PIAGGIO MSS Fly 50 4T Workshop Manual
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PIAGGIO MSS Fly 50 4T Workshop Manual

PIAGGIO MSS Fly 50 4T Workshop Manual

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WORKSHOP MANUAL
633212
MSS Fly 50 4T

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  • Page 1 WORKSHOP MANUAL 633212 MSS Fly 50 4T...
  • Page 2 Not all versions shown in this publication are available in all countries. The availability of single models should be checked at the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 MSS Fly 50 4T This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
  • Page 5 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

    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.

  • Page 8: Vehicle Identification

    MSS Fly 50 4T Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Engine prefix C442M ÷ 1001 Chassis prefix ZAPM44200 ÷ 1001 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Length 1,880 Maximum height 1150 mm Seat height Width Wheelbase 1,340...
  • Page 9 MSS Fly 50 4T Characteristics Engine ENGINE Specification Desc./Quantity Engine type Single cylinder 4-stroke Piaggio Hi-PER4 Bore x stroke 39 X 41.8 mm Cubic capacity 49.93 cm³ Compression ratio 11.5 :1 Timing system single overhead camshaft, driven by a chain to the left side.

  • Page 10: Electrical System

    MSS Fly 50 4T Characteristics Transmission RANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V- belt, automatic clutch, gear reduction unit. Capacities CAPACITY Specification Desc./Quantity Rear hub oil Quantity: approx. 85 cc Engine oil Capacity: approx. 850 cm³...

  • Page 11: Wheels And Tyres

    MSS Fly 50 4T Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front wheel rim Die-cast aluminium alloy 3.50 x 12" Front tyre Tubeless, 120/70-12" Rear wheel rim Die-cast aluminium alloy: 3.00"x12" Rear tyre Tubeless, 120/70 - 12" Front tyre pressure 1.8 bar...

  • Page 12: Tightening Torques

    MSS Fly 50 4T Characteristics Kehin KEHIN CARBURETTOR Specification Desc./Quantity Type CVK 18 Throttle valve diameter: Ø 18,5 Choke diameter Ø 17 Marking on body: Z61B Maximum thrust Maximum air thrust (on body) Ø1,1 Marking on conical needle: NGBA Throttle spring: 100 ÷...
  • Page 13 MSS Fly 50 4T Characteristics Cylinder - piston assy. CONNECTION PISTON AND CYLINDER Name Initials Cylinder Piston Play on fitting Cylinder (with asso pis- 38,993 ÷ 39,000 38,954 ÷ 38,961 0.032 ÷ 0.046 ton/right way) Cylinder (with shiram 38,993 ÷ 39,000 38,949 ÷...
  • Page 14 MSS Fly 50 4T Characteristics Piston rings SEAL RINGS Name Description Dimensions Initials Quantity 1st Compression ring 39 x 1 0.08 ÷ 0.20 2nd Compression ring 39 x 1 0.05 ÷ 0.20 Oil scraper ring 39 x 2 0.20 ÷ 0.70 1st Compression ring 39.2 x 1...
  • Page 15 MSS Fly 50 4T Characteristics Crankcase - crankshaft - connecting rod END PLAY BETWEEN DRIVING SHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, transmission 14 +0 -0.005 side Flywheel-side half-shaft 16 +0 -0.005 Connecting rod 14.8 +0.05 -0 Spacer tool 45.00 / Fits and clearan-...
  • Page 16 MSS Fly 50 4T Characteristics Products TABLE OF RECOMMENDED PRODUCTS 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...
  • Page 17 INDEX OF TOPICS TOOL OOLING...
  • Page 18 MSS Fly 50 4T Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y008 Pliers to extract 17 mm ø bearings 001467Y009 Driver for OD 42-mm bearings 004499Y Camshaft bearing extractor 005095Y Engine support 008119Y009 Tube to assemble shafts and axles...
  • Page 19 MSS Fly 50 4T Tooling Stores code Description 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for Ø 17 mm roller case...
  • Page 20 MSS Fly 50 4T Tooling Stores code Description 020265Y Bearing fitting base 020288Y Fork to assemble piston on cylinder 020291Y Valve fitting/ removal tool 020306Y Punch for assembling valve sealing rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing...
  • Page 21 MSS Fly 50 4T Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 21...
  • Page 22 MSS Fly 50 4T Tooling Stores code Description 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40-mm Adaptor 020359Y 42x47-mm Adaptor 020360Y 52x55-mm Adaptor 020362Y 12 mm guide TOOL - 22...
  • Page 23 MSS Fly 50 4T Tooling Stores code Description 020363Y 20 mm guide 020364Y 25-mm guide 020376Y Adaptor handle 020431Y Valve oil seal extractor 020432Y Tool to fit the start-up sector spring 020439Y 17 mm guide TOOL - 23...
  • Page 24 MSS Fly 50 4T Tooling Stores code Description 020448Y Pin lock fitting tool 020449Y Piston position check support 020450Y Camshaft fitting/removal tool 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner...
  • Page 25 MSS Fly 50 4T Tooling Stores code Description 494929Y Exhaust fumes analyser TOOL - 25...
  • Page 26 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 27: Maintenance Chart

