Piaggio Fly 125 i.e - 150 i.e Leader MY 2011 (EN)

SERVICE STATION MANUAL677566 (EN)

Fly 125 i.e - 150 i.e Leader (2011)

SERVICE STATIONMANUAL

Fly 125 i.e - 150 i.e Leader (2011)

The descriptions and images in this publication are given for illustrative purposes only and are not binding.While the basic specifications as described and illustrated in this manual remain unchanged, Piaggio

Việt Nam reserves the right, at any time and without being required, to update this publication beforehand,to make any changes to components, parts or accessories, which it considers necessary to improve the

product or which are required for manufacturing or construction reasons.Not all versions/models shown in this publication are available in all countries. The availability of single

models should be checked at the official Piaggio sales network."© Copyright 2012 - PIAGGIO VIỆT NAM. All rights reserved. Reproduction of this publication in whole

or in part is prohibited."PIAGGIO VIỆT NAM- After Sales

LOT M - BINH XUYEN INDUSTRIAL ZONE - VINCH PHUC - VIET NAMCUSTOMER SERVICE CENTREPlease contact with us following:

Hot line: 1800 5555 85Email:

[email protected]:

www.piaggio.com.vn

mailto:[email protected]

http://www.piaggio.com.vn/

SERVICE STATION MANUALFly 125 i.e - 150 i.e Leader (2011)

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops ofPiaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicleshas a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significantchanges to vehicle characteristics or to specific repair operations will be communicated by updates tothis manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and toolsare unavailable. It is therefore advisable to read the sections of this manual concerning special tools,along with the special tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personalinjury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water

and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working

area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that

you do not breathe in the dust produced by the wear of the friction material. Even though the latter

contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or

non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all

the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,

nuts and screws are not interchangeable with coupling members using English measurements. Using

unsuitable coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make

sure the electrical connections have been made properly, particularly the ground and battery connec-

tions.

Fly 125 i.e - 150 i.e Leader (2011) Characteristics

CHAR - 7

Vehicle identification

The chassis prefix is stamped on the right strut.

The engine prefix is stamped on the rear wall of

the transmission crankcase.

VEHICLE IDENTIFICATION (125)Specification Desc./QuantityChassis prefix M77200Engine prefix M772M

VEHICLE IDENTIFICATION (150)Specification Desc./QuantityChassis prefix M77600Engine prefix M776M

Characteristics Fly 125 i.e - 150 i.e Leader (2011)

CHAR - 8

Dimensions and mass

WEIGHTS AND DIMENSIONSSpecification Desc./Quantity

dry weight 123 kgWheelbase 1330 mm

Length 1,870 mmWidth (handlebar) 695 mm

Height (without mirrors) 1140 mm

Engine

SPECIFICATIONS - 125 ENGINESSpecification Desc./Quantity

Type Single-cylinder, 4-strokeCubic capacity 124 cm³Bore x stroke 57.0 x 48.6 mm

Compression ratio 10.6 ± 0.5: 1Engine idle speed 1700 ± 100 rpm

Timing system 2 valves, single overhead camshaft, chain-driven.Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm

Max. power 7.6 kW at 8,250 rpmMAX. torque 9.2 Nm at 6,500 rpmTransmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmissionhousing with forced-circulation air cooling.

Final reduction gear Gear reduction unit in oil bath.Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.Cooling Forced-air circulation cooling.Starter ElectricIgnition Capacitive discharge ignition, with variable advance and sep-

arate HV coil.Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR8EB - DENSO U24ESR-NB


CHAR - 9

Specification Desc./QuantityFuel system Electronic injection with Ø 28 mm throttle body, single injector

Fuel Unleaded petrolExhaust silencer Absorption-type exhaust muffler with catalytic converter.

Emissions compliance EURO 3

SPECIFICATIONS - 150 ENGINESSpecification Desc./Quantity

Type Single-cylinder, 4-strokeCubic capacity 149.5 cm³Bore x stroke 62.6 x 48.6 mm

Compression ratio 10.6 ± 0.5 : 1Engine idle speed 1,650±100 rpm

Timing system 2 valves, single overhead camshaft, chain-driven.Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm

Max. power 8.6 kW at 8,000 rpmMAX. torque 11.2 Nm at 6,250 rpmTransmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmissionhousing with forced-circulation air cooling.

Final reduction gear Gear reduction unit in oil bath.Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.Cooling Forced-air circulation cooling.Starter ElectricIgnition Capacitive discharge ignition, with variable advance and sep-

arate HV coil.Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR7EB - DENSO U22ESR-NBFuel system Electronic injection with Ø 28 mm throttle body, single injector

Fuel Unleaded petrolExhaust silencer Absorption-type exhaust muffler with catalytic converter.

Emissions compliance EURO 3

Transmission

TRANSMISSIONSpecification Desc./QuantityPrimary drive Automatic expandable pulley variator with torque server, V-

belt, automatic self-ventilating centrifugal dry clutchFinal reduction Gear reduction unit in oil bath.

Capacities

CAPACITIESSpecification Desc./Quantity

Engine oil 1.10 lTransmission oil 200 cm3

Fuel tank capacity ~ 7 litres (1.5 l of which is reserve)

Electrical system

ELECTRICAL COMPONENTSSpecification Desc./Quantity

Spark plug (125 cc) NGK CR8EB - DENSO U24ESR-NBSpark plug (150 cc) NGK CR7EB - DENSO U22ESR-NB

Battery Sealed, 12 V / 6 AhFuses 1 of 30A - 1 of 5A - 1 of 10A - 4 of 7.5A


CHAR - 10

Specification Desc./QuantityGenerator alternating current

Ignition/advance Capacitive discharge electronics (CDI) and variable advance

CHECKING REMOTE CONTROLS «A» OPER-

ATING AS CIRCUIT BREAKERS

1) Check that, given regular conditions, there is no

continuity between terminals 30 and 87.

2) Apply 12V voltage to power terminals 85 and 86

of the remote control.

3) With the remote control powered, check that

there is continuity between terminals 30 and 87.

4) If these conditions are not fulfilled, the remote

control is damaged and must be replaced.

To check buttons and switches, check that, according to their position, the continuity of contacts is

correct as indicated in the following charts.

FUEL INJECTOR

Type: 3 holes

Conicity of the nozzle: 20°

Resistance at terminals: 13.7 - 15.2 Ohm

FUEL PUMP UNIT

Mechanical type pressure regulator operating at a

pressure of 2.5 BAR

Pump winding resistance: ~ 1.5 Ohm

Input current during regular functioning: 1.4 - 1.8

A


CHAR - 11

SPEED/PHASE SENSOR

Resistance between pin 20 (-) and 29 (+): 100 to

150 Ohm at approx. 20°

ENGINE TEMPERATURE SENSOR

0° = 9440 Ohm

+10° = 5660 Ohm

+20° = 3500 Ohm

+30° = 2265 Ohm

+80° = 357 Ohm

MINIMUM OIL PRESSURE SENSOR

Normally closed switch

Activation threshold: 0.3 - 0.6 BAR

With the engine off: continuity between terminal

and ground

HV COIL

<DIV class=O v:shape="_x0000_s3074">

- Resistance of the primary = 0.5 Ohm ± 8%

- Resistance between primary and ground = infinite

- Resistance between primary and HV output = 3.1 KOhm ± 9%

- Presence of battery voltage between pins 1 and

9 of the interface cable harness upon

shifting to ON and for 2 sec.


CHAR - 12

STATOR

Power: 450 W

Resistance between terminals: 0.2 - 1 Ohm

terminal insulation from ground

Frame and suspensions

FRAME AND SUSPENSIONSpecification Desc./Quantity

Frame Tubular steel frameFront suspension Hydraulic telescopic fork with Ø 32-mm stem, 76 mm travel.Rear suspension Adjustable 4-position spring preloading single shock absorber,

73 mm travel

Brakes

BRAKESSpecification Desc./QuantityFront brake Disc brake (Ø 220 mm) with hydraulic control (lever on the far

right of the handlebar) and floating calliper.Rear brake Ø 140-mm drum brake with mechanical control activated by the

handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRESSpecification Desc./QuantityWheel rim type Light alloy wheel rims.Front wheel rim 12'' x 3.00Rear wheel rim 12" x 3.00

Front tyre Tubeless 120/70-12"Rear tyre Tubeless 120/70 - 12"

Front tyre pressure 1.8 barRear tyre pressure 2 bar


CHAR - 13

Specification Desc./QuantityRear wheel pressure (rider and passenger): 2.3 bar

Tightening Torques

ENGINEName Torque in Nm

Ignition spark plug 10 - 15 NmHead cover screws 11 - 13

Head-cylinder stud bolt nuts 6 to 7 + 90° + 90° *Screws fixing head and cylinder to crankcase 8 - 10

Tensioner fastening screws: 8 - 10 NmTiming chain tensioner central screw 5 - 6

Camshaft pulley screw 12 - 14Valve clearance adjustment lock nuts 7 - 9 Nm

Engine oil pre-filter cover: 25 - 28 NmEngine oil drainage cap 25 - 28Alternator flywheel nut 52 - 58 Nm

Stator screws 3 - 4Pick-up screws 3 - 4

Oil pump bulkhead screw 4 - 5Oil pump sprocket gear screw 8 - 10

Screws fixing oil pump to the crankcase 5 - 6Oil pump coupling screws 7 - 9 Nm

Oil sump screws 8 - 10 NmInlet manifold screw 7 - 9

Throttle body/manifold clamp screws 1.2 - 1.5 NmScrews fixing cables to starter motor 1.5 - 2.5

Starter motor screws 11 - 13Transmission cover screws 11 - 13 Nm

Camshaft retention plate screw 5 - 6Pressure reducer counterweight retainer 7 - 8.5

Flywheel air duct screw 3 - 4Oil filter on crankcase fitting 27 - 33

Nut fixing muffler to cylinder head 16 - 18Minimum oil pressure switch 12 - 14

Nut locking clutch unit on pulley 55 - 60 NmDrive pulley nut (°) 75 - 83

Driven pulley shaft nut 54 - 60Hub oil drainage screw 3 - 5 NmRear hub cap screws 24 - 26 Nm

Wheel axle nut 115 - 125Crankcase half union screw 8 - 10

In order to ensure an adequate locking torque, lubricate the nuts before fitting them.* When fitting the new stud bolts, nut tightening involves 3 turns of 90° each after the first locking at 6 - 7 Nm, consequently: 6 -7 Nm + 90° + 90° + 90° at crossed passages.(°) Apply LOCTITE 243 type threadlock.

GRUPPO STERZOName Torque in Nm

Steering upper ring nut 34.3 - 39.2Steering lower ring nut 11.7 - 13.7Handlebar fixing screw 60 - 65

GRUPPO TELAIOName Torque in Nm

Engine arm bolt - frame arm 40 to 45Engine-swinging arm bolt 40 to 45Frame-swinging arm bolt 50 to 55

Silent block support to chassis bracket fastener bolts 20 ÷ 25Side stand bolt 12 - 16

Centre stand pin 39.2 - 44.1


CHAR - 14

SOSPENSIONE ANTERIOREName Torque in Nm

Fork bottom screw 20 ÷ 25Screws fastening stem to fork plate 36 to 44

Front wheel axle 45 ÷ 50Front wheel axle screw on fork leg 8 - 8.5

Front mudguard to plate fixing screw 4.5 to 7

REAR SUSPENSIONName Torque in Nm

Rear wheel axle 104 ÷ 126Lower shock absorber clamp 40 to 45Shock absorber/Chassis nut: 20 ÷ 25

Shock absorber to crankcase bracket fastener 20 ÷ 25

FRONT AND REAR BRAKEName Torque in Nm

Brake fluid pump-hose fitting 20 ÷ 25Brake fluid pipe-calliper fitting 20 ÷ 25

Calliper tightening screw 24.5 to 27.5Disc tightening screw (Apply LOCTITE 243 medium-strength

threadlock)8 - 12 Nm

Oil bleeding valve 8 - 12Rear brake adjustment nut 5

Overhaul data

Assembly clearances

Cylinder - piston assy.

PISTON TO CAST IRON CYLINDER COUPLING (125)Name Initials Cylinder Piston Play on fitting

Coupling M 56.997 - 57.004 56.944 - 56.951 0.046 - 0.060Coupling N 57.004 - 57.011 56.951 - 56.958 0.046 - 0.060Coupling O 57.011 - 57.018 56.958 - 56.965 0.046 - 0.060Coupling P 57.018 - 57.025 56.965 - 56.972 0.046 - 0.060

coupling 1st oversize M1 57.197 - 57.204 57.144 - 57.151 0.046 - 0.060coupling 1st oversize N1 57.204 - 57.211 57.151 - 57.158 0.046 - 0.060coupling 1st oversize O1 57.211 - 57.218 57.158 - 57.165 0.046 - 0.060coupling 1st oversize P1 57.218 - 57.225 57.165 - 57.172 0.046 - 0.060

Coupling 2nd oversize M2 57.397 - 57.404 57.344 - 57.351 0.046 - 0.060Coupling 2nd oversize N2 57.404 - 57.411 57.351 - 57.358 0.046 - 0.060Coupling 2nd oversize O2 57.411 - 57.418 57.358 - 57.365 0.046 - 0.060Coupling 2nd oversize P2 57.418 - 57.425 57.365 - 57.372 0.046 - 0.060Coupling 3rd oversize M3 57.597 - 57.604 57.544 - 57.551 0.046 - 0.060Coupling 3rd oversize N3 57.604 - 57.611 57.551 - 57.558 0.046 - 0.060Coupling 3rd oversize O3 57.611 - 57.618 57.558 - 57.565 0.046 - 0.060Coupling 3rd oversize P3 57.618 - 57.625 57.565 - 57.572 0.046 - 0.060

COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER(125)

Name Initials Cylinder Piston Play on fittingCoupling A 56.980 - 56.987 56.933 - 56.940 0.040 - 0.054Coupling B 56.987 - 56.994 56.940 - 56.947 0.040 - 0.054Coupling D 57.001 - 57.008 56.954 - 56.961 0.040 - 0.054Coupling C 56.994 - 57.001 56.947 - 56.954 0.040 - 0.054


CHAR - 15

Name Initials Cylinder Piston Play on fittingcoupling 1st oversize A1 57.180 - 57.187 57.133 - 57.140 0.040 - 0.054coupling 1st oversize B1 57.187 - 57.194 57.140 - 57.147 0.040 - 0.054coupling 1st oversize D1 57.201 - 57.208 57.154 - 57.161 0.040 - 0.054coupling 1st oversize C1 57.194 - 57.201 57.147 - 57.154 0.040 - 0.054

Coupling 2nd oversize A2 57.380 - 57.387 57.333 - 57.340 0.040 - 0.054Coupling 2nd oversize B2 57.387 - 57.394 57.340 - 57.347 0.040 - 0.054Coupling 2nd oversize C2 57.394 - 57.401 57.347 - 57.354 0.040 - 0.054Coupling 2nd oversize D2 57.401 - 57.408 57.354 - 57.361 0.040 - 0.054Coupling 3rd oversize A3 57.580 - 57.587 57.533 - 57.540 0.040 - 0.054Coupling 3rd oversize B3 57.587 - 57.594 57.540 - 57.547 0.040 - 0.054Coupling 3rd oversize C3 57.594 - 57.601 57.547 - 57.554 0.040 - 0.054Coupling 3rd oversize D3 57.601 - 57.608 57.554 - 57.561 0.040 - 0.054

COUPLING BETWEEN (ASSO-WERKE) PISTON AND CYLINDER (150)Name Initials Cylinder Piston Play on fitting

Coupling A 62.580 - 62.587 62.533 - 62.540 0.040 - 0.054Coupling B 62.587 - 62.594 62.540 - 62.547 0.040 - 0.054Coupling C 62.594 - 62.601 62.547 - 62.554 0.040 - 0.054Coupling D 62.601 - 62.608 62.554 - 62.561 0.040 - 0.054

coupling 1st oversize A1 62.780 - 62.787 62.733 - 62.740 0.040 - 0.054coupling 1st oversize B1 62.787 - 62.794 62.740 - 62.747 0.040 - 0.054coupling 1st oversize C1 62.794 - 62.801 62.747 - 62.754 0.040 - 0.054coupling 1st oversize D1 62.801 - 62.808 62.754 - 62.761 0.040 - 0.054

Coupling 2nd oversize A2 62.980 - 62.987 62.933 - 62.940 0.040 - 0.054Coupling 2nd oversize B2 62.987 - 62.994 62.940 - 62.947 0.040 - 0.054Coupling 2nd oversize C2 62.994 - 63.001 62.947 - 62.954 0.040 - 0.054Coupling 2nd oversize D2 63.001 - 63.008 62.954 - 62.961 0.040 - 0.054Coupling 3rd oversize A3 63.180 - 63.187 63.133 - 63.140 0.040 - 0.054Coupling 3rd oversize B3 63.187 - 63.194 63.140 - 63.147 0.040 - 0.054Coupling 3rd oversize C3 63.194 - 63.201 63.147 - 63.154 0.040 - 0.054Coupling 3rd oversize D3 63.201 - 63.208 63.154 - 63.161 0.040 - 0.054

COUPLING BETWEEN (RIGHT WAY) PISTON AND CYLINDER (150)Name Initials Cylinder Piston Play on fitting

Coupling A 62.580 - 62.587 62.541 - 62.548 0.032 - 0.046Coupling B 62.587 - 62.594 62.548 - 62.555 0.032 - 0.046Coupling C 62.594 - 62.601 62.555 - 62.562 0.032 - 0.046Coupling D 62.601 - 62.608 62.562 - 62.569 0.032 - 0.046

Piston rings

SEALING RINGS (125)Name Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 - 0.30Oil scraper ring 57x1 A 0.10 - 0.30Oil scraper ring 57x2.5 A 0.10 - 0.35

Compression ring 1stoversize

57.2 x 1 A 0.15 - 0.30


CHAR - 16

Name Description Dimensions Initials QuantityOil scraper ring 1st

oversize57.2x1 A 0.10 - 0.30

Oil scraper ring 1stoversize

57.2x2.5 A 0.10 - 0.35

Compression ring 2ndoversize

57.4x1 A 0.15 - 0.30

Oil scraper ring 2ndoversize

57.4x1 A 0.10 - 0.30


57.4x2.5 A 0.10 - 0.35

Compression ring 3rdoversize

57.6x1 A 0.15 - 0.30

Oil scraper ring 3rdoversize

57.6x1 A 0.10 - 0.30


57.6x2.5 A 0.10 - 0.35

Maximum clearance after use: 1 mm

SEALING RINGS (150)Name Description Dimensions Initials Quantity

Compression ring 62.6x1 A 0.15 - 0.30Oil scraper ring 62.6x1 A 0.20 - 0.40Oil scraper ring 62.6x2.5 A 0.20 - 0.40

Compression ring 1stoversize

62.8x1 A 0.15 - 0.30


62.8x1 A 0.20 - 0.40


62.8x2.5 A 0.20 - 0.40

Compression ring 2ndoversize

63.0 x 1 A 0.15 - 0.30


63.0 x 1 A 0.20 - 0.40


63.0 x 2.5 A 0.20 - 0.40

Compression ring 3rdoversize

63.2 x 1 A 0.15 - 0.30


63.2 x 1 A 0.20 - 0.40


63.2 x 2.5 A 0.20 - 0.40

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING RODName Description Dimensions Initials Quantity

Half-shaft, transmissionside

16.6 +0-0.05 A D = 0.20 - 0.50

Flywheel-side half shaft 16.6 +0-0.05 B D = 0.20 - 0.50Connecting rod with PP 18 -0.10 -0.15 C 0.20 to 0.50

Crank pin width 51.400 E

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGSName Description Dimensions Initials Quantity

Crankshaft Category 1 28.998 - 29.004Crankshaft Category 2 29.004 - 29.010Crankcase Category 1 32.953 - 32.959Crankcase Category 2 32.959 - 32.965

Crankshaft half-bearing Category B - blue 1.973 - 1.976Crankshaft half-bearing Category C - yellow 1.976 - 1.979Crankshaft half-bearing Category E - green 1.979 - 1.982Crankshaft category 1 -Crankcase category 1

E - E


CHAR - 17

Name Description Dimensions Initials QuantityCrankshaft category 1 -Crankcase category 2

C - C

Crankshaft category 2 -Crankcase category 1

C - C

Crankshaft category 2 -Crankcase category 2

B - B

CharacteristicCrankshaft/crankcase axial clearance «A»:

0.15 - 0.40

Slot packing system

- Provisionally fit the piston into the cylinder, without any base gasket.

- Assemble a dial gauge on the specific tool

- Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping

the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.

- Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation)


CHAR - 18

- Calculate the difference between the two measurements: use the chart below to identify the thickness

of the cylinder base gasket to be used for refitting. Correctly identify the cylinder base gasket thickness

to keep the correct compression ratio.

- Remove the special tool and the cylinder.

Specific tooling020428Y Piston position check mounting

CharacteristicCompression ratio (125/150)

10.6 ± 0.5 to 1

SHIMMING SYSTEM (125)Specification Desc./Quantity

Value measured 0 - 0.1Thickness 0.8 ± 0.05

Value measured 0.1 - 0.3Thickness 0.6 ± 0.05


SHIMMING SYSTEM (150)Specification Desc./Quantity

Value measured 1 - 1.1Thickness 0.8 ± 0.05



Products

RECOMMENDED PRODUCTS TABLEProduct Description Specifications

Lubricant for gearboxes and transmis-sions

Lubricant for gearboxes and transmis-sions.

