PIAGGIO Fly 50 4t 4v Manual
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PIAGGIO Fly 50 4t 4v Manual

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PIAGGIO WOULD LIKE TO THANK YOU
for choosing one of its products. We have prepared this manual to help you to get the very best from your vehicle. Please read it carefully before riding
the vehicle for the first time. It contains information, tips and precautions for using your vehicle. It also describes features, details and devices to assure
you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new scooter and it will serve you
well for a long time to come. This booklet forms an integral part of the vehicle; should the vehicle be sold, it must be transferred to the new owner.
Fly 50 4t 4v
Ed. 02_04/2012

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Summary of Contents for PIAGGIO Fly 50 4t 4v

  • Page 1 PIAGGIO WOULD LIKE TO THANK YOU for choosing one of its products. We have prepared this manual to help you to get the very best from your vehicle. Please read it carefully before riding the vehicle for the first time. It contains information, tips and precautions for using your vehicle. It also describes features, details and devices to assure you that you have made the right choice.
  • Page 2 The instructions given in this manual are intended to provide a clear, simple guide to using your vehicle; this booklet also details routine maintenance procedures and regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre. The booklet also contains instructions for simple repairs.
  • Page 3 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 dam- aging 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.

  • Page 5: Table Of Contents

    INDEX VEHICLE..................Engine oil change..............31 Dashboard................Hub oil level................32 Analogue instrument panel............10 Tyres..................33 Clock..................11 Spark plug dismantlement............34 Key switch................. 12 Checking the brake oil level............35 Locking the steering wheel............ 12 Battery..................37 Releasing the steering wheel..........12 Checking the electrolyte level..........

  • Page 7: Vehicle

    Fly 50 4t 4v Chap. 01 Vehicle...

  • Page 8: Dashboard

    01_01 Dashboard (01_01) A = Ignition switch B = RUN/OFF emergency stop switch...
  • Page 9 C = Horn button D = Turn indicator switch E = Rear brake lever F = Headlight switch G = Analogue instrument panel H = Front brake lever I = Throttle grip L = Starter button...

  • Page 10: Analogue Instrument Panel

    01_02 Analogue instrument panel (01_02) A = Trip counter B = Speedometer C = Turn indicator warning light...

  • Page 11: Clock

    D = High-beam warning light E = Headlight warning light C = Immobilizer warning light (not connected) G = Low fuel warning light H = Fuel gauge L = Digital clock Clock (01_03) Hours and minutes are displayed in a 1 to 12, AM or PM, format on the instrument panel.

  • Page 12: Key Switch

    Key switch (01_04) LOCK = Ignition disabled, extractable key, steering lock engaged front glove-box locked. OFF = Ignition disabled, extractable key, steering lock disengaged, front glove-box unlocked. ON = Ready to start position, anti-theft device disabled, non-extractable key, glove- box unlocked. 01_04 Locking the steering wheel Turn the handlebar to the left (as far as it will go), turn the key to «LOCK»...

  • Page 13: Switch Direction Indicators

    Switch direction indicators (01_05) To set the left turn indicators flashing, move lever «D» to the left; to set the right turn indicators flashing, move it to the right. The lever automatically returns to the central position and the indicators remain on. To turn the indicators off, press the lever towards the switch.

  • Page 14: Light Switch

    01_07 Light switch (01_07) 0 = Low-beam and taillight 1 = High-beam and taillight 2 = High-beam flash (passing) WARNING THE «PASSING» FUNCTION IS ACTIVE DEPENDING ON THE MARKET COUN- TRIES. CAUTION DO NOT PLACE, TRANSPORT OBJECTS AND/OR CLOTHES OVER THE FRONT HEADLIGHT ASSEMBLY, WHEN THE HEADLIGHT IS TURNED ON OR OFF.

  • Page 15: Start-Up Button

    Start-up button (01_08) To start the engine, pull either brake lever and then push the button «M». 01_08 Engine stop button (01_09) The engine can be started when the emergency stop switch «B» is in position «1» RUN; if the emergency stop switch «B» is in position «0» OFF it is not possible to start the engine or it will switch off if started.

