PIAGGIO Fly Workshop Manual
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PIAGGIO Fly Workshop Manual

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WORKSHOP MANUAL
633204
Fly

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Summary of Contents for PIAGGIO Fly

  • Page 1 WORKSHOP MANUAL 633204...

  • Page 2: Workshop Manual

    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 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 WORKSHOP MANUAL This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle.

  • Page 8: Dimensions And Mass

    Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Frame prefix ZAPM44100 ÷ 1001 Engine prefix C441M ÷ 1001 Dimensions and mass DIMENSIONS AND MASS Specification Desc./Quantity Dry weight 97 Kg Length 1,880 Maximum height 1150 mm Seat height Width Wheelbase 1,340 CHAR - 8...
  • Page 9 Characteristics Engine ENGINE Specification Desc./Quantity Engine type Two-stroke, single cylinder Piaggio Hi-PER2 Bore x stroke 40 X 39.3 mm Cubic capacity 49.40 cc Compression ratio 10,3 :1 Carburettor DELL'ORTO PHVA 17.5 CO adjustment 3.5% ± 0.5 Engine idle speed 1800 to 2000 r.p.m.

  • Page 10: Wheels And Tyres

    Characteristics Transmission RANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V- belt, automatic clutch, gear reduction unit. Capacities CAPACITIES Specification Desc./Quantity Rear hub oil Quantity: approx. 85 cc oil mixer tank Plastic, capacity ~ 1.2 l Fuel tank capacity approx.

  • Page 11: Secondary Air

    Characteristics Specification Desc./Quantity Rear wheel rim Die-cast aluminium alloy: 3.00"x12" Rear tyre Tubeless, 120/70 - 12" Front tyre pressure 1.8 bar Rear tyre pressure 2 bar Rear wheel pressure (rider and passenger): 2.3 bar Secondary air Follow these steps to clean the sponge filters of the secondary air system: 1) Remove the snap-on plastic cover (1) on the transmission cover using a small screwdriver as a...

  • Page 12: Tightening Torques

    Characteristics Dell'Orto DELLORTO CARBURETTOR Specification Desc./Quantity Type PHVA 17.5 RD Diffuser diameter Ø 17.5 Regulation reference number 8423 Maximum nozzle: Maximum air nozzle (on the body): Ø 1.5 Tapered pin stamped code: Pin position (notches from above): Diffuser: 209 HA Minimum nozzle: Minimum air nozzle (on the body): Free...

  • Page 13: Assembly Clearances

    Characteristics Name Torque in Nm Flywheel hood fixing screws 1 ÷ 2 Cylinder hood fixing screws 3.5 ÷ 5 Stator clamping screws 3 ÷ 4 Pick-Up clamping screw 4 ÷ 5 Mixer clamping screws 3 ÷ 4 Screw fixing brake lever to the journal on the engine 12 ÷...

  • Page 14: Piston Rings

    Characteristics Piston rings SEALING RING Name Description Dimensions Initials Quantity Compression ring 0.10 to 0.25 Compression ring 1st 40.2 0.10 to 0.25 oversize Compression ring 2nd 40.4 0.10 to 0.25 Oversize Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD Name Description Dimensions...
  • Page 15 Characteristics For 25 km/h engine type versions, use 2 gaskets between cylinder and crankcase. Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 2-stroke engines: SAE 5W-40, API (brake, throttle control and mixer, odom-...
  • Page 16 INDEX OF TOPICS TOOL OOLING...
  • Page 17 Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y009 Driver for OD 42-mm bearings 001467Y013 Pliers to extract ø 15-mm bearings 001467Y014 Pliers to extract ø 15-mm bearings TOOL - 17...
  • Page 18 Tooling Stores code Description 001467Y017 Bell for bearings, OD 39 mm 001467Y021 Extraction pliers for ø 11 mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer- ing tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut...
  • Page 19 Tooling Stores code Description 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020165Y Start-up crown lock 020166Y Pin lock fitting tool TOOL - 19...
  • Page 20 Tooling Stores code Description 020261Y Starter spring fitting 020262Y Crankcase splitting plate 020265Y Bearing fitting base 020325Y Pliers for brake-shoe springs 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing TOOL - 20...
  • Page 21 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 21...
  • Page 22 Tooling Stores code Description 020335Y Magnetic mounting for dial gauge 020350Y Electrical system check instrument 020357Y 32x35-mm Adaptor 020359Y 42x47-mm Adaptor 020376Y Adaptor handle 020412Y 15-mm guide TOOL - 22...
  • Page 23 Tooling Stores code Description 020456Y Ø 24 mm adaptor 020483Y 30-mm guide 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser TOOL - 23...