    MSS Fly 50 4T Maintenance Maintenance chart AFTER 1,000 KM OR 4 MONTHS Action Hub oil - change Valve clearance - check Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear...
  • Page 28 MSS Fly 50 4T Maintenance 24000 48000 VERY KM OR Action Engine oil - replacement Hub oil level - check Spark plug / electrode gap - check / replacement Air filter - clean Oil filter (net filter) - clean Valve clearance - check...
  • Page 29 MSS Fly 50 4T Maintenance Action Valve clearance - check Idle speed (*) - adjustment Throttle lever - adjustment Variable speed rollers - check or replacement Driving belt - replacement Cylinder ventilation system - check Odometer gear - greasing Steering - adjustment...

  • Page 30: Checking The Spark Advance

    MSS Fly 50 4T Maintenance 1. Needle valve - 2. Idle speed adjustment screw - 3. Max jet - 4. Accelerating pump - 5. Tapered pin - 6. Jet holder - 7. Float - 8. Chamber - 9. Starter device - 10. Vacuum valve - 11. Cover - 12. Minimum jet.

  • Page 31: Spark Plug

    MSS Fly 50 4T Maintenance Spark plug Detach the spark plug cap and then remove the spark plug. - Carefully examine the spark plug, and replace it if the insulator is damaged or chipped. - With the aid of a feeler gauge, measure the spark gap and, if necessary, adjust by bending outer electrode with care.
  • Page 32 MSS Fly 50 4T Maintenance Direct the jet of compressed air into the round groove between the threaded metal part and the ceramic part of the inner electrode while turning the spark plug to allow removal of the oil in excess.

  • Page 33: Engine Oil

    MSS Fly 50 4T Maintenance 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;...

  • Page 34: Engine Oil Filter

    MSS Fly 50 4T Maintenance - Start the engine, let it idle for about a minute and then switch it off. - Wait for at least ten minutes and then top up by adding oil to the «MAX» level. Check Check oil level every time the vehicle is used, with the engine cold.

  • Page 35: Checking The Ignition Timing

    MSS Fly 50 4T Maintenance - Refill the engine with oil through the oil filling hole located in the oil sump. - Engine oil capacity: ~ 850 cc. - Lock the cap manually. N.B. Run the engine for a couple of minutes and check the oil level when the engine is cold.

  • Page 36: Checking The Valve Clearance

    MSS Fly 50 4T Maintenance Checking the valve clearance - Remove the spark plug access cover, undo the 4 fixing screws indicated in the figure and remove the tappet cover. - To check valve clearance, centre the reference marks of the timing system point as described above.
  • Page 37 MSS Fly 50 4T Maintenance MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU- TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED. CO check The check may be necessary in the event of irreg- ularities in the engine performances, or when ad- justing the engine idle speed.
  • Page 38 MSS Fly 50 4T Maintenance 9) Adjust the flow screw so to obtain a "CO" read- ing of 3.2 % ± 0.5 %. 10) Slowly twist the throttle handgrip, bringing the engine up to a speed of 4,000 rpm and then re- lease it;...
  • Page 39 MSS Fly 50 4T Maintenance MAIN - 39...
  • Page 40 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 41: Rear Wheel Spins At Idle

    MSS Fly 50 4T 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 The carburettor is dirty;...