  • Page 16: Opening The Saddle

    Opening the saddle (01_10) Insert the key into the saddle lock «A», turn it anticlockwise and tip the saddle forward. 01_10 Keys (01_11) The vehicle is supplied with two keys (one spare) which serve to start the engine and unlock the saddle compartment. The keys are accompanied by a tag marked with the identification code to be quoted when ordering duplicates.

  • Page 17: Identification

    Identification (01_12, 01_13) The identification numbers consist of a prefix stamped on the chassis and on the en- gine, followed by a number. They must be quoted when ordering spare parts. We recommend that you check that the prefix and chassis number stamped on the vehicle correspond with those in the vehicle documents.

  • Page 18: Bag Clip

    Bag clip (01_14) To use the retractable bag hook «B» located at the front end of the saddle, pull it forward lightly. 01_14...

  • Page 19: Use

    Fly 50 4t 4v Chap. 02...

  • Page 20: Checks

    Checks (02_01) Before using the vehicle, check: 1. that the fuel tank is full. 2. The oil level in the rear hub. 3. engine oil level (see section «Engine oil level»). 4. That tyres are properly inflated. 5. correct functioning of headlights, rear taillight and turn indicators. 02_01 6.

  • Page 21: Tyre Pressure

    CAUTION USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE OF THE ENGINE. Characteristic Fuel tank capacity approx. 7 litres (of which 1.5 l reserve) Tyre pressure CAUTION TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.INCOR- RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID- ING DANGEROUS.

  • Page 22: Running In

    TYRE INFLATION PRESSURE Front tyre pressure 1.8 bar Rear tyre pressure (with 2.0 bar (2.3 bar) passenger) Running in (02_03) WARNING DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80% OF ITS MAXIMUM SPEED. AVOID TWISTING THE THROTTLE GRIP FULLY OR KEEP- ING A CONSTANT SPEED ALONG LONG SECTIONS OF ROAD.
  • Page 23 - Keep the throttle grip to idle speed. - Insert the key into the ignition switch «D» and turn it to «ON». - Push the starter button «A» after pulling the front brake lever « C» or the rear brake lever «B».

  • Page 24: Precautions

    Precautions CAUTION NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID POSSIBLE DAMAGE. BE CAREFUL NEVER TO EXCEED THE MAXIMUM SPEED WHILE RUNNING DOWNHILL, IN ORDER TO AVOID DAMAGING THE ENGINE. IN ANY CASE, IN ORDER TO PRESERVE THE ENGINE FROM PROLONGED OVERREVVING, THE REVOLUTION LIMITER WILL BE ACTIVATED IF THE EN- GINE SPEED EXCEEDS THE ESTABLISHED THRESHOLD.

  • Page 25: Stopping The Engine

    Stopping the engine (02_06) Stop acceleration, then turn the key switch «D» to «OFF » to stop the engine (ex- tractable key). CAUTION DUE TO THE HIGH TEMPERATURES THE CATALYTIC CONVERTER CAN REACH, ALWAYS TAKE CARE, WHEN PARKING THE VEHICLE, THAT THE EX- 02_06 HAUST DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS, TO AVOID SERIOUS BURNS.

  • Page 26: Automatic Transmission

    Automatic transmission To ensure simple, pleasurable riding, the vehicle is equipped with automatic trans- mission with regulator and centrifugal clutch. The system is designed to give the best possible performance in terms of both acceleration and consumption, on level ground and uphill, thanks to the adjustments made to engine speed and transmitted torque.
  • Page 27 1. Before riding off, remember to put on your helmet and fasten it correctly. 2. Reduce speed and ride cautiously on uneven roads. 3. Remember that after riding on a long stretch of wet road without using the brakes, the braking effect is initially lower. Under these conditions, it is a good idea to operate the brakes from time to time.
  • Page 28 DEN BY LAW, AND RENDERS THE VEHICLE NO LONGER CONFORMING TO THE APPROVED TYPE AND DANGEROUS FOR RIDING.

  • Page 29: Maintenance

    Fly 50 4t 4v Chap. 03 Maintenance...

  • Page 30: Engine Oil Level

    Engine oil level (03_01) In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can seriously dam- age the engine. In all 4T engines the decay of oil characteristics as well as some consumption is normal.

