DISASSEMBLED OR EXCESS WEAR OF CYLINDER AND PISTON WILL RESULT.
Recommended products
AGIP FILTER OIL Special product for the treatment of foam filters. -
Engine oil
In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Replacement
Change oil and replace filter as indicated in the scheduled maintenance table. The engine must be emptied by draining off the oil through the drainage plug of the mesh pre-filter, flywheel side; furthermore to facilitate oil drainage, loosen or remove the cap/dipstick. Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter and remove it. To carry out this operation the complete exhaust must be removed. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from oil dipstick/cover. Then start up the vehicle, leave it running for a few minutes and switch it off: After about five minutes, check the level and, if necessary, top-up but never
MAIN - 43
Maintenance
Fly 50 4t 4v
exceeding the MAX level reference mark. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.
N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
Recommended products
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3
Characteristic
Engine oil ~ 850 cm
Check
This operation must be carried out with the engine cold and following the procedure below: - Place the vehicle on its centre stand and on flat ground. - Undo cap/dipstick, dry it off with a clean cloth and reinsert it, screwing down completely. - Remove the cap/dipstick again and check that the level is between the MIN and MAX reference marks; top up if necessary. The MAX level mark indicates a quantity of around 850 cc of oil in the engine. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level. Engine oil top-up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoration of the level from MIN to MAX requires approximately 200 cc.
MAIN - 44
Fly 50 4t 4v
Maintenance
IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF GREASE, WE RECOMMEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH.
Recommended products
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3
MAIN - 45
Maintenance
Fly 50 4t 4v
Characteristic
Valve clearance Intake: 0.10 mm (when cold) Exhaust: 0.15 mm (when cold)
Braking system
MAIN - 46
Fly 50 4t 4v
Maintenance
Level check
Proceed as follows: - Rest the vehicle on its centre stand with the handlebars perfectly horizontal; - Check the level of liquid with the related warning light A. A certain lowering of the level is caused by wear on the brake pads.
Top-up
Proceed as follows: - Remove the front handlebar cover. - Remove the reservoir cap by loosening the two screws, remove the gasket and top-up using only the fluid specified without exceeding the maximum level.
CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLUID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE. N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4
MAIN - 47
Maintenance
Fly 50 4t 4v
See also
Front handlebar cover
Headlight adjustment
Proceed as follows: 1. Position the vehicle in running order and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit white screen; ensure that the longitudinal axis of the vehicle is perpendicular to the screen; 2. Turn on the headlight and check that the boundary of the light beam projected onto the screen is not higher than 9/10 or lower than 7/10 of the distance between the centre of the headlight and the ground; 3. If this is not the case, adjust the headlight by operating the screw indicated.
N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.
Anti-evaporation system
The fuel tank vapours breather is realised through a valve fixed on the left strut of the chassis. To access the valve it is necessary to remove the legshield.
See also
Legshield
MAIN - 48
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Troubleshooting
Fly 50 4t 4v
Excessive drive belt wear Lack of compression: parts, cylinder and valves worn Oil level exceeds maximum Excess of scales in the combustion chamber Incorrect timing or worn timing system elements Muffler obstructed Inefficient automatic transmission
Wrong valve adjustment Overheated valves Valve seat distorted Worn cylinder, Worn or broken piston rings
Starting difficulties
DIFFICULTY STARTING UP
Possible Cause Flat battery Operation Check the state of the battery. If it shows signs of sulphation, replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1/10 of the capacity of the battery itself. Replace the spark plug Inspect the head and/or restore the correct clearance Check starter motor. Drain off the fuel no longer up to standard; then, refill Remove the sponge, wash with water and car shampoo, then soak it in a mixture of 50% petrol and 50% specific oil. Press with your hand without squeezing, allow it to drip dry and refit. Check the pump.
Faulty spark plug Incorrect valve sealing or valve adjustment Starter motor and start-up system fault Altered fuel characteristics Air filter obstructed or dirty.
TROUBL - 50
Fly 50 4t 4v
Troubleshooting
Insufficient braking
INEFFICIENT OR NOISY BRAKING
Possible Cause Worn brake pads or shoes Front brake disk loose or deformed Operation Replace the brake pads or shoes and check for brake disk or drum wear conditions. Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Carefully bleed the hydraulic braking system, (there must be no flexible movement of the brake lever). Failing elastic fittings, plunger or brake pump seals, replace Adjust the clearance with the appropriate adjuster located on the back part of the crankcase.
Air bubbles inside the hydraulic braking system Fluid leakage in hydraulic braking system Excessive clearance in the rear brake control cable
Brakes overheating
BRAKES OVERHEATING
Possible Cause Rubber gaskets swollen or stuck Compensation holes on the pump clogged Brake disc slack or distorted Operation Replace gaskets. Clean carefully and blast with compressed air Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Check calliper and replace any damaged part.
Electrical system
TROUBL - 51
Troubleshooting
Fly 50 4t 4v
Battery
BATTERY
Possible Cause Battery Operation The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 5 to 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keeping in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+. Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries.
Noisy suspension
NOISY SUSPENSION
Possible Cause NOISY SUSPENSION Operation If the front suspension is noisy, check: That the shock absorber works properly inside the stanchions and that the steering ball bearings are in good condition. Finally, check the locking torque of the wheel axle nut, the brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly.
TROUBL - 52
Fly 50 4t 4v
Troubleshooting
TROUBL - 53
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Fly 50 4t 4v
Electrical system
1. Light remote control 2. Light switch 3.Town light bulb 4. Instrument panel lighting bulbs 5. Headlight warning light 6. Filament for rear position light 7. High-beam warning light 8. Headlight bulb 9.Automatic starter 10.NTC temperature sensor 11.Electronic ignition device 12. Turn indicator switch 13. Left turn indicator bulbs 14. Turn indicator warning light 15. Right turn indicator bulbs 16.HV coil 17.Key switch contacts 18.Diagnostics socket 19.Fuse 20.PTC 21.Horn button 22.Horn 23.Stop buttons 24.Low fuel warning light 25.Fuel gauge 26.S.I.S. Valve 27.Voltage regulator 28.Fuel level transmitter 29.Stop light filament 30.Starter button 31.Starter motor 32.Starter remote control switch 33.Fuse 34.Battery 35.Key switch contacts 36.Fuse 37.Magneto flywheel 38.Pick-Up ELE SYS - 55
Electrical system
Fly 50 4t 4v
Colours of the electrical cables: B = White, Bl = Blue, G = Yellow, Mr = Brown, N = Black, Gr = Grey, Rs = Pink, R = Red, Vi = Purple, V = Green
Components arrangement
ELE SYS - 56
Fly 50 4t 4v
Electrical system
1. Battery: to access open the front panel. 2. Diagnostic socket: to access open the front panel.
3. Fuses: remove the legshield to reach it. 4. Fuse for electronic starter device: remove the legshield to reach it. 5. Lights logic solenoid switch: remove the legshield to reach it. 6. Side stand solenoid switch: remove the legshield to reach it. 7. Horn; remove the legshield to reach it. 8. Main fuse: to access open the front panel.
9. Starter switch: remove the legshield to reach it. 10. Start-up solenoid: remove the legshield to reach it.
ELE SYS - 57
Electrical system
Fly 50 4t 4v
11. Electronic starter device: remove the front part of the front shield to access it. 12. Front left turn indicator: remove the legshield to reach it. 13. Front right turn indicator: remove the legshield to reach it.
15. Left stop switch: remove the front headlight to reach it. 16. Right stop switch: remove the front headlight to reach it.
17. Instrument panel connectors: remove the front headlight to reach it.
ELE SYS - 58
Fly 50 4t 4v
Electrical system
18. Horn button: remove the front headlight to reach it. 19. Turn indicators switch: remove the front headlight to reach it.
21. Engine stop switch: remove the front headlight to reach it. 22. Starter button: remove the front headlight to reach it.
23. Petrol pump: remove the footrest to reach it. 24. Fuel gauge: remove the footrest to reach it. 25. Connectors for fuel reserve indicator: remove the footrest to reach it.
ELE SYS - 59
Electrical system
Fly 50 4t 4v
26. HV coil: remove the helmet compartment to reach it. 27. Voltage regulator: remove the helmet compartment to reach it.
29. Stator connection: remove the spark plug access panel located under the saddle to reach it. 30. Spark plug: remove the spark plug access panel located under the saddle to reach it.
31. Automatic starter: remove the helmet compartment to reach it. 32. P.T.C.: remove the helmet compartment to reach it. 33. Engine temperature sensor: remove the helmet compartment to reach it.
ELE SYS - 60
Fly 50 4t 4v
Electrical system
35. S.I.S. Valve: remove the central cover to reach it. 36. Ambient temperature sensor: remove the central cover to reach it
37. Taillight: remove the rear light assembly to reach it. 38. Rear left turn indicator: remove the rear light assembly to reach it. 39. Rear right turn indicator: remove the rear light assembly to reach it.
40. License plate light: remove the helmet compartment to reach it.
ELE SYS - 61
Electrical system
Fly 50 4t 4v
Ground points
On the vehicle there is a chassis ground on the front side of the steering tube. Remove the legshield to reach it.
There is a ground point of the voltage regulator. Disassembly the helmet compartment to reach it.