SAE 80W/90, API GL4 - API GL5

Brake fluid Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116- DOT 3/4 - ISO 4925 - CUNA NC 956

DOT 4Stand, throttle, brake lever lubrication Grease for brake levers, throttle, stand White calcium complex soap-based

spray grease with NLGI 2; ISO-L-XBCIB2Oil for air filter sponge Special product for the treatment of foam

filters.-


CHAR - 19

Product Description SpecificationsSynthetic oil for 4-stroke engines Synthetic-based lubricant for four stroke

engines.SAE 5W-40, API SL, ACEA A3, JASO MA

Grease Yellow-brown, lithium-base, medium-fi-bre multi-purpose grease.

ISO L-X-BCHA 3 - DIN 51 825 K3K -20

Transmission flexible hoses - lubrication Synthetic-based lubricant for four strokeengines.

SAE 5W-40, API SL, ACEA A3, JASO MA


CHAR - 20

INDEX OF TOPICS

TOOLING TOOL

SPECIFIC TOOLSStores code Description

001330Y Tool for fitting steering seats

001467Y009 Bell for OD 42-mm bearings

001467Y013 Pliers to extract ø 15-mm bearings

002465Y Pliers for circlips

005095Y Engine support

006029Y Punch for fitting fifth steering bearing onsteering tube

008564Y Flywheel extractor

Tooling Fly 125 i.e - 150 i.e Leader (2011)

TOOL - 22

Stores code Description020004Y Punch for removing fifth wheels from

headstock

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crankshaftalignment

020150Y Air heater support

020151Y Air heater

020193Y Oil pressure check gauge

Fly 125 i.e - 150 i.e Leader (2011) Tooling

TOOL - 23

Stores code Description020262Y Crankcase splitting plate

020263Y Driven pulley assembly sheath

020271Y Tool for removing-fitting silent bloc

020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing


TOOL - 24

Stores code Description020331Y Digital multimeter

020332Y Digital rpm indicator

020334Y Multiple battery charger

020335Y Magnetic support for dial gauge

020359Y 42x47-mm Adaptor


TOOL - 25

Stores code Description020360Y 52x55-mm Adaptor

020363Y 20-mm guide

020364Y 25-mm guide

020368Y driving pulley lock wrench

020375Y 28 x 30 mm adaptor

020376Y Adaptor handle


TOOL - 26

Stores code Description020382Y Valve cotters equipped with part 012 re-

moval tool

020382Y011 adapter for valve removal tool

020412Y 15-mm guide

020423Y Driven pulley lock wrench

020424Y Driven pulley roller casing fitting punch

020425Y Punch for flywheel-side oil seal


TOOL - 27

Stores code Description020426Y Piston fitting fork

020427Y Piston assembly band

020428Y Piston position check mounting

020430Y Pin lock fitting tool

020431Y Valve oil seal extractor

020434Y Oil pressure check fitting


TOOL - 28

Stores code Description020439Y 17-mm guide

020444Y Tool for fitting/ removing the driven pulleyclutch

020480Y Petrol pressure check kit

020565Y Flywheel lock calliper spanner

020622Y Transmission-side oil seal punch

020922Y Diagnosis Tool


TOOL - 29

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

MAINTENANCE TABLEI: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARYC: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE* Check every 3,000 km** Replace every 2 years

km x 1,000 1 6 12 18 24 30 36 42 48 54 60Safety fasteners I I I I I ISpark plug I R I R I R I R I RCentre stand / Side stand L L L L L L L L L LDrive belt I R I R I R I R I RThrottle control A A A A A AAir filter * C C C C C C C C C COil filter R R R R R R R R R RMesh oil filter C C C C C C C C C C CValve clearance A A A AElectrical system and battery I I I I I I I I I I ICylinder ventilation system C CBrake levers L L L L L LBrake fluid ** I I I I I I I I I I IEngine oil * R R R R R R R R R R RHub oil R R R R R R R R R R RHeadlight direction adjustment A A A A ABrake pads I I I I I I I I I I ISliding shoes / CVT rollers I R I R I R I R I RTyre pressure and wear I I I I I I I I I I IVehicle road test I I I I I I I I I I IOdometer gear L L L L LSuspension I I I I ISteering A A A A A ATransmission L L L L LOperation time 80' 170' 180' 170' 195' 115' 290' 115' 195' 170' 180'

Spark plug

- Position the vehicle on the stand

- Remove the external engine inspection panel,

unscrewing the indicated screws.

Fly 125 i.e - 150 i.e Leader (2011) Maintenance

MAIN - 31

- Disconnect the spark plug H.V. cable cap.

- Slide the internal cover upwards.

- Unscrew the spark plug.

- Check the conditions of the spark plug, make

sure the insulation is intact, that the electrodes are

not excessively worn or sooty, the conditions of the

washer, and measure the distance between the

electrodes using the appropriate feeler gauge.

-Adjust the distance, if necessary, by bending the

side electrode very carefully. In case of anomaly

(as described before), replace the spark plug with

another of the recommended type.

- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the

special spanner to tighten it.

- Refit the cover.

Maintenance Fly 125 i.e - 150 i.e Leader (2011)

MAIN - 32

- Fit the cap on the spark plug as far as it will go.

- Carry out refit operations.CAUTION

THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD.THE SPARK PLUG MUSTBE REPLACED EVERY 12,000 KM. THE USE OF NON CONFORMING ELECTRONIC IGNITIONCONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLYDAMAGE THE ENGINE.

CharacteristicElectrode gap

0.7 to 0.8 mm

Spark plug (125 cc)

NGK CR8EB - DENSO U24ESR-NB

Spark plug (150 cc)

NGK CR7EB - DENSO U22ESR-NB

Locking torques (N*m)Ignition spark plug 10 - 15 Nm

Hub oil

Check

- Park the vehicle on flat ground and rest it on the

centre stand.

- Unscrew the oil dipstick/cover, dry it with a cloth

and reinsert it screwing it in thoroughly.

- Remove the dipstick/cover and check that the oil

level is between MIN and MAX.

- If the level is below the MIN value, restore the

proper amount of oil in the hub.

- Screw the oil dipstick back and check it is locked.


MAIN - 33

Replacement

- Remove the oil dipstick/cover.

- Remove the rear wheel.

- Prepare an adequately sized container.

- Unscrew the oil drainage plug and drain out all

the oil.

See alsoRemoving the rear wheel

- Screw in the drainage cap again and fill the hub with the prescribed oil.

Recommended productsLubricant for gearboxes and transmissions Lubricant for gearboxes and transmissions.

SAE 80W/90, API GL4 - API GL5

CharacteristicRear hub oil

~ 200 cm³

Locking torques (N*m)Hub oil drainage screw 3 - 5 Nm


MAIN - 34

Air filter

- Remove the saddle and the helmet compartment.

- Remove the lower cover.

- Remove the front central cover.

- Remove the grab handle.

- Remove the side fairings.

- Remove the footrest.

- Remove the spoilers.

- Remove the air duct.

- Loosen the 6 screws and remove the air filter

cover.

- Remove the filtering element and clean it with

water and shampoo; then dry it with a clean cloth

and short blasts of compressed air. Finally, im-

merse it in a mixture of 50% oil of the recommen-

ded type and 50% petrol. Then gently squeeze the

filter element between your hands, allow it to drip

and then refit it.CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NEC-ESSARY TO CARRY OUT MAINTENANCE CHECKS OFTHE AIR FILTER MORE OFTEN TO AVOID DAMAGING THEENGINE.

Recommended productsOil for air filter sponge Special product for thetreatment of foam filters.-

See alsoHelmet bayLower coverFront central coverRear rackSide fairingsFootrestspoiler

Engine oil

In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and

the thermal group. An insufficient quantity of oil can cause serious damage to the engine.


MAIN - 35

In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should

be considered normal, especially if during the run-in period. Consumption levels in particular can be

influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Change oil and replace filter as indicated in the

scheduled maintenance table. The engine must be

emptied by draining off the oil through the drainage

plug of the mesh pre-filter, flywheel side; further-

more to facilitate oil drainage, loosen or remove

the cap/dipstick. Once all the oil has drained

through the drainage hole, unscrew the oil car-

tridge filter and remove it. To carry out this opera-

tion, it is not necessary to remove the whole

silencer.

Make sure the pre-filter and drainage plug O-rings

are in good conditions.

Lubricate them and refit the mesh filter and the oil

drainage plug, screwing them up to the prescribed

torque.

Refit the new cartridge filter being careful to lubri-

cate the O-ring before fitting it.

Change the engine oil.

Since a certain quantity of oil still remains in the

circuit, oil must be filled from oil dipstick/cover.

Then start up the vehicle, leave it running for a few

minutes and switch it off: After about five minutes,

check the level and, if necessary, top-up but never

exceeding the MAX level reference mark. The car-

tridge filter must be replaced every time the oil is

changed. Use new oil of the recommended type

for topping up and changing purposes.N.B.THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended productsEngine oil Synthetic-based lubricant for fourstroke engines.SAE 5W-40, API SL, ACEA A3, JASO MA


MAIN - 36

CharacteristicEngine oil1100 cm³

Locking torques (N*m)Engine oil drainage cap 25 - 28

Check

This operation must be carried out with the engine cold and following the procedure below:

- Place the vehicle on its centre stand and on flat ground.

- Undo cap/dipstick, dry it off with a clean cloth and reinsert it, screwing down completely.

- Remove the cap/dipstick again and check that the level is between the MIN and MAX reference marks;

top up if necessary.

The MAX level mark indicates a quantity of around 1100 cc of oil in the engine. If the check is carried

out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to

carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped,

so as to get the correct level.

Engine oil top-up

The oil should be topped up after having checked

the level and in any case by adding oil without

ever exceeding the MAX. level.

Restoration of the level from MIN to MAX requires

approximately 200 cc.

Engine oil filter

The oil filter must be replaced every time the oil is changed.

Use new oil of the recommended type for topping up and changing purposes and comply with the

regulations regarding timing and mileage, as described in the periodic maintenance table.

Make sure the pre-filter and drainage plug O-rings are in good conditions.


MAIN - 37

Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed

torque. Refit the new oil filter being careful to lubricate the O-ring before fitting it.

Change the engine oil.WARNING

IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OFGREASE, WE RECOMMEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH.

Recommended productsEngine oil Synthetic-based lubricant for four stroke engines.

SAE 5W-40, API SL, ACEA A3, JASO MA

Oil pressure warning light

The vehicle is equipped with a telltale light on the

dashboard that lights up when the key is turned to

the «ON» position. However, this light should

switch off once the engine has started.

If the light turns on during braking, at idling

speed or while turning a corner, it is necessary

to check the oil level and the lubrication sys-

tem.

Checking the ignition timing

-Remove the flywheel fan.

-Rotate the flywheel until the reference (arrow)

matches the crankcase operation end as shown in

the figure (TDC). Make sure that the 2V reference

point on the camshaft control pulley is aligned with

the reference point on the head as shown in the

second figure. If the reference mark is opposite the

indicator on the head, make the crankshaft turn

once more.

-The TDC reference mark is repeated also be-

tween the flywheel cooling fan and the flywheel

cover.

To use this reference mark, remove the spark plug

and turn the engine in the opposite direction to the

normal direction of rotation using a compass span-


MAIN - 38

ner applied to the camshaft drive sprocket hous-

ing.N.B.TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.

Checking the valve clearance

-To check valve clearance, centre the reference marks of the timing system.

- Use a feeler gauge to check that the clearance between the valve and the register corresponds with

the indicated values. When the valve clearance values, intake and exhaust respectively, are different

from the ones indicated below, adjust them by loosening the lock nut and operate on the set screw with

a screwdriver.

CharacteristicValve clearance

Intake: 0.10 mm (when cold)

Exhaust: 0.15 mm (when cold)

Locking torques (N*m)Valve clearance adjustment lock nuts 7 - 9 Nm

Braking system

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 brake pads.


MAIN - 39

Top-up

Proceed as follows:

- Remove the front handlebar cover.

- Remove the reservoir cap by loosening the two

screws, remove the gasket and top-up using only

the fluid specified without exceeding the maximum

level.CAUTIONONLY USE DOT 4-CLASSIFIED BRAKE FLUID.CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUREYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTALCONTACT, WASH WITH WATER.CAUTIONBRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; DONOT LET IT COME INTO CONTACT WITH PAINTED PARTS.CAUTIONBRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBSMOISTURE FROM THE SURROUNDING AIR. IF THE CON-TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS ACERTAIN VALUE, BRAKING WILL BE INEFFICIENT.NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLYUSED CONTAINERS.UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLU-ID AS INDICATED IN THE SCHEDULED MAINTENANCETABLE.N.B.SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TOTHE CHANGING OF BRAKE FLUID AND THE BLEEDINGOF AIR FROM THE CIRCUITS.

Recommended productsAGIP BRAKE 4 Brake fluid.Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4

- ISO 4925 - CUNA NC 956 DOT 4

Locking torques (N*m)Brake pump reservoir screws 15 to 20

See alsoFront handlebar cover


MAIN - 40

Headlight adjustment

Proceed as follows:

1. Position the vehicle in running order and with

the tyres inflated to the prescribed pressure, onto

a flat surface 10 m away from a half-lit white

screen; ensure that the longitudinal axis of the ve-

hicle is perpendicular to the screen;

2. Turn on the headlight and check that the boun-

dary of the light beam projected onto the screen is

not higher than 9/10 or lower than 7/10 of the dis-

tance between the centre of the headlight and the

ground;

3. If this is not the case, adjust the headlight by

operating the screw indicated.N.B.THE ABOVE PROCEDURE COMPLIES WITH THE EURO-PEAN STANDARDS REGARDING MAXIMUM AND MINI-MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-TORY REGULATIONS IN FORCE IN EVERY COUNTRYWHERE THE VEHICLE IS USED.

Anti-evaporation system

The fuel tank vapours breather is realised through

a valve fixed on the left strut of the chassis.

To access the valve it is necessary to remove the

legshield.

See alsoLegshield


MAIN - 41

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Engine

Poor performance

POOR PERFORMANCEPossible Cause Operation

Air filter blocked or dirty Remove the sponge, wash with water and car shampoo, thensoak it in a mixture of 50% petrol and 50% specific oil. Presswith your hand without squeezing, allow it to drip dry and refit.

Excessive drive belt wear Check it and replace, if necessaryLack of compression: parts, cylinder and valves worn Replace the worn parts

Oil level exceeds maximum Check for causes and fill to reach the correct levelExcess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves

Incorrect timing or worn timing system elements Time the system again or replace the worn partsMuffler obstructed Replace

Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-aged parts and lubricate the movable guide of the driven pulley

with grease.Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace the valvesValve seat distorted Replace the head unit

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings

Starting difficulties

DIFFICULTY STARTING UPPossible Cause Operation

Flat battery Check the state of the battery. If it shows signs of sulphation,replace it and bring the new battery into service by charging itfor not more than ten hours at a current of 1/10 of the capacity

of the battery itself.Faulty spark plug Replace the spark plug

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearanceStarter motor and start-up system fault Check starter motor.

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refillAir filter obstructed or dirty. Remove the sponge, wash with water and car shampoo, then

soak it in a mixture of 50% petrol and 50% specific oil. Presswith your hand without squeezing, allow it to drip dry and refit.

Fuel pump fault Check the pump.

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTIONPossible Cause Operation

Wrong valve adjustment Adjust the valve clearance properlyOverheated valves Remove the head and the valves, grind or replace the valves

Misshapen/worn valve seats Replace the head unitWorn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings

Worn or broken piston rings or piston rings that have not beenfitted properly

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling sealWorn valve oil guard Replace the valve oil sealWorn valve guides Check and replace the head unit if required

Fly 125 i.e - 150 i.e Leader (2011) Troubleshooting

TROUBL - 43

Insufficient lubrication pressure

POOR LUBRICATION PRESSUREPossible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean theBy-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump componentsOil filter too dirty Replace the cartridge filterOil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible Cause Operation

Slippage or irregular functioning Check that there is no grease on the masses.Check that the faying surface between the clutch masses andthe clutch housing is mainly in the middle and with equivalent

specifications on the three masses.Check that the clutch housing is not scored or worn abnormally

Insufficient braking

INEFFICIENT OR NOISY BRAKINGPossible Cause Operation

Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk ordrum wear conditions.

Front brake disk loose or deformed Check the brake disc screws are locked; use a dial gauge anda wheel mounted on the vehicle to measure the axial shift of

the disc.Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be

no flexible movement of the brake lever).Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Excessive clearance in the rear brake control cable Adjust the clearance with the appropriate adjuster located onthe back part of the crankcase.

Brakes overheating

BRAKES OVERHEATINGPossible Cause Operation

Rubber gaskets swollen or stuck Replace gaskets.Compensation holes on the pump clogged Clean carefully and blast with compressed air

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge anda wheel mounted on the vehicle to measure the axial shift of

the disc.Defective piston sliding Check calliper and replace any damaged part.

Electrical system

Troubleshooting Fly 125 i.e - 150 i.e Leader (2011)

TROUBL - 44

Battery

BATTERYPossible Cause Operation

Battery The battery is the electrical device in the system that requiresthe most frequent inspections and thorough maintenance. If thevehicle is not used for some time (1 month or more) the battery

needs to be recharged periodically. The battery runs downcompletely in the course of 5 to 6 months. If the battery is fittedon a motorcycle, be careful not to invert the connections, keep-

ing in mind that the black ground wire is connected to thenegative terminal while the red wire is connected to the terminalmarked+. Follow the instructions in the ELECTRICAL SYSTEM

chapter for the recharging of the batteries.

Steering and suspensions

Heavy steering

STEERING HARDENINGPossible Cause Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-larities continue in turning the steering even after making theabove adjustments, check the seats in which the ball bearingsrotate: if they are recessed or if the balls are squashed, replace

them.

Excessive steering play

EXCESSIVE STEERING CLEARANCEPossible Cause Operation

Excessive steering clearance Check the tightening of the top ring nut. If irregularities continuein turning the steering even after making the above adjust-ments, check the seats in which the ball bearings rotate: re-

place if they are recessed.

Noisy suspension

NOISY SUSPENSIONPossible Cause Operation

NOISY SUSPENSION If the front suspension is noisy, check: That the shock absorberworks properly inside the stanchions and that the steering ballbearings are in good condition. Finally, check the locking torqueof the wheel axle nut, the brake calliper and the disc. Check

that the swinging arm connecting the engine to the chassis andthe rear shock absorber work properly.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSIONPossible Cause Operation

Faulty or broken seals Replace the shock absorber Check the condition of wear of thesteering covers and the adjustments.

Fly 125 i.e - 150 i.e Leader (2011) Troubleshooting

TROUBL - 45

Troubleshooting Fly 125 i.e - 150 i.e Leader (2011)

TROUBL - 46

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

1 Ignition switch

2 Fuses N. 3 - 7.5A

3 Fuses N. 6 - 5A

4 Fuses N. 4 - 7.5A

5 Fuses N. 5 - 7.5A

6 Fuses N. 1 - 10A

7 Fuses N. 2 - 7.5A

8 Starter remote control contact

9 Starter relay coil

10 Battery

11 Chassis ground

12 Chassis engine ground

13 Chassis engine earth braid

14 Voltage regulator

15 Flywheel

16 Front ground node

17 Rear ground node

18 Rear left turn indicator

19 Front left turn indicator

20 Front right turn indicator

21 Rear right turn indicator

22 Turn indicator warning light

23 Turn indicators control device

24 High beam warning light

25 Complete front headlamp

26 Light switch

27 Horn

Electrical system Fly 125 i.e - 150 i.e Leader (2011)

ELE SYS - 48

28 C.D.I. control unit

29 Lights logic relay

30 Starter button

31 Stop light bulbs

32 Stop switch

33 Fuel injector

34 Injection relay

35 Light switch

36 Horn button

37 Rear daylight running light

38 Front daylight running light

39 License plate bulb

40 Panel lighting bulb

41 Daylight running light warning light

42 Immobilizer LED

43 Injection warning light

44 Oil pressure warning light

45 Oil pressure sensor

46 Fuel gauge

47 Immobilizer antenna

48 Engine temperature sensor

49 Stand button

50 Pickup

51 Lambda probe

52 HV coil

53 Diagnostics socket

54 Fuel pump

55 Starter motor

56 Engine stop switch

57 Fuses N. 7 - 30A

KEY

Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

Fly 125 i.e - 150 i.e Leader (2011) Electrical system

ELE SYS - 49

Components arrangement


ELE SYS - 50

1. Horn - For access remove the leg shield back

plate as described in the «Bodywork» chapter.

2. Voltage regulator - remove the front shield to

reach it.

3. Battery, 4. Main fuse, 5. Diagnostics connec-

tor - For access, remove the battery inspection

cover inside the compartment in the leg shield

back plate.

6. Starter relay - Remove the legshield, as de-

scribed in chap. «Bodywork» to reach it.


ELE SYS - 51

7. Fuse box, 8. Injection load and headlight

relays - For access remove the central cover of the

front shield.

9. Turn indicator intermittence - It is fixed within

the front shield.

10. Fuel pump - 11. Fuel level transmitter - They

are mounted on the tank, remove the footrest, as

described in chap «Bodywork» to reach it.

12. Flywheel, 13. Oil pressure sensor, 14. En-

gine speed sensor (Pick-up) - remove the fan

cover cap, as described in the chap. «Engine» to

reach it. To access the connectors of the flywheel

stator and engine speed sensor, you must remove

the right spoiler as described in the chap. «Body-

work».