  • Page 24: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 25: Maintenance Chart

    Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change AFTER 1000 KM Action Hub oil - change Oil mixer/throttle linkage - adjustment Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check...
  • Page 26 Maintenance Action Hub oil level - check Spark plug/electrode gap - replacement Air filter - cleaning Oil mixer/throttle linkage - adjustment Driving belt - replacement Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check SAS box (sponge) (**) - cleaning...
  • Page 27 Maintenance (*) See regulations in the «Adjusting the idle speed» section (**) See regulations in the «Secondary air system» section 60000 K FTER 150' Action Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idling speed (*) - adjustment Cylinder cooling system - check/cleaning Oil mixer/throttle linkage - adjustment Driving belt - replacement...

  • Page 28: Checking The Spark Advance

    Maintenance 1. Automatic starter - 2. Idle air set screw - 3. Idle speed set screw - 4. Throttle valve spring - 5. Throttle valve tapered pin - 6. Throttle valve - 7. Carburettor body - 8. Pin - 9. Min. jet - 10. Float - 11. Max. jet - 12.
  • Page 29 Maintenance - Engage the spark plug with the due inclination and screw it right down by hand, then do it up with the wrench at the prescribed torque; -Put the hood on the sparking plug as far as it will - Refit the central flap.

  • Page 30: Air Filter

    Maintenance Replacement - Remove the oil filler cap «A». - Loosen the oil draining cap «B» and let the oil completely drain the tank. - Tighten the draining cap and refill the hub with oil (approx. 75 cc). Air filter -Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter.

  • Page 31: Checking The Ignition Timing

    Maintenance Checking the ignition timing - Adjust the control cables: Mix cable: see procedure indicated in "Mixer tim- ing". Throttle cable: adjust the set screw on the carbu- rettor in such a way that the sheath has no back- lash. Splitter control cable: adjust set screw on the throt- tle control to the handlebar in such a way that there is no backlash on the throttle control.

  • Page 32: Level Check

    Maintenance Level check Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars 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 pads.

  • Page 33: Headlight Adjustment

    Maintenance Headlight adjustment Proceed as follows: 1. Place the vehicle, in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10-m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;...
  • Page 34 Maintenance - If the parameters found do not agree with the above figures, act upon the idle adjusting screw. Oth- erwise, check the automatic choke device Specific tooling 020320Y Exhaust gases analyser 020332Y Digital rpm indicator The check must be carried out after having care- fully cleaned all carburettor components, with the air filter clean, and the spark plug in good condi- tions.
  • Page 35 Maintenance - Attach the special tool and move the joints as shown in the figure. - Start the engine, adjust the idle speed to 1,700 ± 100 rpm and check the CO value is equal 3.5 ± 1% - If the parameters found do not agree with the above figures, act upon the idle adjusting screw.

  • Page 36: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 37: Poor Performance

    Troubleshooting This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed air Excess of encrustations in the combustion chamber Remove the encrustations...
  • Page 38 Troubleshooting Possible Cause Operation to keep the cap in contact with the spark plug and the spark plug grounded but away from its hole. Refit a dry spark plug and start the vehicle. Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill Faulty spark plug Remove the encrustation, restore the plug gap or replace being sure to use the types of spark plug recommended at all times.

  • Page 39: High Fuel Consumption

    Troubleshooting High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty. Clean according to the procedure Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and power supply SAS malfunctions SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF- FLER Possible Cause Operation...

  • Page 40: Brakes Overheating

    Troubleshooting Brakes overheating BRAKES OVERHEATING Possible Cause Operation Defective piston sliding Check calliper and replace any damaged part. Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the wheel correctly fitted or the concentricity of the rear drum. Electrical system Battery BATTERY...

  • Page 41: Noisy Suspension

    Troubleshooting Noisy suspension NOISY SUSPENSION Possible Cause Operation NOISY SUSPENSION If the front suspension is noisy, check: the efficiency of the front shock absorbers; the condition of the ball bearings and relevant lock-nuts, the limit switch rubber buffers and the movement bushings.

