Piaggio Fly 50 4t 4v (EN)

WORKSHOP MANUAL677586 EN

Fly 50 4t 4v

WORKSHOPMANUAL

Fly 50 4t 4v

The descriptions and images in this publication are given for illustrative purposes only and are not binding.While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,to make any changes to components, parts or accessories, which it considers necessary to improve the

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

model should be checked at the official PIAGGIO sales network.© Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or

in part is prohibited.Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy

www.piaggio.com

http://www.piaggio.com/

WORKSHOP MANUALFly 50 4t 4v

This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggiodealers and sub-agents. It is assumed that the person utilizing this manual for servicing or repairingPiaggio vehicles has knowledge of the principles of mechanics and standard procedures required forgeneral vehicle repair. Any relevant changes concerning the vehicle characteristics or specific repairoperations will be divulged in the form of updates to this manual. Satisfactory repair or service cannotbe achieved without the necessary equipment and tools. Refer to the pages of this manual concerningspecific tools and equipment and the special tools 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

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 50 4t 4v Characteristics

CHAR - 7

Vehicle identificationThe chassis prefix is stamped on the right strut.

The engine prefix is stamped on the rear wall of

the transmission crankcase.

VEHICLE IDENTIFICATIONSpecification Desc./QuantityChassis prefix RP8C52Engine prefix C522M

Dimensions and mass

Characteristics Fly 50 4t 4v

CHAR - 8

WEIGHTS AND DIMENSIONSSpecification Desc./QuantityKerb weight 117 kgWheelbase 1345 mm

Length 1,870 mmWidth (handlebar) 705 mm

Height (without mirrors) 1150 mm

Engine

ENGINESpecification Desc./Quantity

Type single-cylinder, four-stroke and four-valve, air-cooled engineBore 39 mm

Stroke 41.8 mmEngine capacity 49.93 cm³

Max. power 3.2 kW at 8250 rpmMAX. torque 3.8 Nm at 7,750 rpm

Compression ratio 12.0±0.5Timing system single overhead camshaft, chain-driven, on the left-hand side,

three-arm rocking levers set up with threaded set screwEngine idle speed 1900 to 2000 rpm

Air filter Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and50% unleaded petrol).

Starting system electric starter/kick starterLUBRICATION engine lubrication with lobe pump (in the crankcase), chain-

driven. Mesh pre-filter and centrifugal filter on the crankshaftFuel system Gravity feed, with unleaded petrol (with a minimum octane rat-

ing of 95) with carburettor.Valve clearance (cold engine) intake 0.10 mm

discharge 0.15 mmCARBURETTOR depression type, KEIHIN NCV ø 20

Cooling forced air circulation

OIL PUMPSpecification Desc./Quantity

Type TrochoidalDistance between the rotors Admissible limit clearance: 0.15 mm

Axial rotor clearance Limit values admitted: 0.09 mmDistance between the outer rotor and the pump body Admissible limit clearance: 0.20 mm

Levelness 0.1 mm

OIL FILTERSpecification Desc./Quantity

Type mesh, plastic and centrifugal filter, before the oil pump and co-axially mounted onto the crankshaft keyed on the right crank

Transmission

TRANSMISSIONSpecification Desc./QuantityTransmission With automatic expandable pulley variator, torque server, V-

belt, automatic clutch, gear reduction unit.


CHAR - 9

Capacities

CAPACITYSpecification Desc./Quantity

Fuel tank 7±0.5 ltRear hub 85 cm³Engine oil ~ 850 cc

Electrical system

When the advance check is carried out with a stroboscopic gun, add 10° flywheel keying to the table

below.

ELECTRICAL COMPONENTSSpecification Desc./Quantity

1 Ignition advance reference in table2 Spark plug NGK ER9EH-N3 Battery 12V - 9Ah4 Fuses 1 15A - 1 10A - 1 7.5A5 Generator single-phase alternating current

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.


CHAR - 10

TURN INDICATOR SWITCH

IGNITION KEY

LIGHT SWITCH

STARTER BUTTON


CHAR - 11

HORN BUTTON

STOP BUTTON

Resistance between green cable and ground con-

nection: approx. 170 Ohm

- Primary resistance: 0.5 to 0.6 Ohm

- Resistance between primary and ground con-

nection: infinite

- Resistance between primary and HV output: 3 to

3.6 kOhm

- Shielded cap: 5000 Ohm


CHAR - 12

- Power: 120 W

- resistance between BLUE cable and GROUND

CONNECTION: 1 Ohm

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

Rear wheel pressure (rider and passenger): 2.3 bar

Tightening Torques

ENGINE ASSEMBLYName Torque in Nm

Ignition spark plug: 10 to 15 NmFloating head cover screws 6 to 7Head-cylinder stud bolt nuts 6 to 7 + 90° + 90° *

Screws fixing head and cylinder to crankcase 8 - 10Chain tensioner pad screw 5 to 7 Nm

Timing chain tensioner central screw 5 - 6


CHAR - 13

Name Torque in NmCamshaft pulley screw 12 - 14

Rocking lever axle and camshaft bearing screw 3 to 4 NmRocking levers adjusting nuts: 7 to 9 Nm

Engine oil pre-filter cover: 25 - 28 NmEngine oil drainage cap 25 - 28

Flywheel nut 40 to 44 N.mStator screws 3 to 4

Pick-up screws 3 - 4Oil pump bulkhead screw 4 - 5

Timing chain/oil pump compartment cover screws 4 to 5Oil decantation labyrinth sheet screws 7 to 8

Oil pump sprocket gear screw 8 - 10Screws fixing oil pump to the crankcase 5 - 6

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

Carburettor/manifold clamp screw 1.2 to 1.5Screws fixing cables to starter motor 1.5 - 2.5

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

Start-up lever screw 11 to 13Crankcase cooling cover screw 2 to 2.5

Clutch assembly nut 55 to 60Crankshaft pulley nut 18 to 20 + 90° NmDriven pulley shaft nut 40 to 44 NmHub oil drainage screw 3 - 5 NmRear hub cap screws 11 to 13

Crankcase half union screw 8 - 10

STEERING ASSEMBLYName Torque in Nm

Steering upper ring nut 35 to 40Steering lower ring nut 8 ÷ 10Handlebar fixing screw 50 to 55

CHASSIS ASSEMBLYName 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 swinging arm retaining bolts 36 to 44Side stand bolt 12 - 16

Centre stand pin 40 to 45

FRONT SUSPENSIONName Torque in Nm

Fork bottom screw 20 ÷ 25Front wheel axle 45 ÷ 50

Wheel axle clamp screws 6 - 7 NmFront 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 27.5


CHAR - 14

Name Torque in NmDisc 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.

COUPLING BETWEEN PISTON AND CYLINDERName Initials Cylinder Piston Play on fitting

Cylinder A 38.993 to 39.000 38.954 to 38.961 0.032 to 0.046Cylinder B 39.000 to 39.007 38.961 to 38.968 0.032 to 0.046Piston C 39.007 to 39.014 38.968 to 38.975 0.032 to 0.046Piston D 39.014 to 39.021 38.975 to 38.982 0.032 to 0.046

Cylinder 1st oversize A1 39.193 to 39.200 39.154 to 39.161 0.032 to 0.046Cylinder 1st oversize B1 39.200 to 39.207 39.161 to 39.168 0.032 to 0.046Piston 1st oversize C1 39.207 to 39.214 39.168 to 39.175 0.032 to 0.046Piston 1st oversize D1 39.214 to 39.221 39.175 to 39.182 0.032 to 0.046

Cylinder 2nd oversize A2 39.393 to 39.400 39.354 to 39.361 0.032 to 0.046Cylinder 2nd oversize B2 39.400 to 39.407 39.361 to 39.368 0.032 to 0.046Piston 2nd oversize C2 39.407 to 39.414 39.368 to 39.375 0.032 to 0.046Piston 2nd oversize D2 39.414 to 39.421 39.375 to 39.382 0.032 to 0.046

Cylinder 3rd oversize A3 39.593 to 39.600 39.554 to 39.561 0.032 to 0.046Cylinder 3rd oversize B3 39.600 to 39.607 39.561 to 39.568 0.032 to 0.046Piston 3rd oversize C3 39.607 to 39.614 39.568 to 39.575 0.032 to 0.046Piston 3rd oversize D3 39.614 to 39.621 39.575 to 39.582 0.032 to 0.046

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARKFACING UPWARDS.


CHAR - 15

- Measure the outer diameter of the gudgeon pin.

CharacteristicPin outside diameter13 +0 -0.004 mm

Minimum admissible diameter gudgeon pin12.990 mm

- Measure the diameter of the bearings on the pis-

ton.

CharacteristicPin seat diameter13 +0.005 + 0.010 mm

- Calculate the piston pin coupling clearance.N.B.

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENTMUST BE MADE ACCORDING TO THE PISTON AXIS

CharacteristicStandard clearance

0.005 to 0.014 mm

- 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.N.B.MEASURE THE CLEARANCE BY INSERTING THE BLADEOF THE FEELER GAUGE FROM THE SECOND SEAL RINGSIDE.

Fitting clearanceTop piston ring - standard coupling clearance0.03 to 0.065 mm Top piston ring - maximum clear-ance allowed after use 0.07 mm Middle pistonring - standard coupling clearance 0.02 to 0.055mm Middle piston ring - maximum clearance al-lowed after use 0.06 mm oil scraper ring - stand-ard coupling clearance 0.04 to 0.16 mm oil scraper


CHAR - 16

ring - maximum clearance allowed after use0.17 mm

- 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

Piston rings

- Alternately insert the three sealing rings into the

cylinder, in the area where it retains its original di-

ameter. Using the piston, insert the rings perpen-

dicularly to the cylinder axis.

- Measure the opening, see figure, of the sealing

rings using a thickness gauge.

- If any measurements are greater than specified,

replace the piston rings.N.B.BEFORE REPLACING ONLY THE PISTON RINGS, ENSURETHAT THE CLEARANCE BETWEEN THE PISTON RINGSAND THE PISTON RING GROOVES, AND BETWEEN THEPISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANYCASE, NEW PISTON RINGS USED IN COMBINATION WITHA USED CYLINDER MAY HAVE DIFFERENT BEDDINGCONDITIONS THAN THE STANDARD.