ELE SYS - 62
Fly 50 4t 4v
Electrical system
ELE SYS - 63
Electrical system
Fly 50 4t 4v
9. Battery negative terminal connection 10. Positive battery pole connection 11. Main fuse 12.Diagnostics connection
ELE SYS - 64
Fly 50 4t 4v
Electrical system
13. Front left turn indicator 14. Front turn indicator connections 15. At the right turn indicator 16. Resistance 17. Electronic ignition device
ELE SYS - 65
Electrical system
Fly 50 4t 4v
18. Ignition switch 19. Horn 20. Lights logic and side stand solenoid switches 21. Service fuses
22. Front right turn indicator 23. Connection branches on tank, engine sensors and rear part ELE SYS - 66
Fly 50 4t 4v
Electrical system
24. Starter motor connection branch 25. Solenoid switches and fuses branch
ELE SYS - 67
Electrical system
Fly 50 4t 4v
28. Fuel gauge 29. Fuel reserve indicator connections 30. At the engine flywheel connection 31. Sensors connection on the engine branch 32. Rear part branch 33. Starter motor connection branch
ELE SYS - 68
Fly 50 4t 4v
Electrical system
Back side
1. High voltage coil connection
2. Voltage regulator 3. Ambient temperature sensor connection 4. S.I.S. valve connection ELE SYS - 69
Electrical system
Fly 50 4t 4v
7. Automatic starter 8. At the P.T.C. connection 9. At the engine temperature sensor connection
Fly 50 4t 4v
Electrical system
Conceptual diagrams
1. External temperature sensor 2. Front and rear brake light 3. Fuel reserve sensor 4. Starter motor 5. Start-up solenoid ELE SYS - 71
Electrical system
Fly 50 4t 4v
6. 12v-6Ah battery 7. 15a Fuse 8. Starter button 9. Low fuel warning light 12V - 1.7W 10. Instrument electronics 11. Horn 12. Horn button 13. Fuel gauge 14. Fuel level transmitter 15. 21W filament for brake light in bulb 12V - 5/21W 16. Side stand solenoid switch 17. Fuse 7.5A 18. Ignition switch contacts 19. Magneto flywheel 20. Voltage regulator 21. S.I.S. Valve 22. PTC 23. Side stand switch 24. HV coil 25. 2 12V - 1.7W bulbs for turn indicator warning lights 26. Turn indicators switch 27. 4 12V - 10W bulbs for turn indicators 28. On Off-lock 29. Engine stop switch 30. 5W filament for rear daylight running light in bulb 12V - 5/21W 31. License plate light bulb 12V - 5W 32. 1 bulb for instrument LCD back lighting 33. 3 bulbs for dashboard lighting 12V - 1.7W 34. 2 city light bulbs 12V - 5W 35. High-beam warning light 12V - 1.7W 36. Headlight bulb 12V - 35/35W 37. Light switch 38. Light relay 39. Automatic starter 40. NTC temperature sensor 41. Electronic ignition device 42. Fuse 10A 43. Diagnostics socket ELE SYS - 72
Fly 50 4t 4v
Electrical system
Ignition
Ignition 3. Fuel reserve sensor 6. 12v-6Ah battery 7. 15a Fuse 9. Low fuel warning light 12V - 1.7W 13. Fuel gauge 14. Fuel level transmitter 17. Fuse 7.5A 18. Ignition switch contacts Lights and turn indicators
ELE SYS - 73
Electrical system
Fly 50 4t 4v
Lights and turn indicators 2. Front and rear brake light 6. 12v-6Ah battery 7. 15a Fuse 15. 21W filament for brake light in bulb 12V - 5/21W 17. Fuse 7.5A 18. Ignition switch contacts 20. Voltage regulator 25. 2 12V - 1.7W bulbs for turn indicator warning lights 26. Turn indicators switch 27. 4 12V - 10W bulbs for turn indicators 30. 5W filament for rear daylight running light in bulb 12V - 5/21W 31. License plate light bulb 12V - 5W 32. 1 bulb for instrument LCD back lighting 33. 3 bulbs for dashboard lighting 12V - 1.7W 34. 2 city light bulbs 12V - 5W 35. High-beam warning light 12V - 1.7W 36. Headlight bulb 12V - 35/35W 37. Light switch 38. Light relay 41. Electronic ignition device Enabling buttons and level indicators 3. Fuel reserve sensor 6. 12v-6Ah battery ELE SYS - 74
Fly 50 4t 4v
Electrical system
7. 15a Fuse 9. Low fuel warning light 12V - 1.7W 13. Fuel gauge 14. Fuel level transmitter 17. Fuse 7.5A 18. Ignition switch contacts
Battery recharge and start up 2. Front and rear brake light 4. Starter motor ELE SYS - 75
Electrical system
Fly 50 4t 4v
5. Start-up solenoid 6. 12v-6Ah battery 7. 15a Fuse 8. Starter button 15. 21W filament for brake light in bulb 12V - 5/21W 16. Side stand solenoid switch 17. Fuse 7.5A 18. Ignition switch contacts 19. Magneto flywheel 20. Voltage regulator 23. Side stand switch 28. On Off-lock 29. Engine stop switch 41. Electronic ignition device 42. Fuse 10A Devices and accessories
Devices and accessories 1. External temperature sensor 6. 12v-6Ah battery 7. 15a Fuse 10. Instrument electronics 11. Horn 12. Horn button 17. Fuse 7.5A ELE SYS - 76
Fly 50 4t 4v
Electrical system
18. Ignition switch contacts 20. Voltage regulator 21. S.I.S. Valve 22. PTC 38. Light relay 39. Automatic starter 40. NTC temperature sensor 41. Electronic ignition device 42. Fuse 10A 43. Diagnostics socket
A = Odometer B = Speedometer C = Turn indicators D = High-beam warning light E = Headlight warning light F = Immobiliser LED G= Low fuel warning light H = Fuel gauge L = Digital clock
ELE SYS - 77
Electrical system
Fly 50 4t 4v
12V-1.7W 12V-1.7W
ELE SYS - 78
Fly 50 4t 4v
Electrical system
If the failure persists, check the generator and the stator components as follows: After visually checking the electrical connections, use a specific tester to measurement the stator winding and the pickup (see table). If any failure is found after checking the loading coil and the pick-up, replace the stator and the damaged parts. Disconnect the connector on the flywheel cover and measure the resistance between either contact and the earthing.
Specific tooling
020331Y Digital multimeter
PICK-UP CHECK
1 Specification 1) Green and ground cable Desc./Quantity ~ 170
Ignition circuit
All the control operations of the system that require the disconnection of cables (checks of the connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged.
No spark plug
Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure: - Check the Pick-Up. Disconnect the electronic starter connector and check continuity between terminal No. 3 (Green) and terminal No. 4 (Black). The check includes the Pick-Up and its power line. If a break in the circuit is found, check again the flywheel and the engine earth connectors. If non-
ELE SYS - 79
Electrical system
Fly 50 4t 4v
conforming values are measured, replace the Pick-Up; otherwise, repair the cable harness.
Electric characteristic
Pick - up resistance approx. 170 Ohm - HV primary coil check Disconnect the electronic starter connector and check continuity between terminal No. 3 (purple) and terminal No. 1 (black) (see figure). If non-conforming values are measured, check again the HV coil primary directly on the positive and negative terminals. If the values are correct, repair the cable harness or reset the connections; otherwise, replace the HV coil
Electric characteristic
HV coil primary resistance 0.5 0.6 Ohm - HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.
Electric characteristic
HV coil secondary resistance 3000 3600 Ohm
ELE SYS - 80
Fly 50 4t 4v
Electrical system
- Pick-Up Disconnect the ECU connector and connect the positive terminal to connector No. 3 (green) and the negative terminal to connector No. 4 (black). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up. Replace Pick-Up if non-conforming values are measured.
N.B. THE MULTIMETER MUST BE SELECTED TO DETECT CONTINUOUS VOLTAGE.
Electric characteristic
Pick-Up voltage value Pick-Up voltage value: > 2 Volt - H.V. coil With the electronic starter and the HV coil connected to the system, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor and by connecting the positive terminal to the ground lead and the negative terminal to the coil positive connector. If non-conforming values are measured, replace the control unit.
THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK.
Electric characteristic
High voltage coil voltage value High voltage coil voltage value: > 100 Volt
Stator check
- Using a tester, check the resistance between the brown-earth and black-earth terminal.
N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE LEADS TO VALUES HIGHER THAN THOSE STATED.
Electric characteristic
Stator : Brown-earth ~ 170 (Pick-Up) Stator : Black-earth
ELE SYS - 81
Electrical system
Fly 50 4t 4v
~ 1 (Stator)
Fly 50 4t 4v
Electrical system
- Voltage supplied at 2000 rpm must be about 25 35V. If no value is obtained even with this test, replace the regulator because it is obviously failing.
N.B. TO MEASURE THE ABOVE VOLTAGE USE AN ANALOGUE TESTER THAT CAN MEASURE ALTERNATING VOLTAGES AND KEEP THE ENGINE AT IDLE TO HAVE AN ALTERNATING VOLTAGE OF A FREQUENCY AS CLOSE AS POSSIBLE TO 50HZ SO AS TO DETECT THE EFFICIENT VOLTAGE VALUE SUPPLIED BY THE REGULATOR (ABOUT 12V).