  • Page 31: Engine Oil Top-Up

    Always check oil level before carrying out top-ups and add oil without exceeding the MAX level. An engine oil check-up and top-up should be carried out every 3,000 km at an Authorised Piaggio Service Centre. Engine oil change (03_03, 03_04, 03_05) Change oil and clean the filter after every 6,000 km at an Authorised Service Cen- tre.

  • Page 32: Hub Oil Level

    03_05 Hub oil level (03_06, 03_07) Check that there is oil in the rear hub; the oil in an upright vehicle should barely reach the notch of the dipstick «A». CAUTION RUNNING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH THE IN- ADEQUATE LUBRICANTS ACCELERATES WEAR AND TEAR OF THE MOVING 03_06 PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE.

  • Page 33: Tyres

    N.B. THE NOTCHES ON THE HUB OIL LEVEL DIPSTICK, EXCEPT THE ONE INDI- CATING THE MAXIMUM AND MINIMUM LEVEL, REFER TO OTHER MODELS BY THE MANUFACTURER AND HAVE NO SPECIFIC FUNCTION FOR THIS MODEL. Recommended products Lubricant for gearboxes and transmissions Lubricant for gearboxes and transmissions.

  • Page 34: Spark Plug Dismantlement

    TYRES Front tyre 120/70 - 12" Tubeless Rear tyre 120/70 - 12" Tubeless TYRE INFLATION PRESSURE Front tyre pressure 1.8 bar Rear tyre pressure (with 2.0 bar (2.3 bar) passenger) Spark plug dismantlement (03_09, 03_10) In order to inspect the spark plug, follow the operation described when the engine is cold: 1.

  • Page 35: Checking The Brake Oil Level

    WARNING THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. THE USE OF A SPARK PLUG WITH THERMAL GRADE OR THREAD OTHER THAN THE INDICATED TYPE (SEE «DATA» SECTION) CAN SERIOUSLY DAMAGE THE EN- GINE. REPLACE SPARK PLUGS AT THE INTERVALS INDICATED IN THE SCHEDULED MAINTENANCE TABLE.
  • Page 36 CAUTION THE SYSTEM MUST ONLY BE TOPPED UP WITH DOT4 TYPE BRAKE FLUID. WARNING IN NORMAL CLIMATIC CONDITIONS IT IS ADVISABLE TO REPLACE THE 03_12 ABOVE-MENTIONED FLUID EVERY 2 YEAR. NEVER USE BRAKE FLUID CON- TAINED IN CONTAINERS WHICH ARE ALREADY OPEN OR PARTIALLY USED. CAUTION THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE.

  • Page 37: Battery

    Battery (03_13) To have access to the battery it is necessary to open the front case and remove access door to the battery by unscrewing the two star-shaped screws as shown in the picture The battery is the electrical device that requires the most frequent attention and the most thorough maintenance.

  • Page 38: Long Periods Of Inactivity

    to top up the battery with water too frequently, check the vehicle's electrical system because the battery is being overloaded, causing it to lose power quickly. CAUTION ELECTROLYTE CONTAINS SULPHURIC ACID: AVOID CONTACT WITH EYES, SKIN AND CLOTHES. IN CASE OF ACCIDENTAL CONTACT, RINSE WITH ABUN- DANT WATER AND CONSULT A DOCTOR.

  • Page 39: Fuses

    10A fuse and a 7.5 A fuse. The two above mentioned fuses are located under the front grill. To reach them: - remove the PIAGGIO clip-on badge «A»; - unscrew and remove the screw «B»; - remove the grill «C».
  • Page 40 CAUTION MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPEC- IFICATIONS OF THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK OF FIRE. CAUTION 03_15 BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW.
  • Page 41 FUSES Fuse No. 1 Capacity: 15A Location:battery compartment. Protected circuits: general. Fuse No. 2 Capacity: 10A Location:front part. Protected circuits: electronic ignition device. Fuse No. 3 Capacity: 7.5 A Location:front part Protected circuits: fuel gauge, horn, stop light, starter button, instrument panel.
  • Page 42 Quantity: 1 RHS + 1 LHS Front turn indicator light bulb Type: Spherical Power: 12V - 10W Quantity: 1 RHS + 1 LHS Rear turn indicator light bulb Type: Spherical Power: 12V - 10W Quantity: 1 RHS + 1 LHS Stop and tail light bulb Type: Spherical Power: 12V 21/5W...