  • Page 42: Engine Tends To Cut Out At Full Throttle

    MSS Fly 50 4T Troubleshooting Possible Cause Operation Automatic starter failure Check: mechanical movement, electric connection and fuel supply, replace if required. Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.
  • Page 43 MSS Fly 50 4T Troubleshooting Possible Cause Operation Incorrect idle adjustment Adjust using the rpm indicator Pressure too low at the end of compression Check the thermal group seals and replace worn components Faulty spark plug or incorrect ignition advance...
  • Page 44 MSS Fly 50 4T Troubleshooting Insufficient braking NSUFFICIENT BRAKING Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits;...

  • Page 45: Rear Wheel

    MSS Fly 50 4T Troubleshooting Rear wheel REAR WHEEL ROTATES WITH ENGINE AT IDLE Possible Cause Operation Idling rpms too high Adjust the engine idle speed and the CO%, if necessary. Clutch fault Check the springs / clutch masses Controls...
  • Page 46 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 47 MSS Fly 50 4T Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Front left turn indicator Front turn indicator bulbs Front turn indicator bulbs 12V-10W x 2 Horn button Indicators switch Light switch Rear stop switch Headlight bulb 12V-35/35W Front tail light bulb...
  • Page 48 MSS Fly 50 4T Electrical system Specification Desc./Quantity Front brake stop button Starter button Key switch front right turn indicator Fuel level transmitter Automatic starter Starter remote control rear right turn indicator Rear light assembly Stop and tail light bulb...
  • Page 49 MSS Fly 50 4T Electrical system IGNITION Specification Desc./Quantity Magneto flywheel Pick - up Key switch contacts Electronic ignition device Fuse 10 A Voltage regulator Battery 12V-9Ah Headlights and automatic starter section HEADLIGHTS Specification Desc./Quantity Magneto flywheel Voltage regulator Light switch...
  • Page 50 MSS Fly 50 4T Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP SECTION Specification Desc./Quantity Voltage regulator Magneto flywheel Automatic starter Battery 12V-9Ah Remote starter switch Starter motor Start up button Brake light filament 12V-21W Front and rear brake light button...
  • Page 51 MSS Fly 50 4T Electrical system Level indicators and enable signals section START PERMISSIVE BUTTONS AND LEVEL INDICATORS Specification Desc./Quantity Voltage regulator Fuel gauge Fuel level sender Low fuel warning light 12V - 1.2W Front and rear brake light button...

  • Page 52: Turn Signal Lights

    MSS Fly 50 4T Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity Indicators switch Horn button Horn Two (2) turn signal warning light bulbs 12V - 2W 4 Turn indicator bulbs 12V-10W Voltage regulator Key switch contacts...
  • Page 53 MSS Fly 50 4T 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 dam- aged parts.
  • Page 54 MSS Fly 50 4T Electrical system 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 TEMPERA- TURE LEADS TO VALUES HIGHER THAN THOSE STATED.
  • Page 55 MSS Fly 50 4T Electrical system Insert the positive terminal from the tester (setting the tester on AC mode) on terminal no. 1 (yellow- black wire) and the negative terminal on terminal no. 2 (black wire); check for voltage (see figure).
  • Page 56 MSS Fly 50 4T Electrical system a) Bursting of protection fuse (regulator short- circuited). Check the wiring running from the fuse to the ig- nition key-switch is not damaged, as this may cre- ate a short-circuit with earth (thus excluding possible regulator failures);...
  • Page 57 MSS Fly 50 4T Electrical system horn, current values of ≥ 5A may be found, with voltage readings of 14 - 14.5V (regulator threshold voltage). If the readings do not match the above figures, replace the regulator; otherwise check wiring and connections.
  • Page 58 MSS Fly 50 4T Electrical system 3 The float must be freed Dry-charge battery The battery is an electrical device which requires careful monitoring and diligent 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.
  • Page 59 MSS Fly 50 4T Electrical system INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger WARNING - Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact with eyes, skin and clothing.
  • Page 60 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 61 MSS Fly 50 4T Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Undo the 2 screws fixing the muffler to the hous- ing; then remove the whole muffler paying atten- tion to the interference between its supporting bracket and the cooling cover.
  • Page 62 INDEX OF TOPICS NGINE...

  • Page 63: Automatic Transmission

    MSS Fly 50 4T Engine 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 vehi- cle, it is necessary to remove the transmission cooling coupling and the air filter housing retain- ers.