ELE SYS - 83
Electrical system
Fly 50 4t 4v
Start the engine (temporarily connect the red cable to the battery positive terminal in order to avoid damaging the device that measures current). Check that there is a 13V voltage minimum (battery charged) and a recharge current of 1.5 2A with the lighting system but the starter disabled. To disable the lighting system, remove the light remote control. As the engine rpm increases, so do the current and the recharge voltage; with rpm over 4000 there must be a recharge current of about 4.5A; enabling both the lighting system and the starter, the stop light and if the horn is powered, current values 5A and a voltage value of 14 14.5V ( regulator threshold voltage) can be found. If values other than those above are detected, replace the regulator; contrariwise, check the cable harness and the connections.
Electric characteristic
Voltage regulator resistance ~ 8 M
ELE SYS - 84
Fly 50 4t 4v
Electrical system
- If the above tests have positive results, jump contacts 5 (blue/black) and 3 (white) on the connector, set the key switch to ON and turn the turn indicator switch to the left and right to see when the lights are steadily on (as they are directly powered by the battery). If even after this operation the turn indicators fail to turn on, check that the wiring is not damaged and the switch works properly. If these last two tests have a positive result, replace the regulator because it is certainly not functioning properly.
Specific tooling
020331Y Digital multimeter
Dry-charge battery
Where provided
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN Commissioning dry-charged batteries: 1) - Remove the short closed tube and the plugs, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1.26, corresponding to 30 B at a minimum temperature of 15C. until the upper level is reached. 2) - Leave to rest for at least 2 hours; then, restore the level with sulphuric acid. 3) - Within the following 24 hours, recharge using the specific battery charger (single) or (multiple) at a density of about 1/10 of the battery nominal capacity until fully charged; check that the acid den-
ELE SYS - 85
Electrical system
Fly 50 4t 4v
sity is about 27, corresponding to 31 Be, and that these values are stabilised. 4) - Once the charge is over, level the acid (by adding distilled water). Close and clean carefully. 5) Once the above operations have been performed, install the battery on the vehicle ensuring that it is wired up properly. 1 Hold the vertical tube 2 Look at the level 3 The float must be freed
WARNING - ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.
Specific tooling
020333Y Single battery charger 020334Y Multiple battery charger Battery maintenance The battery is an electrical device which requires careful monitoring and careful maintenance. The maintenance rules are: 1) Check the level of the electrolyte The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If water topping is required too often, check the vehicle electrical system: the battery works overcharged and is subject to quick wear. 2)Load status check After topping-up the electrolyte level, check its density using an appropriate densitometer (see figure). When the battery is charged, you should detect a density of 30 to 32 B corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15 C. A density reading of less than 20 B indicates that the battery is completely flat and it must therefore be recharged. If the vehicle is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign. 3) Recharging the battery ELE SYS - 86
Fly 50 4t 4v
Electrical system
Remove the battery from the vehicle removing the negative clamp first. Regular bench charging must be carried out with the specific battery charger, (single) or (multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connecting the corresponding poles (+ to+ and - to -). 4) Cleaning the battery The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. THE USE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VEHICLE OR EVEN CAUSE A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE. LACK OF PROPER CHARGING OF THE BATTERY BEFORE FIRST USE AT LOW ELECTROLYTE LEVEL, CAN LEAD TO PREMATURE BATTERY LIFE.
Specific tooling
020333Y Single battery charger 020334Y Multiple battery charger
Battery installation
Where provided VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN
ELE SYS - 87
Electrical system
Fly 50 4t 4v
1) Battery preparation Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.
2) Electrolyte preparation. Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulphuric acid.
3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow of electrolyte from pausing or stopping. 4) Control the flow of electrolyte Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times. Do not remove the container from the battery. 5) Take out the container. Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point. 6) Battery closing. Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery.
ELE SYS - 88
Fly 50 4t 4v
Electrical system
Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery. The filling process is now complete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. Place the battery down for 1 to 2 hours prior to the charging from the battery. 7) Recharging the new battery With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged. If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle. The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between 12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).
ELE SYS - 89
Electrical system
Fly 50 4t 4v
e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.
f - Check the ignition of the green LED indicated with a red arrow in figure.
g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place
h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
ELE SYS - 90
Fly 50 4t 4v
Electrical system
Connectors
ELECTRONIC STARTER CONNECTOR A 1. H.V. coil control (Black): 2. Engine stop command (Blue) 3. H.V. coil positive (Violet)
CONNECTOR B 1. Key positive (Orange-Black) 2. Starter power (White-Black) 3. Pick-Up Signal (Green) 4. Ground lead (Black) 5. Solenoid valve (Brown) 6. NTC temperature sensor signal (Yellow-Red) 7. Lights logic solenoid command (Light Blue) 8. Diagnostics socket (Red-Black) VOLTAGE REGULATOR 1. Lighting system power (alternating) (Yellow) 2. Ground lead (Black) 3. Battery positive (live) (Orange) 4. Flywheel power (alternating) (Blue) 5. Turn indicator power (Blue-Black)
ELE SYS - 91
Electrical system
Fly 50 4t 4v
INSTRUMENT PANEL CONNECTOR A 1. Left turn indicator warning light command (Pink) 2. Left turn indicator warning light command (White-Blue) 3. Instrument panel illumination bulb power (alternating) (Yellow-Black) 4. Instrument panel ground (Black) 5. Fuel level transmitter signal (White-Green) 6. Battery positive (live) (White) CONNECTOR B 1. instrument LCD backlight power (alternating) (Yellow-Blue) 2. High beam warning light command (alternating) (Violet) 3. Low fuel warning light command (Yellow-Green)
ELE SYS - 92
INDEX OF TOPICS
ENG VE
Fly 50 4t 4v
- Loosen the exhaust fixing screws to the crankcase, then remove the whole exhaust.
SUPPORT THE VEHICLE ADEQUATELY. - Disconnect the battery. - Remove the helmet compartment. - Remove the lower cover. - Slide the HV wire cap off the spark plug. - Remove the full muffler unit.
ENG VE - 94
Fly 50 4t 4v
- Remove the 3 screws of the rear brake transmission retainer brackets indicated in the picture. - Disconnect the rear brake transmission by unscrewing the adjuster screw.
- Remove the ground cable and the positive cable of the starter motor indicated in figure.
ENG VE - 95
Fly 50 4t 4v
- Remove the fuel supply pipe from the carburettor - Remove the carburettor vacuum pipe tap from the manifold. - Disconnect the fuel heater connector. - Remove the piping from the solenoid valve.
ENG VE - 96
Fly 50 4t 4v
- Disconnect the throttle control cable from the throttle body pulley, acting on the indicated adjuster screws.
- Undo the two fixing screws from the bracket with silent block to the frame. - Disconnect the return spring from the bracket.
ENG VE - 97
Fly 50 4t 4v
- Support the vehicle adequately (with a jack) and remove the shock absorber lower clamping.
- Unscrew and remove the nut in correspondence with the swinging arm fixing on the chassis side with that on the engine side.
- Remove the pin from the opposite side. - Remove the engine complete with engine side swinging arm.
See also
Lower cover Helmet bay Exhaust assy. Removal
ENG VE - 98
INDEX OF TOPICS
ENGINE
ENG
Engine
Fly 50 4t 4v
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- Remove the 12 fixing screws. - Remove the oil filling cap and then slide out the cover. If this operation is carried out directly on the vehicle, it is necessary to remove the transmission cooling coupling and the air filter housing retainers.
N.B. USE A MALLET ON THE APPROPRIATE COUPLINGS TO REMOVE THE COVER.
Kickstart
-To remove the start up pinion push the starter lever to facilitate extracting the pinion. -Remove the kick-start screw and lever. -Remove the Seeger ring and the washer indicated in the figure. -Pull out the toothed sector.
WARNING THE SECTOR KEEPS THE SPRING SET, BE CAREFUL SO AS NOT TO CAUSE ANY ACCIDENTS
Air duct
- To remove the intake throat on the transmission cover, just remove the three fixing screws indicated in the figure.
ENG - 100
Fly 50 4t 4v
Engine
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE COVER PAINTED SURFACE.
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 101
Engine
Fly 50 4t 4v
Characteristic
clutch housing diameter/standard value 107+0.2 +0 mm clutch housing diameter/max. value allowed after use 107.5 mm Eccentricity measured /max. 0.20 mm
- Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw by undoing spring of the driven pulley unit - Separate the components.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch
ENG - 102
Fly 50 4t 4v
Engine
Characteristic
Check minimum thickness 1 mm
- Remove the three guide pins and the mobile half pulley.
ENG - 103
Engine
Fly 50 4t 4v
Specific tooling
001467Y029 Bell for bearings, O.D. 38 mm - Remove the ball bearing retention snap ring. - Expel the ball bearing from the side of the clutch housing by means of the special tool.
N.B. PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVE BELT
Specific tooling
020376Y Adaptor handle 020363Y 20-mm guide
Characteristic
Stationary driven half-pulley/Standard diameter 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diameter admitted after use 33.96 mm
ENG - 104
Fly 50 4t 4v
Engine
Characteristic
Mobile driven half-pulley/ Maximum diameter allowed 34.08 mm - Check the belt contact surfaces. - Insert the new oil seal and O-rings on the mobile half-pulley. - Fitting the half-pulley on the bushing.