ELE SYS - 52

15. Immobilizer antenna - Remove the front

shield to reach it, as described in the «Bodywork»

chapter.

16. Injection ECU - Remove the helmet compart-

ment to reach it.

17. Side stand switch - The connector is located

behind the left spoiler.


ELE SYS - 53

18. Engine temperature sensor - 19. Fuel injec-

tor - For access remove the helmet compartment.

20. H.V. coil - 21. Oxygen sensor. - To access

the coil and the connector of the oxygen sensor,

remove the right spoiler. The sensor is fixed on the

exhaust pipe.


ELE SYS - 54

Ground points

There is a chassis ground point on the vehicle, on

the front side of the steering tube. Remove the

legshield to reach it.

On the engine there is a ground point on the starter

motor.

On the left side of the frame, under the spoiler,

there is the engine ground - frame cable.

Electrical system installation


ELE SYS - 55

Front side

1. Immobilizer LED connector

2. Instrument panel connector (A)

3. Instrument panel connector (B)

4. Headlight connector

5. Front stop button connector

6. Rear stop button connector

7. Light switch

8.Turn indicator connector

9. Horn button

10.Engine stop switch connector

11. Light switch connector

12. Starter button


ELE SYS - 56

13. Instruments and controls branch of the main

wiring

14. Start-up solenoid

15. Battery positive cable

16. Battery negative cable

17. Main fuse box 1

18. Branch of the fuse box connection main wiring

and diagnostics socket

19. Branch of the turn indicators connection main

wiring

20. Front right turn indicator connector

21. Front left turn indicator connector

22. Regulator

23. Regulator / flywheel connector

24. Main regulator / wiring connector

25.Front and rear ground point connectors

26. Immobilizer antenna connector

27. Ignition switch

28.Turn indicator intermittence cable

29.Injection and lighting loads relay connection

cables

30. Fuse box


ELE SYS - 57

31.Branch of the antenna connection main wiring,

ignition switch and injection load relay and lights

32. Front branch of the main wiring

33. Horn connectors

34.Side stand / main wiring button connector

35.Centre branch of the main wiring

36.Fuel pump connector

37.Fuel level transmitter connector

Back side

1. Centre branch of the main wiring

2. Rear branches of the main wiring

3. Lambda probe cable

4. Coil / spark plug cable


ELE SYS - 58

5. Starter motor positive cable

6. Starter motor negative cable

7.Engine and injector temperature sensor cables

8. Main control unit / wiring connector

9. Engine temperature sensor connector

10. Injector connector

11.Coil connector

12. Pick-up connector / main wiring

13. Regulator / flywheel connector

14. License plate light cable

15. Taillight connector

16.Left rear indicator connector

17. Right rear indicator connector


ELE SYS - 59

Ignition

1 Ignition switch

3 Fuses N. 6 - 5A

7 Fuses N. 2 - 7.5A

10 Battery

11 Chassis ground



34 Injection relay

42 Immobilizer LED


49 Stand button

52 HV coil


57 Fuses N. 7 - 30A


ELE SYS - 60

Battery recharge and starting

1 Ignition switch

2 Fuses N. 3 - 7.5A



10 Battery

11 Chassis ground

13 Chassis engine earth braid

14 Voltage regulator

15 Flywheel



30 Starter button

31 Stop light bulbs

32 Stop switch

55 Starter motor

57 Fuses N. 7 - 30A


ELE SYS - 61

Level indicators and enable signals section

1 Ignition switch

2 Fuses N. 3 - 7.5A

3 Fuses N. 6 - 5A

7 Fuses N. 2 - 7.5A

10 Battery

11 Chassis ground




33 Fuel injector

34 Injection relay


42 Immobilizer LED

43 Injection warning light

44 Oil pressure warning light

45 Oil pressure sensor

46 Fuel gauge


48 Engine temperature sensor

49 Stand button

50 Pickup

51 Lambda probe


57 Fuses N. 7 - 30A


ELE SYS - 62

Devices and accessories

1 Ignition switch

2 Fuses N. 3 - 7.5A

3 Fuses N. 6 - 5A

7 Fuses N. 2 - 7.5A

10 Battery

11 Chassis ground



17 Rear ground node


34 Injection relay

36 Horn button


53 Diagnostics socket

54 Fuel pump

57 Fuses N. 7 - 30A


ELE SYS - 63

Lights and turn indicators

1 Ignition switch

2 Fuses N. 3 - 7.5A

4 Fuses N. 4 - 7.5A

5 Fuses N. 5 - 7.5A

6 Fuses N. 1 - 10A



10 Battery


17 Rear ground node

18 Rear left turn indicator

19 Front left turn indicator

20 Front right turn indicator

21 Rear right turn indicator

22 Turn indicator warning light


24 High beam warning light

25 Complete front headlamp

26 Light switch


29 Lights logic relay

30 Starter button

31 Stop light bulbs

32 Stop switch

35 Light switch


ELE SYS - 64


38 Front daylight running light

39 License plate bulb

40 Panel lighting bulb


57 Fuses N. 7 - 30A

Checks and inspections

Immobiliser

The electronic ignition system is controlled by the

control unit with the integrated Immobilizer sys-

tem. The immobiliser is an antitheft system which

allows the vehicle to function only if it is activated

by means of the coded keys that the control unit

recognises. The code is integrated in a transpond-

er in the key block. This allows the driver clear

operation without having to do anything other than

just turning the key. The Immobilizer system con-

sists of the following components:

- Control unit

- Immobilizer aerial

- master and service keys with built-in transponder

- HV coil

- diagnosis LED

The diagnosis led also works as a blinking light to

deter theft. This function is activated every time the

ignition switch is turned to "OFF" and it remains

active 48 hours so as not to damage the battery

charging process.

When the ignition switch is turned to "ON", it inter-

rupts the function of the immobiliser lamp and a

start enable lamp comes "ON".

The duration of the flash depends on the program-

ming of the electronic control unit


ELE SYS - 65

If the LED is off regardless of the position of the

ignition switch and/or the instrument panel is not

initiated, check if:

• there is battery voltage

• fuse No. 2 and fuse No. 6 efficiency.

• there is power to the control unit as

specified below:

Remove the connector mounting bracket shown in

the photograph and disconnect the connector from

the control unit. Check the following conditions:

With the key switch set to OFF:

• there is battery voltage between terminals 9-7

and terminal 9-chassis ground (fixed power sup-

ply). If there is no voltage, check that fuse 6 and

its cable harness are in working order.

With the key switch in the ON position:

• there is battery voltage between terminals 6-7

and terminal 6-chassis ground (fixed power sup-

ply). If there is no voltage, check the ignition key

contacts, that fuse 2 and its cable are in working

order.


ELE SYS - 66

After removing the leg shield back plate, remove

the electrical connection from the aerial as shown

in the picture.

Remove the protective base from the connector.

With the ignition switch at ON check if there is bat-

tery voltage between the Orange-Blue and Black

cables

Virgin circuit

When the ignition system is not encrypted, any key

will start the engine but limited to 2000 rpm. The

keys can only be recognised if the control unit has

been programmed properly.

The data storage procedure for a previously un-

programmed control unit provides for the recogni-

tion of the red key (master key) as the first key to

be stored to memory: this becomes particularly

important because it is the only key that enables


ELE SYS - 67

the control unit to be wiped clean and reprogram-

med for the memorisation of the service keys.

The master and service keys must be used to code

the system as follows:

- Insert the Master key, turn it to «ON» and keep

this position for two seconds (lower and upper lim-

its 1 to 3 seconds).

- Insert the blue key and set to «ON» for 2 seconds.

- If you have copies of the key, repeat the operation

with each key.

- Insert the MASTER key again and turn it to «ON»

for 2 seconds.

The maximum time to change keys is 10 seconds.

A maximum of 7 service keys (blue) can be pro-

grammed at one time.

It is essential to adhere to the times and the pro-

cedure. If you do not, start again from the begin-

ning.

Once the system has been programmed, master

key transponder, decoder and control unit are

strictly matched.

With this link established, it is now possible to en-

code new service keys, in the event of losses,

replacements, etc.

Each new programming deletes the previous one

so, in order to add or eliminate keys, you must re-

peat the procedure using all the keys you intend to

keep using.

If a service key becomes uncoded, the efficiency

of the high voltage circuit shielding must be thor-

oughly inspected. In any case it is advisable to use

resistive spark plugs.

CharacteristicShielded cap resistance~ 5000 Ω.


ELE SYS - 68

Diagnostic codes

The immobiliser system is tested each time the ig-

nition-key switch is turned from OFF to ON. During

this diagnosis phase a number of control unit sta-

tuses can be seen and various light codes dis-

played. Regardless of the code transmitted, if at

the end of the diagnosis the led remains off per-

manently, the ignition is enabled. If, however, the

led remains on permanently, it means the ignition

is inhibited:

1. Previously unused control unit - key inser-

ted: a single 2 second flash is displayed, after

which the LED remains off permanently. The keys

can be stored to memory, the vehicle can be star-

ted but with a limitation imposed on the number of

revs.

2. Previously unused control unit - transpond-

er absent or cannot be used: The LED is per-

manently ON; in this condition, no operations are

possible, not even starting the vehicle.

3. Programmed control unit - service key in-

serted (normal conditions of use): a single 0.7

second flash is displayed, after which the LED re-

mains off permanently. The engine can be started.

4. Programmed control unit - Master key inser-

ted: a 0.7-sec flash is displayed followed by the

LED remaining off for 2 sec and then by short 0.46-

sec flashes, the same number of times as there

are keys stored in the memory including the Mas-

ter key. When the diagnosis has been completed,

the LED remains permanently OFF. The engine

can be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,

after which the LED remains on permanently. The engine cannot be started. The codes that can be

transmitted are:

• 1-flash code

• 2-flash code


ELE SYS - 69

• 3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the se-

rial line is not present or is not detected. Check the

Immobilizer aerial wiring and change it if necessa-

ry.

Diagnostic code - 2 flashes

A two-flash code shows a system where the con-

trol unit does not show the transponder signal. This

might depend on the inefficiency of the immobiliser

aerial or the transponder.

Turn the switch to ON using several keys: if the

code is repeated even with the Master key, check

the aerial wiring and change it if necessary. If this

is not the case, replace the defective key and/or

reprogram the control unit. Replace the control unit

if the problem continues.

Diagnostic code - 3 flashes

A three-flash code indicates a system where the

control unit does not recognise the key. Turn the

switch to ON using several keys: if the error code

is repeated even with the Master key, replace the

control unit. If this is not the case, reprogram the

decoder.

Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel.

The generator is directly connected to the voltage regulator.


ELE SYS - 70

This, in its turn, is connected directly to the ground and the battery positive terminal passing through

the 30A protective fuse. 07 (30A).

The three-phase alternator provides good recharge power and at low revs a good compromise is ach-

ieved between generated power and idle stability.

Stator check

Checking the stator windingsWARNING

THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1) Remove the right side panel.

2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the

picture.

3) Measure the resistance between each of the yellow terminals and the other two.

Electric characteristicResistance:

0.2 - 1 Ω

4) Check that there is insulation between the each

yellow cable and the ground.

5) If values are incorrect, replace the stator.

See alsoSide fairings

Recharge system voltage check

Look for any leakage

1) Access the battery by removing the specific cover.

2) Check that the battery does not show signs of losing fluid before checking the output voltage.

3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole

(-) of the battery and the black cable and only then disconnect the black cable from the negative pole

(-) of the battery.

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

Charging current checkWARNING


ELE SYS - 71

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK-ING ORDER.1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the multimeter leads between the battery

terminals..

3) Start the engine, being careful to keep the lights off (light switch moved to the right), increase the

engine revs and simultaneously measure the voltage.

Electric characteristicVoltage ranging between 14.0 and 15.0V at 5000 rpm.Maximum current output check.

- With the engine off and the panel at «ON» turn on the vehicle lights, moving the lights switch to the

left, and allow the battery voltage to stop at 12V.

- Connect a current clamp to the recharge positive (Red-Black cable) coming out of the regulator.

- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter.

With an efficient battery a value must be detected: > 20A

VOLTAGE REGULATOR/RECTIFIERSpecification Desc./Quantity

Type Non-adjustable three-phase transistorVoltage 14 to 15V at 5000 rpm with lights off

See also

Battery

Starter motor


ELE SYS - 72

KEY

1. Starter motor

2. Starter relay

3. Battery

4. Fuse No. 7

5. Ignition switch contacts

6. Fuse No. 3

7. Stop buttons

8. Starter button

9. Injection ECUWARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.

1) Check fuses No. 07 and No. 03.

2) Check ignition key contacts.

3) Check the contacts of the stop buttons and the starter button.

4) With the ignition switch set to «ON», stand raised the brake pulled and the starter button pressed,

check if there is voltage between the Orange-White cable of the start-up solenoid switch and the ground

connection, also check the wiring.

5) Check the start-up remote control switch.

6) Check that the Red cable between the battery and the start-up remote control switch is not interrupted.

Also check continuity between the latter and the starter motor.

7) Check the starter motor ground connection.

8) Check if there is continuity of the Purple-White cable between the start-up relay and the control unit

(pin 10).


ELE SYS - 73

Horn control

KEY

1. Battery

2. Fuse No. 7

3. Ignition key contacts

4. Fuse No. 3

5. Horn button

6. HornWARNING



2) Check the ignition switch and horn button contacts.

3) With the ignition switch set to «ON» and the horn button pressed, check if there is voltage between

the Grey-Black cable of the horn device and the ground connection. If there is not, check the cable

harnesses.

4) Check the horn device ground connection.


ELE SYS - 74

Turn signals system check

KEY

1. Battery

2. Fuse No. 7

3. Ignition key contacts

4. Fuse No. 3

5. Turn indicator control device

6. Turn indicator switch

7. Right turn indicator bulbs

8. Left turn indicator bulbs

9. Turn indicator warning light bulbWARNINGALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.1) Check that bulbs operate properly.


3) Check ignition key contacts.

4) With the ignition key set to «ON», check if there is voltage between the Blue-Black cable of the turn

indicators switch and the ground connection. If there is not, check the cable harnesses and the con-

nections of the turn indicator control device.

5) Check the turn indicator switch contacts.

6) With the turn indicator switch pressed to the right, check if there is voltage between the White-Blue

cable of the switch and the ground connection. If there is not, check the cable harnesses.


ELE SYS - 75

7) With the turn indicator switch pressed to the left, check if there is voltage between the Pink cable of

the switch and the ground connection. If there is not, check the cable harnesses.

8) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.

level indicatorsWARNING


If faults are detected:

1) With a multimeter, check resistance values be-

tween the White-Green cable and the Black cable

of the fuel level transmitter under different condi-

tions.

2) If the transmitter operates correctly but the in-

dication on the instrument panel is not exact,

check that the cable harnesses between them are

not interrupted.

Electric characteristicResistance value when the tank is full<= 7 Ω

Resistance value when the tank is empty90 +13/-3 Ω


ELE SYS - 76

Lights list

KEY

1. Battery

2. Fuse No. 7

3. Fuse No. 1

4. ignition key contacts

5. Headlight relay

6. Fuse No. 5

7. Fuse No. 4

8. Light switch

9. Electronic control unit

10. Daylight running light bulbs

11. Instrument panel lighting lights daylight running light warning light

12. Low beam bulb filament

13. High beam light bulb filament

14. High-beam warning light bulb

15. Light switch

16.License plate bulbWARNINGALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORSDISCONNECTED.LINE FOR DAYLIGHT RUNNING LIGHTS, LICENSE PLATE LIGHT AND DASHBOARD LIGHTING

BULB


ELE SYS - 77

1) Check that bulbs operate properly.

2) Check fuses No. 07 and 04.

3) Check the ignition switch and light switch contacts.

4) With the ignition key set to «ON» and the horn button pressed, check if there is voltage between the

Grey-Black cable of the horn device and the ground connection. If there is not, check the cable har-

nesses.


HIGH BEAM/LOW BEAM LIGHTS LINE

1) Check that bulbs operate properly.

2) Check fuses No. 07, 05 and 01.

3) Check the ignition switch and light switch contacts.

4) Check that there is battery voltage between the Grey cable (30) of the headlight relay and the ground.

If there is not, check the cable harness.

5) With the ignition witch at «ON», the light switch moved to the left and the engine started, check for

voltage between the Grey cable (87) of the headlight relay and the ground. If there is not, check the

cable harness.

6) Check that the White-Black cable connecting the headlight solenoid and the control unit (pin 33) is

not interrupted.

7) Check the headlight remote control switch.

8) Check that the continuity between the Grey cable of the light switch and the headlight remote control

is not interrupted.

9) Check the light switch contacts.


BULBSSpecification Desc./Quantity

1 High/low beam light bulb Type: Halogen (H4)Power: 12V - 35/35W

Quantity: 12 Front side light bulb Type: All glass

Power: 12V - 5WQuantity: 1 RHS + 1 LHS

3 Front turn indicator light bulb Type: SphericalPower: 12V - 10W

Quantity: 1 RHS + 1 LHS4 Rear turn indicator light bulb Type: Spherical

Power: 12V - 10WQuantity: 1 RHS + 1 LHS

5 Stop and tail light bulb Type: SphericalPower: 12V 21/5W

Quantity: 16 12V - 1.7W warning light bulbs Type: All glass

Function: turn indicators, engine oil pressureQuantity: 3

7 Instrument panel lighting bulbs Type: All glassPower: 12V 1.7W

Quantity: 28 License plate bulb Type: ALL GLASS

Power: 12V - 5W


ELE SYS - 78

Specification Desc./QuantityQuantity: 1

Fuses

The electrical system is protected by:

- six fuses located under the front grill. Undo the

screw underneath the PIAGGIO clip-on badge and

remove the front grille to reach fuses.

- a fuse (No. 7) of 30A (7) located next to the bat-

tery;CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS-TEM, PERFORMED INCORRECTLY OR WITHOUT STRICTATTENTION TO THE TECHNICAL SPECIFICATIONS OFTHE SYSTEM CAN CAUSE MALFUNCTIONING AND RISKOF FIRE.CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVETHE FAILURE THAT CAUSED IT TO BLOW. NEVER TRYTO REPLACE THE FUSE WITH ANY OTHER MATERIAL(E.G., A PIECE OF ELECTRIC WIRE).

FUSE CHARTSpecification Desc./Quantity

1 Fuse No. 1 Threshold of operation: 10ALocation: front part

Protected circuits: battery power, lights relay.2 Fuse no. 2 Threshold of operation: 7.5 A

Location: front partProtected circuits: battery-powered injection solenoid,

injection control unit, Immobilizer LED.3 Fuse no. 3 Threshold of operation: 7.5 A

Location: front partProtected circuits: Ignition switched live, turn indicators

intermittence, horn, instrument panel, stop lights.4 Fuse no. 4 Threshold of operation: 7.5 A

Location: front part


ELE SYS - 79

Specification Desc./QuantityProtected circuits: Ignition switched live light switchand solenoid, daylight running lights, and dashboard

lighting.5 Fuse No. 5 Threshold of operation: 7.5 A

Location: front partProtected circuits: Ignition switched live, flasher func-

tion.6 Fuse No. 6 Threshold of operation: 5A

Location: front partProtected circuits: Ignition switched live injection con-trol unit, immobilizer antenna, injection load remote con-

trol.7 Fuse No. 7 Threshold of operation: 30 A

Location: battery compartmentProtected circuits: Battery power, recharge circuit, ve-

hicle general (flywheel, voltage regulator).

Dashboard

A = Trip counter

B = Speedometer

F = Low oil pressure warning light

D = Turn indicator warning light

E = High beam warning light

F = Headlight warning light

G = Immobilizer warning light

H = Injection fault

I = Fuel gauge

L = Digital clock

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge

and recharging, if necessary.

These operations should be carried out before delivering the vehicle, and on a six-month basis while

the vehicle is stored in open circuit.

Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-

quired, before storing the vehicle and afterwards every six months.

INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE

1) Voltage check

Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 to 14.70V

- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity


ELE SYS - 80

- Charge time:

10 to 12 h recommended

Minimum 6 h

Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the battery rated capacity

- Charge time: Maximum 5 h

Battery installation

VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CON-TACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTESAND SEEK IMMEDIATE MEDICAL ATTENTION.IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGEQUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.SEEK IMMEDIATE MEDICAL ATTENTION.BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS ORCIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES.KEEP OUT OF THE REACH OF CHILDREN

1) Battery preparation

Position the battery on a flat surface. Remove the

adhesive sheet closing cells and proceed as quick-

ly as possible to run the subsequent activation

phases.

2) Electrolyte preparation.

Remove the container of the electrolyte from the

pack. Remove and preserve cover strips from the

container, in fact, the strip will later be used as a

closing cover.

Note: Do not pierce the sealing of the container or

the container itself because inside there is sulphu-

ric acid.


ELE SYS - 81

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with

the six areas sealed in line with the six battery filler

holes. Push the container down with enough force

to break the seals. The electrolyte should start to

flow inside the battery.

Note: Do not tilt the container to prevent the flow

of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20

minutes or more.

Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container

two or three times. Do not remove the container from the battery.

5) Take out the container.

Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte

remains in the container. Now, gently pull the container out from the battery, only do this when the

container is completely empty, and proceed immediately to the next point.

6) Battery closing.

Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure

that the strip is levelled with the top part of the battery.

Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect

your hands and do not bring your face close to the battery.

