Table Of Contents - PIAGGIO Fly 150 4T Workshop Manual

Table of Contents

Index Of Topics5
Characteristics6
Safety Rules7
Maintenance Rules7
Vehicle Identification8
Dimensions And Mass8
Vehicle View9
Engine Data9
Transmission Data10
Capacities10
Electrical System Data10
Frame And Suspension Data10
Wheels And Tyres Data11
Carburetor Data12
Tightening Torques13
Overhaul Data14
Assembly Clearances14
Cylinder - Piston Assy Data15
Piston Rings Data17
Crankcase - Crankshaft - Connecting Rod Data18
Fly 125 - 150 4T19
Slot Packing System19
Products20
Tooling21
Tools View And Identification22
Maintenance31
Maintenance Chart32
Checking The Spark Advance35
Spark Advance Variation36
Braking System38
Level Check38
Top-Up38
Headlight Adjustment39
Co Check40
Sas Filters Inspection And Cleaning42
Troubleshooting44
Engine Troubleshooting45
Poor Engine Performance45
Rear Wheel Spins At Idle45
Starting Difficulties46
Excessive Oil Consumptions/Exhaust Smoke46
Insufficient Lubrication Pressure47
Engine Tends To Be Cut-Off At Full Throttle47
Engine Tends To Cut-Off At Idle47
High Fuel Consumption47
Transmission And Brakes Troubleshooting48
Clutch Grabbing Or Performing Inadequately48
Insufficient Braking48
Brakes Overheating48
Electrical System Troubleshooting49
Battery Troubleshooting49
Turn Signal Lights Malfunction49
Steering And Suspensions Troubleshooting49
Excessive Steering Play50
Noisy Suspension50
Suspension Oil Leakage50
Electrical System51
Electrical System Diagram52
Front Side Diagram55
Front Installation55
Back Side Diagram58
Rear Installation58
Conceptual Diagrams60
Ignition Diagram61
Headlights And Automatic Starter Section Diagram62
Battery Recharge And Starting Diagram63
Level Indicators And Enable Signals Section64
Turn Signal Lights Diagram65
Instruments And Warning Lights Control Board Diagram66
Checks And Inspections66
Immobiliser67
Virgin Circuit68
Diagnostic Codes69
Diagnostic Code - 2 Flashes69
Diagnostic Code - 3 Flashes70
Ignition Circuit70
No Spark Plug71
- Pick-Up72
- H.v. Coil72
Battery Recharge Circuit73
Stator Check73
Voltage Regulator Check74
Recharge System Voltage Check74
Choke Inspection74
Turn Signals System Check75
Sealed Battery76
Dry-Charge Battery76
Engine From Vehicle79
Exhaust Assy. Removal80
Removal Of The Engine From The Vehicle80
Engine83
Automatic Transmission84
Transmission Cover84
Air Duct85
Removing The Driven Pulley Shaft Bearing85
Refitting The Driven Pulley Shaft Bearing86
Removing The Driven Pulley86
Inspecting The Clutch Drum86
Removing The Clutch87
Inspecting The Clutch88
Pin Retaining Collar89
Removing The Driven Half-Pulley Bearing89
Inspecting The Driven Fixed Half-Pulley90
Inspecting The Driven Sliding Half-Pulley90
Refitting The Driven Half-Pulley Bearing90
Refitting The Driven Pulley91
Inspecting The Clutch Spring92
Refitting The Clutch92
To Refit The Driven Pulley94
Drive-Belt94
Removing The Driving Pulley95
Inspecting The Rollers Case95
Refitting The Driving Pulley96
Refitting The Transmission Cover97
End Gear97
Removing The Hub Cover97
Removing The Wheel Axle98
Removing The Hub Bearings98
Removing The Wheel Axle Bearings98
To Remove The Driven Pulley Shaft Bearing99
Inspecting The Hub Shaft99
Inspecting The Hub Cover100
Refitting Driven Pulley Shaft Bearing100
Refitting The Wheel Axle Bearing100
Refitting The Hub Cover Bearings101
Refitting The Hub Bearings101
Refitting The Ub Cover102
Flywheel Cover102
Cooling Hood102
Cooling Fan103
Removing The Stator103
Refitting The Stator104
Flywheel And Starting104
Removing The Flywheel Magneto104