  • Page 64: Removing The Driven Pulley

    MSS Fly 50 4T Engine Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

  • Page 65: Inspecting The Clutch Drum

    MSS Fly 50 4T Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the inner diameter of the clutch bell. Characteristic Clutch bell diameter/standard value Ø 107+0.2 +0 mm Clutch bell diameter/max. value allowed after Ø...
  • Page 66 MSS Fly 50 4T Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
  • Page 67 MSS Fly 50 4T Engine 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 68 MSS Fly 50 4T Engine 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. Characteristic Mobile driven half-pulley/ Maximum diameter allowed Ø...
  • Page 69 MSS Fly 50 4T Engine 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation...

  • Page 70: Refitting The Driven Pulley

    MSS Fly 50 4T 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...

  • Page 71: Removing The Driving Pulley

    MSS Fly 50 4T 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.
  • Page 72 MSS Fly 50 4T 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 Refitting the driving pulley - Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.
  • Page 73 MSS Fly 50 4T Engine Refitting the transmission cover - Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and its seating in the crankcase and the re- turn spring. - Remove the damaged components.
  • Page 74 MSS Fly 50 4T Engine Removing the hub cover - Drain the rear hub oil - Remove driven pulley - Remove the rear brake shoes - Remove the 5 screws fixing the cover to the crankcase - Remove the cover with the wheel axle and pull it...
  • Page 75 MSS Fly 50 4T Engine 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...
  • Page 76 MSS Fly 50 4T Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents.
  • Page 77 MSS Fly 50 4T 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...
  • Page 78 MSS Fly 50 4T Engine Gasket Locking torques (N*m) hub cap screws 24 - 26 Flywheel cover Cooling hood - Remove the manifold and the carburettor undo- ing the 2 fixing screws on the head - Remove the fastening clamp of the secondary air...

  • Page 79: Removing The Stator

    MSS Fly 50 4T 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.
  • Page 80 MSS Fly 50 4T Engine Removing the starter motor - Undo the screw on the power positive contact and disconnect the cable - Undo the 2 screws fixing the starter motor to the crankcase and recover the power wiring. Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner.
  • Page 81 MSS Fly 50 4T Engine Inspecting the flywheel components - Check that the flywheel internal magnets are in good conditions. - Check that the flywheel splines exhibit no loos- ening. - Check there are no deformations that may cause rubbing on the stator and the Pick-Up.
  • Page 82 MSS Fly 50 4T Engine Refitting the flywheel magneto - Refit the stator and the pick-up being careful to pass the wiring through the appropriate crankcase couplings. - Refit the flywheel to the crankshaft being careful to respect the keying, then lock rotation with the specific tool and tighten the nut to the prescribed torque.
  • Page 83 MSS Fly 50 4T Engine Removing the rocker-arms cover - Remove the cooling covers - Remove the 4 retainers of the tappet cover - Remove the cover and the O-ring - Remove the 4 screws and then remove the Blow-...
  • Page 84 MSS Fly 50 4T Engine - 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 cam- shaft crown with the specific tool.

  • Page 85: Removing The Cylinder Head

    MSS Fly 50 4T Engine 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 - Pull out the rocking lever bolt operating on the flywheel hole and remove the rocking levers at the same time.

  • Page 86: Removing The Valves

    MSS Fly 50 4T Engine Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves. - Remove the oil seals with the appropriate tool.

  • Page 87: Inspecting The Small End

    MSS Fly 50 4T Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANK-...
  • Page 88 MSS Fly 50 4T Engine - Measure the coupling clearance between the sealing rings and the piston grooves using a thickness gauge, as shown in the figure. - If the clearances detected exceed the limits specified in the table, the piston and the piston rings should be replaced.
  • Page 89 MSS Fly 50 4T Engine - The pistons are oversized due to cylinder rectifi- cation and are subdivided into two categories 1st and 2nd with 0.2-0.4mm oversize. They are also classified into 4 categories A-A, B-B, C-C, D-D. Inspecting the piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter.