  • Page 42: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...

  • Page 43: Electrical System Diagram

    Electrical system ELECTRICAL SYSTEM DIAGRAM Specification Desc./Quantity Stop button on rear brake Light switch Turn indicator switch Horn button Horn Front turn indicator bulbs Front turn indicator bulbs 12V-10W x 2 Front left turn indicator Heater control device Magneto flywheel Electronic ignition device Starter motor ELE SYS - 43...
  • Page 44 Electrical system Specification Desc./Quantity Fuse box Battery 12V - 4Ah rear left turn indicator Rear turn indicator bulbs Two, 12V-10W, spherical Stop and tail light bulb Type: Spherical Power: 12V 21/5W Quantity: 1 Rear light assembly rear right turn indicator Voltage regulator Mixer oil warning light control Start-up remote control switch...
  • Page 45 Electrical system Ignition IGNITION Specification Desc./Quantity Electronic control unit Magneto flywheel Pick - up Key switch Spark plug ELE SYS - 45...
  • Page 46 Electrical system Headlights and automatic starter section LIGHTS Specification Desc./Quantity Voltage regulator Magneto flywheel Light switch Rear light bulb 12V - 5W Headlight bulb 12V-35/35W High-beam warning light 12V - 1.2W N°3 instrument lighting bulbs 12V - 1.2W Taillight bulb 12V - 5W Headlight warning light 12V - 1.2W...
  • Page 47 Electrical system Battery recharge and starting BATTERY RECHARGE AND STARTING Specification Desc./Quantity Magneto flywheel Voltage regulator Main fuse 7,5A Brake light filament 12V - 21W Front and rear brake light button Start up button Starter motor Remote starter switch Battery 12V - 4Ah ELE SYS - 47...
  • Page 48 Electrical system Level indicators and enable signals section START PERMISSIVE BUTTONS AND LEVEL INDICATORS Specification Desc./Quantity Magneto flywheel Voltage regulator Key switch Main fuse 7,5A Brake light filament 12V - 21W Front and rear brake light button Start up button Starter motor Remote starter switch Battery...

  • Page 49: Turn Signal Lights

    Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity Battery 12V - 4Ah Main fuse 7,5A Key switch Magneto flywheel Voltage regulator Horn button Horn Indicators switch Two (2) turn signal warning light bulbs 12V - 2W 4 Turn indicator bulbs 12V-10W Checks and inspections 1) No-load test: the starter motor, when unloaded,...
  • Page 50 Electrical system - Rated voltage 12V. - Rated power 0.25 kW. - Left-hand rotation view from pinion side. - Connected to the engine by pinion and crown wheel on crankshaft, transmission side. - Push-button control. - Battery used for the test:12V-3,6Ah. N.B.

  • Page 51: Ignition Circuit

    Electrical system Ignition circuit 1) Check the state of the spark plug (clean it with a metallic brush, remove all incrustations, blow it with compressed air, and replace it if necessary). 2) Without removing the stator, perform the checks described below: After a visual inspection of the electrical connec- tions, carry out the measurements on the charging coil and pick-up (see table), and check for con-...

  • Page 52: Stator Check

    Electrical system Stator check - Using a tester, check the resistance between the stator wiring. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE LEADS TO VALUES HIGHER THAN THOSE STATED. Electric characteristic Stator : Grey ÷...
  • Page 53 Electrical system FAULT 2: a) Make sure the stator is supplying voltage cor- rectly: disconnect the regulator connector and place tester 020331 y between the grey-blue wire (2) and the black wire (6) to measure the alternat- ing voltage and make sure that the voltage sup- plied at 3000 rpm, is between 25 and 30V (FIG>...
  • Page 54 Electrical system If the values thus obtained are lower than prescri- bed, proceed by replacing the regulator. Before carrying out inspections on the regulator and its electrical system, it is always advisable to check for continuity between the black wire and earth. FAULT 5 (FIG.
  • Page 55 Electrical system FAULT 6 Oil reserve check warning light not working (FIG H) - Disconnect the voltage regulator con- nector. - Supply 12V to the terminal marked with number 5; with a digital tester check that the terminal num- ber 4 has a similar output (12V) for about 5 sec- onds.
  • Page 56 Electrical system WARNING -WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CONTINUOUS RECHARG- ING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
  • Page 57 Electrical system NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE. CAUTION DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BAT- TERY: USE DISTILLED WATER ONLY.