The filling process is now complete.

Do not remove the strip of caps under any circumstances, do not add water or electrolyte.

Place the battery down for 1 to 2 hours prior to the charging from the battery.

7) Recharging the new battery

With the above-mentioned procedure, the battery

will have gained around 70% - 75% of its total

electrical capacity. Before installing the battery on

the vehicle, it must be fully charged and then must

be recharged.

If the battery is to be installed on the vehicle

prior to this pre-charged one, the battery will

not be able to exceed 75% charge without jeop-

ardising its useful life on vehicle.

The dry charge battery MF like the completely loa-

ded YTX, must have a no-load voltage between


ELE SYS - 82

12.8 - 13.15 V Bring the battery to full charge, us-

ing the 020648Y battery charger:

a - select the type of battery with the red switch on

the left of the panel battery charger panel

b - select NEW on the yellow timer

c - connect the clamps of the battery charger to the

battery poles (black clamp to negative pole (-) and

red clamp to positive pole (+)).

d - Press the red button, as shown in figure.

e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-

ure.

f - Check the ignition of the green LED indicated

with a red arrow in figure.


ELE SYS - 83

g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED

has taken place

h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less

than 12.8 V, proceed with a new recharge of the

battery starting from point c of the recharge pro-

cedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,

disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

Connectors

DIAGNOSTICS CONNECTOR

1. Not connected

2. Ground lead (Black)

3. Electronic control unit (Orange-Black)

PICKUP CONNECTOR

1. Control unit positive (Red)

2. Negative from control unit (Brown)

3. Oil pressure warning light (White-Pink)


ELE SYS - 84

FUEL PUMP CONNECTOR


2. Power from solenoid (Black - Green)

3. Not connected

4. Not connected

5.Not connected

ELECTRONIC CONTROL UNIT CONNECTOR

1. HV coil (Pink-Black)

2. Not connected

3. Not connected

4. Engine stop switch (Green-Black)

5. Not connected

6. Key-on power (Orange-Blue)

7. Ground lead 1 (Black)

8. Not connected

9. Battery powered (Red-White)

10. Start-up enabling switch (Purple-White)

11. Lambda probe positive (Green-Blue)

12. Lambda probe negative (Sky blue-Black)

13. Engine temperature sensor (Sky blue-Green)

14. Immobilizer antenna (Orange-White)

15. Sensor ground (Black)

16. Diagnosis (Orange-Black)

17. Immobilizer warning light (Yellow)

18. Not connected

19. Side stand (Brown - Red)

20. Engine speed sensor negative / pick-up

(Brown)

21. Not connected

22. Injection load solenoid (Black-Purple)

23. Ground 2 (Black)

24. Not connected

25. Injection warning light (Brown-White)

26. Not connected

27. Not connected


ELE SYS - 85

28. Not connected

29. Engine speed sensor positive/pick-up (Red)

30. Not connected

31. Oxygen Sensor Resistance (Sky Blue-Red)

32. Not connected

33. Enabling lights (White-Black)

34. Injector (Red-Yellow)

ENGINE TEMPERATURE SENSOR CONNEC-

TOR

1. Electronic control unit (Sky blue - Green)

2. Ground lead (Grey-Green)

INJECTOR CONNECTOR


2. Electronic control unit (Red - Yellow)

LAMBDA PROBE CONNECTOR

1. Positive from control unit (Green-Blue)

2. Negative from control unit (Sky Blue-Black)

3. Negative resistance from control unit (Sky Blue-

Black)



ELE SYS - 86

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red-Black)


INSTRUMENT PANEL CONNECTOR «A»

1. Power for instrument panel backlights and igni-

tion switched live for daylight running light and low

beam lights (Yellow-Black)

2. Right turn indicator warning light (White-Blue)

3. Left turn indicator warning light (Pink)

4. Key powered for engine management indicator

light, oil pressure and fuel level indicator light

(White)

5. Fuel level indicator (White-Green)

6. Indicator ground daylight running lights and low

beam lights, high beam indicator light and instru-

ment panel lighting (Black)

INSTRUMENT PANEL CONNECTOR «B»

1. High beam warning light (Purple)

2. Engine management warning light (Brown-

White)

3. Not connected

4. Oil pressure warning light (White-Red)


ELE SYS - 87

LIGHT SWITCH CONNECTOR

1. Headlight power from relay (Grey-Blue)

2. Daylight running lights, number plate and in-

strument panel illumination power from light switch

(Yellow-Black)

3. Ignition switched live for lights (Grey-White)

H.V. COIL CONNECTOR


2. Electronic control unit (Pink - Black)

IMMOBILIZER ANTENNA CONNECTOR

1. Ignition switched live (Orange-Blue)


3. Electronic control unit (Orange-White)

FUEL LEVEL INDICATOR CONNECTOR

1. Fuel level indicator (White - Green)



ELE SYS - 88

LIGHT SWITCH CONNECTOR

1. Key-on power (Grey-Red)

2. Low beam light (Brown)

3. Power from relay (Grey)

4. High beam light (Purple)

TURN INDICATOR SWITCH CONNECTOR

1. Left turn indicator (Pink)

2. Right turn indicator (White-Blue)

3. turn indicator intermittence (Blue-Black)


ELE SYS - 89

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the

head

- Remove the Lambda probe from its support and

disconnect it.

- Release the lambda probe cable from the brack-

ets on the fan cover.

- Loosen the 2 exhaust fixing screws to the crank-

case, then remove the whole exhaust.

- Remove the lambda probe from the manifold.

Locking torques (N*m)Nut fixing silencer to cylinder head 16 - 18

Fly 125 i.e - 150 i.e Leader (2011) Engine from vehicle

ENG VE - 91

Removal of the engine from the vehicleCAUTION

SUPPORT THE VEHICLE ADEQUATELY.

- Disconnect the battery.

- Remove the helmet compartment.

- Remove the lower cover.

- Slide the HV wire cap off the spark plug.

- Remove the full muffler unit.

- Remove the 3 screws of the rear brake transmis-

sion retainer brackets indicated in the picture.

- Disconnect the rear brake transmission by un-

screwing the adjuster screw.

- Disconnect the two connectors of the magneto

flywheel cabling and remove from below, freeing it

from the chassis retainer brackets.

Engine from vehicle Fly 125 i.e - 150 i.e Leader (2011)

ENG VE - 92

- Remove the ground cable and the positive cable

of the starter motor indicated in figure.

- Disconnect the cable camp bracket from the

throttle body and remove the injection ECU con-

nector.

- Remove the cable retainer bracket from the fly-

wheel stator cover.

- Release the wiring and H.V. cable from the re-

spective retaining brackets on the flywheel stator

cover.


ENG VE - 93

- Disconnect the main cable harness from the en-

gine temperature sensor.

- Disconnect the fuel hoses and the main cable

harness from the injector.

- Disconnect the throttle control cable from the

throttle body pulley, acting on the indicated adjust-

er screws.

- Disconnect from the left side of the engine the

engine - chassis ground cable and the fuel piping

support bracket.

- Remove the clamp on the transmission crank-

case ventilation duct and disconnect it from the air

intake on the frame.

- Remove the two screws fixing the bracket with

silent block to the chassis.

- Remove the return spring from the bracket.


ENG VE - 94

- Support the vehicle adequately (with a jack) and

remove the shock absorber lower clamping.

- Unscrew and remove the nut in correspondence

with the swinging arm fixing on the chassis side

with that on the engine side.

- Remove the pin from the opposite side.

- Remove the complete engine of the engine side

swinging arm.

Locking torques (N*m)Frame-swinging arm bolt 50 to 55

See alsoLower coverHelmet bayExhaust assy. Removal


ENG VE - 95


ENG VE - 96

INDEX OF TOPICS

ENGINE ENG

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- To remove the transmission cover it is necessary

to remove the rear plastic cover first by inserting a

screwdriver in the corresponding slotted holes.

Using the clutch housing lock wrench, remove the

driven pulley axle locking nut and recover the

washer.

- Remove the cap/dipstick from the engine oil filling

hole.

- Remove the 10 screws and the ground cable fas-

tened under one of them.

- Remove the transmission cover. If this operation

is performed directly on the vehicle, it is necessary

to remove the cooling air sleeve and the three air

filter housing retainers.

Specific tooling020423Y Driven pulley lock wrench

Air duct

- Unscrew the Torx screws fixing the air duct bulk-

head and remove the bulkhead.

- Remove the 3 screws, then take out the duct as

well as the filter.

Engine Fly 125 i.e - 150 i.e Leader (2011)

ENG - 98

Air duct filter

- Unscrew the 2 fixing screws and slide off the filter.

- Clean with water and mild soap.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Use the specific tools to remove the bearing from

the crankcase.CAUTIONUSE AN APPROPRIATE REST SURFACE TO AVOID DAM-AGING THE COVER PAINT.

Specific tooling020376Y Adaptor handle


Fly 125 i.e - 150 i.e Leader (2011) Engine

ENG - 99

Refitting the driven pulley shaft bearing

- Heat up the crankcase inside with the hot air gun.

- Insert the bearing in its housing, refit the Seeger

ring.N.B.ALWAYS REPLACE THE BEARING WITH A NEW ONEUPON REFITTING.

Specific tooling020151Y Air heater



020412Y 15-mm guide

Removing the driven pulley

- Remove the spacer, the clutch housing and the

whole driven pulley unit.N.B.THE UNIT CAN ALSO BE REMOVED WITH THE DRIVINGPULLEY MOUNTED.

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

CharacteristicMax. value clutch housingMax. value: Ø 134.5 mm

clutch housing standard valueStandard value: Ø 134 - 134.2 mm


ENG - 100

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2

bearings (inside diameter: 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft unit on the support to check

the crankshaft alignment.

- Using a feeler dial gauge and the magnetic base,

measure the bell eccentricity.

- Repeat the measurement in 3 positions (Central,

internal, external).

- If faults are found, replace the bell.

Specific tooling020074Y Support base for checking crankshaftalignment


Characteristicclutch housing inspection: Limit eccentricity.Admissible limit eccentricity: 0.15 mm

Removing the clutch

- Prepare the locking tool for the driven pulley with

the pins half-screwed in the tool set to «C».

- Introduce the adapter ring 11 with the chamfering

facing the inside of the tool.


ENG - 101

- Fit the driven pulley unit in the tool so as the bolt

get into the masses clutch support holes. After-

wards make the support screw make contact with

a minimum force.

- Using the specific wrench, inserted 46 mm from

the side, remove the clutch central locking nut.

- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BETIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THESPECIFIC TOOL.

Specific tooling020444Y Tool for fitting/ removing the driven pulley clutch

020444Y011 adapter ring

020444Y009 wrench 46 x 55

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 DIFFERENTFROM ONE ANOTHER.VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TOTEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLS TO PREVENTA VARIATION IN THE RETURN SPRING LOAD.

CharacteristicCheck minimum thickness1 mm


ENG - 102

Pin retaining collar

- Simultaneously turn and pull the collar manually

to remove it.N.B.USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL-TY.N.B.BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOOFAR TO AVOID DAMAGE THAT COULD COMPROMISETHE O-RING SEAL.

Removing the driven half-pulley bearing

- Remove the retainer ring using two flat blade

screwdrivers.

- Using a hammer and pin, knock the ball bearing

out as shown in the figure.

- Remove the roller bearing using the specific ex-

tractor.N.B.REST THE HALF-PULLEY ON A WOOD SURFACE TOAVOID DAMAGING THE THREADED RINGLET OF THEDRIVEN PULLEY UPON REMOVING IT.

Specific tooling020375Y 28 x 30 mm adaptor


020439Y 17-mm guide


ENG - 103

Inspecting the driven fixed half-pulley

- Measure the outside diameter of the pulley bush-

ing.

CharacteristicMinimum diameter permittedØ 40.96 mm

Standard diameterØ 40.965 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.

CharacteristicMinimum admissible diameter:Ø 41.08 mm

Standard diameterØ 41.035 mm

Refitting the driven half-pulley bearing

- Assemble a new roller bearing using the specific

punch, fit the bearing with the label facing outward

and insert it completely up to the punch on the half-

pulley.N.B.REST THE HALF-PULLEY ON A WOOD SURFACE TOAVOID DAMAGING THE THREADED RINGLET OF THEDRIVEN PULLEY UPON REMOVING IT.

Specific tooling020424Y Driven pulley roller casing fittingpunch


ENG - 104

- To assemble the new ball bearing insert it com-

pletely down in its housing with the specific punch

and finally assemble the Seeger ring.

Specific tooling020375Y 28 x 30 mm adaptor


020439Y 17-mm guide

Refitting the driven pulley

- Check that the faying surfaces between the 2

half-pulleys and the belt do not show any signs of

wear, scoring and grease.

- Insert the new oil seals and O-rings on the mov-

able half-pulley.

- Assemble the half-pulley on the ringlet with the

appropriate protection sheath.

- Make sure the pins and collar are not worn, re-

assemble the pins and collar.

- Use a greaser with a curved spout to lubricate the

driven pulley unit with around 6 g of grease. This

operation must be done through one of the holes

inside the bushing until grease comes out of the

opposite hole. This operation is necessary to avoid

the presence of grease beyond the O-rings.

Specific tooling020263Y Driven pulley assembly sheath

Recommended productsAGIP GREASE SM 2 Gray black smooth-tex-tured lithium grease, containing molybdenumdisulphide.-


ENG - 105

Inspecting the clutch spring

- Measure the length of the spring when it is relaxed.

CharacteristicStandard length:

106 mm

Acceptable limit after use

102.5 mm (4.035 in)

Refitting the clutch

- Support the driven pulley spring compressor spe-

cific tool with the control screw in vertical axis.

- Arrange the tool with the medium length pins

screwed in position "C" on the inside.

- Introduce the adapter ring No. 11 with the cham-

fering facing upwards.

- Insert the clutch on the adapter ring.

- Lubricate the end of the spring that abuts against

the torque server closing collar.

- Insert the spring with its plastic holder in contact

with the clutch.

- Insert the pulley group in the spring compressor

tool.

- Slightly preload the spring.

- Make sure that the clutch is perfectly inserted into

the adapter ring before proceeding to tighten the

clutch nut.

- Place the tool in the clamp with the control screw

on the horizontal axis.


ENG - 106

- Fully preload the spring.

- Apply the clutch fixing nut and tighten it to the

prescribed torque using the special 46x55 wrench.

- Loosen the tool clamp and insert the belt accord-

ing to its direction of rotation.

- Lock the driven pulley again using the specific

tool.

- Preload the clutch return spring with a traction/

rotation combined action and place the belt in the

smaller diameter rolling position.

- Remove the driven pulley /belt unit from the tool.N.B.DURING THE SPRING PRELOADING PHASE, BE CARE-FUL NOT TO DAMAGE THE PLASTIC SPRING STOP ANDTHE BUSHING THREADING.N.B.FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-TED IN CONTACT WITH THE CLUTCH.

Specific tooling020444Y Tool for fitting/ removing the drivenpulley clutch

020444Y011 adapter ring

020444Y009 wrench 46 x 55

Locking torques (N*m)Nut locking clutch unit on pulley 55 - 60 Nm

Refitting the driven pulley

- Reassemble the driven pulley / belt group on the

driven pulley shaft.


ENG - 107

- Reassemble the clutch housing and spacer.

Drive-belt

- Make sure the drive belt is not damaged and does not show abnormal wear.

- Replace as indicated in the scheduled maintenance table.

Removing the driving pulley

- Lock the driving pulley with the specific tool as

shown in the figure. - Disassemble the central nut

and the cup washer, remove the drive and the 2

washers. - Remove the stationary half pulley and

the steel washer.

Specific tooling020368Y driving pulley lock wrench

- Remove the belt and slide the movable half-pul-

ley with the relevant bush, taking care of the falling

free assembled rollers.

- Remove the return rollers plate with the relative

guide sliders.

Inspecting the rollers case

- Check that the internal bushing is not abnormally worn and measure inner diameter.N.B.

DO NOT LUBRICATE OR CLEAN THE BUSHING.


ENG - 108

BUSHING ROLLER HOUSINGSpecification Desc./Quantity

Maximum allowable diameter Ø 26.121 mmStandard diameter Ø 26+0 +0.021 mm

BUSH SLIDE PULLEYSpecification Desc./Quantity

Minimum diameter permitted Ø 25.950 mmStandard diameter Ø 26-0.020 -0.041 mm

CVT ROLLERSSpecification Desc./Quantity

Minimum diameter permitted Ø 18.5 mmStandard diameter Ø 26±0.1 mm

- Check the guide shoes for the variator back-plate

are not worn.

- Check there is no wear in the roller housing, and

the surfaces in contact with the belt on either of the

pulley halves.

- Pre-assemble the movable half-pulley with the

roller contrast plate by placing the rollers as shown

in the figure, that is, during insertion, the closed

side should be on the left side of the pulley thrust.

- Mount the complete bushing unit on the crank-

shaft.


ENG - 109

Refitting the driving pulley

- Reassemble the parts of the unit (internal lining,

fixed half-pulley, external lining, drive and nut),

spread threadlock on the thread and screw the nut

to the prescribed torque.

-Avoid the half-pulley rotation using a calliper

spannerN.B.REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT

Specific tooling020368Y driving pulley lock wrench

Recommended productsLoctite 243 Medium-strength threadlockMedium Loctite 243 threadlock

Locking torques (N*m)Drive pulley nut (°) 75 - 83

Refitting the transmission cover

- Check that there are 2 alignment dowels and that

the sealing gasket for the oil sump on the trans-

mission cover is adequately fitted.

- Replace the cover and tighten the 10 screws to

the specified torque.

- Refit the oil loading cap/bar.

- Refit the steel washer and the driven pulley nut.

- Tighten the nut to the prescribed torque using the

lock wrench and the torque wrench tools.

- Refit the plastic cover.


ENG - 110

Specific tooling020423Y Driven pulley lock wrench

Locking torques (N*m)Transmission cover screws 11 - 13 Driven pulleyshaft nut 54 - 60

End gear

Removing the hub cover

- Remove the brake shoes and the relative springs.

- Remove the brake shoes activation lever, un-

screwing the relative fixing screw to access the

rear screw of the cover.

- Drain the rear hub oil through the oil drainage

plug located on the lower part of the hub cover.

- Remove the rubber plug and unscrew the 7

screws with flanged heads indicated in the figure.

- Remove the hub cover and the relative gaskets.

Removing the wheel axle

Remove the intermediate gear and the complete

hub cover.


ENG - 111

Removing the hub bearings

- Check the state of the bearings being examined

(wear, clearance and noisiness). If faults are de-

tected, do the following.

- Use the specific bearing extractor to remove the

three 15 mm bearings (2 in the crankcase and 1 in

the hub cover).

Specific tooling001467Y009 Bell for OD 42-mm bearings


Removing the wheel axle bearings

- Take out the clip on the outside of the hub cover.

- Remove the bearing with the adequate tools ad-

equately supporting the hub cover, as shown in the

figure.


020364Y 25-mm guide

With the appropriate tools, remove the oil seal as

shown in the figure.



Removing the driven pulley shaft bearing

If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven

pulley.

- Extract the driven pulley shaft from its bearing.

- Remove the oil seal using a screwdriver, working from inside the bearing and being careful not to

damage the housing, make it come out of the belt transmission side.

- Remove the Seeger ring shown in the figure


ENG - 112

With the sectional punch, remove the driven pulley

shaft bearing.



020363Y 20-mm guide

See alsoRemoving the driven pulley

Inspecting the hub shaft

- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and

the oil seal housings.

- If faults are found, replace the damaged compo-

nents.

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted. - Check the load capacity of the bearings and

the brake camshaft. - If faults are found, replace the hub cover.

Refitting the driven pulley shaft bearing

- Heat up the parts using the specific heat gun.

Specific tooling020150Y Air heater support

020151Y Air heater

- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of

the hub cover using the adequate tools



ENG - 113

- Refit the Seeger ring with the opening facing the

bearing as shown in the figure and fit a new oil seal

flush with the crankcase.

Refitting the wheel axle bearing

- Heat up the parts using the specific heat gun

Specific tooling020151Y Air heater

020150Y Air heater support

-The wheel axle bearing on the cover, should be assembled with the specific tools

Specific tooling020364Y 25-mm guide



• Assemble the Seeger ring.

• Assemble the oil seal flush with the in-

ternal surface as shown in the figure to

the hub using the adequate tools and

with the seal lip towards the inside of

the hub.



Refitting the hub cover bearings

- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the

specific heat gun.

Specific tooling020150Y Air heater support

020151Y Air heater


ENG - 114

- The three 15 mm bearings must be fitted using

the appropriate tools.

Refitting the hub bearings

- Insert the cover prepared in the crankcase taking

care of inserting the gear of the pulley shaft on the

intermediary gear.

Refitting the ub cover

- Fit a new gasket together with the alignment

dowels.

- Fit the gearbox cover, making sure the breather

pipe is in the correct position.

- Screw the 7 screws to the specified torque, po-

sitioning the support plate of the pipe in the posi-

tion shown in the figure.

- Remove the control pin of the shoe taking care

so as the long tooth coincides with the groove on

the control lever.

Locking torques (N*m)Rear hub cap screws 24 - 27


ENG - 115

Flywheel cover

Cooling hood

- Remove the fan cover cap acting on the 4 fixing screws.CAUTION

DURING REMOVAL SLIDE THE CABLE GROMMET FROM THE HOUSING ON THE CAP.

- Slide the access flap to the spark plug.