Inspecting The Flywheel Components105
Refitting The Flywheel Magneto105
Refitting The Starter Motor105
Cylinder Assy. And Timing System105
Removing The Timing System Drive106
Removing The Cam Shaft107
Removing The Cylinder Head107
Removing The Valves108
Removing The Cylinder - Piston Assy.108
Inspecting The Small End109
Inspecting The Wrist Pin109
Inspecting The Piston111
Removing The Piston111
Refitting The Piston Rings112
Refitting The Cylinder113
Inspecting The Cylinder Head113
Inspecting The Timing System Components114
Inspecting The Valve Sealings114
Inspecting The Valve Housings114
Inspecting The Valves115
Inspecting The Springs And Half-Cones117
Refitting The Valves117
Inspecting The Cam Shaft117
Refitting The Head And Timing System Components119
Crankcase - Crankshaft122
Splitting The Crankcase Halves123
Inspecting The Crankshaft Alignment125
Inspecting The Crankcase Halves126
Inspecting The Crankshaft Plain Bearings128
Refitting The Crankcase Halves129
Lubrication130
Lubrication - Conceptual Diagrams131
Oil Pressure Check132
Crankshaft Oil Seals132
Removal133
Refitting133
Oil Pump Removal135
Oil Pump Inspection136
Oil Pump Refitting137
Removing The Oil Sump138
Inspecting The By-Pass Valve138
Refitting The Oil Sump139
Fuel Supply139
Removing The Carburettor140
Refitting The Carburettor146
Level Check (Carburetor)149
Inspecting The Valve And Needle151
Inspecting The Automatic Choke Device153
Adjusting The Idle154
Suspensions157
Front Suspension158
Removing The Front Wheel158
Front Wheel Hub Overhaul158
Refitting The Front Wheel159
Handlebar Removal160
Handlebar Refitting160
Front Fork Overhaul160
Replacement Of Seal Ring Rod Disassembly160
Front Fork Refitting161
Steering Column Refitting162
Steering Bearing Removal162
Removing The Rear Wheel163
Refitting The Rear Wheel163
Shock Absorbers Removal163
Centre-Stand164
Braking System Section165
Front Brake Caliper Removal166
Front Brake Caliper Overhaul166
Front Brake Caliper Refitting168
Front Brake Disc Removal168
Front Brake Disc Refitting168
Disc Inspection169
Front Brake Pads Removal169
Front Brake Pads Refitting169
Fill - Front170
Front Brake Pump171
Front Brake Pump Removal172
Front Brake Pump Refitting172
Rear Drum Brake173
Chassis174
Removing The Ignition Key-Switch When On *Off*175
Removing The Ignition Key-Switch When On *Lock*175
Footrest175
Air Filter176
Rear Mudguard176
Helmet Bay177
Fuel Tank177
Pre-Delivery178
Aesthetic Inspection179
Tightening Torques Inspection179
Electrical System Inspection179
Levels Check180
Road Test180
Static Test181
Functional Inspection181
Time182
Engine View183
Crankcase View184
Crankshaft View185
Cylinder Assy.186
Cylinder Head Assy. View187
Rocker Arms Support Assy.view188
Cylinder Head Cover View189
Chain Tensioner View190
Oil Filter View191
Flywheel Cover View192
Driven Pulley View193
Oil Pump View194
Final Gear Assy. View195
Driving Pulley View196
Transmission Cover View197
Starter Motor View198
Flywheel Magneto View199
Belt Cooling Duct199
Carburetor View200
Exhaust Pipe View201
Air Cleaner View202
Frame View203
Legshield Spoiler View204
Rear Cover View205
Central Cover View206
Underseat Compartment207
Plate Holder View208
Mudguard View209
Fuel Tank View210
Rear Shock-Absorber View211
Steering Column Bearings View212
Handlebar Covers View213
Handlebar Components View214
Swing-Arm View215
Brake Hoses View216
Seat View217
Turn Signal Lights Exploded View218
Front Wheel View219
Rear Wheel View220
Electric Devices View221
Electronic Controls222
Transmissions - Diagram222
Front Suspension View223