  • Page 58: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 59 Engine from vehicle Removal of the engine from the vehicle Remove the engine from the frame -Disconnect the battery. -Remove the muffler assembly. - Remove the rear wheel. - Remove the mechanical transmission of the rear brake. -Disconnect the electric terminals. - Remove the throttle grip and mixer transmissions.
  • Page 60 INDEX OF TOPICS NGINE...

  • Page 61: Automatic Transmission

    Engine Automatic transmission Transmission cover - Loosen the 15 screws and remove the transmis- sion cover with the aid of a mallet. N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE. Kickstart - Remove the seeger ring located on the exterior of the crankshaft.

  • Page 62: Removing The Driven Pulley Shaft Bearing

    Engine Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 - Remove the screws shown in the figure and re- move the engine starting lever. - For the assembly, work in reverse and tighten the screws to the prescribed torque.. Locking torques (N*m) Starter lever replacement 12 to 13 Nm...

  • Page 63: Removing The Driven Pulley

    Engine Removing the driven pulley - Lock the clutch bell housing with the specific tool. - Remove the nut, the clutch bell housing and the whole of the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.
  • Page 64 Engine - Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw thereby undoing the driven pulley unit - Separate the components. Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch Inspecting the clutch - Check the thickness of the clutch mass friction material.
  • Page 65 Engine - Remove the three guide pins and the mobile half pulley. Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
  • Page 66 Engine Stationary driven half-pulley/Standard diame- Ø 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diam- eter admitted after use Ø 33.96 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings. - Measure the inside diameter of the mobile half- pulley bushing.
  • Page 67 Engine Refitting the driven half-pulley bearing - Fit a new ball bearing with the specific tool. - Fit the ball bearing retention snap ring. - Fit the new roller bearing with the wording visible from the outside. CAUTION PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED.

  • Page 68: Refitting The Driven Pulley

    Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE NUT IN CONTACT WITH THE CLUTCH Locking torques (N*m) Nut locking clutch unit on pulley 55 ÷...

  • Page 69: Removing The Driving Pulley

    Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley. - 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.
  • Page 70 Engine 4) Check the integrity of the sliding blocks of the contact plate. - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inside diameter «A». - Measure outside diameter «B» of the pulley slid- ing bushing shown in the figure.
  • Page 71 Engine ORDER TO AVOID WRONG TIGHTENING AND CONSE- QUENTLY DAMAGING THE CRANKSHAFT KNURLING. Specific tooling 020451Y Starting ring gear lock Locking torques (N*m) Crankshaft pulley nut 18 to 20 + 90° Nm For 25 km/h engine type versions, the limit washer is 5.5 mm thick End gear Removing the hub cover - Drain the rear hub oil...
  • Page 72 Engine 020477Y 37 mm adaptor Removing the driven pulley shaft bearing - Remove the seeger ring - Heat the engine crankcase but do not direct the hot air towards the bearing - Extract the driven pulley shaft together with the bearing with a few mallet blows ENG - 72...
  • Page 73 Engine - Remove the bearing off the driven pulley shaft using the specific tool and a press N.B. USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALL- ER INTERNAL DIAMETER Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Inspecting the hub shaft - Check the three shafts for wear or distortion of...
  • Page 74 Engine Refitting the driven pulley shaft bearing - Support the inner track of the bearing from the outside of the hub cover with the specific tool posi- tioned under the press and insert the driven pulley axle. - Refit the oil seal flush with the cover. Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft...
  • Page 75 Engine 020363Y 20-mm guide 020359Y 42x47-mm Adaptor Refitting the hub bearings - Remove the wheel axle on the cover and pay at- tention not to damage the sealing lip of the oil seal - Apply a thin layer of grease on the two shim washers of the intermediate gear and fit one on the cap so that it does not interfere with the wheel axle gear when placing the transmission shaft...

  • Page 76: Flywheel Cover

    Engine Gasket Locking torques (N*m) hub cap screws 24 - 26 Flywheel cover Cooling hood - Remove the four fixings shown in the figure. - Remove the fan cover - Remove the oil piping retention band from the hood - Remove the 2 screws shown in the figure Cooling fan - Remove the cooling fan by acting on the three fixings indicated in the figure.