  • Page 43: Front Light Group

    Power: 12V - 5W Quantity: 1 Front light group (03_18, 03_19, 03_20, 03_21, 03_22, 03_23, 03_24) To access the headlight bulbs, remove the front of the handlebar cover, as follows: 1) Remove the rear-view mirrors; for this operation follow the instructions described and illustrated in the «Rear-view mirrors»...
  • Page 44 03_20 03_21 03_22...
  • Page 45 CAUTION DO NOT PLACE, TRANSPORT OBJECTS AND/OR CLOTHES OVER THE FRONT HEADLIGHT ASSEMBLY, WHEN THE HEADLIGHT IS TURNED ON OR OFF. FAILURE TO FOLLOW THIS PRECAUTION MAY CAUSE OVERHEATING AND THE SUBSEQUENT FUSION OF THE GLASS. Daylights To replace the lamp position open the front case, remove the bulb holder from the seat;...

  • Page 46: Headlight Adjustment

    Headlight adjustment (03_25, 03_26) Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pres- sure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen;...

  • Page 47: Rear Optical Unit

    03_28 Rear optical unit (03_29, 03_30) In order to reach the rear light bulb, remove the helmet compartment by loosening the 6 fixing screws. Gently push and turn the bulb about 30° and then remove it. To refit follow the same steps but in reverse order. WARNING FOR REPLACEMENT OF THE TURN INDICATOR BULBS PLEASE SEE AN AU- THORISED SERVICE CENTRE.

  • Page 48: Number Plate Light

    Number plate light (03_31) Remove the tail light by operating on the fixing screws «E». Remove the bulb holder from the seat; gently pull the lamp. To refit, proceed in reverse order. 03_31 Rear-view mirrors (03_32, 03_33) To adjust mirrors, loosen lock nut «A», place the mirror stem adequately and tighten the lock nut.

  • Page 49: Front Disc Brake

    03_33 Front disc brake (03_34) The brake disc and pad wear is automatically compensated, therefore it has no effect on the functioning of the front and rear brakes. For this reason it is not necessary to adjust the brakes. An excessively elastic brake lever stroke may indicate the presence of air in the braking circuit or an irregular brake operation.

  • Page 50: Rear Drum Brake

    CAUTION BRAKING SHOULD BEGIN AFTER ABOUT 1/3 OF THE BRAKE LEVER STROKE. Rear drum brake (03_35) Operate adjusting nut «B» and loosen lock nut «A» shown in the figure. Note that when the throttle is in idle the wheel should rotate free. After the adjustment, screw lock nut «A».

  • Page 51: Periods Of Inactivity

    Periods of inactivity We recommend carrying out the following operations: 1. General cleaning of the vehicle. 2 - With the engine off and the piston at bottom dead centre position, remove the spark plug and pour 1÷2 cc of motor oil through its hole. Operate the starter motor 3-4 times letting the engine perform a few revolutions, then remount the spark plug.
  • Page 52 WARNING To avoid the appearance of oxidations, wash the vehicle every time it is used in certain areas or in special conditions of: · Environmental / seasonal conditions: use of salt, de-icer chemical products on the road in winter. · Air pollution: city and/or industrial areas. ·...
  • Page 53 WARNING NEVER WASH THE VEHICLE UNDER DIRECT SUNLIGHT, ESPECIALLY IN SUM- MER WHEN THE BODYWORK IS STILL HOT, AS THE CAR SHAMPOO MAY DRY BEFORE BEING RINSED OFF, AND COULD DAMAGE THE PAINTWORK. NEVER USE RAGS SOAKED IN PETROL OR DIESEL OIL TO CLEAN THE PAINTED OR PLASTIC SURFACES, IN ORDER TO PREVENT THEM LOSING THEIR SHINE AND MECHANICAL CHARACTERISTICS.
  • Page 54 GNITION PROBLEMS No spark from spark plug. Due to Make sure the electrodes are the presence of high voltage, this properly adjusted. Check that they check should only be carried out by are (clean with pure petrol and a an expert. metal brush or with emery cloth).
  • Page 55 INEFFICIENT BRAKING Oil on drum or disc. Worn Pads/ Contact an Authorised Service Shoes Centre incorrect rear brake adjustment Adjust INEFFICIENT SUSPENSION Inefficient shock absorbers, oil Contact an Authorised Service leakage, deteriorated end of stroke Centre buffers. AUTOMATIC TRANSMISSION PROBLEMS Deteriorated roller housing or belt.
  • Page 56 STARTER LEVER DOES NOT RETURN TO CORRECT POSITION Presence of dirt Clean and grease...