- Remove the two self threading screws, left and

right and the lateral left fixing screw on the crank-

case base.

- Take off the two caps from the thermal group.

- Remove the gasket seal of the housing on the

head.


ENG - 116

Cooling fan

- Remove the fan cover cap.

- Remove the cooling fan by acting on the three

fixings indicated in the figure.

Removing the stator

- Remove the magneto flywheel.

- Remove the electric terminal of the minimum oil

pressure switch.

- Remove the two Pick-Up screws and the one for

the wiring harness bracket as well as the two stator

fixing screws shown in the figure.

- Remove the stator and its wiring.

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-

ers to the specified torque.

- Place the cable harness as shown in the figure.N.B.THE PICK-UP WIRE SHOULD BE POSITIONED BETWEENTHE UPPER SCREW AND THE REFERENCE DOWEL ASSHOWN IN THE DETAIL DRAWING.

Locking torques (N*m)Stator screw 3 - 4


ENG - 117

Flywheel and starting

Removing the starter motor

- Remove the two screws indicated in the figure.

- Take the starter motor out of its seat.

Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper

spanner.

- Remove the nut.CAUTIONTHE USE OF A CALLIPER SPANNER OTHER THAN THEONE SUPPLIED COULD DAMAGE THE STATOR COILS

Specific tooling020565Y Flywheel lock calliper spanner

- Extract the flywheel with the extractor.

Specific tooling008564Y Flywheel extractor

Inspecting the flywheel components

- Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate.


ENG - 118

Refitting the flywheel magneto

- Fit the flywheel being careful to insert the key

properly.

- Lock the flywheel nut to the prescribed torque

- Check that the Pick-Up air gap is between 0.34

to 0.76 mm.

The air gap cannot be modified when assembling

the Pick-Up.

Different values result from deformations visible

on the Pick-Up mounting.N.B.A VARIATION IN THE AIR GAP DISTANCE MODIFIES THEIGNITION SYSTEM IDLE SPEED

Locking torques (N*m)Flywheel nut 52 - 58

Refitting the starter motor

- Fit a new O-ring on the starter and lubricate it.

- Fit the starter motor on the crankcase and lock

the 2 screws to the prescribed torque.N.B.REFIT THE REMAINING PARTS AS DESCRIBED IN THECYLINDER HEAD, TIMING, LUBRICATION, FLYWHEELAND TRANSMISSION CHAPTERS.

Locking torques (N*m)Starter motor screws 11 - 13

Cylinder assy. and timing system


ENG - 119

Removing the timing system drive

- Remove the parts listed below first: transmission

cover, belt driving pulley, oil pump pulley cover and

pinion separator washer.

- Remove the tappet cover.

- Remove the central screw fastener and the au-

tomatic valve lifter retaining cover, as shown in the

figure.

- Remove the return spring of the automatic valve

lifter unit and the automatic valve lifter unit and its

end of stroke washer.

- Loosen the central screw on the tensioner first.

- Remove the two fixings shown in the figure.

- Remove the tensioner with its gasket.

- Remove the internal hex screw and the counter-

weight shown in the figure.

- Remove the camshaft control pulley with its

washer.

- Remove the control sprocket wheel and the tim-

ing chain.

- Remove the screws indicated in the figure, the

spacer bar and the tensioner slider.

The tensioner pad must be removed from the

transmission side. As regards the lower chain

guide slider, it may only be removed after the head

has been removed.N.B.IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-SURE THAT THE INITIAL DIRECTION OF ROTATION ISMAINTAINED.

See alsoRemoving the driving pulley

Transmission coverRemoval


ENG - 120

Removing the cam shaft

- Remove the 2 screws and the camshaft retainer

shown in the diagram.

- Remove the cam shaft.

- Remove the pin of the rocking levers from the

flywheel side holes.

- Remove the rocking levers and the elastic wash-

er.N.B.MARK THE ROCKERS ASSEMBLE POSITION, SO AS TOAVOID THE INVERSION OF INTAKE WITH THE EXHAUST.

Removing the cylinder head

- Remove the spark plug.

- Remove the 2 side fixings shown in the figure.

- Loosen the 4 head-cylinder fastening nuts in two

or three stages and in criss-cross fashion.

- Remove the head, the two alignment dowels and

the gasket.N.B.IF NEEDED, THE HEAD MAY BE REMOVED WITH THECAMSHAFT, ROCKER PINS AND FIXING BRACKET. THEHEAD CAN ALSO BE REMOVED WITHOUT REMOVINGTHE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.


ENG - 121

Removing the valves

- Using the specific tool fitted with the element

shown in the figure, remove the cotters, the caps

and the spring between the valves.

Specific tooling020382Y Valve cotters equipped with part 012removal tool


- Remove the oil seals with the appropriate tool.

- Remove the lower spring supports.

Specific tooling020431Y Valve oil seal extractor

Removing the cylinder - piston assy.

- Remove the chain guide slider.

- Remove the cylinder base gasket.CAUTIONTO AVOID DAMAGING THE PISTON, SUPPORT IT WHILEREMOVING THE CYLINDER.

- Remove the two retainer rings, the wrist pin and

the piston.

- Remove the 3 piston rings from the piston.N.B.BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR-ING REMOVAL.


ENG - 122

Inspecting the small end

- Measure the internal diameter of the connecting

rod small end using an internal micrometer.N.B.IF THE DIAMETER OF THE CONNECTING ROD SMALLEND EXCEEDS THE MAXIMUM DIAMETER ADMISSIBLE,SHOWS SIGNS OF WEAR OR OVERHEATING REPLACETHE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASEAND CRANKSHAFT" CHAPTER".

CharacteristicConnecting rod small end check-up: Maximumdiameter15.030 mm

Connecting rod small end check-up: Standarddiameter15+0.015+0.025 mm

Inspecting the wrist pin

- Check the outer diameter of the gudgeon pin.

CharacteristicStandard pin diameter14.996 - 15 mm

Minimum diameter permittedØ 14.994 mm

- Calculate the piston pin coupling clearance.N.B.THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.FOR THIS REASON MEASUREMENT OF THE DIAMETERMUST BE CARRIED OUT ACCORDING TO THE AXIS OFTHE PISTON.

CharacteristicPiston pin bore - standard diameterØ 15+0.001 +0.006


ENG - 123

- Measure the outside diameter of the piston, per-

pendicular to the gudgeon pin axis.

- Measure 36.5 mm from the piston crown's shown

in the figure.N.B.THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.FOR THIS REASON MEASUREMENT OF THE DIAMETERMUST BE CARRIED OUT ACCORDING TO THE AXIS OFTHE PISTON.

- Using a bore meter, measure the inner cylinder

diameter at three different points according to the

directions shown in the figure.

- Check that the coupling surface with the head is

not worn or misshapen.

- Pistons and cylinders are classified into catego-

ries based on their diameter. The coupling is car-

ried out in pairs (A-A, B-B, C-C, D-D).

CharacteristicMaximum allowable run-out:0.001 over 0.05 mm

- The cylinder rectifying operation should be car-

ried out with a surfacing that respects the original

angle.

- The cylinder surface roughness should be 0.9

micron.

- This is indispensable for a good seating of the

sealing rings, which in turn minimises oil consump-

tion and guarantees optimum performance.

- The pistons are oversized due to cylinder rectifi-

cation and are subdivided into three categories

1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They

are also classified into 4 categories A-A, B-B, C-

C, D-D.

Inspecting the piston- Carefully clean the seal housings.

- Measure the coupling clearance between the sealing rings and the piston grooves using suitable

sensors, as shown in the diagram.

- If the clearance is greater than that indicated in the table, replace the piston.


ENG - 124

STANDARD COUPLING CLEARANCEName Description Dimensions Initials Quantity

Top piston ring 0.025 - 0.070Middle piston ring 0.015 - 0.060

oil scraper 0.015 - 0.060

MAXIMUM ADMITTED CLEARANCE AFTER USEName Description Dimensions Initials Quantity

Top piston ring 0.080 mmMiddle piston ring 0.070 mm

oil scraper 0.070 mm

Inspecting the piston ringsN.B.

TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-TER.

See alsoPiston rings

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 retainer ring onto the appropriate tool.

Specific tooling020430Y Pin lock fitting tool


ENG - 125

- With the opening in position indicated on the tool,

take retainer ring in the closed position using the

punch.

- Fit the pin retainer ring using the plug as shown

in the figureN.B.THE TOOL FOR INSTALLING THE RETAINER RINGS MUSTBE USED MANUALLY.CAUTIONUSING A HAMMER TO POSITION THE RINGS CAN DAM-AGE THE LOCKING HOUSING.

Choosing the gasket

- To identify the thickness of the cylinder base gasket to be used in refitting, see the CHARACTERIS-

TICS chapter.

Specific tooling020428Y Piston position check mounting


ENG - 126

Refitting the piston rings

- Place the oil scraper spring on the piston.

- Refit the oil scraper ring with the join of spring

ends on the opposite side from the ring gap and

the word 'TOP' towards the piston crown. The ta-

pered side of the middle piston ring should always

be facing away from the piston crown.

- Fit the middle piston ring with the identification

letter facing the piston crown. In any case, the step

must be facing opposite the piston crown.

- Fit the top piston ring with the word 'top' or the

reference mark facing the crown of the piston.

- Offset the piston ring gaps on the three rings by

120° to each other as shown in the figure.

- Lubricate the components with engine oil.N.B.SO AS TO OBTAIN THE BEST CONFIGURATION THE 2SEALING RINGS ARE MADE WITH A CONTACT CONICALCYLINDER SECTION.

Refitting the cylinder

- Insert the cylinder base gasket with the thickness

determined above.

- Using the fork support and the piston ring retain-

ing band, refit the cylinder as shown in the figure.N.B.BEFORE FITTING THE CYLINDER, CAREFULLY BLOWOUT THE LUBRICATION DUCT AND OIL THE CYLINDERLINER.

Specific tooling020426Y Piston fitting fork


ENG - 127

020427Y Piston assembly band

Inspecting the cylinder head

- Using a trued bar check that the cylinder head

surface is not worn or distorted.

- Check that the camshaft and rocking lever pin

bearings show no signs of wear.

- Check that the cylinder head cover surface, the

intake manifold and the exhaust manifold are not

worn.

CharacteristicMaximum admitted unevenness: Cylinderhead check0.05 mm

STANDARD DIAMETERSpecification Desc./Quantity

Standard diameter A Ø 32.5 - 32.525Standard diameter B Ø 20 - 20.021Standard diameter C Ø 12 - 12.018

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.

- Ensure that the camshaft drive pulley, the chain

assembly and the sprocket wheel are not worn.

- If sings of wear are found, replace the parts. if the

chain, pinion or pulley are worn, replace the whole

assembly.


ENG - 128

- Remove the central screw and the tensioner

spring. Check that the one-way mechanism is not

worn.

- Check the condition of the tensioner spring.

- If examples of wear are found, replace the whole

unit.

Inspecting the valve sealings

- Measure the width of the sealing surface on the valve seats.

VALVE SEAL SURFACESpecification Desc./Quantity

Intake valve - seal surface 2.4 - 2.8 mmExhaust valve - seal surface 2.2 - 2.6 mm

Inspecting the valve housings

- Remove any carbon formation from the valve guides.

- Measure the inside diameter of each valve guide.

- Take the measurement at three different heights in the rocker arm push direction.

CharacteristicStandard drainage guide diameter

5.012 mm

Standard intake guide diameter

5.012 mm


ENG - 129

- If the width of the impression on the valve seat or

the diameter of the valve guide exceed the speci-

fied limits, replace the cylinder head.

- Check width of the impression on the valve seat

«V»

CharacteristicWear limits:Max. 1.6 mm.

Inspecting the valves

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

- Calculate the clearance between valve and valve

guide.

CharacteristicMinimum diameter admitted - Intake:4.96 mm

Minimum diameter admitted - Exhaust:4.95 mm

Standard clearance - Intake:0.013 - 0.040 mm

Standard clearance - Exhaust:0.025 - 0.052 mm

Maximum clearance admitted- Intake:0.062 mm

Maximum clearance admitted - Exhaust:0.072 mm

- Check that there are no signs of wear on the

contact surface with the articulated register termi-

nal.

- If the sealing surface on the valves is wider than

the specified limit, damaged in one or more points

or curved, replace the valve with a new one.

CharacteristicStandard valve length - Intake:80.6 mm

Valve standard length: Exhaust


ENG - 130

79.6 mm

- If no faults are found during the above checks,

you can use the same valves. For best sealing re-

sults, it is advisable to grind the valves. Grind the

valves gently with a fine-grained lapping com-

pound. During grinding, keep the cylinder head in

a horizontal position. This will prevent the lapping

compound residues from penetrating between the

valve stem/guide coupling.CAUTIONTO AVOID SCORING THE FAYING SURFACE, DO NOTKEEP ROTATING THE VALVE WHEN NO LAPPING COM-POUND IS LEFT. CAREFULLY WASH THE CYLINDERHEAD AND THE VALVES WITH A SUITABLE PRODUCTFOR THE TYPE OF LAPPING COMPOUND BEING USED.

- 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.

Inspecting the springs and half-cones

- Check that the upper spring caps and the cotter

halves show no signs of abnormal wear.

- Check the unloaded springs length.

CharacteristicValve spring length33.9 - 34.4 mm


ENG - 131

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the lower caps of the valve spring on the

head.

- Use the punch to fit the 2 sealing rings one at a

time.

Specific tooling020306Y Punch for assembling valve sealrings

- Fit the valves, the springs and the spring retaining

caps. Using the appropriate tool with adapter 11,

compress the springs and insert the cotters in their

seats.

Specific tooling020382Y Valve cotters equipped with part 012removal tool


Inspecting the cam shaft

- Inspect the cam shaft for signs of abnormal wear

on the cams.

CharacteristicStandard diameter Bearing AØ: 32.5 mm -0.025 -0.050 mm

Standard diameter Bearing B20 -0.020 -0.041 mm

Minimum admitted diameter bearing AØ: 32.440 mm

Minimum admitted diameter bearing BØ: 19.950 mm

Intake cam height27.512 mm

Exhaust cam height27.212 mm


ENG - 132

- Check there is no wear on the cam shaft retaining

plate and its associated groove on the cam shaft.

- 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.

CharacteristicMaximum axial clearance admitted0.42 mm

- Check there are no signs of wear on the auto-

matic valve lifter cam, or the end-of stroke roller,

or the rubber buffer on the automatic valve-lifter

retaining cover.

- Check that the valve lifter spring has not yielded.

- Replace any defective or worn components.

- Check there are no signs of scoring or wear on

the rocking lever bolt.

Check there are no signs of wear on the pad from

contact with the cam and on the jointed adjustment

plate.

- Measure the internal diameter of each rocking

lever.

-Check that the elastic washer dedicated to the

axle clearance of the rocking levers is not worn. -

In case of failure, replace the damaged compo-

nents.

CharacteristicMinimum diameter permittedØ 11.970 mm

Maximum diameter allowedØ 12.030 mm

Refitting the head and timing system components

- Fit the timing chain guide slider.

- Insert the head and cylinder alignment dowels, fit the head gasket and the head on the cylinder.


ENG - 133

-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.

Locking torques (N*m)Head-cylinder stud bolt nuts 6 to 7 + 90° + 90° *

- Fit the two screws on the outside of the timing

chain side and tighten them to the specified torque.N.B.BEFORE INSTALLING THE HEAD, MAKE SURE THAT THELUBRICATION CHANNEL IS CLEAN USING A COM-PRESSED AIR JET.

Locking torques (N*m)Screws fixing head and cylinder to crankcase8 - 10

- Fit the timing chain sprocket wheel on the crank-

shaft, with the chamfer facing the insertion side.

- Loop the timing chain around the sprocket on the

crankshaft.

- Fit the tensioner pad by the cylinder head.

- Fit the spacer and the screw fastener.

- Fit the pin, the exhaust rocking lever, the spring

washer and the intake rocking lever.

- Lubricate the 2 rocking levers through the holes

at the top.

- Lubricate the 2 bearings and insert the camshaft

in the cylinder head with the cams opposing the

rocking levers.

- Insert the retention plate and tighten the two

screws shown in the figure to the prescribed tor-

que.

Locking torques (N*m)Camshaft retention plate screw 5 - 6


ENG - 134

- Refit the spacer on the camshaft.

- Rotate the engine so that the piston is at top dead

centre, using the reference marks on the flywheel

and the crankcase.

- While doing so, fit the chain onto the control cam-

shaft pulley and keep the reference 2V in corre-

spondence with the reference mark on the head.

- Fit the pulley onto the camshaft.

- Assemble the counterweight with the corre-

sponding fixing screw and tighten to the specified

torque.

Locking torques (N*m)Pressure reducer counterweight retainer 7 - 8.5

-Fit the end-stop ring on the automatic valve lifter

cam and fit the automatic valve lifter cam to the

cam shaft.

- Fit the automatic valve lifter return spring.

- During this operation the spring must be loaded

approximately 180°.N.B.GREASE THE END STOP RING TO PREVENT IT COMINGOUT AND FALLING INTO THE ENGINE.

- Fit the automatic valve-lifter retaining dish, using

the counterweight screw fastener as a reference.

- Tighten the clamping screw to the prescribed tor-

que.

Locking torques (N*m)Camshaft pulley screw 12 - 14

- Set the tensioner cursor in the rest position.

- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the specified

torque.


ENG - 135

Locking torques (N*m)Tensioner fastening screws: 8 - 10 Nm

- Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed

torque.

Locking torques (N*m)Timing chain tensioner central screw 5 - 6

- Adjust the valve clearance.

- Fit the spark plug

CharacteristicSpark plug (125 cc)NGK CR8EB - DENSO U24ESR-NB

Spark plug (150 cc)NGK CR7EB - DENSO U22ESR-NB

Electric characteristicElectrode gap0.7 - 0.8 mm

Locking torques (N*m)Ignition spark plug 10 - 15 Nm

- Assemble the casing sealing gasket on the head.

On the fitting direction, use the supplements on the

timing side as reference.

- Assemble the screw fixing the housing to the

crankcase to the specified torque and the 2 self-

tapping screws joining the half-shells.

- Take care that the gasket is well inserted in its

housing during the assembly stage.

- Place the spark plug access cap.

Locking torques (N*m)Flywheel air duct screw 3 - 4

- Refit the cylinder head cover, tightening the 4

clamping screws to the prescribed torque.

- Refit the fan and the housing.

- Reassemble the oil pump control, the chain com-

partment cover, the by-pass and the oil sump as

described in the lubrication chapter.


ENG - 136

- Reassemble the driving pulley, the belt and the

transmission cover as described in the transmis-

sion chapter.

Locking torques (N*m)Head cover screws 11 - 13

Crankcase - crankshaft

- Precautionary remove the following units:

transmission cover, driving pulley, driven pulley

and belt, rear hub cover, gears, bearings and oil

seals as described in the transmission chapter.

- Remove the oil sump, the by-pass, the chain

compartment cover and the oil pump as in the lu-

brication chapter.

- Remove the flywheel cover, the fan, the flywheel

and the stator as described in the magneto fly-

wheel chapter.

- Remove the oil filter and the oil pressure bulb.

- Remove the cylinder-piston-head unit as descri-

bed in the cylinder head timing system chapter.

- Remove the 2 retainers indicated in the figure

and the starter motor.

- Before opening the crankcase, it is advisable to

check the axial clearance of the crankshaft. To do

this, use a plate and a support with specific tool

dial gauge.

Specific tooling020262Y Crankcase splitting plate


CharacteristicStandard clearance0.15 - 0.40 mm


ENG - 137

Splitting the crankcase halves

Remove the 11 coupling screws to the crankcase.

- Separate the crankcase while keeping the crank-

shaft in one of the two halves of the crankcase.

Remove the crankshaft.CAUTIONIF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC-CIDENTALLY FALL.

- Remove the coupling gasket of the crankcase

halves.

- Remove the two screws and the internal shield

shown in the diagram.CAUTIONWHILE OPENING THE CRANKCASES AND REMOVINGTHE CRANKSHAFT, CHECK THAT THE THREADEDSHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-INGS. FAILURE TO OBSERVE THIS PRECAUTION CANDAMAGE THE MAIN BUSHINGS.

- Remove the oil seal on the flywheel side.

- Remove the oil filter fitting shown in the diagram

- Check the axial clearance on the connecting rod.



ENG - 138

- Check the radial clearance on the connecting rod.

-Check the surfaces that limit the axial clearance

are not scored and measure the width of the crank-

shaft between these surfaces, as shown in the

diagram.CAUTIONBE CAREFUL NOT TO LET THE MEASUREMENT BE AF-FECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.


- If the axial clearance between crankshaft and

crankcase is exceeding and the crankshaft does

not have any defect, the problem must be due to

either excessive wear or wrong machining on the

crankcase.CAUTIONTHE CRANKSHAFT CAN BE REUSED WHEN THE WIDTHIS WITHIN THE STANDARD VALUES AND THE SURFACESSHOW NO SIGNS OF SCORING.

CharacteristicDistance between the shoulders55.67 - 55.85 mm

- Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces

shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart

below.

STANDARD DIAMETERSpecification Desc./Quantity

Category 1 28.998 - 29.004Category 2 28.004 to 29.010


ENG - 139

Inspecting the crankshaft alignment

To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated

in figure.

- Check that the crankshaft cone, the tab seat, the

oil seal capacity, the toothed gear and the threa-

ded tangs are in good working order.

- In case of failures, replace the crankshaft.