  • Page 77: Removing The Stator

    Engine Removing the stator - Remove the three stator fixings shown in the photo - Remove the two pick-up fixings shown in the photo - Remove the stator with the wiring Refitting the stator - Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
  • Page 78 Engine Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS - Extract the flywheel with the extractor. Specific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor...

  • Page 79: Removing The Intake Manifold

    Engine N.B. A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING, KNOCKING ETC. Locking torques (N*m) Flywheel nut 40 to 44 N.m Refitting the starter motor - Fit a new O-ring on the starter and lubricate it. - Fit the starter on the crankcase, locking the two screws to the prescribed torque.

  • Page 80: Inspecting The Small End

    Engine Removing the cylinder - piston assy. Remove the cylinder very carefully Remove the snap rings and remove the pin CAUTION AFTER EACH REMOVAL OPERATION REPLACE THE PIN RETENTION SNAP RINGS Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer.

  • Page 81: Inspecting The Piston

    Engine Inspecting the wrist pin - Check the wrist pin external diameter using a mi- crometer Characteristic Wrist pin: standard diameter 12 +0.005 +0.001 mm Inspecting the piston - Measure the bearings on the piston using a bore meter - Calculate the piston-pin coupling clearance. Characteristic Wrist pin housing: standard diameter 12 +0.007 +0.012...

  • Page 82: Removing The Piston

    Engine Inspecting the cylinder - Check that the cylinder does not show seizures. Otherwise, replace it or adjust it respecting the al- lowable increases - Measure the internal diameter of the cylinder with a bore meter, according to the directions given in the figure - Check that the fitting surface with the head is not dented or distorted.
  • Page 83 Engine - Use new wrist pin snap rings. - Use new cylinder base gasket. - Before refitting carefully clean all the surfaces. - Use oil to be mixed during the fitting of the piston and the cylinder. CAUTION POSITION THE ARROW PRINTED ON THE PISTON CROWN TOWARDS THE EXHAUST OPENING.

  • Page 84: Crankcase - Crankshaft

    Engine Inspecting the timing system components CAUTION CHECK THE CORRECT REED UNIT SEAL; NO LIGHT MUST PASS BETWEEN THE SUPPORT AND LAMELLA. Crankcase - crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners. Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side Specific tooling...

  • Page 85: Removing The Crankshaft

    Engine Removing the crankshaft - Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length. - Remove the crankshaft from the transmission side half crankcase Specific tooling 020163Y Crankcase splitting plate Removing the crankshaft bearings The bearings can stay on either the half crankcase or the crankshaft indifferently...
  • Page 86 Engine Refitting the crankshaft bearings Heat the bearings in an oil bath at around 150°C and fit them on the crankshaft, if necessary using a section of tube that acts on the bearing's inner track Specific tooling 020265Y Bearing fitting base Inspecting the crankshaft alignment With the specific tool shown check that the eccen- tricity of the surfaces of diam.
  • Page 87 Engine - Firmly insert the crankshaft until the bearing rea- ches the end-of-stroke stop - Let the temperature of the half crankcase settle at the temperature of the crankshaft. - Again install the special crankcase separation plate NOT installing the crankshaft protection - During the assembly phase keep the central thrust screw loose.

  • Page 88: Crankshaft Oil Seals

    Engine - Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement - Insert at least three clamping screws and tighten up rapidly - Insert the other 5 screws and tighten them to the specified torque.
  • Page 89 Engine Refitting - Install a new flywheel-side oil seal only with the special tool's punch The flywheel-side oil seal is recognised by its smaller diameter N.B. THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE WITH THE FITTED WRENCH Specific tooling 020340Y Flywheel and transmission oil seals fitting punch - Install a new transmission side oil seal using the...

  • Page 90: Fuel Supply

    Engine Remove the tube passage seal from the crank- case shown in the figure Refitting To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure Fuel supply - Completely empty the fuel tank.
  • Page 91 Engine - 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.
  • Page 92 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 93: Removing The Front Wheel

    Suspensions This section is devoted to operations that can be carried out on the suspensions. Front Removing the front wheel - Remove the wheel axle lock nut. - Remove the wheel axle and the wheel. - Upon removal take care not to damage the sen- sor that detects movement in the odometer.