CHAR - 17

SEALING RINGSName Description Dimensions Initials Quantity

1st Compression ring 39 x 1 A 0.08 to 0.202nd Compression ring 39 x 1 A 0.05 to 0.20

Oil scraper ring 39 x 2 A 0.20 to 0.701st Compression ring

1st Oversize39.2 x 1 A 0.08 to 0.20

2nd Compression ring1st Oversize

39.2 x 1 A 0.05 to 0.20

Oil scraper ring 1stOversize

39.2 x 2 A 0.20 to 0.70

1st Compression ring2nd Oversize

39.4 x 1 A 0.08 to 0.20

2nd Compression ring2nd Oversize

39.4 x 1 A 0.05 to 0.20

Oil scraper ring 2ndOversize

39.4 x 2 A 0.20 to 0.70

1st Compression ring3rd Oversize

39.6 x 1 A 0.08 to 0.20

2nd Compression ring3rd Oversize

39.6 x 1 A 0.05 to 0.20

Oil scraper ring 3rdOversize

39.6 x 2 A 0.20 to 0.70


CHAR - 18

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASEName Description Dimensions Initials Quantity

Half-shaft, transmissionside

14 +0 -0.005 A

Flywheel-side half shaft 16 +0 -0.005 BConnecting rod 14.8 +0.05 -0 C

Spacer tool 45.00 / Fits and clearan-ces D = 0.15 to 0.30

E

CharacteristicClearance between crankshaft and connecting rod

A = 0.15 to 0.30 mm


CHAR - 19

Measure the bearings along X and Y axes

CharacteristicCrankshaft bearing, transmission side20 -0.012 -0.025 mm

Crankshaft bearing, flywheel side17 +0.007 0 mm

- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded

tangs are in good working order.

- In case of failures, replace the crankshaft.

Specific tooling020074Y Support base for checking crankshaft alignment


CHAR - 20

To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated

in figure.N.B.IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC-TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-SERTING A WOODEN WEDGE BETWEEN THE HALFSHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-DED. IF EVEN AFTER THIS OPERATION THE VALUES ARENOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.

CharacteristicOff-line maximum admitted - A0.15 mm

Off-line maximum admitted - B0.02 mm

Off-line maximum admitted - C0.02 mm

Off-line maximum admitted - D0.10 mm

- Using a bore gauge, measure the connecting rod

small end diameter.N.B.IF THE CONNECTING ROD SMALL END DIAMETER EX-CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OROVERHEATING, PROCEED TO REPLACE THE CRANK-SHAFT AS DESCRIBED IN THE CRANKCASE ANDCRANKSHAFT CHAPTER.

CharacteristicRod small end diameter13 +0.015 + 0.025 mm

Max. diameter admitted: check the small end13.030 mm

Calculate the coupling clearance between pin and rod small end

CharacteristicPin - connecting rod clearance

0.015 - 0.029 mm

Cylinder Head

Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of

the springs and the valves so as not to change the original position during refitting


CHAR - 21

- 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.

- It is advisable to replace the head if any failure is

found.

CharacteristicMaximum allowable run-out:0.1 mm

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust

valves.

- 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.

Measure the camshaft bearing seats and rocking

lever support pins with a bore meter

HEAD CHECKSpecification Desc./Quantity

Standard diameter (mm) A Ø 32.015 to 32.025Standard diameter (mm) B Ø 16.0 to 16.018Standard diameter (mm) C Ø 11.0 to 11.018


CHAR - 22

Measure the unloaded spring length.

• Standard length: 31.3 mm

• Limit allowed after use: 29.3

- Remove any carbon deposits from the valve

seats.

- Check the width of the mark on the valve seat

«V» with Prussian blue.

CharacteristicStandard value:1 - 1.3 mm

Admissible limit:1.6 mm

- If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45°

milling cutter and then grind.

- In case of excessive wear or damage, replace the head.

STANDARD VALVE LENGTHSpecification Desc./Quantity

Inlet: standard length 74.9 mmOutlet: standard length 74.35 mm


CHAR - 23

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

STANDARD DIAMETERSpecification Desc./Quantity

Intake 3.970 to 3.985 mmExhaust 3.960 to 3.975 mm

MINIMUM DIAMETER PERMITTEDSpecification Desc./Quantity

Intake 3.958 mmExhaust 3.945 mm

- Calculate the clearance between valve and valve guide.

- Check the concentricity of the valve head by

placing a dial gauge at right angles to the valve

head and rotating it on the «V» shaped support.

CharacteristicAdmissible limit:0.03 mm

- Check the deviation of the valve stem by resting

it on a «V» shaped support and measuring the ex-

tent of the deformation using a dial gauge.

CharacteristicLimit values admitted:0.1 mm


CHAR - 24

Measure the valve guides

VALVE GUIDE DIAMETERSpecification Desc./QuantityValve guide Standard diameter: 4 + 0.012 mmValve guide Maximum admissible diameter: 4 + 0.022 mm

- After measuring the valve guide diameter and the

valve stem diameter, check clearance between

guide and stem.

INTAKESpecification Desc./Quantity

Standard clearance 0.015 to 0.042 mmAdmissible limit 0.06 mm

EXHAUSTSpecification Desc./Quantity

Standard clearance 0.025 - 0.052 mmAdmissible limit 0.07 mm

- If no faults are found during the above checks, you can use the same valves. To obtain better sealing

performance, grind the valve seats. Grind the valves gently with a fine-grained lapping compound.

During the grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent

the lapping compound residues from penetrating between the valve stem and the guide (see figure).CAUTION

TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NOLAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVESWITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.CAUTION

DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).


CHAR - 25

- Inspect the camshaft for signs of abnormal wear

on the cams.

CharacteristicStandard diameter - Bearing A:Ø 12 +0.002 +0.010

mm Standard diameter - Bearing B:Ø 16-0.015 -0.023 mm

Minimum diameter allowed - Bearing A:Ø 11.98 mm

Minimum diameter allowed - Bearing B:Ø 15.96 mm

- Using a gauge, measure the height of the cams.

Check the axial clearance of the camshaft

- 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.N.B.A BALL BEARING IS FITTED ON BEARING «A»; CONSE-QUENTLY, BEARING «B» IS THE MOST IMPORTANT AS ITWORKS DIRECTLY ON THE HEAD ALUMINIUM

CharacteristicStandard height - Inlet24.397 mm

Standard height - Outlet23.996 mm

Fitting clearanceMaximum admissible axial clearance: 0.5 mm

- Measure the outside diameter of the rocking lever pins

- Check the rocking lever pins do not show signs of wear or scoring.

- Measure the internal diameter of each rocker.

- Check that the pad in contact with the cam is not worn.

ROCKING LEVERS AND PIN DIAMETER:Specification Desc./Quantity

Rocking levers - Inside diameter 11.015 to 11.035 mmRocking levers - Pins diameter 10.977 to 10.985 mm


CHAR - 26

Slot packing system

CharacteristicCompression ratio11.5 to 12 : 1

PISTON PROTRUSION CHECKName Measure A Thickness

shimming_1 1.7 to 1.95 0.25shimming_2 1.95 to 2.2 0.35

Products

RECOMMENDED PRODUCTS TABLEProduct Description Specifications

AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis-sions.

API GL-4

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

DOT 4eni i-Ride PG 5W-40 Synthetic based lubricant for high-per-

formance four-stroke engines.JASO MA, MA2 - API SL - ACEA A3

AGIP FILTER OIL Special product for the treatment of foamfilters.

-

AGIP GREASE MU3 Yellow-brown, lithium-base, medium-fi-bre multipurpose grease.

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

AGIP GP 330 Water repellent stringy calcium spraygrease.

R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 -I.A.T.A. 2 - I.M.D.G. class 2 UN 1950

Page 9022 EM 25-89


CHAR - 27

INDEX OF TOPICS

TOOLING TOOL

SPECIFIC TOOLSStores code Description

001330Y Tool for fitting steering seats

001467Y008 Pliers to extract 17 mm ø bearings

001467Y029 Bell for bearings, O.D. 38 mm

002465Y Pliers for circlips

004499Y Bearing extractor. Fitted with: 1 Bell, 2Sleeve, 3 Screw, 6 Ring, 7 Half rings, 27

Half rings, 34 Half rings

005095Y Engine support

006029Y Punch for fitting fifth steering bearing onsteering tube

Fly 50 4t 4v Tooling

TOOL - 29

Stores code Description008119Y009 Tube to assemble shafts and axles

020004Y Punch for removing fifth wheels fromheadstock

020055Y Wrench for steering tube ring nut

020150Y Air heater support

020151Y Air heater

020162Y Flywheel extractor

020171Y Punch for Ø 17 mm roller bearing

Tooling Fly 50 4t 4v

TOOL - 30

Stores code Description020193Y Oil pressure check gauge

020265Y Bearing fitting base

020271Y Tool for removing-fitting silent bloc

020288Y Fork to assemble piston on cylinder

020291Y Valve fitting/ removal tool

020306Y Punch for assembling valve seal rings


TOOL - 31

Stores code Description020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020332Y Digital rpm indicator

020334Y Multiple battery charger


TOOL - 32

Stores code Description020335Y Magnetic support for dial gauge

020340Y Flywheel and transmission oil seals fittingpunch

020359Y 42x47-mm Adaptor


020363Y 20-mm guide


TOOL - 33

Stores code Description020364Y 25-mm guide

020376Y Adaptor handle

020431Y Valve oil seal extractor

020432Y Tool to fit the start-up sector spring

020439Y 17-mm guide

020444Y Tool for fitting/ removing the driven pulleyclutch


TOOL - 34

Stores code Description020448Y Pin lock fitting tool

020449Y Piston position check support

020450Y Camshaft fitting/removal tool

020451Y Starting ring gear lock

020452Y Tube for removing and refitting the drivenpulley shaft

020456Y Ø 24-mm adaptor


TOOL - 35

Stores code Description020480Y Petrol pressure check kit

020565Y Flywheel lock calliper spanner

020683Y Valve pressing member


TOOL - 36

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

SCHEDULED MAINTENANCE TABLEI: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.C: CLEAN, R:REPLACE, A: ADJUST, L:LUBRICATE* Replace every 2 years

Km x 1000 1 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60Safety fasteners I I I I I ISpark plug R R R R R R R R R RDrive belt I R I R I R I R I RThrottle control A A A A A ATyre condition andwear

I I I I I

Air filter C C C C COil filter (mesh) C C C C C C C C C CSolenoid filter C C C C C C C C C CValve clearance I I I I I IElectrical systemand battery

I I I I I I I I I I I

Cylinder ventila-tion system

I I

Brake levers L L L L L LBrake oil level (*) I I I I I I I I I I IHub oil level R I R I R I R I R I REngine oil R I R I R I R I R I R I R I R I R I R I RBrake Pads/Shoes I I I I I I I I I I ITyre pressure I I I I I I I I I I IHeadlight A A A A AVehicle road test I I I I I I I I I I IIdle speed A A A A A AOdometer gear L L L L LCVT rollers I R I R I R I R I RSuspension I I I I ISteering A A A A A ATransmission L L L L LOperation time 90' 10' 60' 10' 13

0'10' 60' 10' 18

0'10' 60' 10' 16

5'10' 60' 10' 18

0'10' 60' 10' 13

0'

Carburettor

The carburettor features a solenoid valve "A" that,

via an ECU, manages an extra flow of air.

It is connected to the carburettor via flexible pipes

as shown in the figure.

The valve is positioned under the helmet compart-

ment.

The piping is joined to a filter positioned inside the

body. The solenoid filter should be cleaned ac-

cording to the kilometres travelled as instructed in

the scheduled maintenance chart.

Maintenance Fly 50 4t 4v

MAIN - 38

- Disassemble the carburettor in its parts, wash all

of them with solvent, dry all body grooves with

compressed air to ensure adequate cleaning.