The big end bushings cannot be replaced. For the

same reason, the connecting rod may not be re-

placed and, when cleaning the crankshaft, be very

careful that no impurities get in through the shaft's

lubrication holes.

In order to prevent damaging the connecting rod

bushings, do not attempt cleaning the lubrication

duct with compressed air.

- Make sure that the 2 caps on the crankpin are

properly fitted.

- A wrong installation of a cap can seriously affect

the bushing lubrication pressure.N.B.THE MAIN BEARINGS ARE NOT GRINDABLE

Specific tooling020074Y Support base for checking crankshaftalignment

CharacteristicOff-line maximum admittedA = 0.15 mmB = 0.01 mmC = 0.01 mmD = 0.10 mm


ENG - 140

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.

- On the transmission side crankcase half, take

particular care cleaning the housing and oil ducts

for the following components: the oil pump, the oil

by-pass valve, the main bushings and the cooling

jet on the transmission side (see diagram).

- Take particular care, also, that there are no signs

wear in the oil by-pass valve housing (see Chapter

Lubrication), as this could prevent a good seal in

the piston, which regulates the oil pressure.N.B.THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-ER OPERATION OF THIS COMPONENT IMPROVES PIS-TON CROWN COOLING. CLOGGING HAS EFFECTS THATARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-ERABLE DROP IN THE LUBRICATION PRESSURE FORMAIN BUSHINGS AND CONNECTING ROD.

- On the flywheel side crankcase half, take partic-

ular care cleaning the oil ducts for the main bush-

ings, the oil duct for the jet that lubricates the

cylinder head and the oil drainage duct at the fly-

wheel side oil seal.N.B.THE HEAD LUBRICATION CHANNEL IS PROVIDED WITHA SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEADLUBRICATION; THIS CHOICE WAS MADE TO REDUCETHE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-ING MECHANISMS. A JET FAILURE CAUSES A DE-CREASE OF THE MAIN BUSHING AND CONNECTING RODLUBRICATION PRESSURE.

- Inspect the mating surfaces on the crankcase

halves for scratches or deformation, taking partic-

ular with the surfaces that mate with the cylinder

and the mating surfaces between the crankcase

halves.

- Defects in the crankcase coupling gasket or the

surfaces indicated in the figure can cause a drop

in the oil pressure and affect the lubricating pres-

sure for the main bushings and the connecting rod.


ENG - 141

- Check the main bearing seats that limit axial

clearance in the crankshaft show no signs of wear.

The dimension between these seats is measured

by way of the procedure described previously for

measuring the crankshaft axial clearance and di-

mensions.

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is neces-

sary to have both an optimal lubricating pressure

(4 bar) and a good oil flow rate; the bushings must

be correctly positioned so as not to obstruct the oil

supply channels.

- The main bushings are comprised of two half-

bearings, one with holes and channels for lubrica-

tion whereas the other is solid.

- The solid half-bearing is intended to stand the

thrusts caused by combustion, and for this reason

it is arranged opposite the cylinder.

- To prevent shutters in the oil feeding channels,

the matching surface of the two half-bearings must

be perfectly orthogonal to the cylinder axis, as


- The oil feeding channel section is also affected

by the bushings driving depth compared with the

crankshaft axial clearance of the limiting surface.N.B.TO KEEP THIS POSITION OF THE BUSHINGS ON THECRANKCASE, FITTING IS FORCED ON STEEL RINGS IN-SERTED IN THE CASTING OF BOTH CRANKCASEHALVES.

CharacteristicStandard driving depth1.35 - 1.6

- Check the inside diameter of the main bushings in the three directions indicated in the diagram.

- Repeat the measurements for the other bushing half. see diagram.

- The standard bushing diameter after driving is variable on the basis of a coupling selection.


ENG - 142

- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like

those for the crankshaft.

- The main bushings are subdivided into 3 thickness categories; see the table below:N.B.

DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCETHE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.

MAIN BEARINGSSpecification Desc./Quantity

B BlueC YellowE Green

Refitting the crankcase halves

- Fit the internal shield by locking the two screws

to the prescribed torque.

Locking torques (N*m)Oil pump bulkhead screw 4 - 5

- Fit the oil filter joint and tighten it to the prescribed

torque.

- Place a new gasket on one of the crankcase

halves, preferably on the transmission side, to-

gether with the alignment dowels.

Locking torques (N*m)Oil filter on crankcase fitting 27 - 33


ENG - 143

- Lubricate the main bushings and insert the crank-

shaft in the transmission side crankcase half.

- Reassemble both crankcase halves.

- Fit the 11 screws and tighten them to the pre-

scribed torque.N.B.WHEN FITTING THE HALF CASING AND THE CRANK-SHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREA-DED TANGS.

Locking torques (N*m)Half casing joint bolts: 8 - 10 Nm

- Fit a new O-ring on the pre-filter and lubricate it.

- Insert the pre-filter on the engine with its corre-

sponding cover to the specific torque.N.B.REMOVE ANY EXCESS FROM THE CRANKCASE COU-PLING GASKET ON THE CYLINDER PLANE, TO ENSUREBETTER SEALING PERFORMANCE.

Locking torques (N*m)Engine oil pre-filter cover 25 - 28 Nm

Lubrication


ENG - 144

Conceptual diagrams


ENG - 145

Oil pressure check

- After removing the fan cover housing as descri-

bed in the "Flywheel" chapter, disconnect the elec-

trical connection of the minimum oil pressure

switch and then remove the switch.

- With the engine idling at 1650 rpm and the oil

temperature at ~90°C, check that the oil pressure

is between 0.5 to 1.2 atm.

- With the engine idling at 6000 rpm and the oil

temperature at ~90°C, check that the oil pressure

is between 3.2 to 4.2 atm.

- Remove the appropriate tools once the meas-

urement is complete, refit the oil pressure switch

and washer, tightening it to the specified torque

and fit the flywheel cover.

- If the oil pressure is not within the specified limits,

in the following order, check: the oil filter, the oil

by-pass valve, the oil pump and the crankshaft

seals.N.B.THE CHECK MUST BE CARRIED OUT WITH OIL AT THECORRECT LEVEL AND WITH AN OIL FILTER IN PROPERCONDITION.

CharacteristicMinimum pressure admitted3.2 atm.

Locking torques (N*m)Minimum oil pressure switch 12 - 14

Crankshaft oil seals


ENG - 146

Removal

- Remove the transmission cover and the com-

plete drive pulley beforehand

- Install the base of the appropriate tool on the oil

seal using the screws provided.

- Screw the threaded bar onto the base of the tool

and extract the oil seal.

Specific tooling020622Y Transmission-side oil seal punch

Refitting

- Prepare the new oil seal, lubricating the sealing

lip. Warning: do not lubricate the surface for keying

onto the engine crankcase.CAUTIONDO NOT LUBRICATE THE KEYING SURFACE ONTO THEENGINE CRANKCASE.


ENG - 147

- Preassemble the oil seal with the appropriate

tool, positioning the screws

- Place the sheath over the crankshaft

- Insert the tool with the oil seal on the crankshaft

until it comes into contact with the crankcaseCAUTIONORIENT THE OIL SEAL BY POSITIONING THE CHAINHOUSING CHANNEL FACING DOWNWARDS. WHEN THEPOSITION IS REACHED, DO NOT RETRACT THE OILSEAL. FAILURE TO COMPLY WITH THIS RULE CANCAUSE A WRONG POSITIONING OF THE OIL SEALSHEATH.

- Orientate the oil seal by inserting the bracket

which is part of the specific tool.

- Tighten the threaded bar onto the crankshaft as

far as it will go.


ENG - 148

- Use the nut to move the base of the tool until you

can see end of the oil seal driving stroke

- Remove all of the tool components following the procedure in reverse orderCAUTION

FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THEENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.

Assemble a new oil seal on the flywheel side using

the specific tool as shown in the photographN.B.FAILURE TO USE THE SPECIFIC TOOL CAN RESULT INAN INCORRECT DEPTH POSITION AND AS A CONSE-QUENCE IN INADEQUATE OIL SEAL.

Specific tooling020425Y Punch for flywheel-side oil seal

Oil pump

Removal

- Remove the cover of the pump control pulley us-

ing the two retainers, as shown in the figure.

- Block the rotation of the oil pump control pulley

using a screwdriver inserted through one of its two

holes.


ENG - 149

- Remove the central screw with cup washer, as

shown in the diagram.

- Remove the chain with the pulley.

- Remove the crankshaft control pinion.

- Remove the oil pump acting on the 2 retainers as


- Remove the oil pump seal.IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-SURE THAT THE INITIAL DIRECTION OF ROTATION ISMAINTAINED.

Inspection

- Remove the two screws and the oil pump cover.

- Remove the circlip retaining the innermost rotor.

- Remove and wash the rotors thoroughly with pet-

rol and compressed air.

- Reassemble the rotors in the pump body, keep-

ing the two reference marks visible Replace the

retainer ring.

- Using a feeler gauge, check the distance be-

tween the rotors in the position shown in the figure.

CharacteristicMaximum clearance admitted0.12 mm


ENG - 150

Measure the distance between the outer rotor and

the pump body; see figure.

CharacteristicAdmissible limit clearance:0.20 mm

Check the axial clearance of the rotors with a trued

bar as reference, as shown in the figure.

CharacteristicLimit values admitted:0.09 mm

Refitting

- Check there are no signs of wear on the oil pump

shaft or body.

- Check there are no signs of scoring or wear on

the oil pump cover.

- If you detect non-conforming measurements or

scoring, replace the faulty parts or the assembly.

- Fit the pulley to the pump, the central screw to

the specified torque and the cup washer.

-Fit the oil pump cover, by tightening the two

screws to the prescribed torque.N.B.FIT THE CUP WASHER SO THAT ITS OUTER (CURVED)RIM TOUCHES THE PULLEY.

Locking torques (N*m)Oil pump sprocket gear screw 8 - 10 Oil pumpcoupling screws 7 - 9 Nm


ENG - 151

Removing the oil sump

- Remove the oil filler plug, the transmission cover,

the complete drive pulley assembly with belt and

the sprocket wheel, as described in the Transmis-

sion chapter.

- Drain the oil from the sump as described above.

- Remove the 7 screws indicated in the figure and

the 2 rear brake transmission fixing brackets.

- Remove the spring, the by-pass piston and the

gasket shown in the second image.

Inspecting the by-pass valve

- Check the unloaded spring length.

- Check that the small piston is not scored.

- Ensure that it slides freely on the crankcase and

that it guarantees a good seal.

- If not, eliminate any impurities or replace defec-

tive parts.

CharacteristicBy-pass check up: Standard length54.2 mm


ENG - 152

Refitting the oil sump

- Refit the by-pass piston in its housing.

- Insert the pressure-regulating spring.

- Fit a new sump seal.

- Refit the sump, taking care to locate the spring in

the appropriate recess machined into the inside of

the sump.

- Refit the rear brake transmission mounting brack-

ets and the screws in the reverse order from which

they were removed.

- Tighten the screws to the prescribed torque.

- Refit the driving pulley assembly, the drive belt,

the sprocket wheel and the transmission cover, as

described in the "Transmission" chapter.

- When testing the lubrication system, refer to

the "Crankcase and Crankshaft" chapter, re-

garding lubrication of the connecting rod as-

sembly

Locking torques (N*m)Oil sump screws 8 - 10 Nm


ENG - 153

INDEX OF TOPICS

INJECTION INJEC

COMPONENT TRANSPOSITIONSpecification Desc./Quantity

1 Instrument panel2 Throttle body and electronic injection control unit (MIU)3 Diagnostics socket connector4 Fuel pump5 Engine temperature sensor6 Fuel injector7 HV coil8 Engine Speed sensor9 Lambda sensor

Fly 125 i.e - 150 i.e Leader (2011) Injection

INJEC - 155

Specification Desc./Quantity10 Injection load solenoid11 Battery 12V - 10Ah

MIU injection system

This vehicle is fitted with an integrated injection and ignition system.

Injection is indirect in the manifold through an electro-injector.

The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the

crankshaft (24-2 teeth) and pick-up sensor.

Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further

corrections are made according to the following parameters:

- Engine temperature

- Intake air temperature

- Lambda probe

The system implements cold engine idle fuel/air mixture correction with a stepper motor on a by-pass

circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening time,

thereby ensuring the idle steadiness and the proper combustion.

In all conditions of use, mixture preparation is managed by modifying the injector opening time.

The fuel pressure is kept constant in relation to ambient pressure.

The fuel system circuit consists of:

- Fuel pump

- Fuel filter

- Injector

- Pressure regulator

The pump, the filter and the regulator are placed inside the fuel tank on a single support.

The injector is connected by a pipe with fast-release fittings. The pressure regulator is located at the

beginning of the circuit.

The fuel pump is controlled by the MIU control unit; this ensures safety of the vehicle.

The ignition circuit consists of:

- HV coil

- HV cable

- Shielded cap

- MIU control unit

- Spark plug

The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only

in the compression phase) at the same time.

The MIU injection-ignition system controls engine functions by means of a pre-set program.

Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to

reach a service station.

Injection Fly 125 i.e - 150 i.e Leader (2011)

INJEC - 156

Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the

control circuits:

- Fuel pump

- HV coil

- Injector

The control unit is provided with a self-diagnosis

system connected to an indicator light in the in-

strument panel.

Failures are detected and restored by the diag-

nostic tester.

In any case, when the fault is no longer present,

the data storage is automatically cleared after 16

cycles of use (cold start, running at regular engine

temperature, stop).

The diagnostic tester is also required to adjust the

idle mixture.

Specific tooling020922Y Diagnosis ToolThe MIU control unit has a decoder for the anti-

theft immobilizer system.

The MIU control unit is connected to a diagnostic

LED on the instrument panel, that also carries out

the deterrent flashing functions.

PrecautionsTroubleshooting tips

1 A MIU failure is more likely to be due to the connections than to the components.

Before troubleshooting the MIU system, carry out the following checks:

A: Electrical power supply


INJEC - 157

a. Battery voltage

b.Burnt fuse

c.Remote control switches

d.Connectors

B: Chassis ground

C: Fuel system

a. Faulty fuel pump

b.Dirty fuel filter

D: Ignition system

a. Faulty spark plug

b.Faulty coil

c.Faulty screened cap

E: Intake circuit

a. Air filter dirty

b.Dirty by-pass circuit

c.Faulty stepper motor

F: Other

a. Wrong distribution timing

b.Incorrect idle speed carburetion

c.Incorrect reset of the throttle valve position sensor

2 MIU system faults may be caused by loose connectors. Make sure that all connections have been

correctly made.

Check the connectors taking into consideration the following point:

A check that the terminals are not bent.

B check that the connectors have been properly connected.

C - Check whether the malfunction can be fixed by shaking the connector slightly.

3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU, install the

original control unit again and check if the fault occurs again.

4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instru-

ments that are not suitable might damage the MIU central control unit. Use instruments with definitions

over 0.1V and 0.5 W , the precision must be greater than 2%.

1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not

disconnect the battery before checking for faults.

2. The fuel system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release fitting of

the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to avoid

spraying fuel to your eyes.

3. When fixing electric components, operate with the battery connected only when actually required.


INJEC - 158

4. When functional checks are performed, check that the battery voltage is over 12V.

5. Before any attempt to start the vehicle, check to make sure there is at least two litres of fuel in the

tank. Failure to respect this norm will damage the fuel pump.

6. If the vehicle is expected to remain unused for a long time, refill the tank up to a little over half the

level. This will ensure the pump will be covered by fuel.

7. When washing the vehicle, be careful with the electric components and cable harnesses.

8. When an ignition problem is detected, start the checks from the battery and the injection system

connections.

9. Before disconnecting the MIU ECU connector, perform the following steps in the order shown:

- Set the switch to «OFF»

- Disconnect the battery

Failure to respect this norm may damage the control unit.

10. Do not invert the poles when fitting the battery.

11. To avoid causing any damage, disconnect and reconnect the MIU system connectors only if re-

quired. Before reconnecting, check that the connectors are dry.

12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not

take measurements not specifically foreseen by the manual.

13. At the end of every check performed with the diagnostic tester, remember to protect the system

connector with its cap. Failure to observe this precaution may damage the MIU control unit.

14. Before reconnecting the quick couplers of the power supply system, check that the terminals are

perfectly clean.

Terminals setup

1. Bobina A.T. (Rosa-Nero)

2. Non collegato

3. Non collegato

4. Interruttore arresto motore (Verde-Nero)

5. Non collegato

6. Alimentazione da chiave (Arancio-Blu)

7. Massa 1 (Nero)


INJEC - 159

8. Non collegato

9. Alimentazione da batteria (Rosso-Bianco)

10. Abilitazione avviamento (Viola-Bianco)

11. Positivo sonda lambda (Verde-Blu)

12. Negativo sonda lambda (Azzurro-Nero)

13. Sensore temperatura motore (Azzurro-Verde)

14. Antenna Immobilizer (Arancio-Bianco)

15. Massa sensori (Nero)

16. Diagnostica (Arancio-Nero)

17. Spia Immobilizer (Giallo)

18. Non collegato

19. Cavalletto laterale (Marrone-Rosso)

20. Negativo sensore giri motore / pick-up (Marrone)

21. Non collegato

22. Teleruttore carichi iniezione (Nero-Viola)

23. Massa 2 (Nero)

24. Non collegato

25. Spia iniezione (Marrone-Bianco)

26. Non collegato

27. Non collegato

28. Non collegato

29. Positivo sensore giri motore/pick-up (Rosso)

30. Non collegato

31. Resistenza Sonda Lambda (Azzurro-Rosso)

32. Non collegato

33. Abilitazione luci (Bianco-Nero)

34. Iniettore (Rosso-Giallo)


INJEC - 160

EMS circuit diagram

1 Commutatore a chiave

2 Fusibile n.3 - 7.5 A

3 Fusibile n.6 - 5 A

7 Fusibile n.2 - 7.5 A

10 Batteria

11 Massa telaio

12 Massa motore telaio

16 Nodo massa anteriore

17 Nodo massa posteriore

28 Centralina C.D.I.

33 Iniettore carburante

34 Relè iniezione

43 Spia iniezione

47 Antenna immobilizer

48 Sensore temperatura motore

50 Pick up

51 Sonda lambda

52 Bobina A.T.

54 Pompa carburante

56 Deviatore arresto motore

57 Fusibile n.7 - 30 A

Troubleshooting procedure


INJEC - 161

Engine does not start

ENGINE DOES NOT START IF ONLY PULLEDPossible Cause Operation

Immobiliser enabling signal System not encodedSystem not efficient, repair according to the indications of the

self-diagnosisPresence of faults detected by the self diagnosis Pump relay

HV coilInjector

Revolution timing sensorFuel system Fuel in the tank

Fuel pump activationFuel pressure (low)

Injector capacity (low)Power to the spark plug Shielded spark plug cap HV coil (secondary insulation)

Parameter reliability Engine temperatureDistribution timing - injection ignition

Intake air temperatureEnd of compression pressure End of compression pressure

Starting difficulties

ENGINE STARTER PROBLEMSPossible Cause Operation

Presence of faults detected by the self diagnosis Pump relayHV coilInjector

Revolution timing sensorAir temperature

Engine temperatureStart-up speed Starter motor and solenoid

BatteryGround connections

End of compression pressure End of compression pressurePower to the spark plug Spark plug

Shielded capHV coil

Speed-timing sensorIgnition advance

Fuel system Fuel pressure (low)Injector capacity (low)Injector sealing (poor)

Correctness of the parameters Engine temperatureStepper throttle valve position intake air temperature (steps

and actual opening)Cleaning the throttle valve, air filter efficiency

Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOWPossible Cause Operation



Engine temperatureIgnition efficiency Spark plug

Ignition timingCorrectness of the parameters Throttle valve position sensor


INJEC - 162

Possible Cause OperationStepper

Engine temperature sensorIntake air temperature sensor

Intake system cleaning Air filterDiffuser and throttle valve

StepperIntake system sealing (infiltrations) Intake manifold - head

Throttle body - manifoldAir cleaner joint

Filter boxFuel system (low pressure) Fuel pump

Pressure regulatorFuel filter

Injector capacity

Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGHPossible Cause Operation



Engine temperatureIgnition efficiency Ignition timing

Correctness of the parameters Throttle valve position sensorStepper


Intake system sealing (infiltrations) Intake manifold - headThrottle body - manifold

Air cleaner jointFilter box

Fuel system (low pressure) Fuel pumpPressure regulator

Fuel filterInjector capacity

Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATINGPossible Cause Operation



Engine temperatureLambda sensor

Correctness of the parameters Throttle valve position sensorStepper


Intake system sealing (infiltrations) Intake manifold - headThrottle body - manifold

Air cleaner jointFilter box

Fuel system (low pressure) Fuel pumpPressure regulator

Fuel filterInjector capacity

Exhaust system sealing (infiltrations) Manifold - head


INJEC - 163

Possible Cause OperationManifold - silencersilencer welding

Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPENPossible Cause Operation

Intake system cleaning Air filterDiffuser and throttle valve

StepperIntake system sealing Air cleaner joint

Filter boxIgnition system Spark plug wear check

Parameter reliability Throttle valve position signalEngine temperature signal

Intake air temperature indicatorIgnition advance

TPS reset successful TPS reset successfulPresence of faults detected by the self diagnosis Pump relay

HV coilInjector



Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-ANCE ON PICKUP

Possible Cause OperationPresence of faults detected by the self diagnosis Pump relay

HV coilInjector



Spark plug power supply Spark plugShielded cap

HV cableHV coil

Intake system Air filterFilter box (sealing)

Air cleaner joint (sealing)Parameter reliability Throttle valve position signal

Engine temperature signalIntake air temperature indicator

Ignition advanceFuel system Fuel level in the tank

Fuel pressureFuel filter

Injector capacity

Engine knocking

PRESENCE OF KNOCKING (COMBUSTION SHOCKS)Possible Cause Operation

Presence of faults detected by the self diagnosis Pump relay


INJEC - 164

Possible Cause OperationHV coilInjector



Ignition efficiency Spark plugParameter reliability Throttle valve position signal

Engine temperature signalIntake air temperature indicator

Ignition advanceIntake system sealing Air cleaner joint

Filter boxTPS reset successful TPS reset successful

Fuel system Fuel pressureFuel filter

Injector capacityFuel quality

Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness

Fuel supply system

The fuel system circuit includes the electric pump,

the filter, the pressure regulator, the electro-injec-

tor and the fuel delivery pipes.