  • Page 94: Refitting The Front Wheel

    Suspensions - Check that the bearings do not show flaws or jamming. Otherwise, replace them. - Check that the internal spacer does not show ab- normal wear. Otherwise, replace it. - 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...

  • Page 95: Front Fork

    Suspensions Handlebar Removal Handlebars removal Remove the handlebar cover before carrying out this operation,. - After removing the transmissions and discon- necting the electrical terminals, remove the termi- nal fixing the handlebar to the steering. - Check all components and replace faulty parts. N.B.

  • Page 96: Steering Column

    Suspensions - Remove the upper screw (2). - Add 30 cc ±1 "Fork PG" oil (SAE 20W oil for forks). - Refit all components. Locking torques (N*m) Upper screw tightening torque Lower 20 to 25 Nm screw tightening torque: 20 to 25 Nm Steering column Refitting Lower and upper bearing races to frame...

  • Page 97: Removing The Rear Wheel

    Suspensions To remove the bearing seats from the chassis, use the appropriate tool as shown in the figure. N.B. To remove the lower seating of the lower bearing just use a screwdriver as a lever between the seating and the shell. OWER AND UPPER SEATING FROM THE CHASSIS Titolo Durata/Valore...

  • Page 98: Refitting The Rear Wheel

    Suspensions Refitting the rear wheel -Refit the parts in the reverse order as for removal, lock the wheel nut to the specified torque. WARNING - FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN OR- DER TO AVOID BACKSLASH BETWEEN THE CAP AND THE WHEEL AXLE.
  • Page 99 Suspensions - Work on the screws shown in the figure. - When refitting, secure to the prescribed torque. Locking torques (N*m) Stand screw torque 18.5 to 19 Nm Centre-stand bolt removal from mounting bracket - Remove the stand support bracket from the en- gine.
  • Page 100 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 101: Front Brake Disc

    Braking system Once the muffler and the wheel have been re- moved, follow these steps: 1.Remove the shoe spring using the specific span- ner. 2. Remove the shoe with the aid of a lever. 3. Refit the new shoes giving a few taps with the mallet.

  • Page 102: Front Brake Pads

    Braking system Front brake pads Removal - To facilitate this operation remove the two calliper fixings. With the calliper detached from its support but still connected to the brake fluid line, remove the plastic cover by prising it with a screwdriver. - Remove the outside circlip from the brake pad pin, the leaf spring and the pads.
  • Page 103 Braking system DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP. WARNING - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT AB- SORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX- CEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED.
  • Page 104 Braking system Removal - Bleed the circuit and drain the brake fluid through the bleeding screw located on the calliper and ac- tuate the brake lever until no more fluid flows out. -Remove the oil pump from the handlebar; remove the brake lever and then remove the wheel cylin- der.
  • Page 105 Braking system 5. Sealing ring. 6. Piston. 7. Gasket. 8. Spring. BRAK SYS - 105...
  • Page 106 INDEX OF TOPICS CHAS HASSIS...
  • Page 107 Chassis Carrozzeria Removing the ignition key-switch when on *off* • Remove the shield back plate • Push the lock body until the stop spring does not show grooves. • Keep the lock body blocked with a screwdriver and remove the spring with a pair of pliers. •...

  • Page 108: Rear Mudguard

    Chassis Rear mudguard - Remove the side fairings - Remove the 4 screws shown in the photograph Helmet bay - Remove the side fairings - Remove the helmet compartment by undoing the 4 screws indicated in the figure CHAS - 108...
  • Page 109 Chassis Fuel tank - Remove the side fairings - Remove the rear mudguard - Remove the crews shown in the photograph - Remove the shock absorber upper clamping in order to create the necessary space to take out the tank. CHAS - 109...
  • Page 110 INDEX OF TOPICS PRE DE DELIVERY...

  • Page 111: Electrical System

    Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing Front wheel axle nut Wheel hub nut Frame - swinging arm bolt * Swinging arm bolt - Engine...

  • Page 112: Static Test

    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.

  • Page 113: Functional Inspection

    Pre-delivery - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. Functional inspection Functional check up: Braking system (hydraulic)
  • Page 114 INDEX OF TOPICS TIME...
  • Page 115 Time This section is devoted to the time necessary to carry out repairs. The description and code for each operation is in- dicated. Engine ENGINE Code Action Duration 001001 engine from frame - removal and re- fitting TIME - 115...
  • Page 116 Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement TIME - 116...
  • Page 117 Time Crankshaft RANKSHAFT Code Action Duration 001118 Main bearings - Replacement 001100 Clutch-side oil seal - Replacement 001099 Oil seal, flywheel side - Replacement 001117 Crankshaft - Replacement TIME - 117...