  • Page 90: Removing The Piston

    MSS Fly 50 4T Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the pin stop ring onto the appropriate tool. Specific tooling...
  • Page 91 MSS Fly 50 4T Engine - Provisionally fit the piston into the cylinder, without any base gasket. - Fit a dial gauge on the specific tool, then rest both on a stop surface. - Zero set the dial gauge on the stop surface. Keeping the zero position, assemble the tool on the cylinder and lock it with 2 nuts as shown in the figure.
  • Page 92 MSS Fly 50 4T Engine CYLINDER BASE GASKET THICKNESS Specification Desc./Quantity Cylinder height 57.15 ± 0.05 Head gasket thickness (steel) 0.3 ± 0.05 Measure detected 0.20 ± 0.05 Base gasket thickness Measure detected 0.30 ± 0.05 Base gasket thickness This engine is manufactured with two different head gasket solutions: - Fibre gasket drw.
  • Page 93 MSS Fly 50 4T Engine Refitting the piston rings - Fit the oil scraper ring starting from the spring, taking care that the spring ends do not superim- pose. Fit the two piston rings so that their gaps and that of the oil scraper ring are never aligned.

  • Page 94: Inspecting The Cylinder Head

    MSS Fly 50 4T Engine NATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD. SEALING RINGS Name Descripti Dimensio Initials Quantity Top piston 0.08 ÷ 0.35 mm ring 0.20 mm Middle pis- 0.05 ÷ 0.30 mm ton ring 0.20 mm...
  • Page 95 MSS Fly 50 4T Engine 0.05 mm HEAD CHECK Specification Desc./Quantity Standard diameter (mm) A Ø 32.015 ÷ 32.025 mm Standard diameter (mm) B Ø 16.0 ÷ 16.018 Standard diameter (mm) C Ø 11.0 ÷ 11.018 Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out.
  • Page 96 MSS Fly 50 4T Engine 1.6 mm - Insert the valves into the cylinder head. - Test the 2 valves alternatively. - 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.
  • Page 97 MSS Fly 50 4T Engine Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between the valve and the valve guide. Characteristic Minimum diameter allowed: Intake 4.970 mm...
  • Page 98 MSS Fly 50 4T Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with graphite grease. - Place the lower plates of the valve spring on the head.
  • Page 99 MSS Fly 50 4T Engine Ø 11.98 mm Minimum diameter allowed - Bearing B: Ø 15.96 mm - 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.
  • Page 100 MSS Fly 50 4T Engine Refitting the head and timing system components - Fix the head on a workbench. - Screw the tool to fit the camshaft fully down on the bearing's inner track. - Fit the camshaft fully into its seating together with the bearing with the aid of a mallet.
  • Page 101 MSS Fly 50 4T Engine - Finish the head tightening following the proce- dure 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.
  • Page 102 MSS Fly 50 4T Engine - Bring the screw closer but without reaching its final locking point. - Push the tensioner pad lightly so as to check the correct timing. - Use the specific tool to lock the camshaft crown gear and tighten the screw.
  • Page 103 MSS Fly 50 4T Engine Refitting the rocker-arms cover - Carry out the removal procedure but in reverse order and tighten the four fixing screws to the specified torque. N.B. FIT A NEW O-RING ON THE TAPPET COVER. Locking torques (N*m) Timing chain tensioner screws 8 ÷...
  • Page 104 MSS Fly 50 4T Engine Splitting the crankcase halves - Remove the ten crankshaft coupling screws. -Separate the crankcase halves keeping the half casing driving shaft engaged on the transmission side. - Remove the crankshaft. CAUTION IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC- CIDENTALLY FALL.
  • Page 105 MSS Fly 50 4T Engine - 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 Removing the crankshaft bearings - Remove the flywheel bearing fitted on the driving shaft using the specific tool.
  • Page 106 MSS Fly 50 4T Engine - Support the crankcase on a surface and place it with the driving shaft axle in a vertical position. - Warm the crankcase at ~ 120° C with a thermal gun (and support). - Fit the punch with guide and adaptor, place the bearing on the punch using grease (to keep it from falling).
  • Page 107 MSS Fly 50 4T Engine 020074Y Support base for checking crankshaft alignment Refitting the crankcase halves -Be careful to place the two centring dowels pref- erably on the flywheel side half casing. -Insert the crankshaft on the half casing on the transmission side.
  • Page 108 MSS Fly 50 4T Engine Crankshaft oil seals Removal - 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.

  • Page 109: Oil Pump

    MSS Fly 50 4T Engine - 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.
  • Page 110 MSS Fly 50 4T Engine - 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.
  • Page 111 MSS Fly 50 4T Engine - 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.