The electrical pump is located in the tank from

which the fuel is pumped and sent to the injector

through the filter.

The pressure is controlled by the pressure regu-

lator situated in the pump assembly in the tank.

Removing the injector

- Rimuovere il vano portacasco.

- Staccare il connettore dall'iniettore.

- Rimuovere la fascetta di ritegno del tubo carbur-

ante sull'iniettore.

TO PERFORM THE OPERATION MORE EASILY, WE REC-OMMEND DISCONNECTING THE FUEL TANK FROM THESECURING POINTS ON THE FRAME AND LIFTING IT,LEAVING IT CONNECTED TO THE HOSES AND THE ELEC-TRICAL SYSTEM.


INJEC - 165

- Undo the fixing screws and slide the injector from

the manifold being careful not to damage the seal-

ing OR gasket.CAUTIONDO NOT DISASSEMBLE THE INJECTOR COMPONENTS.

See alsoHelmet bay

Refitting the injector

For refitting, perform the removal operations in re-

verse order and lubricate the sealing OR gasket

with grease for internal application before fitting

the injector on the manifold.


INJEC - 166

Removing the butterfly valve

- Rimuovere il vano portacasco.

- Rimuovere la vite di fissaggio staffetta ritegno

cavi indicata in figura.

- Rimuovere il connettore centralina MIU.

- Allentare le fascette di fissaggio del raccordo

depuratore al corpo filtro aria e al corpo farfallato:

rimuovere il raccordo.

- Rimuovere il tubo benzina dall'iniettore.

- Rimuovere il connettore iniettore.

- Remove the three screws with anti-tampering

device that secure the manifold to the head.

See alsoHelmet bay

- Loosen the throttle control cable adjuster screws.

- Release the cable ends of the throttle body pul-

ley.

- Remove the throttle body complete with manifold

and injector.


INJEC - 167

Refitting the butterfly valve

To refit, follow the removal operations in reverse,

being careful to direct the air cleaner fitting, insert-

ing it into the reference teeth on the filter box and

on the throttle body as illustrated in the photo.

- To adjust the throttle control cables, act on the

specific adjuster screws.

Locking torques (N*m)Inlet manifold screw 7 - 9


INJEC - 168

Pump supply circuit

Legenda

1. Commutatore a chiave

2. Fusibile N.3 - 7.5 A

3. Fusibile N.6 - 5 A


10. Batteria


INJEC - 169

11. Massa telaio

12. Massa motore telaio

16. Nodo massa anteriore

17. Nodo massa posteriore

28. Centralina C.D.I.

33. Iniettore carburante

34. Relè iniezione

41. Spia luci di posizione

43. Spia iniezione

47. Antenna immobilizer

48. Sensore temperatura motore

50. Pick up

51. Sonda lambda

52. Bobina A.T.

54. Pompa carburante

56. Deviatore arresto motore


When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine

starts, in the presence of rpm timing signal the pump is continuously supplied.

ELECTRICAL DATA

• Pump winding resistance ~ 1.5 Ohm

• Input current during normal functioning 1.4 to 1.8 A

• input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel

pressure)

Check the efficiency of fuses No. 02 (7.5A) and

No. 06 (5A) located under the front grill.


INJEC - 170

Check functionality of the injection load relay, also

located behind the front grille: check the resistance

of the energising coil between pins 86 and 85: 40

to 80 Ohm

Apply a voltage of 12V to pins 86 and 85; make

sure that there is continuity between pins 30 and

87 of the relay.WARNINGTO INDICATE THE RELAY OF THE DESIRED FUNCTION,REFER TO THE PIN-CABLE COLOUR RELATIONSHIPWITH THE ATTACHED ELECTRIC SYSTEM DIAGRAM.

Check the power supply line of the injection load

remote control energising coil: after switching to

"ON", make sure there is battery voltage, for 2

seconds, between the Orange-Blue cable and

Black-Purple cable of the solenoid base. Other-

wise check the continuity of the Orange-Blue cable

between the fuse-box and the relay base and of

the Black-Purple cable between pin 22 of the con-

trol unit and the relay base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (RELAYS, CONTROLUNIT, FUSES ETC.).

Check the presence of fixed voltage between the

Red-White cable of the relay base and ground.

Otherwise, check the continuity of the Red-White

cable between the fuse-box (No. 02 7.5, A) and the

relay base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (RELAYS, CONTROLUNIT, FUSES ETC.).

See also

Fuses


INJEC - 171

Check, on switching to "ON", that there is battery

voltage, for about two seconds, to the Black-Green

cable of the pump connector and ground with

pump connector disconnected. Otherwise, check

the continuity of the Black-Green cable between

the pump connector and the remote control base.

Check the efficiency of the ground line of the fuel

pump by measuring the continuity between the

pump connector black cable, system side, and the

ground.

Specific tooling020331Y Digital multimeter

Circuit leak test

Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.

Check during regular operation by placing the ap-

propriate tool between the pump and the injector.

With the battery voltage > 12 V check that the fuel

pressure is 2.5 BAR and that the input current is

1.4 to 1.8 A.

With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe

equipped with the pressure gauge of the appropriate tool. Make a graded burette available with a flow

rate of approximately 1 L. Rotate the pump using the active diagnosis of the palm top computer. Using

a pair of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5

bar. Check that within 15 seconds the pump has a flow rate of approx. 110 cm³.

Specific tooling020480Y Petrol pressure check kit


INJEC - 172

Fuel filter check

After removing from the tank, disconnect the elec-

tric pump terminals.

Remove the screw shown in the picture

Remove the clip fixing the piping to the filter shown

in the picture

Separate the lower part of the pump mounting as

shown in the picture.


INJEC - 173

Remove the filter from the pump mounting


INJEC - 174

Inspecting the injector circuit

Legenda

1. Commutatore a chiave




10. Batteria


INJEC - 175

11. Massa telaio

12. Massa motore telaio

16. Nodo massa anteriore

17. Nodo massa posteriore

28. Centralina C.D.I.

33. Iniettore carburante

34. Relè iniezione

41. Spia luci di posizione

43. Spia iniezione

47. Antenna immobilizer

48. Sensore temperatura motore

50. Pick up

51. Sonda lambda

52. Bobina A.T.

54. Pompa carburante

56. Deviatore arresto motore


Check the resistance at the injector ends: 14.5 ± 5% Ohm

Check the efficiency of fuses No. 02 (7.5A) and

No. 06 (5A) located under the front grill.

Check functionality of the injection load relay, also

located behind the front grille: check the resistance

of the energising coil between pins 86 and 85: 40

to 80 Ohm

Apply a voltage of 12V to pins 86 and 85; make

sure that there is continuity between pins 30 and

87 of the relay.WARNINGTO INDICATE THE RELAY OF THE DESIRED FUNCTION,REFER TO THE PIN-CABLE COLOUR RELATIONSHIPWITH THE ATTACHED ELECTRIC SYSTEM DIAGRAM.


INJEC - 176

Check the power supply line of the injection load

remote control energising coil: after switching to

"ON", make sure there is battery voltage, for 2

seconds, between the Orange-Blue cable and

Black-Purple cable of the solenoid base. Other-

wise check the continuity of the Orange-Blue cable

between the fuse-box and the relay base and of

the Black-Purple cable between pin 22 of the con-

trol unit and the relay base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (RELAYS, CONTROLUNIT, FUSES ETC.).

Check the presence of fixed voltage between the

Red-White cable of the relay base and ground.

Otherwise, check the continuity of the Red-White

cable between the fuse-box (No. 02 7.5, A) and the

relay base.N.B.CONTINUITY TESTS MUST BE CARRIED OUT WITH THECOMPONENTS DISCONNECTED. (RELAYS, CONTROLUNIT, FUSES ETC.).

See also

Fuses

Check, on switching to "ON", that there is battery

voltage, for about two seconds, to the Black-Green

cable of the pump connector and ground with

pump connector disconnected. Otherwise, check

the continuity of the Black-Green cable between

the pump connector and the remote control base.

Check the efficiency of the ground line of the fuel

pump by measuring the continuity between the

pump connector black cable, system side, and the

ground.

Specific tooling020331Y Digital multimeter


INJEC - 177

Switch to «ON» and check if there is voltage, with

injector disconnected and control unit connected,

between the Black-Green cable of the injector con-

nector and the ground lead

With injector disconnected and the injector load solenoid disconnected, check the continuity of the

Black-Green cable between the injector connector and solenoid base.

Inspecting the injector hydraulics

TO PERFORM THE OPERATION MORE EASILY, WE RECOMMEND DISCONNECTING THE FUELTANK FROM THE SECURING POINTS ON THE FRAME AND LIFTING IT, LEAVING IT CONNEC-TED TO THE HOSES AND THE ELECTRICAL SYSTEM.

To check the injector you must remove the intake

manifold.

Unscrew the three screws with anti-tampering de-

vice that secure the manifold to the head.

Loosen the connection clamp that connects the

throttle body to the manifold and remove the mani-

fold complete with injector, leaving it connected to

the fuel supply system.


INJEC - 178

Free the hose that supplies fuel to the injector, dis-

connecting the upper cap of the thermal group.

Install the appropriate tool for checking fuel pres-

sure and position the manifold over a container

graduated by at least 100 cm³. Connect the injec-

tor with the cable making up part of the supply for

the injection tester. Connect the clamps of the ca-

ble to an auxiliary battery. Activate the fuel pump

with the active diagnosis. Check that, within fifteen

seconds, approximately 40 cm³ of fuel is dis-

pensed with an adjustment pressure of approxi-

mately 2.5 BAR.

Specific tooling020480Y Petrol pressure check kit

Proceed with the injector seal test.

Dry the injector outlet with a blast of compressed

air. Activate the fuel pump. Wait for one minute,

making sure there are no leaks coming from the

injector. Slight oozing is normal.

Value limit = 1 drop per minute

Zeroing the throttleResetting the throttle valve position signal (TPS reset)

The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.

Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of

air under pre-set reference conditions.


INJEC - 179

Pre-calibration ensures optimal air flow to control idling.

This regulation must not be tampered with in any way whatsoever.

The injection system will complete the management of the idling through the Stepper motor and the

variation of the ignition advance.

The throttle body after the pre-calibration has an opened valve with an angle that can vary depending

on the tolerances of the machining of the pipe and the valve itself.

The valve position sensor can also assume various fitting positions. For these reasons the mV of the

sensor with the valve at idle can vary from one throttle body to another.

To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to

match the throttle body with the control unit following the procedure known as TPS resetting.

With this operation we inform the control unit, as the starting point, of the mV value corresponding to

the pre-calibrated position.

To reset, proceed as follows.

Connect the diagnostic tester.

Switch to «ON».

Select the functions of the diagnostic tester on «TPS RESET».

Specific tooling020922Y Diagnosis Tool

Make sure that the throttle valve with the control is supporting the stop screw.

Reset should be performed in the following cases:

- on first fitting.

- if the injection control unit is replaced.N.B.THE TPS RESET PROCEDURE MUST NOT BE CARRIEDOUT WITH A USED THROTTLE BODY BECAUSE POSSI-BLE VALVE WEAR AND STOP WEAR FOR THE MINIMUMOPENING MAKE THE AIR FLOW DIFFERENTLY FROMTHAT OF PRE-CALIBRATION.

Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.


INJEC - 180

INDEX OF TOPICS

SUSPENSIONS SUSP

Front

Removing the front wheel

- Loosen the wheel axle lock nut, by keeping the wheel axle blocked on the opposite side.

- Loosen the two wheel axle safety screws located on the fork leg (odometer gear side)

- Pull out the wheel axle.

- Remove the front wheel.

- Slide off the odometer gear from the wheel hub.CAUTIONDO NOT ACT ON THE FRONT BRAKE LEVER ONCE THEFRONT WHEEL IS REMOVED. BY DOING SO, THE CAL-LIPER PISTONS COULD COME OUT FROM THEIR HOUS-ING AND ALSO THE BRAKE FLUID MIGHT SPILL OUT.

Front wheel hub overhaulBall bearings on wheel hub

- Remove the front wheel

- Keep the wheel level by means of two wooden

wedges

- With the appropriate pliers and tool remove the

wheel bearing on the side the rpm indicator detects

movement, as shown in the photograph

Suspensions Fly 125 i.e - 150 i.e Leader (2011)

SUSP - 182

- Remove the internal spacer

- Use appropriate handle, adaptor and guide and

hit with a mallet to extract the bearing and the

spacer bushing on the brake disc side; insert han-

dle on the side the rpm indicator detects move-

ment, as shown in the photo

- Check that the bearings do not show flaws or

jamming. If it is, replace the coupling

- Check that the internal spacer does not show ab-

normal wear. If it is, replace the coupling

- With a hot air gun heat the seat of the bearing on

the brake calliper side

- With an appropriate tool remove the bearing on

the brake disc side

- Insert the spacer bushing on the brake disc side

- With a hot air gun heat the seat of the bearing on

the side the rpm indicator detects movement

- Insert the internal spacer with the centring ring

facing to the brake disc side, as shown in the photo

- Use an appropriate tool to insert the bearing on

the side the rpm indicator detects movement

Specific tooling001467Y009 Bell for OD 42-mm bearings




020412Y 15-mm guide

020456Y Ø 24-mm adaptor

Fly 125 i.e - 150 i.e Leader (2011) Suspensions

SUSP - 183

Refitting the front wheel

- First shift by 90° the inner stop of the odometer

drive with respect to the one on the wheel.

- Grease the indicated surfaces of the odometer

movement intake.

- Inserire l'asse ruota, dopo averlo ingrassato, dal

lato opposto disco freno centrando il fermo sul

gambale forcella nei rilievi della presa movimento

contaKm.

- Far compiere alcune corse alla forcella per as-

sestare i gambali sull'asse ruota.

- Mantenendo fermo l'asse ruota, bloccare il dado

sul lato opposto alla coppia prescritta.

- Bloccare le due viti di sicurezza poste sul gam-

bale alla coppia prescritta.

Locking torques (N*m)Front wheel axle nut 45 - 50 Front wheel axlescrew on fork leg 8 - 8.5

Handlebar


SUSP - 184

Removal

- Remove the front and rear handlebar covers.

- Detach the front brake pump from the handlebar.

- Disconnect the rear brake, throttle control and

odometer control cables.

- Remove the screw fixing the handlebar to the

steering tube.

- Remove the handlebar.N.B.IF THE HANDLEBAR IS BEING REMOVED TO REMOVETHE STEERING, TILT THE HANDLEBAR FORWARD TOAVOIDING DAMAGING THE TRANSMISSIONS.

See alsoFront handlebar coverRear handlebar coverFrontbrake pumpRear drumbrake

Refitting

- Rimontare il manubrio sul tubo sterzo prestando

attenzione al centraggio, facendo collimare la gola

ricavata sul manubrio con quella sul tubo sterzo,

come mostrato in figura.

- Serrare la vite di fissaggio manubrio al tubo ster-

zo alla coppia prescritta.

- Lubrificare il dado con olio motore prima del mon-

taggio.

Locking torques (N*m)Handlebar fixing screw 60 - 65

Front fork

Removal

To remove the front fork, remove the front and rear handlebar covers.

Remove the handlebar from the steering tube and place it on the rear shield back plate being careful

not to damage the bodywork supporting points.

Remove the front wheel and disconnect the brake calliper from the fork.

Free the fork from the odometer cable and the front brake calliper pipe.


SUSP - 185

Remove the front mudguard.

Remove the upper fifth wheel using a wrench for the steering fifth wheel ring nut.

Lower the fork and the front mudguard.

See alsoFront handlebar coverRear handlebar coverHandlebarFrontbrake calliperRemoving the front wheelFront mudguard

OverhaulSealing ring replacement and stem removal

- Remove the wheel axle.

- Remove the lower screw (1).

- Discharge the oil in the suspension.

- Remove the stem.

- Replace the sealing rings (3-4) with new ones.

- Insert the new sealing rings only after lubricating

their grooves.

- Refit the stem and the lower screw (1).

- Remove the upper screw (2).

- Add 30 cm³ ±1 oil (SAE 20W fork oil).

- Refit all components.

Locking torques (N*m)Fork top screw 20 ÷ 25 Fork bottom screw 20 to 25Nm

Refitting

Per il rimontaggio della forcella procedere con le operazioni in senso inverso allo smontaggio rispet-

tando le coppie di serraggio ralle sterzo

Locking torques (N*m)Steering lower ring nut 11.7 - 13.7 Steering upper ring nut 34.3 - 39.2 Screws fastening stem tofork plate 36 to 44

Steering column


SUSP - 186

Removal

- Posizionare il veicolo sul cavalletto centrale.

- Posizionare un supporto sotto il veicolo in modo

tale che la ruota possa muoversi liberamente ed il

veicolo non cada.

- Rimuovere il manubrio.

- Rimuovere la pinza freno anteriore.

- Liberare la forcella dal cavo del contachilometri

e dal tubo della pinza freno anteriore.

- Allentare la ghiera superiore «1» e recuperare lo

spessore «2».

Specific tooling020055Y Wrench for steering tube ring nut

Locking torques (N*m)Steering upper ring nut 34.3 - 39.2


SUSP - 187

- Rimuovere l'anello superiore (o ghiera inferiore)

«3» del cuscinetto superiore «A».

- Sfilare la forcella e recuperare la gabbia con le

sfere «4» del cuscinetto superiore «A».

Locking torques (N*m)Steering lower ring nut 11.7 - 13.7

See alsoRemovalRemoval

- Remove the balls retainer «7» of the lower bear-

ing «B» from the steering tube.

- Wash carefully all the parts removed.

- To refit, carry out the removal operations but in reverse order.

- Appropriately lubricate the bearings with recommended products.


SUSP - 188

BEARING SEAT REPLACEMENT ON CHASSIS

- Only remove the seats if it is strictly necessary.

- Using the special tool remove the upper bearing

«A» seat «5» by putting the special tool into the

lower part of the headstock as indicated in the fig-

ure.

- Levering with a screwdriver between the bearing

seat and the headstock, remove the lower seat

«6» of the lower steering bearing «B».

Specific tooling020004Y Punch for removing fifth wheels fromheadstock

- Using the special tool, refit the upper «A» and

lower «B» bearing seats on the headstock.

Specific tooling001330Y Tool for fitting steering seats

LOWER BEARING SEAT REPLACEMENT ON

FORK

Check the condition of the lower bearing «B» seat

«8» on the fork (steering tube). Replace if there are

faults.

- Support the fork properly.

- Using the special tool, remove the seat «8» on

the steering tube as shown in the photograph by

applying small mallet blows.

Specific tooling020004Y Punch for removing fifth wheels fromheadstock


SUSP - 189

Always use a new seat on refitting.

- Using the special tool, refit the seat «8» with the

aid of a few mallet blows and bring it as far as the

stop shown in the photo.

Specific tooling006029Y Punch for fitting fifth steering bearingon steering tube

Steering bearing

CHECKING THE BEARINGS CLEARANCE

To check the steering, it is necessary to:

- Position the vehicle on the centre stand.

- Place a support under the motorcycle in such a way that the front wheel is able to move freely and

the vehicle does not fall.

When carrying out this operation, pay attention not to mistake the centre stand clearance with that of

the steering. Repeat this test many times before deciding if the steering clearance must be adjusted.

- Hold the fork sleeves and pull the fork forwards and backwards, with the steering in forward position.

- There should be no clearance forward or backward If there is clearance, the steering must be adjusted.

ADJUSTING THE BEARING CLEARANCE

- Remove the handlebar.

- Loosen the upper ring nut «1» using the specific

wrench.

- Screw in the lower ring nut «3» until the bearing

clearance is totally eliminated.CAUTIONDO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT«3» BECAUSE THE STEERING BEARINGS COULD GETDAMAGED.

- Controllare il gioco come descritto sopra. Assicurarsi che la forcella anteriore possa muoversi per tutta

la sua corsa, da sinistra a destra o viceversa, in una rotazione libera e uniforme.

- Tenere la ghiera inferiore «3» in posizione utilizzando una chiave appropriata e serrare la ghiera

superiore «1» alla coppia prescritta. Controllare nuovamente il gioco dei cuscinetti.

Specific tooling020055Y Wrench for steering tube ring nut

Locking torques (N*m)Steering lower ring nut 11.7 - 13.7 Steering upper ring nut 34.3 - 39.2

See also


SUSP - 190

Handlebar

Rear

Removing the rear wheel

- Position the vehicle on the centre stand.

- Remove the silencer.

- Use a screwdriver to remove the plastic cap.