Recommended products
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide. - Make sure the pins and collar are not worn, reassemble the pins and collar. - Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.
Recommended products
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide. -
Specific tooling
020376Y Adaptor handle
ENG - 105
Engine
Fly 50 4t 4v
020456Y 24-mm adaptor 020362Y 12 mm guide 020171Y Punch for 17 mm roller bearing
Characteristic
Standard length 118 mm Minimum length allowed after use XXXX - Check the thickness of the clutch mass friction material. -The masses must not show traces of lubricants; otherwise, check the driven pulley unit.
N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Minimum thickness permitted: 1 mm
ENG - 106
Fly 50 4t 4v
Engine
- Reassemble the nut securing the clutch and tighten to the prescribed torque.
CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCKET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE NUT IN CONTACT WITH THE CLUTCH
Specific tooling
020565Y Flywheel lock calliper spanner
Drive-belt
- Make sure the drive belt is not damaged and does not have cracks in the toothed grooves. - Check the width of the belt.
Characteristic
Transmission belt/Minimum width 17.5 mm
ENG - 107
Engine
Fly 50 4t 4v
- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.
Specific tooling
020451Y Starting ring gear lock
Characteristic
Driving pulley / Maximum diameter: ENG - 108
Fly 50 4t 4v
Engine
20.12 mm Driving pulley/ Standard diameter: 20.021 mm Driving pulley bushing/ Diameter maximum: XXX mm Driving pulley bushing/ Standard diameter: 20 -0.020/-0.041mm
- Refit the components of the assembly (roller housing assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive, washer and nut). - With the specific tool, tighten the lock nut to 20 Nm and then perform a final 90 locking in order to prevent the rotation of the driving pulley.
N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UTMOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN ORDER TO AVOID WRONG TIGHTENING AND CONSEQUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling
020451Y Starting ring gear lock
ENG - 109
Engine
Fly 50 4t 4v
Recommended products
AGIP GREASE MU3 Yellow-brown, lithiumbase, medium-fibre multipurpose grease. ISO L-X-BCHA 3 - DIN 51 825 K3K -20 - Insert the pinion in its seating by pushing the starter lever. - Fit the intake throat and tighten the 3 screws. -Make sure the oil sump presents centring dowels and sealing gaskets. - Replace the cover tightening the 12 screws to the prescribed torque. -Refit the oil filling cap.
End gear
ENG - 110
Fly 50 4t 4v
Engine
See also
Refitting the clutch
Specific tooling
020363Y 20-mm guide 020376Y Adaptor handle 020358Y 37x40-mm Adaptor
ENG - 111
Engine
Fly 50 4t 4v
Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft - Position the special tube on the internal raceway of the bearing and from the shaft toothed side as indicated in the figure. Expel the driven pulley shaft with the aid of a press.
Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft
ENG - 112
Fly 50 4t 4v
Engine
Specific tooling
020452Y Tube for removing and refitting the driven pulley shaft Heat the hub cover and insert the bearing with the specific punch. Fit the snap ring with the concave or radial part on the bearing side.
N.B. FIT THE BALL BEARING WITH THE SHIELD FACING THE OIL SEAL.
Specific tooling
020151Y Air heater 020376Y Adaptor handle 020439Y 17-mm guide 020358Y 37x40-mm Adaptor
Specific tooling
020151Y Air heater 020376Y Adaptor handle 020363Y 20-mm guide 020359Y 42x47-mm Adaptor
ENG - 113
Engine
Fly 50 4t 4v
ENG - 114
Fly 50 4t 4v
Engine
Cooling fan
- Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.
ENG - 115
Engine
Fly 50 4t 4v
ENG - 116
Fly 50 4t 4v
Engine
Specific tooling
020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor
ENG - 117
Engine
Fly 50 4t 4v
Intermediate gear
- Check that the keying toothing on the crown and the starter motor are in good conditions. - Check that the Bendix opens and returns adequately.
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 118
Fly 50 4t 4v
Engine
ENG - 119
Engine
Fly 50 4t 4v
- Remove the driving pulley - Remove the oil pump chain - Remove the tappet cover - Remove the central screw and the belleville washer indicated in the figure and lock the camshaft crown with the specific tool.
N.B. TO FACILITATE REMOVING THE HEAD COMPONENTS, SET THE CRANKSHAFT TO THE TIMING POINT (TDC OF THE COMPRESSION END).
Specific tooling
020565Y Flywheel lock calliper spanner - Remove the camshaft control pulley and the washer below. - Remove the pinion of the crankshaft timing control - To remove the chain lower guiding pad, remove the head by pulling it upwards
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE DIRECTION OF ROTATION IS MAINTAINED.
See also
Removing the rocker-arms cover Removal Removing the driving pulley ENG - 120
Fly 50 4t 4v
Engine
- Remove the entire camshaft with bearing using the specific tool shown in the figure. - Take out the camshaft bearing with the aid of the specific tool, being careful to mount a screw on the camshaft in order to protect its thread.
N.B. IF A BEARING SEPARATES FROM THE CAMSHAFT, IT IS ESSENTIAL TO FIT A NEW BEAR.
Specific tooling
020450Y Camshaft fitting/removal tool 004499Y Camshaft bearing extractor 004499Y001 Bearing extractor bell 004499Y002 Bearing extractor screw 004499Y006 Bearing extractor ring 004499Y027 Bearing extractor part
ENG - 121
Engine
Fly 50 4t 4v
Specific tooling
020431Y Valve oil seal extractor 020382Y Valve cotters equipped with part 012 removal tool
ENG - 122
Fly 50 4t 4v
Engine
- Remove the two stop rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston.
N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.
Characteristic
Max. diameter admitted: check the small end 13.030 mm Standard diameter: check the small end 13 +0.025+0.015mm
ENG - 123
Engine
Fly 50 4t 4v
Characteristic
Standard diameter: gudgeon pin 13 -0 -0.004mm Minimum admissible diameter gudgeon pin 12.990 mm
Characteristic
Pin seat diameter 13 +0.005 + 0.010 mm
- Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
N.B. MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE SECOND SEAL RING SIDE.
Fitting clearance
Top piston ring - standard coupling clearance 0.03 to 0.065 mm Top piston ring - maximum clearance allowed after use 0.07 mm Middle piston ring - standard coupling clearance 0.02 to 0.055 mm Middle piston ring - maximum clearance allowed after use 0.06 mm oil scraper ring - standard coupling clearance 0.04 to 0.16 mm oil scraper ring - maximum clearance allowed after use
0.17 mm
ENG - 124
Fly 50 4t 4v
Engine
Characteristic
Maximum allowable run-out: 0.001 over 0.05 mm
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
ENG - 125
Engine
Fly 50 4t 4v
SEALING RINGS
Name 1st Compression ring 2nd Compression ring Oil scraper ring 1st Compression ring 1st Oversize 2nd Compression ring 1st Oversize Oil scraper ring 1st Oversize 1st Compression ring 2nd Oversize 2nd Compression ring 2nd Oversize Oil scraper ring 2nd Oversize 1st Compression ring 3rd Oversize 2nd Compression ring 3rd Oversize Oil scraper ring 3rd Oversize Description Dimensions 39 x 1 39 x 1 39 x 2 39.2 x 1 39.2 x 1 39.2 x 2 39.4 x 1 39.4 x 1 39.4 x 2 39.6 x 1 39.6 x 1 39.6 x 2 Initials A A A A A A A A A A A A Quantity 0.08 to 0.20 0.05 to 0.20 0.20 to 0.70 0.08 to 0.20 0.05 to 0.20 0.20 to 0.70 0.08 to 0.20 0.05 to 0.20 0.20 to 0.70 0.08 to 0.20 0.05 to 0.20 0.20 to 0.70
Specific tooling
020448Y Pin lock fitting tool
ENG - 126
Fly 50 4t 4v
Engine
- With the opening in the position indicated on the tool, set the lock ring into position in the tool with the punch. - Rest the tool on the piston paying attention that the 90chamfered side faces upwards as indicated in the figure. - Fit the gudgeon pin stop using the plug.
CAUTION USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING.
ENG - 127
Engine
Fly 50 4t 4v
Specific tooling
020288Y Fork to assemble piston on cylinder If the four cylinder stud bolts should be replaced in this kind of engine, it is necessary to tighten the head nuts strictly following the procedure below. The procedure is different from that indicated in the vehicle manuals: Head tightening nut (only to replace stud bolts) 67 N*m + 135 + 90 The 45 rotation reduction of the key is necessary to avoid stud bolt stretching.
Characteristic
Maximum allowable run-out: 0.1 mm
ENG - 128
Fly 50 4t 4v
Engine
Measure the camshaft bearing seats and rocking lever support pins with a bore meter
HEAD CHECK
Specification Standard diameter (mm) A Standard diameter (mm) B Standard diameter (mm) C Desc./Quantity 32.015 to 32.025 16.0 to 16.018 11.0 to 11.018
ENG - 129
Engine
Fly 50 4t 4v
Characteristic
Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45 milling cutter and then grind. - In case of excessive wear or damage, replace the head. - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
ENG - 130
Fly 50 4t 4v
Engine
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
STANDARD DIAMETER
Specification Intake Exhaust Desc./Quantity 3.970 to 3.985 mm 3.960 to 3.975 mm
- Calculate the clearance between valve and valve guide. - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the V shaped support.