  • Page 112: Fuel Supply

    MSS Fly 50 4T Engine Removing the oil sump - Remove the oil filling cap, the transmission cover, the complete driving pulley assembly with belt and pinion. - Unscrew the oil drainage plug «A» shown in the figure and drain out all the oil from the sump.

  • Page 113: Removing The Carburettor

    MSS Fly 50 4T Engine - Take up the fuel by means of a graded burette. N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR- RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB- TAIN A REDUCED FUEL FLOW RATE.
  • Page 114 MSS Fly 50 4T Engine - Remove the protection, the bracket and the start- er 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...
  • Page 115 MSS Fly 50 4T 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.
  • Page 116 MSS Fly 50 4T Engine - Remove the sprayer tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM- AGE IT.
  • Page 117 MSS Fly 50 4T Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with a degreasing solvent and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For the minimum circuit, make sure the following...
  • Page 118 MSS Fly 50 4T Engine - 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 cylindric part directed to the diffuser.
  • Page 119 MSS Fly 50 4T Engine - Check the diaphragm is in good conditions and remove the remaining components of the acceler- ating pump following these steps: - Insert the O-Ring in the pipe. - Insert the diaphragm together with the pin and its spring.
  • Page 120 MSS Fly 50 4T Engine - 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...
  • Page 121 MSS Fly 50 4T Engine - The starter should disconnect progressively by means of electrical heating. - Check the starter resistance when adjusted to the ambient temperature. Characteristic ambient temperature 24° C Electric characteristic Automatic starter resistance 6 Ω ± 5 % - Use battery to power the automatic starter and check that piston protrudes as much as possible.
  • Page 122 MSS Fly 50 4T Engine - Insert rubber pipes for chamber ventilation. - Insert the O-Ring, the washer, the spring and the idle flow screw in their seatings. - 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.
  • Page 123 MSS Fly 50 4T Engine 40 ÷ 50 cm - Connect the tester thermometer to the sump, us- ing a cover with oil expressly prepared for probes. - Start the engine and before adjusting the idle speed, make sure that the oil temperature is be- tween 70÷80 °C.
  • Page 124 MSS Fly 50 4T Engine loss of engine blows as the mixture is too lean (low CO), ignition failure or, incorrect timing or a clogged or unsealed exhaust valve. If it is difficult to adjust CO values, check accurately: - That the automatic starter is efficient.
  • Page 125 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 126: Removing The Front Wheel

    MSS Fly 50 4T Suspensions Sospensioni anteriore This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the wheel axle lock nut. - Remove the wheel axle and the wheel.
  • Page 127 MSS Fly 50 4T 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...

  • Page 128: Front Fork

    MSS Fly 50 4T Suspensions Handlebar Removal Smontaggio manubrio 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.
  • Page 129 MSS Fly 50 4T 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...

  • Page 130: Steering Column

    MSS Fly 50 4T Suspensions Steering column Refitting Lower and upper bearing races to frame Lower and upper seating on the chassis Removal Rondella e sede superiore cuscinetto superiore After removing the upper seating, tilt the vehicle to a side and take out the steering tube making sure mudflaps have been removed and the calliper dis- connected.

  • Page 131: Removing The Rear Wheel

    MSS Fly 50 4T Suspensions Removing the rear wheel - Use a screwdriver as a lever between the drum and the cover. -Straighten the split pin and remove the cap. -Remove the wheel acting on the central fixing point. WARNING -ALWAYS USE NEW SPLIT PINS FOR REFITTING.
  • Page 132 MSS Fly 50 4T Suspensions - To replace the shock absorber remove the rear cover and battery access flap to get and remove the shock absorber/ chassis anchoring nut. Then remove the shock absorber/engine anchorage nut. Refitting - When refitting, tighten the shock absorber/chassis anchoring nut and the shock absorber/engine pin to the prescribed torque.
  • Page 133 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 134 MSS Fly 50 4T Braking system Front brake calliper Removal - Inspect the condition of the hoses, packing and joint. In the event of fluid leaks from the calliper, this must be replaced. - Detach the oil brake pipe from the calliper; pour the fluid inside a container.
  • Page 135 MSS Fly 50 4T Braking system 2) place the guide rubbers (8) and refit the fixed plate (4); 3) assemble the reaction plate (3) tightening the screws (2), insert the brake pad check spring (9) and then the pads, fixing them with the corre- sponding screws (1);...