- Check carefully that the parts are in good condi-

tion.

-The throttle valve should move freely in the

chamber. Replace valve in case of wear due to

excessive clearance.

- If there are wear marks in the chamber causing

inadequate tightness or a free valve slide (even if

it is new), replace the carburettor.

- It is advisable to replace the gaskets at every refit.WARNINGPETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THEGASKETS TO AVOID PETROL LEAKS

1. Needle valve - 2. Idle adjustment screw - 3. Max jet - 4. Accelerating pump - 5. Tapered pin - 6. Jet

holder - 7. Float - 8. Reservoir - 9. Starter device - 10. Depression valve - 11. Cover - 12. Minimum jet.

Spark plug

- Position the vehicle on the stand

- Remove the external engine inspection panel,

unscrewing the indicated screws.

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

- Slide the internal cover upwards.

Fly 50 4t 4v Maintenance

MAIN - 39

- 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.

- Place the cap fully over the spark plug, and tie down the cable to the bracket.

- Carry out refit operations.CAUTION

THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD.THE SPARK PLUG MUSTBE REPLACED EVERY 20,000 KM. THE USE OF NON CONFORMING ELECTRONIC IGNITIONCONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLYDAMAGE THE ENGINE.

CharacteristicElectrode gap


MAIN - 40

0.7 to 0.8 mm

Spark plug

NGK ER9EH-6N

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.

Replacement

- Remove the oil dipstick/cover.


MAIN - 41

- 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 productsAGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions.

API GL-4

CharacteristicRear hub oil

Quantity: approx. 85 cc

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

Air filter

- Remove the l.h.s. fairing.

- Remove the air-box cover after removing the 6

fixing screws shown in the figure, and then extract

the filtering element.

Cleaning:

- Clean with water and neuter soap;

- Dry with a clean cloth, without squeezing, and

with light jets of air;

- Immerge in a 50% oil-petrol mixture;

- Let it drip and then compress it with your hands,

without squeezing.

- Refit all components in the reverse order.CAUTIONIF THE VEHICLE IS MOSTLY USED ON DUSTY ROADS,THE AIR FILTER NEEDS TO BE CLEANED AT SHORTERINTERVALS THAN INDICATED IN THE SCHEDULED MAIN-TENANCE TABLE.


MAIN - 42

DO NOT RUN THE ENGINE WITH THE AIR FILTER DISAS-SEMBLED OR EXCESS WEAR OF CYLINDER AND PISTONWILL RESULT.

Recommended productsAGIP FILTER OIL Special product for the treat-ment of foam filters.-

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.

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 the complete exhaust must be removed.

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


MAIN - 43

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 productseni i-Ride PG 5W-40 Synthetic based lubricantfor high-performance four-stroke engines.JASO MA, MA2 - API SL - ACEA A3

CharacteristicEngine oil~ 850 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 850 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, 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.


MAIN - 44

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.

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 productseni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines.

JASO MA, MA2 - API SL - ACEA A3

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.


MAIN - 45

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-

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


MAIN - 46

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.

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


MAIN - 47

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

See alsoFront handlebar cover

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 - 48

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

Troubleshooting Fly 50 4t 4v

TROUBL - 50

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

Fly 50 4t 4v Troubleshooting

TROUBL - 51

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.

Troubleshooting Fly 50 4t 4v

TROUBL - 52

Fly 50 4t 4v Troubleshooting

TROUBL - 53

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

1. Light remote control

2. Light switch

3.Town light bulb

4. Instrument panel lighting bulbs

5. Headlight warning light

6. Filament for rear position light

7. High-beam warning light

8. Headlight bulb

9.Automatic starter

10.NTC temperature sensor

11.Electronic ignition device

12. Turn indicator switch

13. Left turn indicator bulbs

14. Turn indicator warning light

15. Right turn indicator bulbs

16.HV coil

17.Key switch contacts

18.Diagnostics socket

19.Fuse

20.PTC

21.Horn button

22.Horn

23.Stop buttons

24.Low fuel warning light

25.Fuel gauge

26.S.I.S. Valve

27.Voltage regulator

28.Fuel level transmitter

29.Stop light filament

30.Starter button

31.Starter motor

32.Starter remote control switch

33.Fuse

34.Battery

35.Key switch contacts

36.Fuse

37.Magneto flywheel

38.Pick-Up

Fly 50 4t 4v Electrical system

ELE SYS - 55

Colours of the electrical cables:

B = White, Bl = Blue, G = Yellow, Mr = Brown, N

= Black, Gr = Grey,

Rs = Pink, R = Red, Vi = Purple, V = Green

Components arrangement

Electrical system Fly 50 4t 4v

ELE SYS - 56

1. Battery: to access open the front panel.

2. Diagnostic socket: to access open the front pan-

el.

3. Fuses: remove the legshield to reach it.

4. Fuse for electronic starter device: remove the

legshield to reach it.

5. Lights logic solenoid switch: remove the leg-

shield to reach it.

6. Side stand solenoid switch: remove the leg-

shield to reach it.

7. Horn; remove the legshield to reach it.

8. Main fuse: to access open the front panel.

9. Starter switch: remove the legshield to reach it.

10. Start-up solenoid: remove the legshield to

reach it.


ELE SYS - 57

11. Electronic starter device: remove the front part

of the front shield to access it.

12. Front left turn indicator: remove the legshield

to reach it.

13. Front right turn indicator: remove the legshield

to reach it.

14. Front headlight: remove the legshield to reach

it.

15. Left stop switch: remove the front headlight to

reach it.

16. Right stop switch: remove the front headlight

to reach it.

17. Instrument panel connectors: remove the front

headlight to reach it.


ELE SYS - 58

18. Horn button: remove the front headlight to

reach it.

19. Turn indicators switch: remove the front head-

light to reach it.

20. Light switch: remove the front headlight to

reach it.

21. Engine stop switch: remove the front headlight

to reach it.

22. Starter button: remove the front headlight to

reach it.

23. Petrol pump: remove the footrest to reach it.

24. Fuel gauge: remove the footrest to reach it.

25. Connectors for fuel reserve indicator: remove

the footrest to reach it.


ELE SYS - 59

26. HV coil: remove the helmet compartment to

reach it.

27. Voltage regulator: remove the helmet com-

partment to reach it.

28. Starter motor: remove the helmet compart-

ment to reach it.

29. Stator connection: remove the spark plug ac-

cess panel located under the saddle to reach it.

30. Spark plug: remove the spark plug access

panel located under the saddle to reach it.

31. Automatic starter: remove the helmet compart-

ment to reach it.

32. P.T.C.: remove the helmet compartment to

reach it.

33. Engine temperature sensor: remove the hel-

met compartment to reach it.


ELE SYS - 60

34. Side stand sensor: remove the footrest to

reach it.

35. S.I.S. Valve: remove the central cover to reach

it.

36. Ambient temperature sensor: remove the cen-

tral cover to reach it

37. Taillight: remove the rear light assembly to

reach it.

38. Rear left turn indicator: remove the rear light

assembly to reach it.

39. Rear right turn indicator: remove the rear light

assembly to reach it.

40. License plate light: remove the helmet com-

partment to reach it.


ELE SYS - 61

Ground points

On the vehicle there is a chassis ground on the

front side of the steering tube. Remove the leg-

shield to reach it.

There is a ground point of the voltage regulator.

Disassembly the helmet compartment to reach it.

Electrical system installation

Front side

1. Right stop button

2. Left stop button

3. Front headlight connection

4. At right command group

5. At left command group

6. Battery connections


ELE SYS - 62

7. Start-up solenoid

8. At the battery connections


ELE SYS - 63

9. Battery negative terminal connection

10. Positive battery pole connection

11. Main fuse

12.Diagnostics connection


ELE SYS - 64

13. Front left turn indicator

14. Front turn indicator connections

15. At the right turn indicator

16. Resistance

17. Electronic ignition device


ELE SYS - 65

18. Ignition switch

19. Horn

20. Lights logic and side stand solenoid switches

21. Service fuses

22. Front right turn indicator

23. Connection branches on tank, engine sensors and rear part


ELE SYS - 66

24. Starter motor connection branch

25. Solenoid switches and fuses branch

26. Side stand sensor connection

27. Side stand sensor


ELE SYS - 67

28. Fuel gauge

29. Fuel reserve indicator connections

30. At the engine flywheel connection

31. Sensors connection on the engine branch

32. Rear part branch

33. Starter motor connection branch


ELE SYS - 68

Back side

1. High voltage coil connection

2. Voltage regulator

3. Ambient temperature sensor connection

4. S.I.S. valve connection


ELE SYS - 69

5. Taillight connection

6. Rear turn indicators connections

7. Automatic starter

8. At the P.T.C. connection

9. At the engine temperature sensor connection

10. Engine temperature sensor connection


ELE SYS - 70

11. P.T.C. connection

Conceptual diagrams

1. External temperature sensor

2. Front and rear brake light

3. Fuel reserve sensor

4. Starter motor



ELE SYS - 71

6. 12v-6Ah battery

7. 15a Fuse

8. Starter button

9. Low fuel warning light 12V - 1.7W

10. Instrument electronics

11. Horn

12. Horn button

13. Fuel gauge

14. Fuel level transmitter

15. 21W filament for brake light in bulb 12V - 5/21W

16. Side stand solenoid switch

17. Fuse 7.5A

18. Ignition switch contacts

19. Magneto flywheel


21. S.I.S. Valve

22. PTC

23. Side stand switch

24. HV coil

25. 2 12V - 1.7W bulbs for turn indicator warning lights

26. Turn indicators switch

27. 4 12V - 10W bulbs for turn indicators

28. On Off-lock

29. Engine stop switch

30. 5W filament for rear daylight running light in bulb 12V - 5/21W

31. License plate light bulb 12V - 5W

32. 1 bulb for instrument LCD back lighting

33. 3 bulbs for dashboard lighting 12V - 1.7W

34. 2 city light bulbs 12V - 5W

35. High-beam warning light 12V - 1.7W

36. Headlight bulb 12V - 35/35W

37. Light switch

38. Light relay


40. NTC temperature sensor


42. Fuse 10A

43. Diagnostics socket


ELE SYS - 72

Ignition

Ignition


6. 12v-6Ah battery

7. 15a Fuse


13. Fuel gauge


17. Fuse 7.5A


Lights and turn indicators


ELE SYS - 73

Lights and turn indicators


6. 12v-6Ah battery

7. 15a Fuse


17. Fuse 7.5A



25. 2 12V - 1.7W bulbs for turn indicator warning lights

26. Turn indicators switch

27. 4 12V - 10W bulbs for turn indicators

30. 5W filament for rear daylight running light in bulb 12V - 5/21W

31. License plate light bulb 12V - 5W

32. 1 bulb for instrument LCD back lighting

33. 3 bulbs for dashboard lighting 12V - 1.7W

34. 2 city light bulbs 12V - 5W

35. High-beam warning light 12V - 1.7W

36. Headlight bulb 12V - 35/35W

37. Light switch

38. Light relay


Enabling buttons and level indicators


6. 12v-6Ah battery


ELE SYS - 74

7. 15a Fuse


13. Fuel gauge


17. Fuse 7.5A


Enabling buttons and level indicators

Battery recharge and start up


4. Starter motor


ELE SYS - 75


6. 12v-6Ah battery

7. 15a Fuse

8. Starter button


16. Side stand solenoid switch

17. Fuse 7.5A


19. Magneto flywheel


23. Side stand switch

28. On Off-lock

29. Engine stop switch


42. Fuse 10A

Devices and accessories

Devices and accessories

1. External temperature sensor

6. 12v-6Ah battery

7. 15a Fuse

10. Instrument electronics

11. Horn

12. Horn button

17. Fuse 7.5A


ELE SYS - 76



21. S.I.S. Valve

22. PTC

38. Light relay


40. NTC temperature sensor


42. Fuse 10A

43. Diagnostics socket

Instruments and warning lights control board

A = Odometer

B = Speedometer

C = Turn indicators

D = High-beam warning light

E = Headlight warning light

F = Immobiliser LED

G= Low fuel warning light

H = Fuel gauge

L = Digital clock


ELE SYS - 77

INSTRUMENT BOARD - WARNING LIGHTS AND INSTRUMENT PANELSpecification Desc./Quantity