  • Page 118: Cylinder Assy

    Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001107 Cylinder / piston - Inspection / clean- TIME - 118...

  • Page 119: Cylinder Head Assy

    Time Cylinder head assy. HEAD Code Action Duration 001097 Cooling hood - Replacement 001093 Spark plug - Replacement 001126 Head - Replacement 001013 Intake manifold - Replacement 001178 Disc pack - Replacement TIME - 119...

  • Page 120: Driven Pulley

    Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001012 Driven pulley - overhaul 001110 Driven pulley- Replacement 001022 Clutch - Replacement 001155 Clutch bell housing - Replacement TIME - 120...

  • Page 121: Oil Pump

    Time Oil pump OIL PUMP Code Action Duration 001028 Mix movement gear socket - Re- placement 001019 Mixer belt - replacement 001018 Mixer - Replacement TIME - 121...

  • Page 122: Driving Pulley

    Time Driving pulley DRIVING PULLEY Code Action Duration 001066 Driving pulley - Removal and refitting 001086 Driving half-pulley - replace 001011 Driving belt - Replacement 001177 Variator rollers / shoes - Replace- ment TIME - 122...

  • Page 123: Transmission Cover

    Time Transmission cover TRANSMISSION COVER Code Action Duration 001087 Flywheel cover - Replacement 001135 Transmission cover bearing - Re- placement 001096 Transmission crankcase cover - Re- placement TIME - 123...

  • Page 124: Flywheel Magneto

    Time Flywheel magneto FLYWHEEL - FAN Code Action Duration 001109 Cooling fan - Replacement 001173 Rotor - Replacement 001067 Stator - Fitting and Refitting 001058 Flywheel - Replacement TIME - 124...
  • Page 125 Time Carburettor CARBURATOR Code Action Duration 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heating tubing - replace- ment 001081 Automatic choke - Replacement TIME - 125...

  • Page 126: Exhaust Pipe

    Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 126...

  • Page 127: Air Cleaner

    Time Air cleaner AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting - Re- placement 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement TIME - 127...
  • Page 128 Time Frame STAND Code Action Duration 004001 Frame - replace 004004 Stand - Replacement 001053 Stand bolt - Replacement TIME - 128...
  • Page 129 Time Legshield spoiler FRONT SHIELD SPOILER Code Action Duration 004159 Plates / Stickers - Replacement 004149 Shield central cover - Replacement 004064 Front shield, front part - Removal and refitting 004015 Footrest - Removal and Refitting 004053 Spoiler - Replacement TIME - 129...

  • Page 130: Rear Cover

    Time Rear cover REAR SHIELD Code Action Duration 004174 Trunk levers - Replacement 004065 Legshield, rear part - Removal and refitting 004081 Top box lid - Replacement TIME - 130...
  • Page 131 Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replace- ment 004106 Under-saddle band - Replacement 004085 Fairing (1) - Replacement 004105 Right side clamp - Replacement 004131 Luggage rack support - Replacement TIME - 131...
  • Page 132 Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 132...
  • Page 133 Time Fuel tank FUEL TANK Code Action Duration 004168 Fuel tank cap - Replacement 005010 Tank float - Replacement 004112 Cock-carburettor hose - Replace- ment 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement 004109 Fuel tank breather - change TIME - 133...

  • Page 134: Oil Reservoir

    Time Tank oil OIL RESERVOIR Code Action Duration 005018 Oil reservoir float - Replacement 004017 Oil reservoir - Replacement 004095 Oil reservoir cock - Replacement 004091 Oil reservoir hose - Replacement Rear shock-absorber TIME - 134...

  • Page 135: Rear Shock Absorber

    Time REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003051 Complete fork - Replacement 003002 Steering fifth wheels - Replacement 003073 Steering clearance - Adjustment TIME - 135...

  • Page 136: Handlebar Covers

    Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004019 Handlebar rear section - Replace- ment 004018 Handlebar front section - Replace- ment 005078 Odometer glass - Replacement 005076 Clock / Cell - Replacement 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs - Replacement TIME - 136...