  • Page 136: Front Brake Disc

    MSS Fly 50 4T Braking system Refitting - When refitting, tighten the nuts to the prescribed torque. - Bleed the system. N.B. WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS. Locking torques (N*m) Oil bleed screw 7 ÷ 10 Calliper tightening screw 24 ÷ 27 Brake fluid pipe-calliper fitting 19 ÷ 24...

  • Page 137: Front Brake Pads

    MSS Fly 50 4T Braking system Disc Inspection - Remove the wheel and check for unevenness of the disc. Maximum permissible out of true is 0.1 mm. If the value measured is greater, fit a new disc and re- peat the check.
  • Page 138 MSS Fly 50 4T Braking system Loctite 243 medium-strength threadlock Locking torques (N*m) Screw tightening calliper to the support 20 ÷ 25 Pad fastening pin 19.6 ÷ 24.5 Fill Front -Once the bleed valve is closed, fill the system with brake liquid to the maximum level.
  • Page 139 MSS Fly 50 4T Braking system 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.

  • Page 140: Rear Drum Brake

    MSS Fly 50 4T Braking system 8 - Spring CAUTION - THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES THE BRAKING EFFICIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY SOLVENT.
  • Page 141 MSS Fly 50 4T Braking system Specific tooling 020325Y Pliers for brake-shoe springs BRAK SYS - 141...
  • Page 142 INDEX OF TOPICS CHAS HASSIS...
  • Page 143 MSS Fly 50 4T Chassis QUESTA SEZIONE È IN LAVORAZIONE 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 144: Rear Mudguard

    MSS Fly 50 4T Chassis Air filter • Unscrew the 7 cover screws and remove the cover to reach the filter sponge. • To disassemble the filter housing, unscrew the 2 bottom screws and disconnect the manifold con- nections, the carburettor and the external air in- take.

  • Page 145: Fuel Tank

    MSS Fly 50 4T Chassis Helmet bay - Remove the side fairings - Remove the helmet compartment by undoing the 4 screws indicated in the figure Fuel tank - Remove the side fairings - Remove the rear mudguard - Remove the crews shown in the photograph...
  • Page 146 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 147 MSS Fly 50 4T Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting plastic parts - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing...
  • Page 148 MSS Fly 50 4T 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.
  • Page 149 MSS Fly 50 4T Pre-delivery 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 CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 150 INDEX OF TOPICS TIME...
  • Page 151 MSS Fly 50 4T 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- fit.
  • Page 152 MSS Fly 50 4T Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement Crankshaft TIME - 152...
  • Page 153 MSS Fly 50 4T Time CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001099 Oil seal, flywheel side - Replacement 001100 Oil seal, clutch side - Replacement 001118 Main bearings - Replacement Cylinder assy. CYLINDER- PISTON Code Action Duration 001002...
  • Page 154 MSS Fly 50 4T Time Cylinder head assy. HEAD Code Action Duration 001056 Head gasket - Replacement 001045 Valves - Replacement 001126 Head - Replacement TIME - 154...
  • Page 155 MSS Fly 50 4T Time Rocker arms support assy. CAMSHAFT SUPPORT Code Action Duration 001049 Valve clearance - Adjustment 001148 Valve rocking levers - Replacement 001044 Camshaft - Replacement TIME - 155...

  • Page 156: Cylinder Head Cover

    MSS Fly 50 4T Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement 001097 Cooling hood - Replacement 001089 Head cover - Replacement TIME - 156...

  • Page 157: Driven Pulley

    MSS Fly 50 4T Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001110 Driven pulley - Replacement 001012 Driven pulley - Overhaul 001022 Clutch - Replacement 001155 Clutch bell housing - Replacement TIME - 157...
  • Page 158 MSS Fly 50 4T Time Oil pump IL PUMP Code Action Duration 001051 Belt/Timing chain - Change 001112 Oil pump - change 001042 Oil pump - Service 001121 Chain cover oil seal - Replacement 001122 Oil pump chain - Replacement...
  • Page 159 MSS Fly 50 4T Time Driving pulley PULLEY REAR VIEW Code Action Duration 001177 Variator rollers / shoes - Replace- ment 001086 rear-view half-pulley - Replacement 001066 Driving pulley - Removal and refitting 001011 Driving belt - Replacement TIME - 159...