1 Instrument panel bulb 12V-1.7W2 Instrument panel bulb 12V-1.7W3 Headlight warning light 12V-1.7W4 Left turn indicator warning light 12V-1.7W5 Right turn indicator warning light 12V-1.7W6 Fuel gauge7 LCD Instrument panel back lighting bulb8 Digital clock9 High beam warning light 12V-1.7W10 Low fuel warning light 12V-1.7W

Checks and inspections

In case the cause of ignition failure or malfunction

cannot be easily identified at sight, first of all re-

place the control unit by another one in operating

conditions.

Remember that the engine must be off to discon-

nect and replace the control unit.

If after replacement the vehicle starts properly, the

control unit is failing and must be replaced.


ELE SYS - 78

If the failure persists, check the generator and the

stator components as follows:

After visually checking the electrical connections,

use a specific tester to measurement the stator

winding and the pickup (see table).

If any failure is found after checking the loading coil

and the pick-up, replace the stator and the dam-

aged parts.

Disconnect the connector on the flywheel cover

and measure the resistance between either con-

tact and the earthing.

Specific tooling020331Y Digital multimeter

PICK-UP CHECKSpecification Desc./Quantity

1 1) Green and ground cable ~ 170 Ω

STATOR WINDING CHECKSpecification Desc./Quantity

1 1) Blue and ground cable ~ 1 Ω

Ignition circuit

All the control operations of the system that require the disconnection of cables (checks of the connec-

tions and the devices making up the ignition circuit) must be done with the engine off: if this is not done,

the controls might be irretrievably damaged.

No spark plug

Once the lack of power to the spark plug has been

detected and the LED indicates it can be ignited,

follow this procedure:

- Check the Pick-Up.

Disconnect the electronic starter connector and

check continuity between terminal No. 3 (Green)

and terminal No. 4 (Black).

The check includes the Pick-Up and its power line.

If a break in the circuit is found, check again the

flywheel and the engine earth connectors. If non-


ELE SYS - 79

conforming values are measured, replace the

Pick-Up; otherwise, repair the cable harness.

Electric characteristicPick - up resistanceapprox. 170 Ohm

- HV primary coil check

Disconnect the electronic starter connector and

check continuity between terminal No. 3 (purple)

and terminal No. 1 (black) (see figure).

If non-conforming values are measured, check

again the HV coil primary directly on the positive

and negative terminals.

If the values are correct, repair the cable harness

or reset the connections; otherwise, replace the

HV coil

Electric characteristicHV coil primary resistance0.5 ÷ 0.6 Ohm

- HV coil secondary check

Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable

terminal and the HV coil negative terminal (see figure).

If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis,

check the peak voltage with the multimeter adaptor.

Electric characteristicHV coil secondary resistance

3000 ÷ 3600 Ohm


ELE SYS - 80

- Pick-Up

Disconnect the ECU connector and connect the

positive terminal to connector No. 3 (green) and

the negative terminal to connector No. 4 (black).

Use the start-up system to run the engine and

measure the voltage produced by the Pick-Up.

Replace Pick-Up if non-conforming values are

measured.N.B.THE MULTIMETER MUST BE SELECTED TO DETECTCONTINUOUS VOLTAGE.

Electric characteristicPick-Up voltage valuePick-Up voltage value: > 2 Volt

- H.V. coil

With the electronic starter and the HV coil connec-

ted to the system, measure the voltage of the coil

primary during the start-up test with the voltage

peak adaptor and by connecting the positive ter-

minal to the ground lead and the negative terminal

to the coil positive connector.

If non-conforming values are measured, replace

the control unit.THE POSITIVE TERMINAL OF THE HV COIL PRIMARY ISBLACK.

Electric characteristicHigh voltage coil voltage valueHigh voltage coil voltage value: > 100 Volt

Stator check

- Using a tester, check the resistance between the

brown-earth and black-earth terminal.N.B.VALUES ARE STATED AT AMBIENT TEMPERATURE. ACHECK WITH THE STATOR AT OPERATING TEMPERA-TURE LEADS TO VALUES HIGHER THAN THOSE STATED.

Electric characteristicStator : Brown-earth~ 170 Ω (Pick-Up)

Stator : Black-earth


ELE SYS - 81

~ 1 Ω (Stator)

Voltage regulator check

A malfunction in the voltage regulator might cause the following problems depending on the type of

fault:

1) Bulbs burned out (regulator in short circuit).

2) Malfunction of the lighting system and the electric starter (regulator interrupted).

3) Battery not recharging.

4) Turn indicators not working.

The regulator is earthed through the electrical system, so the regulator body does not earth the circuits

inside the regulator.

There must be insulation between each regulator terminal and the regulator body (use the tester to

check electric resistance).

2) LIGHTS AND STARTER NOT WORKING

Gain access to the voltage regulator by removing

the plastic cover on the legshield; start the engine

and keep running it at idle speed.

Connect the tester positive probe to terminal No.

1 (yellow cable) and the negative probe to terminal

No. 2 (black cable); check if there is voltage.

If there is voltage, check that the light remote con-

trol and its excitation line, coming from the elec-

tronic starter (sky blue PIN 7 - purple PIN 3) work

properly. Check the cable harness from the light

switch to the remote control and whether the

switch works properly .

If no voltage is detected, try connecting the nega-

tive probe directly to earth; if voltage is detected

with this operation, check the earth wiring of the

regulator; otherwise, replace the regulator be-

cause it is failing.

As a last check, the voltage supplied by the stator

can be measured:

- Disconnect the regulator connector and place a

tester to detect alternating voltage between the

Blue cable (4) and the ground connection (see fig-

ure).


ELE SYS - 82

- Voltage supplied at 2000 rpm must be about 25

÷ 35V.

If no value is obtained even with this test, replace

the regulator because it is obviously failing.N.B.TO MEASURE THE ABOVE VOLTAGE USE AN ANALOGUETESTER THAT CAN MEASURE ALTERNATING VOLTAG-ES AND KEEP THE ENGINE AT IDLE TO HAVE AN ALTER-NATING VOLTAGE OF A FREQUENCY AS CLOSE ASPOSSIBLE TO 50HZ SO AS TO DETECT THE EFFICIENTVOLTAGE VALUE SUPPLIED BY THE REGULATOR(ABOUT 12V).

Recharge system voltage check

3) BATTERY NOT RECHARGING

A failure in the direct current section of the voltage

regulator may cause the following problems de-

pending on the type of fault:

a) Protection fuse blows due to overvoltage

(regulator in short circuit) and consequently

the battery fails to recharge.

b) Battery fails to recharge (regulator interrup-

ted).

Measures

a) Protection fuse blows (regulator in short circuit).

Check that the cable harness going from the pro-

tection fuse to the key switch is not damaged,

which may cause a short circuit to ground (thus

preventing damaging the regulator).

Afterwards measure the resistance between con-

tact 3 (Orange) and contact 2 (Black) of the voltage

regulator (with connector disconnected)

If the value measured is far from that indicated,

replace the regulator because it is in short circuit.

b) Battery fails to recharge (regulator interrupted).

To check if there is any failure in the voltage reg-

ulator recharge section, first connect 2 testers to

the battery (one to detect voltage and the other to

detect current) as indicated in the second figure

and follow the procedure below:


ELE SYS - 83

Start the engine (temporarily connect the red cable

to the battery positive terminal in order to avoid

damaging the device that measures current).

Check that there is a 13V voltage minimum (bat-

tery charged) and a recharge current of 1.5 ÷ 2A

with the lighting system but the starter disabled. To

disable the lighting system, remove the light re-

mote control.

As the engine rpm increases, so do the current and

the recharge voltage; with rpm over 4000 there

must be a recharge current of about 4.5A; enabling

both the lighting system and the starter, the stop

light and if the horn is powered, current values ≥

5A and a voltage value of 14 ÷ 14.5V ( regulator

threshold voltage) can be found.

If values other than those above are detected,

replace the regulator; contrariwise, check the

cable harness and the connections.

Electric characteristicVoltage regulator resistance~ 8 MΩ

Turn signals system check

4) TURN INDICATORS NOT WORKING

If the turn indicators do not work, do the following:

- Remove the regulator connector and place the

tester probes between the orange cable (3) and

the black cable (2).

- Turn the key switch to ON and check that the

battery is getting voltage. If no voltage is detected,

repeat the test now between the orange cable and

the ground lead. If there is no voltage even after

this operation, check the cable harness and the

contacts of the key switch and the battery. Con-

versely, if battery voltage is detected (black cable),

check the regulator ground cable harness.


ELE SYS - 84

- If the above tests have positive results, jump con-

tacts 5 (blue/black) and 3 (white) on the connector,

set the key switch to ON and turn the turn indicator

switch to the left and right to see when the lights

are steadily on (as they are directly powered by the

battery).

If even after this operation the turn indicators fail

to turn on, check that the wiring is not damaged

and the switch works properly. If these last two

tests have a positive result, replace the regulator

because it is certainly not functioning properly.


Dry-charge battery

Where providedWARNING

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

Commissioning dry-charged batteries:

1) - Remove the short closed tube and the plugs,

then pour sulphuric acid into the cells using the

type specified for batteries with a specific gravity

of 1.26, corresponding to 30 Bé at a minimum tem-

perature of 15°C. until the upper level is reached.

2) - Leave to rest for at least 2 hours; then, restore

the level with sulphuric acid.

3) - Within the following 24 hours, recharge using

the specific battery charger (single) or (multiple) at

a density of about 1/10 of the battery nominal ca-

pacity until fully charged; check that the acid den-


ELE SYS - 85

sity is about 27, corresponding to 31 Be, and that

these values are stabilised.

4) - Once the charge is over, level the acid (by

adding distilled water). Close and clean carefully.

5) Once the above operations have been per-

formed, install the battery on the vehicle ensuring

that it is wired up properly.