Characteristic
Admissible limit: 0.03 mm
- Check the deviation of the valve stem by resting it on a V shaped support and measuring the extent of the deformation using a dial gauge.
Characteristic
Limit values admitted: 0.1 mm
ENG - 131
Engine
Fly 50 4t 4v
- After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem.
INTAKE
Specification Standard clearance Admissible limit Desc./Quantity 0.015 to 0.042 mm 0.06 mm
EXHAUST
Specification Standard clearance Admissible limit Desc./Quantity 0.025 - 0.052 mm 0.07 mm
ENG - 132
Fly 50 4t 4v
Engine
- Fit the valves, the springs and the upper caps. - Using the appropriate tool, compress the springs and insert the cotters in their seats.
Characteristic
Standard diameter - Bearing A: 12 +0.002 +0.010
mm Standard
diameter - Bearing B:
16-0.015 -0.023 mm Minimum diameter allowed - Bearing A: 11.98 mm Minimum diameter allowed - Bearing B: 15.96 mm - Using a gauge, measure the height of the cams. Check the axial clearance of the camshaft
ENG - 133
Engine
Fly 50 4t 4v
- If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
N.B. A BALL BEARING IS FITTED ON BEARING A; CONSEQUENTLY, BEARING B IS THE MOST IMPORTANT AS IT WORKS DIRECTLY ON THE HEAD ALUMINIUM
Characteristic
Standard height - Inlet 24.397 mm Standard height - Outlet 23.996 mm
Fitting clearance
Maximum admissible axial clearance: 0.5 mm
- Measure the outside diameter of the rocking lever pins - Check the rocking lever pins do not show signs of wear or scoring. - Measure the internal diameter of each rocker. - Check that the pad in contact with the cam is not worn.
Fly 50 4t 4v
Engine
- Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque.
Specific tooling
020450Y Camshaft fitting/removal tool - Fit pins, inlet rocking lever and discharge rocking lever. - Lubricate the 2 rocking levers through the holes.
N.B. IF A BEARING SEPARATES FROM THE CAMSHAFT, IT IS ESSENTIAL TO FIT A NEW BEARING.
- Screw up the limit screw of the rocking lever pins and tighten it to the prescribed torque. - Reposition the Seeger ring retaining the camshaft
- Finish the head tightening following the procedure below: screw the four head nuts to an initial torque at two crossed passes. Afterwards tighten the nuts with 2 turns of 90 each to be done at two crossed passes. -Finish the tightening of the head to the crankcase with the 2 side screws.
N.B. SHOULD THE CRANKCASE OR THE CYLINDER STUD BOLTS BE REPLACED, IT IS NECESSARY TO CARRY OUT AN INITIAL TIGHTENING PLUS OTHER 3 TURNS OF 90 EACH AT 3 CROSSED PASSES
ENG - 135
Engine
Fly 50 4t 4v
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 136
Fly 50 4t 4v
Engine
Camshaft pulley screw 12 - 14 Head cover screw 8 to 10 Nm - Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque. - Insert the spring with the central screw and tighten it to the prescribed torque. - Fit the spark plug.
Electric characteristic
Electrode gap: 0,6 mm Spark plug NGK ER9EH-6N
ENG - 137
Engine
Fly 50 4t 4v
Crankcase - crankshaft
- First remove the following units: Driving pulley Driven pulley Final reduction greasing Oil pump Flywheel with stator Cylinder-piston-head unit Starter motor with cables.
See also
Removing the driving pulley Removal Removing the driven pulley Removing the cylinder - piston assy. Removing the starter motor Removing the stator
THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT. DO NOT WASH WITH SOLVENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT. A CENTRIFUGAL OIL FILTER'S LIFE IS THE SAME AS THE ENGINE'S AND IS MAINTENANCE FREE. - Check the axial clearance on the connecting rod.
Fitting clearance
0.30 mm Max.
Standard connecting rod axial clearance 0.15 to connecting rod clearance 0.5 mm
ENG - 138
Fly 50 4t 4v
Engine
- Check the correct radial clearance of the connecting rod by holding the driving shaft with your hands and, with a dial gauge fitted to the rod small end, measuring the clearance, move the connecting rod vertically as shown in the figure.
Fitting clearance
Connecting rod radial - standard clearance 0.006 to 0.018 mm Connecting rod max. - radial clearance 0.25 mm - Check that the half shaft surfaces are not scored and with the aid of a gauge check the driving shaft width as indicated in the figure.
Characteristic
Standard measure 45 mm
Specific tooling
004499Y Camshaft bearing extractor 004499Y001 Bearing extractor bell 004499Y002 Bearing extractor screw 004499Y006 Bearing extractor ring 004499Y034 Bearing extractor part
ENG - 139
Engine
Fly 50 4t 4v
-Insert the bearing in the crankcase; if needed, use a mallet but do so with extreme care so as not to damage the engine crankcase limit stop.
Specific tooling
020359Y 42x47-mm Adaptor 020364Y 25-mm guide 020376Y Adaptor handle 020360Y 52x55-mm Adaptor - Heat a new main bearing in an oil bath at 120. - Place the driving shaft on the support base and insert the bearing with the aid of an adequate piece of tube if necessary.
N.B. USE A NEW BEARING WHEN REFITTING WARNING THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT. DO NOT WASH WITH SOLVENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT.
Specific tooling
020265Y Bearing fitting base 008119Y009 Tube to assemble shafts and axles
Characteristic
Off-line maximum admitted - A 0.15 mm Off-line maximum admitted - B 0.02 mm Off-line maximum admitted - C 0.02 mm
ENG - 140
Fly 50 4t 4v
Engine
Off-line maximum admitted - D 0.10 mm - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order. - In case of failures, replace the crankshaft.
Specific tooling
020074Y Support base for checking crankshaft alignment
- Fit the gasket recommended for surfaces on the half casing on the transmission side after greasing the two faying surfaces carefully. -Insert the flywheel half casing. - Fit the 10 screws and tighten them to the prescribed torque.
N.B. WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.
Recommended products
Loctite 510 Liquid sealant Gasket
ENG - 141
Engine
Fly 50 4t 4v
- Fit a new O-Ring on the mesh oil filter and on the filling cap; lubricate the rings. - Insert the filter on the engine and lock the cap to the prescribed torque.
- Check that the chain contrast pad is not worn. -Otherwise, replace the pad or fit it inverted to make it work on the other side. - Any operation on the chain cover oil seal should be carried out placing the cover on the workbench on the covering plate side of the oil pump chain. -Remove the oil seal with a tube section of 30 mm in diameter ( 32 mm Max).
ENG - 142
Fly 50 4t 4v
Engine
Refitting
- Apply engine oil on the oil seal and it seating on the crankcase. - From the outside and using the specific punch, place the oil seal fully down until it reaches the bottom of the seating in the crankcase.
N.B. FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEAL.
- Fit a new oil seal on the outer rim with the help of the specific tools below. - Fit a new O-ring and lubricate it with grease. - Install the cover on the engine crankcase, insert the three screws and place the cover in its position. - Tighten the 3 screws to the prescribed torque.
Specific tooling
020376Y Adaptor handle 020358Y 37x40-mm Adaptor
ENG - 143
Engine
Fly 50 4t 4v
- Undo the 2 clamping screws in the figure and remove the cover over the pump control crown gear. - Block the rotation of the oil pump control gear with a screwdriver inserted through one of its pump holes.
- Remove the central screw and the belleville washer - Remove the chain with the crown gear. - Remove the crankshaft control pinion. - Remove the oil pump by undoing the 2 screws indicated in the figure. - Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover. - Remove the clip retaining the innermost rotor. - Remove and wash the rotors thoroughly with a degreasing solvent and compressed air. - Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the clip.
- Measure distance between rotors (inner rotor/ outer rotor) with a thickness gauge in the position shown in the picture.
Characteristic
Admissible maximum clearance 1 0.15 mm
ENG - 144
Fly 50 4t 4v
Engine
Measure the distance between the outer rotor and the pump body (see figure).
Characteristic
Admissible maximum clearance 2 0.20 mm
- Check the axial clearance of the rotors using a trued bar as reference as shown in the figure.
N.B. MAKE SURE THE TRUED BAR IS POSITIONED PROPERLY ON THE TWO POINTS ON THE PUMP BODY.
Characteristic
Admissible maximum clearance 3 0.09 mm
Refitting
- Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the assembly. - Fit the cover on the pump being careful to align the holes (2 on the cover and 2 on the pump body) fixing the oil pump on the crankcase. - Fit the oil pump on the crankcase by tightening the two screws to the prescribed torque. - Fit the pulley on the pump, the central screw to the specified torque and the belleville washer. - Check that there is no seizing and/or friction during the pulley rotation.
N.B. FIT THE CUP WASHER SO THAT ITS OUTER (CURVED) RIM TOUCHES THE PULLEY.
ENG - 145
Engine
Fly 50 4t 4v
Fuel supply
- Disconnect the fuel supply and the suction taking pipe from the carburettor. - Check that there are no fuel leaks between the two tubes. - Close the fuel outlet pipe. - By means of the MITYVAC pump apply 0.1 bar of suction to the tap. - Make sure that the suction is kept stable and that and that there are no fuel leaks. - Reconnect the vacuum pipe to the manifold. - Position the fuel pipe with the outlet at the point of the tap. ENG - 146
Fly 50 4t 4v
Engine
- Turn the engine by using the starter motor for five seconds with the carburettor at minimum. - Take up the fuel by means of a graded burette.