  • Page 160: Transmission Cover

    MSS Fly 50 4T Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - re- place 001132 Transmission air inlet pipe - Replace- ment 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re-...

  • Page 161: Starter Motor

    MSS Fly 50 4T Time Starter motor STARTER MOTOR - START UP LEVER Code Action Duration 001020 Starter motor - change 001017 Starter sprocket wheel - replace 005045 Starter motor with cables unit - Re- plac. 001084 Starter lever - Replacement...

  • Page 162: Flywheel Magneto

    MSS Fly 50 4T Time Flywheel magneto FLYWHEEL FAN Code Action Duration 001067 Stator - Fitting and Refitting 001058 Flywheel - Replacement 001102 Net oil filter - Replacement / Cleaning 001109 Cooling fan - Replacement 001087 Flywheel cover - Replacement...
  • Page 163 MSS Fly 50 4T Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 163...

  • Page 164: Air Cleaner

    MSS Fly 50 4T Time Air cleaner AIR FILTER Code Action Duration 001014 Air filter - Replacement /Cleaning 001015 Air filter box - Replacement TIME - 164...
  • Page 165 MSS Fly 50 4T Time Frame FRAME Code Action Duration 004004 Stand - Replacement 001053 Stand bolt - Replacement 004001 Frame - replace TIME - 165...
  • Page 166 MSS Fly 50 4T 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...
  • Page 167 MSS Fly 50 4T Time Rear cover REAR SHIELD Code Action Duration 004174 Trunk levers - Replacement 004065 Front shield, rear part - Removal and refitting 004081 Glove box door - Replacement TIME - 167...
  • Page 168 MSS Fly 50 4T 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...
  • Page 169 MSS Fly 50 4T Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 169...
  • Page 170 MSS Fly 50 4T 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...
  • Page 171 MSS Fly 50 4T Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting TIME - 171...
  • Page 172 MSS Fly 50 4T Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003051 Complete fork - replace 003002 Steering fifth wheel - Replacement 003073 Steering clearance - Adjustment TIME - 172...

  • Page 173: Handlebar Covers

    MSS Fly 50 4T 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...
  • Page 174 MSS Fly 50 4T 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...
  • Page 175 MSS Fly 50 4T Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine / frame swinging arm fitting - Replacement 003080 Swinging arm on frame - Replace- ment TIME - 175...
  • Page 176 MSS Fly 50 4T Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004068 Passenger handgrip - Replacement TIME - 176...
  • Page 177 MSS Fly 50 4T Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - change 005012 Front turn indicator - Replacement 005067 Front turn indicator bulb - Replace- ment 005008 Front headlamp bulbs - Replacement 005005...

  • Page 178: Front Wheel

    MSS Fly 50 4T 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-...
  • Page 179 MSS Fly 50 4T 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 - 179...
  • Page 180 MSS Fly 50 4T Time Electric devices ELECTRICAL DEVICES Code Action Duration 005011 Start-up remote control switch - Re- placement 005007 Battery - change 005052 Fuse (1) - Replacement TIME - 180...

  • Page 181: Electrical Devices

    MSS Fly 50 4T 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 - 181...
  • Page 182 MSS Fly 50 4T Time Electronic controls ELECTRIC CONTROLS Code Action Duration 005039 Headlight switch - Replacement 005006 Light switch or turn indicators - Re- placement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement...
  • Page 183 MSS Fly 50 4T Time Transmissions TRANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement 002053 Rear brake transmission complete - replacement TIME - 183...

  • Page 184: Brake Callipers

    MSS Fly 50 4T 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-...
  • Page 185 MSS Fly 50 4T 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 - 185...
  • Page 186 MSS Fly 50 4T Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 005046 Battery cover - Replacement TIME - 186...

  • Page 187: Rear Wheel Axle

    MSS Fly 50 4T 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...
  • Page 188 MSS Fly 50 4T 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 -...
  • Page 189 Air filter: 33, 144 Battery: 44, 50, 57, 58 Brake: 134, 136, 137, 139, 140, 184 Carburettor: 11, 29, 113, 117, 162 Engine oil: 33 Fuel: 43, 112, 145, 170 Headlight: 36 Horn: Hub oil: 32 Identification: 8 Maintenance: 7, 27 Oil filter: 34 Saddle: Shock absorbers: 131...

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