1 Hold the vertical tube

2 Look at the level

3 The float must be freedWARNING- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VE-HICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE(WITH CLOSED END) NEAR THE + POSITIVE TERMINALWITH THE CORRESPONDING LONG TUBE (WITH OPENEND), THAT YOU FIND FITTED TO THE VEHICLE, TO EN-SURE THAT THE GASES THAT FORM CAN ESCAPEPROPERLY.

Specific tooling020333Y Single battery charger


Battery maintenance

The battery is an electrical device which requires careful monitoring and careful maintenance. The

maintenance rules are:

1) Check the level of the electrolyte

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled

water, to restore this level. If water topping is required too often, check the vehicle electrical system:

the battery works overcharged and is subject to quick wear.

2)Load status check

After topping-up the electrolyte level, check its density using an appropriate densitometer (see figure).

When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific

weight of 1.26 to 1.28 at a temperature of no lower than 15° C.

A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore

be recharged.

If the vehicle is not used for a given time (1 month or more) it will be necessary to periodically recharge

the battery.

The battery runs down completely in the course of three months. If it is necessary to refit the battery in

the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked

(-) must be connected to the -negative clamp while the other two red wires marked (+) must be con-

nected to the clamp marked with the +positive sign.

3) Recharging the battery


ELE SYS - 86

Remove the battery from the vehicle removing the negative clamp first.

Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),

setting the battery charger selector to the type of battery to be recharged. Connections to the power

supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).

4) Cleaning the battery

The battery should always be kept clean, especially on its top side, and the terminals should be coated

with Vaseline.CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. THEUSE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THEWHOLE VEHICLE OR EVEN CAUSE A FIRE.CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FORTHE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.CAUTION

TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.LACK OF PROPER CHARGING OF THE BATTERY BEFORE FIRST USE AT LOW ELECTROLYTELEVEL, CAN LEAD TO PREMATURE BATTERY LIFE.

Specific tooling020333Y Single battery charger


Battery installation

Where provided

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


ELE SYS - 87

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.

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.


ELE SYS - 88

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

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.


ELE SYS - 89

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.

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.


ELE SYS - 90

Connectors

ELECTRONIC STARTER

CONNECTOR A

1. H.V. coil control (Black):

2. Engine stop command (Blue)

3. H.V. coil positive (Violet)

CONNECTOR B

1. Key positive (Orange-Black)

2. Starter power (White-Black)

3. Pick-Up Signal (Green)

4. Ground lead (Black)

5. Solenoid valve (Brown)

6. NTC temperature sensor signal (Yellow-Red)

7. Lights logic solenoid command (Light Blue)

8. Diagnostics socket (Red-Black)

VOLTAGE REGULATOR

1. Lighting system power (alternating) (Yellow)

2. Ground lead (Black)

3. Battery positive (live) (Orange)

4. Flywheel power (alternating) (Blue)

5. Turn indicator power (Blue-Black)


ELE SYS - 91

INSTRUMENT PANEL

CONNECTOR A

1. Left turn indicator warning light command (Pink)

2. Left turn indicator warning light command

(White-Blue)

3. Instrument panel illumination bulb power (alter-

nating) (Yellow-Black)

4. Instrument panel ground (Black)

5. Fuel level transmitter signal (White-Green)

6. Battery positive (live) (White)

CONNECTOR B

1. instrument LCD backlight power (alternating) (Yellow-Blue)

2. High beam warning light command (alternating) (Violet)

3. Low fuel warning light command (Yellow-Green)


ELE SYS - 92

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the

head

- Loosen the exhaust fixing screws to the crank-

case, then remove the whole exhaust.

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.

Engine from vehicle Fly 50 4t 4v

ENG VE - 94

- 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 magneto flywheel cable harness

connector.

- Remove the ground cable and the positive cable

of the starter motor indicated in figure.

Fly 50 4t 4v Engine from vehicle

ENG VE - 95

- Remove the fuel supply pipe from the carburettor

- Remove the carburettor vacuum pipe tap from

the manifold.

- Disconnect the fuel heater connector.

- Remove the piping from the solenoid valve.


ENG VE - 96

- Disconnect the throttle control cable from the

throttle body pulley, acting on the indicated adjust-

er screws.

- Disconnect the throttle body position control ca-

ble (PTC).

- Undo the two fixing screws from the bracket with

silent block to the frame.

- Disconnect the return spring from the bracket.

Fly 50 4t 4v Engine from vehicle

ENG VE - 97

- 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 engine complete with engine side

swinging arm.

Locking torques (N*m)Frame-swinging arm bolt 64 - 72 Screw that se-cures plate with silent block to the frame 40Shock absorber-engine pin 33 to 41

See alsoLower coverHelmet bayExhaust assy. Removal


ENG VE - 98

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

- Remove the 12 fixing screws.

- Remove the oil filling cap and then slide out the

cover.

If this operation is carried out directly on the vehi-

cle, it is necessary to remove the transmission

cooling coupling and the air filter housing retain-

ers.N.B.USE A MALLET ON THE APPROPRIATE COUPLINGS TOREMOVE THE COVER.

Kickstart

-To remove the start up pinion push the starter

lever to facilitate extracting the pinion.

-Remove the kick-start screw and lever.

-Remove the Seeger ring and the washer indica-

ted in the figure.

-Pull out the toothed sector.WARNINGTHE SECTOR KEEPS THE SPRING SET, BE CAREFUL SOAS NOT TO CAUSE ANY ACCIDENTS

Air duct

- To remove the intake throat on the transmission

cover, just remove the three fixing screws indica-

ted in the figure.

Engine Fly 50 4t 4v

ENG - 100

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side

to avoid damaging the coated surface and use the

driven pulley shaft or a pin of the same diameter

to remove the bearing.N.B.IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-AMETER EXTRACTOR CAN BE USED.

Refitting the driven pulley shaft bearing

Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing

after slightly heating the crankcase from the inside.N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE COVERPAINTED SURFACE.

Removing the driven pulley

- Lock the clutch housing with the specific tool.

- Remove the nut, the clutch housing and the

whole of the driven pulley assembly.N.B.THE UNIT CAN ALSO BE REMOVED WITH THE DRIVINGPULLEY MOUNTED.

Specific tooling020565Y Flywheel lock calliper spanner

Fly 50 4t 4v Engine

ENG - 101

Inspecting the clutch drum

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

- Measure the clutch bell inside diameter.

Characteristicclutch housing diameter/standard valueØ 107+0.2 +0 mm

clutch housing diameter/max. value allowedafter useØ 107.5 mm

Eccentricity measured /max.0.20 mm

Removing the clutch

- Equip the tool with long pins screwed into position

«A» from the outside, insert the entire driven pulley

in the tool and have the central screw make con-

tact.CAUTIONTHE TOOL WILL BE DEFORMED IF THE CENTRAL SCREWIS TIGHTENED UP TOO FAR.

- Using a 34 mm socket wrench remove the clutch

locking nut.

- Loosen the central screw by undoing spring of

the driven pulley unit

- Separate the components.

Specific tooling020444Y Tool for fitting/ removing the drivenpulley clutch

Engine Fly 50 4t 4v

ENG - 102

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

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

- Remove the three guide pins and the mobile half

pulley.

Fly 50 4t 4v Engine

ENG - 103

Removing the driven half-pulley bearing

- Remove the roller bearing with the special ex-

tractor inserted from the bottom of the fixed half-

pulley.CAUTIONPOSITION THE HOLDING EDGE OF THE EXTRACTION PLI-ERS BETWEEN THE END OF THE BEARING AND THEBUILT IN SEAL RING.

Specific tooling001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch

housing by means of the special tool.N.B.PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TODEFORM THE SLIDING SURFACE OF THE DRIVE BELT

Specific tooling020376Y Adaptor handle

020363Y 20-mm guide

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work

surface of the belt. If there are, replace the half-

pulley..

- Make sure the bearings do not show signs of un-

usual wear.

- Measure the outside diameter of the pulley bush-

ing.

CharacteristicStationary driven half-pulley/Standard diame-terØ 33.965 to 33.985 mm

Stationary driven half-pulley / Minimum diam-eter admitted after useØ 33.96 mm

Engine Fly 50 4t 4v

ENG - 104

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.

CharacteristicMobile driven half-pulley/ Maximum diameterallowedØ 34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile

half-pulley.

- Fitting the half-pulley on the bushing.

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

- Make sure the pins and collar are not worn, reassemble 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 procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended productsAGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum di-sulphide.

-

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible

from the outside.CAUTIONPROPERLY SUPPORT THE HALF-PULLEY TO PREVENTDAMAGE TO THE THREADED END WHILE THE BEARINGSARE BEING FITTED.


Fly 50 4t 4v Engine

ENG - 105


020362Y 12 mm guide

020171Y Punch for Ø 17 mm roller bearing

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley

does not show signs of deformation

- Measure the free length of the spring

CharacteristicStandard length118 mm

Minimum length allowed after useXXXX

- Check the thickness of the clutch mass friction

material.

-The masses must not show traces of lubricants;

otherwise, check the driven pulley unit.N.B.UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-ENT FROM ONE ANOTHER. VARIOUS CONDITIONS CANCAUSE THE CLUTCH TO TEAR.CAUTIONDO NOT OPEN THE MASSES USING TOOLS SO AS TOPREVENT A VARIATION IN THE RETURN SPRING LOAD.

CharacteristicMinimum thickness permitted:1 mm

Refitting the clutch

- Preassemble the driven pulley group with spring,

sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the

spring being careful not to damage the plastic

sheath and the end of the threaded shank.

Engine Fly 50 4t 4v

ENG - 106

- Reassemble the nut securing the clutch and tight-

en to the prescribed torque.CAUTIONSO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK-ET WRENCH WITH SMALL CHAMFER.CAUTIONPOSITION THE NON-CHAMFERED SURFACES OF THENUT IN CONTACT WITH THE CLUTCH

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

Refitting the driven pulley

-Refit the driven pulley assembly, the clutch bell

and the nut, using the specific tool.


Locking torques (N*m)Driven pulley shaft nut 40 to 44 Nm

Drive-belt

- Make sure the drive belt is not damaged and does

not have cracks in the toothed grooves.

- Check the width of the belt.

CharacteristicTransmission belt/Minimum width17.5 mm

Fly 50 4t 4v Engine

ENG - 107

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer,

then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the

rollers and contrast plate fitted loosely on it do not come off.

Specific tooling020451Y Starting ring gear lock

Inspecting the rollers case

1) Check that the bushing and the sliding rings of

the mobile pulley do not show signs of scoring or

deformation.

2) Check the roller running tracks on the contact

pulley; there must not be signs of wear and check

the condition of the contact surface of the belt on

the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of

marked facetting on the sliding surface and that

the metallic insert does not come out of the plastic

shell borders.

4) Check the integrity of the sliding shoes of the

contact plate.

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inside

diameter «A».

- Measure outside diameter «B» of the pulley slid-

ing bushing shown in the figure.CAUTIONDO NOT LUBRICATE OR CLEAN THE BUSHING.