N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCORRECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUTLET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUCTION PULSATION AND THEREBY GUARANTEE A CONSTANT TAP FLOW RATE.
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Characteristic
Minimum flow rate 20 cc
- Completely empty the fuel tank. - Remove the petrol delivery pipe and the lowpressure pipe. - Loosen the clip and remove the cock. - Clean the tank and the filter of the cock with a specific solvent. - Refit the cock making sure that there is an ORing. - Turn the cock to the direction it had before it was removed and block the clip.
N.B. THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING.
Engine
Fly 50 4t 4v
- Remove the protection, the bracket and the starter undoing the screw shown in the figure.
CAUTION THE CARBURETTOR FEATURES AN ANTI-VIBRATION RUBBER BUFFER FITTED ON THE LOWER SUPPLEMENT OF THE ACCELERATING PUMP BODY. UPON REFITTING THE CARBURETTOR ON THE ENGINE, MAKE SURE THIS BUFFER IS PRESENT SO THAT THE PETROL IN THE TANK DOES NOT EMULSIFY.
- Remove the 2 fixing screws indicated in the figure, the vacuum chamber cover and the spring. - Remove the vacuum valve together with the diaphragm; the pin, the spring and its plastic guide.
WARNING DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
- Remove the 3 fixing screws and the chamber with the gasket.
- Remove the chamber components following the procedure below. - Undo the 2 screws fixing the intake pump diaphragm cover.
ENG - 148
Fly 50 4t 4v
Engine
- Remove the cover being careful with the spring below, then remove the spring, take out the rubber protection and the diaphragm together with the pipe O-Ring.
-Remove the accelerating pump jet together with the ball spring.
- Remove the screw indicated in the figure fixing the float pin. - Remove the float and the plunger.
-Remove the maximum nozzle. -Remove diffuser. -Remove the minimum nozzle.
ENG - 149
Engine
Fly 50 4t 4v
- Remove the idle flow screw with the O-ring and the spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PIN SEATING, STARTER NOZZLE, THROTTLE VALVE CONTROL VALVE SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS ARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT.
ENG - 150
Fly 50 4t 4v
Engine
- For the minimum circuit, make sure the following points are properly cleaned: air gauging, exhaust section controlled by flow screw, progression holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly. The acceleration nozzle outlet is extremely small and is oriented to the throttle valve.
- Check that the carburettor body has the closing ball for the idle circuit pipe. - Check that the coupling surfaces, the chamber 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.
N.B.
ENG - 151
Engine
Fly 50 4t 4v
- Wash and blow the minimum nozzle properly and reassemble it.
- Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindrical part directed to the diffuser. - Fit the diffuser. -Assemble the maximum nozzle. - Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock absorber pin and the return clamp. - Replace the rod if worn out. - Check that the float is not worn on the pin housing or on the contact plate with the rod and that there are no fuel infiltrations. - Replace it in case of failures. - Fit the float together with the pin and rod in its position and lock it with its screw.
N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
- Insert the ball in the corresponding accelerating pump. - Fit the spring. - Fit the accelerating pump nozzle.
WARNING WHEN REFITTING, PAY SPECIAL ATTENTION TO THE COMPONENTS AS THEY ARE SMALL.
ENG - 152
Fly 50 4t 4v
Engine
- Check the diaphragm is in good conditions and remove the remaining components of the accelerating pump following these steps: - Insert the O-Ring in the pipe. - Insert the diaphragm together with the pin and its spring.
N.B. REPLACE THE DIAPHRAGM IF THERE ARE SIGNS OF UNDULATIONS, CRACKS OR HARDENING.
- Fit the accelerating pump diaphragm cover and tighten the 2 fixing screws making sure the spring below is correctly positioned. - Fit the rubber bellows protecting the pin in the upper part of the accelerating pump.
Level check
- Tilt the carburettor so that the needle valve at the fuel supply is closed and the float weight does not affect it. - Check that the diaphragm closing line and the float central line are parallel as shown in the figure.
- Blow air in to the tank and then assembly it and its gasket on the carburettor body with the 3 fixing screws.
N.B. -ALWAYS USE NEW RINGS AND GASKETS FOR REFITTING. WARNING THE SCREW IN THE TANK BOTTOM IS A BLEEDING ONE AND CONSEQUENTLY IT ONLY REQUIRES CLEANING.
ENG - 153
Engine
Fly 50 4t 4v
- Insert the diaphragm into the throttle valve. - Insert the tapered pin together with the plastic support and the contrast spring into the throttle valve.
N.B. PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH FACING THE INNER SIDE OF THE MEMBRANE TO BE ABLE TO FIT THE LOWER END OF THE THROTTLE VALVE SPRING.
- Fit the vacuum chamber cover with the 2 fixing screws paying special attention to the spring.
Characteristic
Protrusion value 11.5 mm ambient temperature 24 C
ENG - 154
Fly 50 4t 4v
Engine
- The starter should disconnect progressively by means of electric heating. - Check the starter resistance when adjusted to the ambient temperature.
Characteristic
ambient temperature 24 C
Electric characteristic
Automatic starter resistance 20 5 % - Use battery to power the automatic starter and check that piston protrudes as much as possible. - The correct warm up time depends on the ambient temperature. - If protrusion, resistance or timing values are different from the ones prescribed, replace the starter.
Characteristic
Battery 12V-9Ah max. protrusion 15 mm max. time 15 min - Fit the starter, the support bracket and the protection with the screw indicated in the figure.
ENG - 155
Engine
Fly 50 4t 4v
- Insert rubber pipes for chamber ventilation. - Insert the O-Ring, the washer, the spring and the idle flow screw in their seats.
- Refit the carburettor on the engine and connect again the accelerator cable with the sheath and the support plate and the electrical connection of the starter. - Reconnect the fuel supply pipe and tighten the 2 clamping screw fixing the carburettor to the inlet manifold and the air inlet coupling to the filter.
Specific tooling
020331Y Digital multimeter
ENG - 156
Fly 50 4t 4v
Engine
- Using the rpm indicator in the analyser or a separate one, adjust the idle screw.
N.B. THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED.
Specific tooling
020332Y Digital rpm indicator
Characteristic
Idle speed about 1900/2000 rpm
ENG - 157
INDEX OF TOPICS
SUSPENSIONS
SUSP
Fly 50 4t 4v
Suspensions
SUSP - 159
Suspensions
Fly 50 4t 4v
- Remove the internal spacer - Use appropriate handle, adaptor and guide and hit with a mallet to extract the bearing and the spacer bushing on the brake disc side; insert handle on the side the rpm indicator detects movement, as shown in the photo
- Check that the bearings do not show flaws or jamming. If it is, replace the coupling - Check that the internal spacer does not show abnormal wear. If it is, replace the coupling - With a hot air gun heat the seat of the bearing on the brake calliper side - With an appropriate tool remove the bearing on the brake disc side - Insert the spacer bushing on the brake disc side
- With a hot air gun heat the seat of the bearing on the side the rpm indicator detects movement - Insert the internal spacer with the centring ring facing to the brake disc side, as shown in the photo - Use an appropriate tool to insert the bearing on the side the rpm indicator detects movement
Specific tooling
001467Y009 Bell for OD 42-mm bearings 001467Y014 Pliers to extract 15-mm bearings 020357Y 32x35-mm Adaptor 020376Y Adaptor handle 020412Y 15-mm guide 020456Y 24-mm adaptor SUSP - 160
Fly 50 4t 4v
Suspensions
- Insert the wheel axle after greasing it from the brake disc opposite side, centring the retainer on the fork leg onto the projecting parts of the odometer drive. - Make the fork travel to adjust the fork legs on the wheel axle. - Holding the wheel axle, lock the nut on the opposite side to the specified torque. - Tighten the two safety screw on the fork leg to the specified torque.
Handlebar
SUSP - 161
Suspensions
Fly 50 4t 4v
Removal
- Remove the front and rear handlebar covers. - Detach the front brake pump from the handlebar. - Disconnect the rear brake, throttle control and odometer control cables. - Remove the screw fixing the handlebar to the steering tube. - Remove the handlebar.
N.B. IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING, TILT THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS.
See also
Front handlebar cover Rear handlebar cover Front brake pump Rear drum brake
Refitting
- Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on the handlebar with that on the steering tube as shown in the figure. - Tighten the handlebar fixing screw on the steering tube to the specified torque. - Lubricate the nut with engine oil before installation.
Fly 50 4t 4v
Suspensions
Remove the front mudguard. Remove the upper fifth wheel using a wrench for the steering fifth wheel ring nut. Lower the fork and the front mudguard.
See also
Front handlebar cover Rear handlebar cover Handlebar Front brake calliper Removing the front wheel Front mudguard
Overhaul
Sostituzione anello di tenuta e smontaggio stelo - Remove the wheel axle. - Remove the lower screw (1). - Discharge the oil in the suspension. - Remove the stem. - Replace the sealing rings (3-4) with new ones. - Insert the new sealing rings only after lubricating their grooves. - Refit the stem and the lower screw (1). - Remove the upper screw (2). - Add 30 cm 1 oil (SAE 20W fork oil). - Refit all components.