  • Page 57: Technical Data

    Fly 50 4t 4v Chap. 04 Technical data...
  • Page 58 04_01 ENGINE SPECIFICATIONS Type single-cylinder, four-stroke and four-valve, air-cooled engine Cubic capacity 49.93 cm³ Bore 39 mm Stroke 41.8 mm...
  • Page 59 Max. power 3.2 kW at 8250 rpm MAX. torque 3.8 Nm at 7,750 rpm Compression ratio 11.5 - 12.5 1 Timing system single overhead camshaft, chain- driven, on the left-hand side, three- arm rocking levers set up with threaded set screw Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm Spark plug...
  • Page 60 Front brake Disc brake (Ø 220 mm) with hydraulic control (lever on the far right of the handlebar) and floating calliper. Rear brake Ø 140-mm drum brake with mechanical control activated by the handlebar left-side lever. Wheel rim type Light alloy wheel rims. Front wheel rim 12'' x 3.00 Rear wheel rim...

  • Page 61: Toolkit

    Fuel tank capacity approx. 7 litres (of which 1.5 l reserve) Toolkit (04_02) The toolkit includes: 1. Box-spanner to extract the spark plug; 2. Twin screwdriver; 3. An open spanner (13 mm); 4. One torx wrench T30 5. One torx wrench T25 04_02 The toolkit plastic pouch is fastened to the saddle with a clamp.

  • Page 63: Spare Parts And Accessories

    Fly 50 4t 4v Chap. 05 Spare parts and accessories...

  • Page 64: Warnings

    Warnings (05_01) WARNING IT IS RECOMMENDED THAT "ORIGINAL PIAGGIO SPARE PARTS" BE USED, AS THESE ARE THE ONLY ONES OFFERING YOU THE SAME QUALITY AS- SURANCE AS THOSE INITIALLY FITTED ON THE VEHICLE. IT SHOULD BE REMEMBERED THAT USING NON-ORIGINAL SPARE PARTS 05_01 CAUSES YOUR WARRANTY RIGHTS TO EXPIRE.

  • Page 65: Scheduled Maintenance

    Fly 50 4t 4v Chap. 06 Scheduled maintenance...

  • Page 66: Scheduled Servicing Table

    Scheduled servicing table (06_01) Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been suggested, which are included in the summary table on the following page. Any minor faults should be reported without delay to an Authorised Service Centre or Dealer without waiting until the next scheduled service to solve it.
  • Page 67 Km x 1000 Electrical system and battery Cylinder ventilation system Brake levers Brake oil level (*) Hub oil level Engine oil Brake Pads/Shoes Tyre pressure Headlight Vehicle road test Idle speed Odometer gear CVT rollers Suspension Steering Transmission I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R:REPLACE, A: ADJUST, L:LUBRICATE * Replace every 2 years...
  • Page 68 RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions. API GL-4 AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4 eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance JASO MA, MA2 - API SL - ACEA A3...
  • Page 69 TABLE OF CONTENTS Tyres: 33 Battery: 37 Headlight: 46 Puncture: 50 Brake: 35, 49, 50 Horn: 13 Hub oil: 32 Vehicle: 7, 51 Refuelling: 20 Checks: 20 Clock: 11 Identification: 17 Instrument panel: 10 Saddle: 16 Scheduled maintenance: 65 Disc brake: 49 Spark plug: 34 Key switch: 12 Stand: 25...
  • Page 70 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.

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