CharacteristicDriving pulley / Maximum diameter:

Engine Fly 50 4t 4v

ENG - 108

20.12 mm

Driving pulley/ Standard diameter:20.021 mm

Driving pulley bushing/ Diameter maximum:XXX mm

Driving pulley bushing/ Standard diameter:20 -0.020/-0.041mm

Refitting the driving pulley

- Manually move the movable driven half-pulley

away by pulling it towards the clutch unit and insert

the belt observing the direction of rotation of the

first fitting.N.B.IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SOTHAT THE WORDS CAN BE READ IN CASE IT DOES NOTSHOW A FITTING SIDE.

- Refit the components of the assembly (roller

housing assembly with bushing, limiting washer,

stationary half-pulley, cooling fan belt with drive,

washer and nut).

- With the specific tool, tighten the lock nut to 20

Nm and then perform a final 90° locking in order to

prevent the rotation of the driving pulley.N.B.REPLACE THE NUT WITH A NEW ONE AT EVERY REFITCAUTIONUPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-MOST IMPORTANCE THAT THE BELT IS FREE INSIDE INORDER TO AVOID WRONG TIGHTENING AND CONSE-QUENTLY DAMAGING THE CRANKSHAFT KNURLING.

Specific tooling020451Y Starting ring gear lock

Locking torques (N*m)Crankshaft pulley nut 18 to 20 + 90° Nm

Fly 50 4t 4v Engine

ENG - 109

Refitting the transmission cover

- Check the following for wear: toothed section,

toothed section shaft, cover seat bushing, pinion

shaft and its seating in the crankcase and the re-

turn spring.

- Remove the damaged components.

- Grease the spring.

- Remove the toothed sector and load the spring

with an appropriate tool.

- Refit the washer, the Seeger and the Kick-start

lever.

Recommended productsAGIP GREASE MU3 Yellow-brown, lithium-base, medium-fibre multipurpose grease.ISO L-X-BCHA 3 - DIN 51 825 K3K -20

- Insert the pinion in its seating by pushing the starter lever.

- Fit the intake throat and tighten the 3 screws.

-Make sure the oil sump presents centring dowels

and sealing gaskets.

- Replace the cover tightening the 12 screws to the

prescribed torque.

-Refit the oil filling cap.

Locking torques (N*m)Transmission cover screws 11 to 13 Nm

End gear

Engine Fly 50 4t 4v

ENG - 110

Removing the hub cover

• Remove the transmission cover

• Remove the clutch assembly

• Discharge the rear hub oil.

• Remove the 5 screws indicated in the figure.

• Remove the hub cover with driven pulley shaft.

See alsoRefitting the clutch

Removing the wheel axle

- Remove the intermediate gear and the complete

gear wheel axle.

- When removing the intermediate gear pay atten-

tion to the various shim adjustments.

Removing the wheel axle bearings

- Remove the oil seal and the Seeger ring.

- Remove the bearing by pushing from the outside

towards the inside of the gear compartment, using

the appropriate punch.

Specific tooling020363Y 20-mm guide



Fly 50 4t 4v Engine

ENG - 111

Removing the driven pulley shaft bearing

- Remove the Seeger ring inside the cover.

- Remove the oil seal from the outside.

- Remove the centring dowels and position the

cover on a plane.

- Position the special tool on the internal track of

the bearing and remove said bearing with the aid

of a press.

Specific tooling020452Y Tube for removing and refitting thedriven pulley shaft

- Position the special tube on the internal raceway

of the bearing and from the shaft toothed side as

indicated in the figure. Expel the driven pulley shaft

with the aid of a press.


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.

- Check capacity (A) of the transmission gear

(wear, deformations, etc.)

- Check the pulley shaft seating: Superficial wear

(B) may indicate irregularities in the crankcase

seats or in the pulley shaft capacities

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.

Engine Fly 50 4t 4v

ENG - 112

Refitting the driven pulley shaft bearing

- Support the inner track of the bearing from the

outside of the hub cover with the specific tool posi-

tioned under the press and insert the driven pulley

axle.

- Refit the oil seal flush with the cover.


• Heat the hub cover and insert the bearing with

the specific punch.

• Fit the snap ring with the concave or radial part

on the bearing side.N.B.FIT THE BALL BEARING WITH THE SHIELD FACING THEOIL SEAL.

Specific tooling020151Y Air heater


020439Y 17-mm guide


Refitting the wheel axle bearing

- Heat the half crankcase on the transmission side

using a thermal gun.

- After lubricating its outer strip, insert the bearing

with the special adapter with the aid of a hammer.

- Refit the Seeger ring and the oil seal using the 42

x 47 mm adapter and the handle.

Specific tooling020151Y Air heater


020363Y 20-mm guide


Fly 50 4t 4v Engine

ENG - 113

Refitting the ub cover

- Refit the whole wheel axle.

- Refit the intermediate gear paying attention to the

two shim washers.

- Apply LOCTITE 510 for surfaces to the hub cov-

ers and refit the same with driven pulley shaft.

- Refit the 5 screws and tighten them to the speci-

fied torque.N.B.CLEAN THE CONTACT SURFACES OF THE HUB COVERAND THE HALF CRANKCASE OF RESIDUE FROM PREVI-OUS GASKETS BEFORE APPLYING A NEW ONE.

Locking torques (N*m)Locking torque: 11 to 13 Nm

Flywheel cover

Cooling hood

- Remove the manifold and the carburettor undo-

ing the 2 fixing screws on the head

- Remove the fastening clamp of the secondary air

pipe and disconnect it

- Remove the 4 front coupling screws (1 of them is

a knob) and the side fixing screw at the crankcase

base.

- Remove the 4 side screws

- Extract the 3 covers - Remove the cover sealing

gaskets on the head

- For refitting, repeat the removal steps but in re-

verse orderCAUTIONTAKE CARE TO CORRECTLY POSITION THE FLYWHEELCONNECTOR.N.B.WHEN REFITTING THE COVER, TAKE CARE NOT TO DAM-AGE THE STATOR WIRING.

Engine Fly 50 4t 4v

ENG - 114

Cooling fan

- Remove the cooling fan by undoing the 3 screws

fixing it to the rotor

- When refitting the fan, pay attention that the

screw holes in the fan and the rotor coincide, then

tighten screws at the specified torque.

Removing the stator

- Remove the 2 Pick-Up screws and the 2 stator

fixing screws indicated in the figure.

- Remove the stator and its wiring.

Fly 50 4t 4v Engine

ENG - 115

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-

ers to the specified torque.N.B.THE PICK-UP CABLE MUST BE POSITIONED ADHERINGTO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCHA WAY AS TO AVOID BEING CRUSHED BY THE FAN COV-ER ASSEMBLY.

Locking torques (N*m)Pick-up screws 3 ÷ 4 Stator screws 3 - 4

Flywheel and starting

Removing the starter motor

- Undo the screw on the power positive contact

and disconnect the cable

- Undo the 2 screws fixing the starter motor to the

crankcase and recover the power wiring.

Engine Fly 50 4t 4v

ENG - 116

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

- Extract the flywheel with the extractor.


020162Y Flywheel extractor

Inspecting the flywheel components

- Check that the flywheel internal magnets are in

good conditions.

- Check that the flywheel splines exhibit no loos-

ening.

- Check there are no deformations that may cause

rubbing on the stator and the Pick-Up.

- Check that the stator winding, its ferromagnetic

support and the pick-up are in good conditions.

Fly 50 4t 4v Engine

ENG - 117

Starter gear rim

- Check the toothing is level and in good conditions

Intermediate gear

- Check that the keying toothing on the crown and

the starter motor are in good conditions.

- Check that the Bendix opens and returns ade-

quately.

Refitting the flywheel magneto

- Refit the stator and the pick-up being careful to

pass the wiring through the appropriate crankcase

couplings.

- Refit the flywheel to the crankshaft being careful

to respect the keying, then lock rotation with the

specific tool and tighten the nut to the prescribed

torque.N.B.A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TOA VARIATION IN THE IGNITION ADVANCE SUCH AS TOCAUSE PINGING, KNOCKING ETC.


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

Engine Fly 50 4t 4v

ENG - 118

Refitting the starter motor

- Install the starter motor in its seating in the crank-

case.

- Tighten the screw on the head side but do not

lock it, screw the second screw inserting the earth

cable (black), then tighten the 2 screws at the pre-

scribed torque.

- Tighten the locking screw of the positive cable

(red) on the side contact.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

Removing the rocker-arms cover

- Remove the cooling covers

- Remove the 4 retainers of the tappet cover

- Remove the cover and the O-ring

- Remove the 3 screws and then remove the Blow-

by cover

- Clean the nozzle labyrinth and the membrane

(replace it, if necessary), then remove the cover

unit.

Fly 50 4t 4v Engine

ENG - 119

Removing the timing system drive

- Temporarily loosen the tensioner central screw

and remove it together with the spring.

- Unscrew the 2 retainers indicated in the figure

and remove the chain tightener support being

careful to recover the sealing gasket.N.B.SHOULD THE GASKET NOT BE IN GOOD CONDITIONS,REPLACE IT AFTER CAREFULLY CLEANING THE FAYINGSURFACE IN ORDER TO AVOID ENGINE OIL LEAKS

- Remove the driving pulley

- Remove the oil pump chain

- Remove the tappet cover

- Remove the central screw and the belleville

washer indicated in the figure and lock the cam-

shaft crown with the specific tool.N.B.TO FACILITATE REMOVING THE HEAD COMPONENTS,SET THE CRANKSHAFT TO THE TIMING POINT (TDC OFTHE COMPRESSION END).


- Remove the camshaft control pulley and the washer below.

- Remove the pinion of the crankshaft timing control

- To remove the chain lower guiding pad, remove the head by pulling it upwardsN.B.

IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE DIRECTION OF RO-TATION IS MAINTAINED.

See alsoRemoving the rocker-arms coverRemovalRemoving the driving pulley

Engine Fly 50 4t 4v

ENG - 120

Removing the cam shaft

- Remove the limit screw of the rocking lever pins

shown in the figure.

- Remove the Seeger ring retaining the camshaft

bearing.

- Remove pins and rocking levers.

- Remove the calibrated padsN.B.MARK THE ASSEMBLY POSITION OF THE ROCKING LEV-ERS IN ORDER TO AVOID MISPLACING THE INTAKE ANDDISCHARGE ENDS.

- Remove the entire camshaft with bearing using

the specific tool shown in the figure.

- Take out the camshaft bearing with the aid of the

specific tool, being careful to mount a screw on the

camshaft in order to protect its thread.N.B.IF A BEARING SEPARATES FROM THE CAMSHAFT, IT ISESSENTIAL TO FIT A NEW BEAR.

Specific tooling020450Y Camshaft fitting/removal tool

004499Y Camshaft bearing extractor

004499Y001 Bearing extractor bell

004499Y002 Bearing extractor screw

004499Y006 Bearing extractor ring

004499Y027 Bearing extractor part

Fly 50 4t 4v Engine

ENG - 121

Removing the cylinder head

- Remove the cooling covers, the timing control,

the camshaft and the rocking levers.