Refitting
To refit the fork, carry out the removal operations but in reverse order, observing the prescribed tightening torques of the steering fifth wheels.
Steering column
SUSP - 163
Suspensions
Fly 50 4t 4v
Removal
- Position the vehicle on the centre stand. - Set a support under the vehicle in such a way that the wheel is able to move freely and the vehicle does not fall. - Remove the handlebar. - Remove the front brake calliper. - Free the fork from the odometer cable and the front brake calliper pipe. - Loosen the upper ring nut 1 and collect the shim washer 2.
Specific tooling
020055Y Wrench for steering tube ring nut
SUSP - 164
Fly 50 4t 4v
Suspensions
- Remove the upper ring (or lower ring nut) 3 of the upper bearing A. - Slide the fork and collect the cage with the balls 4 of the upper bearing A.
When the specified torque of the lower ring nut is reached, loosen by 90.
See also
Removal Removal - Remove the balls retainer 7 of the lower bearing B from the steering tube.
- Wash carefully all the parts removed. - To refit, carry out the removal operations but in reverse order. - Appropriately lubricate the bearings with recommended products.
SUSP - 165
Suspensions
Fly 50 4t 4v
BEARING SEAT REPLACEMENT ON CHASSIS - Only remove the seats if it is strictly necessary. - Using the special tool remove the upper bearing A seat 5 by putting the special tool into the lower part of the headstock as indicated in the figure. - Levering with a screwdriver between the bearing seat and the headstock, remove the lower seat 6 of the lower steering bearing B.
Specific tooling
020004Y Punch for removing fifth wheels from headstock
- Using the special tool, refit the upper A and lower B bearing seats on the headstock.
Specific tooling
001330Y Tool for fitting steering seats
LOWER BEARING SEAT REPLACEMENT ON FORK Check the condition of the lower bearing B seat 8 on the fork (steering tube). Replace if there are faults. - Support the fork properly. - Using the special tool, remove the seat 8 on the steering tube as shown in the photograph by applying small mallet blows.
Specific tooling
020004Y Punch for removing fifth wheels from headstock
SUSP - 166
Fly 50 4t 4v
Suspensions
Always use a new seat on refitting. - Using the special tool, refit the seat 8 with the aid of a few mallet blows and bring it as far as the stop shown in the photo.
Specific tooling
006029Y Punch for fitting fifth steering bearing on steering tube
Steering bearing
CHECKING THE BEARINGS CLEARANCE To check the steering, it is necessary to: - Position the vehicle on the centre stand. - Place a support under the motorcycle in such a way that the front wheel is able to move freely and the vehicle does not fall. When carrying out this operation, pay attention not to mistake the centre stand clearance with that of the steering. Repeat this test many times before deciding if the steering clearance must be adjusted. - Hold the fork sleeves and pull the fork forwards and backwards, with the steering in forward position. - There should be no clearance forward or backward If there is clearance, the steering must be adjusted. ADJUSTING THE BEARING CLEARANCE - Remove the handlebar. - Loosen the upper ring nut 1 using the specific wrench. - Screw in the lower ring nut 3 until the bearing clearance is totally eliminated.
CAUTION DO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT 3 BECAUSE THE STEERING BEARINGS COULD GET DAMAGED.
- Check clearance as described above. Make sure the front fork can move all long its stroke, from left to right or vice versa, rotating freely and smoothly. - Keep the lower ring nut 3 in position, by using a specific wrench and tighten the upper ring nut 1 to the specified torque. Check again the bearings clearance.
Specific tooling
020055Y Wrench for steering tube ring nut
See also
SUSP - 167
Suspensions
Fly 50 4t 4v
Handlebar
See also
Exhaust assy. Removal - Pull the rear brake and keep it pulled with a clamp. - Unscrew the wheel fixing nut and collect the washer. - Take out the wheel from its housing.
- To refit, carry out the removal operations but in reverse order, be careful to use a new cotter pin.
Swing-arm
SUSP - 168
Fly 50 4t 4v
Suspensions
Removal
- Remove the engine with the engine side swinging arm as described in the "Engine disassembly from the vehicle" section. - Remove the lower spoiler. - Disconnect the chassis side swinging arm from the chassis by unscrewing and removing the nut indicated and removing the pin from the opposite side. - Remove the chassis-side swinging arm. - Operating on the engine side swinging arm, remove the aesthetic cover and the seeger ring indicated in the photo. - Remove the plate with the silent block. - Unscrew the nut on the right-hand side of the engine and slide the pin from the opposite side.
- Unscrew the two clamps and remove the bracket. - To remove the silent block from the bracket, please use the specific tool.
Specific tooling
020271Y Tool for removing-fitting silent bloc
See also
Removal of the engine from the vehicle spoiler
SUSP - 169
Suspensions
Fly 50 4t 4v
Overhaul
Regularly check the clearance of the swinging arm retainer pins. To carry out these operations, proceed as follows: - Position the vehicle on the centre stand. - Hold the rear wheel firmly and try to move it perpendicularly to the travel direction. - If there is any clearance, check all the fastening elements that connect the swinging arm to the engine and chassis as well as the condition of the silent block. - Grease the points indicated in the drawing during the refit.
Shock absorbers
SUSP - 170
Fly 50 4t 4v
Suspensions
Removal
- Adequately support the rear part of the vehicle. - Remove the side fairings. - Unscrew the upper nut fastening the chassis. - Remove the washer.
- Unscrew the lower fixing pin to the transmission crankcase. - Remove the shock absorber from the pads on the chassis.
Refitting
- Before refitting, check the condition of the rubber buffers: if they are deformed or show obvious signs of wear and/or breakage, replace. - To refit, follow the steps described for removal but in reverse order; be careful to tighten to the prescribed torques.
SUSP - 171
Suspensions
Fly 50 4t 4v
Centre-stand
REMOVAL - Use a jack to support the vehicle properly. - Remove the two return springs from the centre stand. - Undo the nut shown in the figure. - Remove the pin from the right side. - Remove the centre stand. FITTING - On refitting tighten the nut to the specified torque.
Side stand
Removal of the side stand - Unhook the springs. - Unscrew the nut. - Undo and remove the screw indicated. Fitting Carry out the previous operations but in reverse order.
SUSP - 172
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
Fly 50 4t 4v
Refitting
- Refit the calliper on the support and tighten the screws to the specified torque. - Refit the tube complete with fitting with new copper gaskets. - Place the tube joint in the original position and tighten it to the specified torque. - Bleed the air from the system.
Fly 50 4t 4v
Braking system
See also
Removing the front wheel
Refitting
When refitting, position the disc correctly making sure that it rotates in the direction indicated on the disc itself.
Recommended products
Loctite 243 Medium-strength threadlock Medium Loctite 243 threadlock
Disc Inspection
- Check the thickness of the disc (value indicated on the disc itself).
Characteristic
Disc minimum thickness: 3.5 mm
Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm.
If a value other than that prescribed is detected, remove the front wheel and check how much the disc protrudes. Maximum permissible out of true is 0.1 mm. If the value measured is greater, fit a new disc and repeat the check.
If the problem persists, check and replace the wheel rim if necessary.
Specific tooling
020335Y Magnetic support for dial gauge BRAK SYS - 175
Braking system
Fly 50 4t 4v
See also
Removing the front wheel
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE. - Check the thickness of the friction material. If thinner than the minimum value, replace it.
Characteristic
Minimum friction material thickness 1.5 mm - In case of uneven wear, replace the brake pads when the friction material thickness difference is 0.5 mm.
CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
Fly 50 4t 4v
Braking system
Refitting
- To refit, carry out the disassembly operations in the inverse order, fitting the inner spring correctly and tightening the fixing screws to the specified torque.
Fill Front
N.B.
IF THERE IS AIR IN THE HYDRAULIC SYSTEM, THE WATER WILL ABSORB MOST OF THE POWER OF THE BRAKE MAIN CYLINDER AND THEREFORE, IT WILL REDUCE THE CALLIPER PERFORMANCE WHEN BRAKING. THE PRESENCE OF AIR IS SIGNALLED BY THE 'SPONGINESS' OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY.
CAUTION
CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY TO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REGULAR MAINTENANCE OPERATIONS. Proceed as follows: - Position the vehicle on a flat surface and on the stand - Loosen the two screws shown in the figure and open the front brake fluid reservoir. - Once the bleed valve is closed, fill the system with brake fluid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system.
Braking system
Fly 50 4t 4v
The operation is finished when just oil comes out of the bleed screws. -Do up the bleed screw. -When the operation is over, tighten up the oil bleed screw to the prescribed torque.
N.B. IF AIR CONTINUES TO COME OUT DURING PURGING, EXAMINE ALL THE FITTINGS: IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. CAUTION - DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL. N.B. DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP. WARNING - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY. CAUTION WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE OIL ON IT.
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Recommended products
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4
Fly 50 4t 4v
Braking system
- Operate on the two U bolt clamps (see figure). - On refitting, perform the operation in reverse. - Tighten the hydraulic line to the prescribed torque and then fill and purge the system.
See also
Front handlebar cover Rear handlebar cover
Drum brake removal - Remove the rear wheel. - Hold the lower shoe and slide it out with the upper one. For fitting: - First assembly two shoes and the springs then place them on the pin and on the cam.