- Remove the cotter pin.

- Remove the cap.

See alsoExhaust assy. Removal

- Pull the rear brake and keep it pulled with a

clamp.

- Unscrew the wheel fixing nut and collect the

washer.

- Take out the wheel from its housing.

- To refit, carry out the removal operations but in reverse order, be careful to use a new cotter pin.

Locking torques (N*m)Rear wheel axle 104 ÷ 126

Swing-arm


SUSP - 191

Removal

- Remove the engine with the engine side swinging

arm as described in the "Engine disassembly from

the vehicle" section.

- Remove the lower spoiler.

- Disconnect the chassis side swinging arm from

the chassis by unscrewing and removing the nut

indicated and removing the pin from the opposite

side.

- Remove the chassis-side swinging arm.

- Operating on the engine side swinging arm, re-

move the aesthetic cover and the seeger ring in-

dicated in the photo.

- Remove the plate with the silent block.

- Unscrew the nut on the right-hand side of the en-

gine and slide the pin from the opposite side.

- Unscrew the two clamps and remove the bracket.

- To remove the silent block from the bracket, please use the specific tool.

Specific tooling020271Y Tool for removing-fitting silent bloc

See alsoRemoval of the engine from thevehiclespoiler


SUSP - 192

Overhaul

Controllare periodicamente il gioco dei perni di fissaggio del braccio oscillante. Per eseguire queste

operazioni, procedere come segue:

- Posizionare il veicolo sul cavalletto centrale.

- Afferrare la ruota posteriore saldamente e provare a muoverla perpendicolarmente alla normale dir-

ezione di marcia.

- Se si osserva un qualche gioco, controllare tutti gli elementi di fissaggio che collegano il braccio

oscillante al motore e al telaio e lo stato del silent block.

- Nel rimontaggio ingrassare i punti indicati nel disegno.

Locking torques (N*m)Silent block support to chassis bracket fastener bolts 20 ÷ 25 Engine-swinging arm bolt 40 to45 Frame-swinging arm bolt 50 to 55

Shock absorbers


SUSP - 193

Removal

- Adequately support the rear part of the vehicle.


- Unscrew the upper nut fastening the chassis.

- Remove the washer.

- Unscrew the lower fixing pin to the transmission

crankcase.

- Remove the shock absorber from the pads on the

chassis.

Locking torques (N*m)Shock absorber - chassis nut 20 to 25 Lowershock absorber clamp 40 to 45

Refitting

- Before refitting, check the condition of the rubber

buffers: if they are deformed or show obvious signs

of wear and/or breakage, replace.

- To refit, follow the steps described for removal

but in reverse order; be careful to tighten to the

prescribed torques.

Locking torques (N*m)Shock absorber - chassis nut 20 to 25 Lowershock absorber clamp 40 to 45


SUSP - 194

Centre-stand

SMONTAGGIO

- Supportare adeguatamente mediante cricchetto

il veicolo.

- Rimuovere le 2 molle di ritorno del cavalletto.

- Svitare il dado indicato in figura.

- Rimuovere il perno dal lato destro.

- Rimuovere il cavalletto.

MONTAGGIO

- Al rimontaggio serrare il dado alla coppia di bloc-

caggio prescritta.

Locking torques (N*m)Centre stand pin 39.2 - 44.1

Side stand

Removal of the side stand

- Unhook the springs.

- Unscrew the nut.

- Undo and remove the screw indicated.

Fitting

Carry out the previous operations but in reverse

order.

Locking torques (N*m)Side stand bolt 12 - 16


SUSP - 195

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Front brake calliper

Removal

- Check that the brake piping, gasket and fitting are

in good condition. If you see any oil on the brake

calliper and/or the components of the system, it is

necessary to replace them.

- Detach the oil brake pipe from the calliper; pour

the fluid inside a container.

- Remove the two clamps shown in the figure.

- Remove the brake calliper from the fork.

Refitting

- Refit the calliper on the support and tighten the

screws to the specified torque.

- Refit the tube complete with fitting with new cop-

per gaskets.

- Place the tube joint in the original position and

tighten it to the specified torque.

- Bleed the air from the system.

Locking torques (N*m)Brake fluid pipe-calliper fitting 20 ÷ 25 Callipertightening screw 24.5 to 27.5 Oil bleeding valve 8- 12

Front brake disc

Removal

Proceed as follows:


- Undo the five screws fixing the disc.

- Remove the brake disc.

Fly 125 i.e - 150 i.e Leader (2011) Braking system

BRAK SYS - 197

See alsoRemoving the front wheel

Refitting

When refitting, position the disc correctly making

sure that it rotates in the direction indicated on the

disc itself.

Recommended productsLoctite 243 Medium-strength threadlockMedium Loctite 243 threadlock

Locking torques (N*m)Disc tightening screw 8 - 12

Disc Inspection

- Check the thickness of the disc (value indicated

on the disc itself).

CharacteristicDisc minimum thickness:3.5 mm

• Using the appropriate tool, measure

how much the disc protrudes when the

wheel is fitted properly. The protrusion,

measured near the external edge of

the disc, must be less than 0.1 mm.

• If a value other than that prescribed is

detected, remove the front wheel and

check how much the disc protrudes.

Maximum permissible out of true is 0.1

mm. If the value measured is greater,

fit a new disc and repeat the check.

• If the problem persists, check and re-

place the wheel rim if necessary.

Specific tooling020335Y Magnetic support for dial gauge

Braking system Fly 125 i.e - 150 i.e Leader (2011)

BRAK SYS - 198

See alsoRemoving the front wheel

Front brake pads

Removal

- Remove the brake calliper.

- Undo and remove the two screws indicated.

- Remove the pads.

- Remove the inner spring.CAUTION

AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPERPLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.

- Check the thickness of the friction material. If thinner than the minimum value, replace it.

CharacteristicMinimum friction material thickness

1.5 mm

- In case of uneven wear, replace the brake pads

when the friction material thickness difference is

0.5 mm.CAUTIONALWAYS REPLACE BOTH PADS AND MAKE SURE THEYARE CORRECTLY POSITIONED INSIDE THE CALLIPER.


BRAK SYS - 199

Refitting

- To refit, carry out the disassembly operations in

the inverse order, fitting the inner spring correctly

and tightening the fixing screws to the specified

torque.

Locking torques (N*m)Brake pad fastening screw 15 to 20

Fill

FrontN.B.

IF THERE IS AIR IN THE HYDRAULIC SYSTEM, THE WATER WILL ABSORB MOST OF THEPOWER OF THE BRAKE MAIN CYLINDER AND THEREFORE, IT WILL REDUCE THE CALLIPERPERFORMANCE WHEN BRAKING. THE PRESENCE OF AIR IS SIGNALLED BY THE 'SPONGI-NESS' OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY.CAUTION

CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARYTO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REG-ULAR MAINTENANCE OPERATIONS.

Proceed as follows:

- Position the vehicle on a flat surface and on the

stand

- Loosen the two screws shown in the figure and

open the front brake fluid reservoir.

- Once the bleed valve is closed, fill the system

with brake fluid to the maximum level.

-Undo the bleed screw.

-Apply the tube of the special tool to the bleed

screws.

When bleeding it is necessary to fill the oil tank in

continuation while working with a MITYVAC pump

on the bleed screws until no more air comes out of

the system.


BRAK SYS - 200

The operation is finished when just oil comes out

of the bleed screws.

-Do up the bleed screw.

-When the operation is over, tighten up the oil

bleed screw to the prescribed torque.N.B.IF AIR CONTINUES TO COME OUT DURING PURGING, EX-AMINE ALL THE FITTINGS:IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAUL-TY, LOOK FOR THE AIR INPUT AMONG THE VARIOUSSEALS ON THE PUMP AND CALLIPER PISTONS.CAUTION- DURING THE OPERATIONS, THE VEHICLE MUST BE ONTHE STAND AND LEVEL.N.B.DURING PURGING FREQUENTLY CHECK THE LEVEL TOPREVENT AIR GETTING INTO THE SYSTEM THROUGHTHE 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 BEREDUCED.THEREFORE, ALWAYS USE FLUID FROM SEALED CON-TAINERS.UNDER NORMAL DRIVING AND CLIMATIC CONDITIONSYOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS.IF THE BRAKES ARE USED INTENSELY AND/OR INHARSH CONDITIONS, CHANGE THE FLUID MORE FRE-QUENTLY.CAUTIONWHEN CARRYING OUT THE OPERATION, BRAKE FLUIDMAY LEAK FROM BETWEEN THE BLEED SCREW AND ITSSEAT ON THE CALLIPER.CAREFULLY DRY THE CALLIPER AND DEGREASE THEDISC SHOULD THERE BE OIL ON IT.

Specific tooling020329Y Mity-Vac vacuum-operated pump

Recommended productsAGIP BRAKE 4 Brake fluid.Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4

- ISO 4925 - CUNA NC 956 DOT 4

Locking torques (N*m)Oil bleed screw 8 to 12


BRAK SYS - 201

Front brake pump

- Remove the front and rear handlebar cover.

- Disconnect the tube, collecting the brake oil in a

container.

-Agire sui due fissaggi del cavallotto (vedi figura).

-Al rimontaggio eseguire l'operazione in senso inverso.

-Bloccare la tubazione idraulica alla coppia prescritta ed effettuare il riempimento e lo spurgo dell'im-

pianto.

Locking torques (N*m)Brake fluid pump-hose fitting 16 ÷ 20 Pump U bolt screw 8

See alsoFront handlebar coverRear handlebar cover

Rear drum brake

Drum brake adjustment

Regulate the point where the rear drum brake in-

tervenes, using the adjustment indicated in the

figure.

With the brake lever at rest, the wheel must turn

freely.

Drum brake removal

- Remove the rear wheel.

- Hold the lower shoe and slide it out with the upper

one.

For fitting:

- First assembly two shoes and the springs then

place them on the pin and on the cam.

See also


BRAK SYS - 202

Removing the rear wheel

Transmission replacement

- Remove the front handlebar cover.

- Remove the leg shield and the footrest.

- Loosen the brake set screw

- Release the transmission from its retainers to the

engine.

See alsoFront handlebar coverLegshieldFootrest

- Release the transmission from the retainers on

chassis and from the control lever.

- Fit the new transmission, fixing and positioning it

like the one replaced.

- Adjust the drum brake activation point.

Locking torques (N*m)Rear brake adjustment nut 5


BRAK SYS - 203


BRAK SYS - 204

INDEX OF TOPICS

CHASSIS CHAS

Seat

- Unscrew the 2 fixing screws and remove the sad-

dle

On the left side a lock is installed to allow access

to the helmet compartment.

-To remove the lock the covering must be lifted in

correspondence with the lock itself in such a way

so as to be able to access the lock spring.

- Remove the lock spring and slide the lock and

the relative housing from the outside.

Side fairings

• Remove the legshield

• Undo the 3 fixing screws and remove the bumper

ring on each side of the legshield

Chassis Fly 125 i.e - 150 i.e Leader (2011)

CHAS - 206

See alsoLegshield

Rear rack

GRAB HANDLE

• Remove the helmet compartment.

• Undo, from both sides of the vehicle, the indica-

ted screw and bolt.

• Remove the handgrip.

See alsoHelmet bay

Driving mirrors

• With the adjustment nut completely tightened,

screw in the mirror stem on the handlebar all the

way.

• Loosen the mirror stem, moving it to the desired

direction.

• Loosen the adjustment nut until locking the stem.

Locking torques (N*m)Mirror set screw 24 ÷ 26

Fly 125 i.e - 150 i.e Leader (2011) Chassis

CHAS - 207

Rear handlebar cover

• Remove the front handlebar cover.

• Unscrew the odometer transmission joint and

slide it off.

• Disconnect the electrical connections of the in-

strument panel.

• Undo the 4 screws that secure the rear handlebar

cover to handlebar.

• Remove the rear handlebar cover complete with

instrument panel assembly.



CHAS - 208

Instrument panel

• Remove the rear handlebar cover

• Unscrew the 4 fixing screws and remove the in-

strument panel

See alsoRear handlebar cover

Front handlebar cover

• Remove the 2 screws in the rear handlebar cover

and the screw under the headlamp.


CHAS - 209

• Remove the cover and undo the 2

screws.

• Pull up and detach the front handlebar cover,

disconnect the headlight assembly connections.

Headlight assy.

• Remove the front handlebar cover.

• Undo the 4 fixing screws to remove the headlight

assembly.

To replace the high/lowbeam headlight bulb, it is

necessary to remove the rubber cap and turn the

supporting plate by 30° anticlockwise.


CHAS - 210

Daylight running light

• To replace the daylight running light

bulb, open the front glove-box and re-

move the bulb holder from the seat; pull

the bulb gently.

Front turn indicators

• To replace the front turn indicator bulb,

open the front case and remove the

bulb holder from the seat; lightly press

the bulb, rotate it about 30° and then

pull it out.



CHAS - 211

Legshield

• Remove the footrest.

• Remove the spoilers.

• Remove the front wheel.

• Remove the 2 screws located behind the front

mudguard.

• Remove on both sides of the vehicle, the screw

on the leg shield back plate.

• Undo the two screws under the lug of the shield.

• Remove the Piaggio clip-on badge, unscrew the

screw underneath and remove the grill by pulling

it upwards.


CHAS - 212

• Unscrew the 3 front fixing screws of the legshield.

• Remove the shield complete with side bumpers

after disconnecting the electrical connections of

the turn indicators and the daylight running lights.

See alsoFootrestspoilerRemoving the front wheel

Knee-guard

• Remove the legshield.

• Open the glove-box and undo the 3 fixing screws

indicated.


CHAS - 213

• Remove the battery.

• Remove the wires through the slots in the leg

shield back plate.

• Remove the screw fixing the bracket of the starter

relay.

• Remove the screw fixing the bracket of the fuse

support and relay.


CHAS - 214

• Remove the screw fixing the leg shield back plate

from the front.

• Remove the shield back plate.

See alsoLegshield

Battery

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.

• Take out the lock block.

See alsoKnee-guard

Removing the ignition key-switch when on *lock*

- Remove the leg shield back plate.

- Remove the switch of the key switch.

- Make a hole on the block using a drill as shown

in the figure.

- Insert the wheel cylinder with the key and with the

anchoring tab facing down halfway on the lock

body taking care that the insertion phase of the key

is oriented matching "ON" (the only position that

enables the cylinder to get into the lock body); now

turn the key leftwards to "OFF" and at the same

time press until the cylinder is completely in.


CHAS - 215

See alsoKnee-guard

Taillight assy.

• Remove the handgrip.

• Remove, on both sides of the vehicle,

the flange side, sliding it from the fit-

tings.

• Undo the side fixing screw from both

sides of the vehicle.


CHAS - 216

• Undo the 2 screws that secure the up-

per cover and remove the cover.

• Remove the lower cover, removing it

from the seat.

• Undo the central headlight fixing

screw.

- Detach the headlight assembly as shown in the

picture.

The bulbs have a bayonet coupling, to remove

them press gently and turn it anticlockwise about

30°.

To refit follow the same steps but in reverse order.


CHAS - 217

License plate light

• Remove the bulb holder from the seat

and gently pull the bulb. To refit, pro-

ceed in reverse order.

Footrest

• Remove the side fairings.

• Remove the 4 screws on the footrest.

• Unscrew, from both sides of the vehicle, the

screw under the spoiler and remove the side mud-

guard.

• Unscrew, from both sides of the vehicle, the 2

screws that secure the footrest to the spoiler.

• Remove the footrest.


CHAS - 218

Side fairings

- Remove the helmet compartment.

- Remove the front central cover.

- Remove the handgrip.

- Remove the rear headlight.

- Undo side screw from both sides of the vehicle.

- Undo the two upper side screws.

- Undo, from both sides of the vehicle, the rear side

screw.


CHAS - 219

- Remove, from both sides of the vehicle, the cover

and the underlying screw.

- Remove, from both sides of the vehicle, the side fairing, pushing it slightly forward.

See alsoHelmet bayFront central coverRear rackTaillight assy.

License plate holder

• Remove the side panels.

• Remove the rear light unit.

• Undo the 3 screws that secure the licence plate

support to the chassis.


CHAS - 220

• Remove the license plate light bulb from the seat

and release the cable from the clamp.

• Remove the license plate support towards the

rear.

See alsoSide fairingsTaillight assy.

Air filter




- Unscrew the two clamps holding the filter housing

to the crankcase.

- Loosen the two clamps indicated.

- Remove the filter housing.

See alsoSide fairingsFootrestspoiler


CHAS - 221

Rear mudguard

• Remove the 2 retainers, which also lock the air

filter box to the crankcase.

• Remove the fixing screw located on the right side.

• Remove the mudguard making it come out on the

muffler side.

Helmet bay

- Lift the saddle.

- Remove the six fixing screws.


CHAS - 222

spoiler


- Undo the 2 front retainers.

- Open, on both sides of the vehicle, the passenger

footrest, and remove the screw shown in the pic-

ture.

- Remove the spoiler.

See alsoFootrest

Fuel tank




- Remove the leg shield back plate.

- Loosen the clamps and disconnect the connec-

tion pipes to the breather valve from the fuel tank

filler.


CHAS - 223

- Disconnect the fuel pipe from the pump.

- Disconnect the electrical connectors of the fuel

pump and level transmitter.

- Unscrew and remove the four screws that secure

the tank to the chassis.

- Remove the tank.

See alsoSide fairingsFootrestspoilerKnee-guard

Front mudguard


- Unscrew the 3 fixing screws and remove them.

- Disconnect the brake calliper pipe.

- Unscrew the screw fastening the brake pipe on

the mudguard and slide it off.

- Remove the mudguard.N.B.N.B. WHEN REFITTING, MAKE SURE TO POSITION THE 2METAL CABLE GROMMETS CORRECTLY.

Locking torques (N*m)front mudguard to plate fixing screw 4.5 to 7

Front central cover

• Remove the lower cover.

• Remove the helmet compartment.

• Undo the 2 lower fixing screws.


CHAS - 224

• Undo the 2 upper fixing screws.

• Remove the cover.

Battery

• Open the glove compartment on the leg shield

back plate.

- Undo the screws indicated and remove the bat-

tery compartment cover.

• Unhook the belt securing the battery.

• Remove the battery from its housing and disconnect the connection cables from the electrical system,

starting with the negative pole.

Lower cover

• Undo the 2 side fixing screws indicated

in the photo.

• Remove the cover.


CHAS - 225

INDEX OF TOPICS

PRE-DELIVERY PRE DE

Aesthetic inspection

Appearance check:

- Paintwork

- Fitting of plastics

- Scratches

- Dirt

Tightening torques inspection

Lock check

- Safety fasteners

- Fixing screws

Safety fasteners:

Rear shock absorber upper fixing

Rear shock absorber lower fixing

Front wheel axle nut

Wheel hub nut

Swinging arm - chassis pin

Engine-swinging arm pin

Engine arm pin - Chassis arm

Handlebar lock nut

Lower steering ring nut

Upper steering ring nut

Electrical system

Electrical system:

- Main switch

- Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights

- Adjusting the headlights according to the regulations currently in force

- Rear light, parking light, stop light

- Front and rear stop light switches

- Turn indicators and their warning lights

- Instrument panel lights

- Instrument panel: fuel and temperature indicator

- Instrument panel warning lights

- Horn

- Starter

Fly 125 i.e - 150 i.e Leader (2011) Pre-delivery

PRE DE - 227

CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFOREIT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINALFIRST.CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-ATIVE ONE.WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FORABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER ORVEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARETO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKINGCLOSE TO BATTERIES.KEEP OUT OF THE REACH OF CHILDRENCAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USINGA FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSEA FIRE.

Levels check

Level check:

- Hydraulic braking system fluid level.

- Rear hub oil level

- Engine coolant level.

Road test

Test ride

- Cold start

- Instrument operations

- Response to the throttle control

- Stability on acceleration and braking

- Rear and front brake efficiency

- Rear and front suspension efficiency

- Abnormal noise

Pre-delivery Fly 125 i.e - 150 i.e Leader (2011)

PRE DE - 228

Static test

Static control after the test ride:

- Starting when warm

- Starter operation

- Minimum hold (turning the handlebar)

- Uniform turning of the steering

- Possible leaksCAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.CAUTION

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Functional inspection

Functional Checks:

Braking system (hydraulic)

- Lever travel

Braking system (mechanical)

- Lever travel

Clutch

- Proper functioning check

Engine

- Throttle travel check

Others

- Check documentation

- Check the chassis and engine numbers

- Tool kit

- License plate fitting

- Check locks

- Check tyre pressures

- Installation of mirrors and any accessories

Fly 125 i.e - 150 i.e Leader (2011) Pre-delivery

PRE DE - 229

AAir filter: 35, 221

BBattery: 45, 61, 70, 72, 80, 81, 215, 225Brake: 185, 186, 197, 199, 202Bulbs:

CChecks: 65

EEngine oil: 35

FFuel: 165, 173, 223Fuses: 79, 171, 177

HHeadlight: 41, 210Horn: 74Hub oil: 33

IIdentification: 8Instrument panel: 209

MMaintenance: 7, 31Mirrors: 207

OOil filter: 37

RRecommended products:

SShock absorbers: 193Spark plug: 31Stand: 195Suspension: 45

TTank: 223

Transmission: 10, 44, 98, 110, 120Turn indicators: 64Tyres: 13

VVehicle: 8, 91, 92, 192

Documents

Piaggio Fly 125 i.e - 150 i.e Leader MY 2011 (EN)