- 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, PINS AND ROCKING LEVERS WITHOUT RE-MOVING THE DRIVING PULLEY UNIT. REMEMBER TOHOLD THE TIMING CHAIN WITH A PIECE OF METAL CA-BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE-FITTING.

Removing the valves

- Using the specific tool fitted with the part shown

in the figure, remove cotters, caps and valve

springs.

- Remove the oil seals with the appropriate tool.

Specific tooling020431Y Valve oil seal extractor

020382Y Valve cotters equipped with part 012removal tool

Engine Fly 50 4t 4v

ENG - 122

Removing the cylinder - piston assy.

- Remove the cylinder paying attention to the 2

cylinder centring dowels in the housing.

- Remove the cylinder base gasket.

To avoid damaging the piston, keep it fixed while

removing the cylinder.

- Remove the two stop 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.

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".

CharacteristicMax. diameter admitted: check the small end13.030 mm

Standard diameter: check the small end13 +0.025+0.015mm

Fly 50 4t 4v Engine

ENG - 123

Inspecting the wrist pin

- Measure the outer diameter of the gudgeon pin.

CharacteristicStandard diameter: gudgeon pin13 -0 -0.004mm

Minimum admissible diameter gudgeon pin12.990 mm

Inspecting the piston

- Measure the diameter of the bearings on the pis-

ton.

CharacteristicPin seat diameter13 +0.005 + 0.010 mm

- 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.N.B.MEASURE THE CLEARANCE BY INSERTING THE BLADEOF THE FEELER GAUGE FROM THE SECOND SEAL RINGSIDE.

Fitting clearanceTop piston ring - standard coupling clearance0.03 to 0.065 mm Top piston ring - maximum clear-ance allowed after use 0.07 mm Middle pistonring - standard coupling clearance 0.02 to 0.055mm Middle piston ring - maximum clearance al-lowed after use 0.06 mm oil scraper ring - stand-ard coupling clearance 0.04 to 0.16 mm oil scraperring - maximum clearance allowed after use0.17 mm

Engine Fly 50 4t 4v

ENG - 124

Inspecting the cylinder

- 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

Inspecting the piston rings

- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di-

ameter. Using the piston, insert the rings perpendicularly to the cylinder axis.

- Measure the opening, see figure, of the sealing rings using a thickness gauge.

- If any measurements are greater than specified, replace the piston rings.N.B.BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEENTHE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THECYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITHA USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.

Fly 50 4t 4v Engine

ENG - 125

SEALING RINGSName Description Dimensions Initials Quantity

1st Compression ring 39 x 1 A 0.08 to 0.202nd Compression ring 39 x 1 A 0.05 to 0.20

Oil scraper ring 39 x 2 A 0.20 to 0.701st Compression ring

1st Oversize39.2 x 1 A 0.08 to 0.20

2nd Compression ring1st Oversize

39.2 x 1 A 0.05 to 0.20

Oil scraper ring 1stOversize

39.2 x 2 A 0.20 to 0.70

1st Compression ring2nd Oversize

39.4 x 1 A 0.08 to 0.20

2nd Compression ring2nd Oversize

39.4 x 1 A 0.05 to 0.20

Oil scraper ring 2ndOversize

39.4 x 2 A 0.20 to 0.70

1st Compression ring3rd Oversize

39.6 x 1 A 0.08 to 0.20

2nd Compression ring3rd Oversize

39.6 x 1 A 0.05 to 0.20

Oil scraper ring 3rdOversize

39.6 x 2 A 0.20 to 0.70

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 tooling020448Y Pin lock fitting tool

Engine Fly 50 4t 4v

ENG - 126

- With the opening in the position indicated on the

tool, set the lock ring into position in the tool with

the punch.

- Rest the tool on the piston paying attention that

the 90°chamfered side faces upwards as indicated

in the figure.

- Fit the gudgeon pin stop using the plug.CAUTIONUSING A HAMMER TO POSITION THE RINGS CAN DAM-AGE THE LOCKING HOUSING.

Refitting the piston rings

- Fit the oil scraper ring starting from the spring,

taking care that the spring ends do not superim-

pose. Fit the two piston rings so that their gaps and

that of the oil scraper ring are never aligned.

- Fit the 2nd sealing ring with the identifying letter

«T» facing towards the piston crown.

- Fit the 1st sealing ring with the reference letter

«T» facing towards the piston crown.

- Misalign the lining openings at 120° as shown in

the figure.

- Lubricate the components with engine oil.N.B.IN ORDER TO OBTAIN A GOOD BEDDING, THE 2 SEALINGPISTON RINGS ARE MADE OF CONE SHAPED CONTACTSECTION TO THE CYLINDER. AS A RESULT IT IS IMPOR-TANT TO RESPECT THE FITTING INSTRUCTION TO AS-SEMBLY THE RINGS WITH THE "T" MARK FACINGUPWARDS.

Fly 50 4t 4v Engine

ENG - 127

Refitting the cylinder

- Insert the cylinder base gasket.

- Fit the cylinder as shown in the figure.

- The piston can be kept out of the housing plane

using the appropriate tool.N.B.BEFORE FITTING THE CYLINDER, CAREFULLY BLOWOUT THE LUBRICATION DUCT AND OIL THE CYLINDERLINER.

Specific tooling020288Y Fork to assemble piston on cylinder

If the four cylinder stud bolts should be replaced in this kind of engine, it is necessary to tighten the

head nuts strictly following the procedure below.

The procedure is different from that indicated in the vehicle manuals:

Head tightening nut (only to replace stud bolts) 6÷7 N*m + 135° + 90°

The 45° rotation reduction of the key is necessary to avoid stud bolt stretching.

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.

- It is advisable to replace the head if any failure is

found.

CharacteristicMaximum allowable run-out:0.1 mm

Engine Fly 50 4t 4v

ENG - 128

Measure the camshaft bearing seats and rocking

lever support pins with a bore meter

HEAD CHECKSpecification Desc./Quantity

Standard diameter (mm) A Ø 32.015 to 32.025Standard diameter (mm) B Ø 16.0 to 16.018Standard diameter (mm) C Ø 11.0 to 11.018

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.

- 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.

Fly 50 4t 4v Engine

ENG - 129

Inspecting the valve sealings

- Remove any carbon deposits from the valve

seats.

- Check the width of the mark on the valve seat

«V» with Prussian blue.

CharacteristicStandard value:1 - 1.3 mm

Admissible limit:1.6 mm

- If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45°

milling cutter and then grind.

- In case of excessive wear or damage, replace the head.

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust

valves.

- 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 valves

STANDARD VALVE LENGTHSpecification Desc./Quantity

Inlet: standard length 74.9 mmOutlet: standard length 74.35 mm

Engine Fly 50 4t 4v

ENG - 130

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

STANDARD DIAMETERSpecification Desc./Quantity

Intake 3.970 to 3.985 mmExhaust 3.960 to 3.975 mm

MINIMUM DIAMETER PERMITTEDSpecification Desc./Quantity

Intake 3.958 mmExhaust 3.945 mm

- Calculate the clearance between valve and valve guide.

- Check the concentricity of the valve head by

placing a dial gauge at right angles to the valve

head and rotating it on the «V» shaped support.

CharacteristicAdmissible limit:0.03 mm

- Check the deviation of the valve stem by resting

it on a «V» shaped support and measuring the ex-

tent of the deformation using a dial gauge.

CharacteristicLimit values admitted:0.1 mm

Fly 50 4t 4v Engine

ENG - 131

Inspecting the valve stem guide clearance

Measure the valve guides

VALVE GUIDE DIAMETERSpecification Desc./QuantityValve guide Standard diameter: 4 + 0.012 mmValve guide Maximum admissible diameter: 4 + 0.022 mm

- After measuring the valve guide diameter and the

valve stem diameter, check clearance between

guide and stem.

INTAKESpecification Desc./Quantity

Standard clearance 0.015 to 0.042 mmAdmissible limit 0.06 mm

EXHAUSTSpecification Desc./Quantity

Standard clearance 0.025 - 0.052 mmAdmissible limit 0.07 mm

Engine Fly 50 4t 4v

ENG - 132

Refitting the valves

- Lubricate the valve guides with graphite grease.

- Place the lower caps of the valve spring on the

head.

- Use the punch to fit the 4 sealing rings one at a

time.

- Fit the valves, the springs and the upper caps.

- Using the appropriate tool, compress the springs

and insert the cotters in their seats.

Inspecting the cam shaft

- Inspect the camshaft for signs of abnormal wear

on the cams.

CharacteristicStandard diameter - Bearing A:Ø 12 +0.002 +0.010

mm Standard diameter - Bearing B:Ø 16-0.015 -0.023 mm

Minimum diameter allowed - Bearing A:Ø 11.98 mm

Minimum diameter allowed - Bearing B:Ø 15.96 mm

- Using a gauge, measure the height of the cams.

Check the axial clearance of the camshaft

Fly 50 4t 4v Engine

ENG - 133

- 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.N.B.A BALL BEARING IS FITTED ON BEARING «A»; CONSE-QUENTLY, BEARING «B» IS THE MOST IMPORTANT AS ITWORKS DIRECTLY ON THE HEAD ALUMINIUM

CharacteristicStandard height - Inlet24.397 mm

Standard height - Outlet23.996 mm

Fitting clearanceMaximum admissible axial clearance: 0.5 mm

- Measure the outside diameter of the rocking lever pins

- Check the rocking lever pins do not show signs of wear or scoring.

- Measure the internal diameter of each rocker.

- Check that the pad in contact with the cam is not worn.

ROCKING LEVERS AND PIN DIAMETER:Specification Desc./Quantity

Rocking levers - Inside diameter 11.015 to 11.035 mmRocking levers - Pins diameter 10.977 to 10.985 mm

Refitting the head and timing system components

- Fix the head on a workbench.

- Screw the tool to fit the camshaft fully down on the bearing's inner track.

- Fit the camshaft fully into its seating together with the bearing with the aid of a mallet.

- Remove the tool.

- Fit the head gasket after cleaning the faying surface carefully.

Engine Fly 50 4t 4v

ENG - 134

- Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque.

Specific tooling020450Y Camshaft fitting/removal tool

- Fit pins, inlet rocking lever and discharge rocking

lever.

- Lubricate the 2 rocking levers through the holes.N.B.IF A BEARING SEPARATES FROM THE CAMSHAFT, IT ISESSENTIAL TO FIT A NEW BEARING.

- Screw up the limit screw of the rocking lever pins

and tighten it to the prescribed torque.

- Reposition the Seeger ring retaining the cam-

shaft

Locking torques (N*m)Rocking lever shafts screw 3 ÷ 4

- Finish the head tightening following the proce-

dure below: screw the four head nuts to an initial

torque at two crossed passes. Afterwards tighten

the nuts with 2 turns of 90° each to be done at two

crossed passes.