See also
Removing the rear wheel BRAK SYS - 179
Braking system
Fly 50 4t 4v
Transmission replacement - Remove the front handlebar cover. - Remove the leg shield and the footrest. - Loosen the brake set screw - Release the transmission from its retainers to the engine.
See also
Front handlebar cover Legshield Footrest - Release the transmission from the retainers on chassis and from the control lever. - Fit the new transmission, fixing and positioning it like the one replaced. - Adjust the drum brake activation point.
Fly 50 4t 4v
Braking system
INDEX OF TOPICS
CHASSIS
CHAS
Fly 50 4t 4v
Chassis
Seat
- Unscrew the 2 fixing screws and remove the saddle
On the left side a lock is installed to allow access to the helmet compartment. -To remove the lock the covering must be lifted in correspondence with the lock itself in such a way so as to be able to access the lock spring. - Remove the lock spring and slide the lock and the relative housing from the outside.
Side fairings
Remove the legshield Undo the 3 fixing screws and remove the bumper ring on each side of the legshield
CHAS - 183
Chassis
Fly 50 4t 4v
See also
Legshield
Rear rack
GRAB HANDLE Remove the helmet compartment. Undo, from both sides of the vehicle, the indicated screw and bolt. Remove the handgrip.
See also
Helmet bay
Driving mirrors
With the adjustment nut completely tightened, screw in the mirror stem on the handlebar all the way. Loosen the mirror stem, moving it to the desired direction. Loosen the adjustment nut until locking the stem.
CHAS - 184
Fly 50 4t 4v
Chassis
Undo the 4 screws that secure the rear handlebar cover to handlebar. Remove the rear handlebar cover complete with instrument panel assembly.
See also
Front handlebar cover
CHAS - 185
Chassis
Fly 50 4t 4v
Instrument panel
Remove the rear handlebar cover Unscrew the 4 fixing screws and remove the instrument panel
See also
Rear handlebar cover
CHAS - 186
Fly 50 4t 4v
Chassis
Pull up and detach the front handlebar cover, disconnect the headlight assembly connections.
Headlight assy.
Remove the front handlebar cover. Undo the 4 fixing screws to remove the headlight assembly. To replace the high/lowbeam headlight bulb, it is necessary to remove the rubber cap and turn the supporting plate by 30 anticlockwise.
CHAS - 187
Chassis
Fly 50 4t 4v
Daylight running light To replace the daylight running light bulb, open the front glove-box and remove the bulb holder from the seat; pull the bulb gently.
Front turn indicators To replace the front turn indicator bulb, open the front case and remove the bulb holder from the seat; lightly press the bulb, rotate it about 30 and then pull it out.
See also
Front handlebar cover
CHAS - 188
Fly 50 4t 4v
Chassis
Legshield
Remove the footrest. Remove the spoilers. Remove the front wheel. Remove the 2 screws located behind the front mudguard. Remove on both sides of the vehicle, the screw on the leg shield back plate.
Undo the two screws under the lug of the shield. Remove the Piaggio clip-on badge, unscrew the screw underneath and remove the grill by pulling it upwards.
CHAS - 189
Chassis
Fly 50 4t 4v
Unscrew the 3 front fixing screws of the legshield. Remove the shield complete with side bumpers after disconnecting the electrical connections of the turn indicators and the daylight running lights.
See also
Footrest spoiler Removing the front wheel
Knee-guard
Remove the legshield. Open the glove-box and undo the 3 fixing screws indicated.
CHAS - 190
Fly 50 4t 4v
Chassis
Remove the battery. Remove the wires through the slots in the leg shield back plate.
Remove the screw fixing the bracket of the fuse support and relay.
CHAS - 191
Chassis
Fly 50 4t 4v
Remove the screw fixing the leg shield back plate from the front. Remove the shield back plate.
See also
Legshield Battery
See also
Knee-guard
CHAS - 192
Fly 50 4t 4v
Chassis
See also
Knee-guard
Taillight assy.
Remove the handgrip. Remove, on both sides of the vehicle, the flange side, sliding it from the fittings.
Undo the side fixing screw from both sides of the vehicle.
CHAS - 193
Chassis
Fly 50 4t 4v
Undo the 2 screws that secure the upper cover and remove the cover.
- Detach the headlight assembly as shown in the picture. The bulbs have a bayonet coupling, to remove them press gently and turn it anticlockwise about 30. To refit follow the same steps but in reverse order.
CHAS - 194
Fly 50 4t 4v
Chassis
Footrest
Remove the side fairings. Remove the 4 screws on the footrest.
Unscrew, from both sides of the vehicle, the screw under the spoiler and remove the side mudguard.
Unscrew, from both sides of the vehicle, the 2 screws that secure the footrest to the spoiler. Remove the footrest.
CHAS - 195
Chassis
Fly 50 4t 4v
Side fairings
- Remove the helmet compartment. - Remove the front central cover. - Remove the handgrip. - Remove the rear headlight. - Undo side screw from both sides of the vehicle.
- Undo, from both sides of the vehicle, the rear side screw.
CHAS - 196
Fly 50 4t 4v
Chassis
- Remove, from both sides of the vehicle, the cover and the underlying screw.
- Remove, from both sides of the vehicle, the side fairing, pushing it slightly forward.
See also
Helmet bay Front central cover Rear rack Taillight assy.
CHAS - 197
Chassis
Fly 50 4t 4v
Remove the license plate light bulb from the seat and release the cable from the clamp. Remove the license plate support towards the rear.
See also
Side fairings Taillight assy.
Air filter
- Remove the side fairings. - Remove the footrest. - Remove the spoilers. - Unscrew the two clamps holding the filter housing to the crankcase.
See also
Side fairings Footrest spoiler
CHAS - 198
Fly 50 4t 4v
Chassis
Rear mudguard
Remove the 2 retainers, which also lock the air filter box to the crankcase. Remove the fixing screw located on the right side. Remove the mudguard making it come out on the muffler side.
Helmet bay
- Lift the saddle. - Remove the six fixing screws.
CHAS - 199
Chassis
Fly 50 4t 4v
spoiler
- Remove the footrest. - Undo the 2 front retainers. - Open, on both sides of the vehicle, the passenger footrest, and remove the screw shown in the picture. - Remove the spoiler.
See also
Footrest
Fuel tank
- Remove the side fairings. - Remove the footrest. - Remove the spoilers. - Remove the leg shield back plate. - Loosen the clamps and disconnect the connection pipes to the breather valve from the fuel tank filler.
CHAS - 200
Fly 50 4t 4v
Chassis
- Disconnect the fuel pipe from the pump. - Disconnect the electrical connectors of the fuel pump and level transmitter. - Unscrew and remove the four screws that secure the tank to the chassis. - Remove the tank.
See also
Side fairings Footrest spoiler Knee-guard
Front mudguard
- Remove the front wheel. - Unscrew the 3 fixing screws and remove them. - Disconnect the brake calliper pipe. - Unscrew the screw fastening the brake pipe on the mudguard and slide it off. - Remove the mudguard.
N.B. N.B. WHEN REFITTING, MAKE SURE TO POSITION THE 2 METAL CABLE GROMMETS CORRECTLY.
CHAS - 201
Chassis
Fly 50 4t 4v
Battery
Open the glove compartment on the leg shield back plate. - Undo the screws indicated and remove the battery compartment cover.
Unhook the belt securing the battery. Remove the battery from its housing and disconnect the connection cables from the electrical system, starting with the negative pole.
Lower cover
Undo the 2 side fixing screws indicated in the photo. Remove the cover.
CHAS - 202
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
Fly 50 4t 4v
Aesthetic inspection
Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt
Electrical system
Electrical system: - Main switch - Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights - Adjusting the headlights according to the regulations currently in force - Rear light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel and temperature indicator - Instrument panel warning lights - Horn - Starter PRE DE - 204
Fly 50 4t 4v
Pre-delivery
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINAL FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Levels check
Level check: - Hydraulic braking system fluid level. - Rear hub oil level - Engine coolant level.
Road test
Test ride - Cold start - Instrument operations - Response to the throttle control - Stability on acceleration and braking - Rear and front brake efficiency - Rear and front suspension efficiency - Abnormal noise
PRE DE - 205
Pre-delivery
Fly 50 4t 4v
Static test
Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks
CAUTION
Functional inspection
Functional Checks: Braking system (hydraulic) - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Throttle travel check Others - Check documentation - Check the chassis and engine numbers - Tool kit - License plate fitting - Check locks - Check tyre pressures - Installation of mirrors and any accessories
PRE DE - 206
A
Air filter: 42, 198
B
Battery: 52, 85, 87, 192, 202 Brake: 162, 163, 174, 176, 179
C
Carburettor: 38, 147, 151 Checks: 78
E
Engine oil: 43
F
Fuel: 146, 200
H
Headlight: 48, 187 Hub oil: 41
I
Identification: 8 Instrument panel: 186
M
Maintenance: 7, 38 Mirrors: 184
O
Oil filter: 45
R
Recommended products:
S
Shock absorbers: 170 Spark plug: 39, 79 Stand: 172 Suspension: 52
T
Tank: 200 Transmission: 9, 51, 100, 110 Tyres: 13
V
Vehicle: 8, 94, 169