  • Page 137: Handlebar Components

    Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 004066 Driving mirror - Replacement 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 003001 Handlebar - Replacement 005017 Stop switch - Replacement 002024 Front brake pump - Removal and Re- fitting 002054 Throttle or splitter transmission com-...

  • Page 138: Swinging Arm

    Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-frame connection swinging arm - Replacement TIME - 138...
  • Page 139 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004068 Passenger handgrip - Replacement TIME - 139...
  • Page 140 Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - Replacement 005012 Front turn indicator - Replacement 005067 Front turn indicator bulb - Replace- ment 005008 Headlight bulbs - Replacement 005005 Taillight - change 005066 Rear light bulbs - Replacement 005022 Rear turning indicators - Replace- ment...

  • Page 141: Front Wheel

    Time Front wheel FRONT WHEEL Code Action Duration 003038 Front wheel axle - Remov. and refitt. 002011 Odometer movement sensor - Re- placement 003040 Front wheel bearings - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim - Removal and Re- fitting 004123 Front wheel - Replacement...
  • Page 142 Time Rear wheel REAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replacement 001071 Rear wheel rim - Removal and Refit- ting 001016 Rear wheel - Replacement 002002 Rear brake pads/shoes - Repl. TIME - 142...

  • Page 143: Electric Start

    Time Electric start ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable harness - Re- placement 001017 Starter sprocket wheel - Replace- ment 001021 Kick starter - Inspection 008008 Starter spring pack - Replacement 001084 Starter lever - Replacement TIME - 143...

  • Page 144: Electric Devices

    Time Electric devices ELECTRICAL DEVICES Code Action Duration 005007 Battery - change 005011 Start-up contactor - Replacement 005052 Fuse (1) - Replacement 005054 Fuse block (1) - Replacement TIME - 144...
  • Page 145 Time ELECTRICAL DEVICES Code Action Duration 005001 Electrical system - Replacement 005009 Voltage regulator - Replacement 001094 Spark plug cap - Replacement 001023 Control unit - Replacement 005114 Electrical system - Service TIME - 145...

  • Page 146: Electronic Controls

    Time Electronic controls ELECTRIC CONTROLS Code Action Duration 005039 Lights switch - Replacement 005006 Light or turning indicator switch - Re- placement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement 005016 Key switch - Replacement 004096 Lock series - Replacement TIME - 146...
  • Page 147 Time Transmissions RANSMISSION Code Action Duration 002051 Odometer transmission assembly - Replacement 002012 Splitter - Replacement 002057 Carburettor / splitter transmission complete - Replacement 002058 Mix / splitter transmission complete - Replacement 002053 Rear brake transmission complete - Replacement 002049 Odometer cable - Replacement 003061 Accelerator transmission - adjust...

  • Page 148: Brake Callipers

    Time Brake callipers CALLIPER Code Action Duration 002021 Front brake hose - Remov. and Re- fitt. 002007 Front brake shoes/pads - Remov. and Refitt 002039 Front brake calliper - Removal and Refitting 002047 Front brake fluid and air bleed sys- tem - Replacement TIME - 148...
  • Page 149 Time Steering column STEERING Code Action Duration 003048 Fork oil seal - Replacement 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003010 Front suspension - Service TIME - 149...

  • Page 150: Helmet Compartment

    Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 005046 Battery cover - change TIME - 150...

  • Page 151: Rear Wheel Axle

    Time Rear wheel axle REAR WHEEL AXLE Code Action Duration 001156 Gear reduction unit cover - Replace- ment 004125 Rear wheel axle - Replacement 001010 Geared reduction unit - Service 003065 Gear box oil - Replacement TIME - 151...
  • Page 152 Time Secondary air box SECONDARY AIR HOUSING Code Action Duration 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning 001162 Secondary air housing - Replace- ment 001163 Muffler secondary air connection - Replacement 001165 Secondary air reed - Replacement TIME - 152...
  • Page 153 Air filter: 30 Battery: 40, 47, 55, 56 Brake: 101–103, 148 Carburettor: 11, 27, 125 Engine stop: Fuel: 39, 90, 109, 133 Headlight: 33 Horn: Hub oil: 29 Identification: 8 Maintenance: 7, 25 Saddle: Shock absorbers: 98 Spark plug: 28 Stand: Start-up: Tank: 109, 133, 134...

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