-Finish the tightening of the head to the crankcase

with the 2 side screws.N.B.SHOULD THE CRANKCASE OR THE CYLINDER STUDBOLTS BE REPLACED, IT IS NECESSARY TO CARRY OUTAN INITIAL TIGHTENING PLUS OTHER 3 TURNS OF 90°EACH AT 3 CROSSED PASSES

Locking torques (N*m)Head-cylinder stud bolt nuts: 6 to 7 +135° +90° Nmfirst fitting, upon refitting tighten again at 6 to 7 90° +90°Nm Head cover screws 8 to 10 Nm

Fly 50 4t 4v Engine

ENG - 135

Refitting the timing chain

- Insert the timing chain pads in their correspond-

ing seatings, the screw and the spacer as indica-

ted in the figure.

- Tighten to the prescribed torque and check the

tensioner pad moves adequately.

- Insert the timing pinion in driving shaft with the

chamfered side facing the insertion (towards the

main bearing).

- Loop the timing chain around the sprocket on the

crankshaft.

Locking torques (N*m)Chain tensioner pad screw 5 to 7 Nm

- 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.

- With this operation, insert the chain on the cam-

shaft control pulley and make the reference notch

coincide with the point on the head.

- Fit the pulley onto the camshaft.

- Fit the belleville washer so that the outer rim

touches the pulley.

- Bring the screw closer but without reaching its

final locking point.

- Push the tensioner pad lightly so as to check the

correct timing.

- Use the specific tool to lock the camshaft crown

gear and tighten the screw.

- Adjust valve clearance.

- Replace the O-ring on the tappet cover.

- Fit the tappet cover and lock it with the 4 fixing

screws indicated in the figure.


Locking torques (N*m)

Engine Fly 50 4t 4v

ENG - 136

Camshaft pulley screw 12 - 14 Head coverscrew 8 to 10 Nm

- 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 prescribed

torque.

- Insert the spring with the central screw and tighten it to the prescribed torque.

- Fit the spark plug.

Electric characteristicElectrode gap:

0,6 mm

Spark plug

NGK ER9EH-6N

Locking torques (N*m)Timing chain tensioner screw 8 to 10 Nm Timing chain tensioner central screw 5 - 6 Ignitionspark plug 10 - 15 Nm

Refitting the rocker-arms cover

- Carry out the removal procedure but in reverse

order and tighten the four fixing screws to the

specified torque.N.B.FIT A NEW O-RING ON THE TAPPET COVER.

Refitting the intake manifold

-Fit the cover sealing gaskets on the head.

-Fit the 2 covers.

- Fit the inlet manifold and do up the 2 screws to

the specified torque.

-Fit the carburettor on the inlet manifold and lock

the clamp.

-Fit the secondary air pipe and fix it with the ap-

propriate clamp.N.B.FIT THE CARBURETTOR THROUGH THE SUPPLEMENTON THE MANIFOLD.

Fly 50 4t 4v Engine

ENG - 137

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

Crankcase - crankshaft

- First remove the following units:

Driving pulley Driven pulley

Final reduction greasing

Oil pump Flywheel with stator

Cylinder-piston-head unit

Starter motor with cables.

See alsoRemoving the driving pulleyRemovalRemoving the driven pulleyRemoving the cylinder - piston assy.Removing the starter motorRemoving the stator

Splitting the crankcase halves

- Remove the ten crankshaft coupling screws.

-Separate the crankcase halves keeping the half

casing driving shaft engaged on the transmission

side.

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

- Remove the oil guard on the flywheel side.CAUTION

THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT. DO NOT WASH WITH SOL-VENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT. A CENTRIFUGALOIL FILTER'S LIFE IS THE SAME AS THE ENGINE'S AND IS MAINTENANCE FREE.

- Check the axial clearance on the connecting rod.

Fitting clearanceStandard connecting rod axial clearance 0.15 to0.30 mm Max. connecting rod clearance 0.5 mm

Engine Fly 50 4t 4v

ENG - 138

- Check the correct radial clearance of the con-

necting rod by holding the driving shaft with your

hands and, with a dial gauge fitted to the rod small

end, measuring the clearance, move the connect-

ing rod vertically as shown in the figure.

Fitting clearanceConnecting rod radial - standard clearance0.006 to 0.018 mm Connecting rod max. - radialclearance 0.25 mm

- Check that the half shaft surfaces are not scored

and with the aid of a gauge check the driving shaft

width as indicated in the figure.

CharacteristicStandard measure45 mm

Removing the crankshaft bearings

- Remove the flywheel bearing fitted on the driving

shaft using the specific tool.

Specific tooling004499Y Camshaft bearing extractor

004499Y001 Bearing extractor bell

004499Y002 Bearing extractor screw

004499Y006 Bearing extractor ring

004499Y034 Bearing extractor part

Refitting the crankshaft bearings

- Support the crankcase on a surface and place it

with the driving shaft axle in a vertical position.

- Warm the crankcase at ~ 120° C with a thermal

gun (and support).

- Fit the punch with guide and adaptor, place the

bearing on the punch using grease (to keep it from

falling).

Fly 50 4t 4v Engine

ENG - 139

-Insert the bearing in the crankcase; if needed, use

a mallet but do so with extreme care so as not to

damage the engine crankcase limit stop.

Specific tooling020359Y 42x47-mm Adaptor

020364Y 25-mm guide



- Heat a new main bearing in an oil bath at 120°.

- Place the driving shaft on the support base and

insert the bearing with the aid of an adequate piece

of tube if necessary.N.B.USE A NEW BEARING WHEN REFITTINGWARNINGTHE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEELAXLE SHAFT. DO NOT WASH WITH SOLVENTS OR BLOWCOMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT.

Specific tooling020265Y Bearing fitting base

008119Y009 Tube to assemble shafts andaxles

Inspecting the crankshaft alignment

To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated

in figure.N.B.IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC-TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-SERTING A WOODEN WEDGE BETWEEN THE HALFSHAFTS OR BY CLOSING THEM WITH A VICE AS NEE-DED. IF EVEN AFTER THIS OPERATION THE VALUES ARENOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.

CharacteristicOff-line maximum admitted - A0.15 mm

Off-line maximum admitted - B0.02 mm

Off-line maximum admitted - C0.02 mm

Engine Fly 50 4t 4v

ENG - 140

Off-line maximum admitted - D0.10 mm

- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded

tangs are in good working order.

- In case of failures, replace the crankshaft.

Specific tooling020074Y Support base for checking crankshaft alignment

Refitting the crankcase halves

-Be careful to place the two centring dowels pref-

erably on the flywheel side half casing.

-Insert the crankshaft on the half casing on the

transmission side.

- Fit the gasket recommended for surfaces on the

half casing on the transmission side after greasing

the two faying surfaces carefully.

-Insert the flywheel half casing.

- Fit the 10 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.

Recommended productsLoctite 510 Liquid sealantGasket

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

Fly 50 4t 4v Engine

ENG - 141

- Fit a new O-Ring on the mesh oil filter and on the

filling cap; lubricate the rings.

- Insert the filter on the engine and lock the cap to

the prescribed torque.

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

Lubrication

Crankshaft oil seals

Removal

- Extract the flywheel oil seal from the crankcase

being careful not to damage or score the crank-

case.

- Check that the chain contrast pad is not worn.

-Otherwise, replace the pad or fit it inverted to

make it work on the other side.

- Any operation on the chain cover oil seal should

be carried out placing the cover on the workbench

on the covering plate side of the oil pump chain.

-Remove the oil seal with a tube section of 30 mm

in diameter (Ø 32 mm Max).

Engine Fly 50 4t 4v

ENG - 142

Refitting

- Apply engine oil on the oil seal and it seating on

the crankcase.

- From the outside and using the specific punch,

place the oil seal fully down until it reaches the

bottom of the seating in the crankcase.N.B.FAILURE TO USE THE SPECIFIC TOOL CAN RESULT INAN INCORRECT DEPTH POSITION AND AS A CONSE-QUENCE IN INADEQUATE OIL SEAL.

- Fit a new oil seal on the outer rim with the help of

the specific tools below.

- Fit a new O-ring and lubricate it with grease.

- Install the cover on the engine crankcase, insert

the three screws and place the cover in its position.

- Tighten the 3 screws to the prescribed torque.



Locking torques (N*m)Timing chain/oil pump compartment coverscrews 4 to 5 Nm

Oil pump

Removal

- Remove the chain compartment cover undoing

the 3 fixing screws indicated in the figure.

- Take out the cover using the appropriate fusion

couplings on the cover with a pair of pliers

Fly 50 4t 4v Engine

ENG - 143

- Undo the 2 clamping screws in the figure and re-

move the cover over the pump control crown gear.

- Block the rotation of the oil pump control gear with

a screwdriver inserted through one of its pump

holes.

- Remove the central screw and the belleville

washer

- Remove the chain with the crown gear.

- Remove the crankshaft control pinion.

- Remove the oil pump by undoing the 2 screws

indicated in the figure.

- 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 clip retaining the innermost rotor.

- Remove and wash the rotors thoroughly with a

degreasing solvent and compressed air.

- Reassemble the rotors in the pump body, keep-

ing the two reference marks visible Replace the

clip.

- Measure distance between rotors (inner rotor/

outer rotor) with a thickness gauge in the position

shown in the picture.

CharacteristicAdmissible maximum clearance 10.15 mm

Engine Fly 50 4t 4v

ENG - 144

Measure the distance between the outer rotor and

the pump body (see figure).


- Check the axial clearance of the rotors using a

trued bar as reference as shown in the figure.N.B.MAKE SURE THE TRUED BAR IS POSITIONED PROPERLYON THE TWO POINTS ON THE PUMP BODY.


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 cover on the pump being careful to align

the holes (2 on the cover and 2 on the pump body)

fixing the oil pump on the crankcase.

- Fit the oil pump on the crankcase by tightening

the two screws to the prescribed torque.

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

the specified torque and the belleville washer.

- Check that there is no seizing and/or friction dur-

ing the pulley rotation.N.B.FIT THE CUP WASHER SO THAT ITS OUTER (CURVED)RIM TOUCHES THE PULLEY.

Locking torques (N*m)

Fly 50 4t 4v Engine

ENG - 145

Central screw 12 to 14 Nm Cover screws 0.7 to 0.9Nm Oil pump screws 5 ÷ 6

Removing the oil sump

- Remove the oil filling cap, the transmission cover,

the complete driving pulley assembly with belt and

pinion.

- Unscrew the oil drainage plug «A» shown in the

figure and drain out all the oil from the sump.

- Remove the 6 screws indicated in the figure.

Refitting the oil sump

- Clean and grease the faying surfaces.

- Apply LOCTITE 510 on the sump surface and

tighten the 6 fixing screws to the specified torque.

- Refit the driving pulley assembly, the belt, the

pinion and the transmission cover.WHEN TESTING THE LUBRICATION SYSTEM, REFER TOTHE "CRANKCASE AND CRANKSHAFT" CHAPTER, RE-GARDING LUBRICATION OF THE CRANKSHAFT ANDCONNECTING ROD

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

Fuel supply

- Disconnect the fuel supply and the suction taking

pipe from the carburettor.

- Check that there are no fuel leaks between the

two tubes.

- Close the fuel outlet pipe.

- By means of the MITYVAC pump apply 0.1 bar

of suction to the tap.

- Make sure that the suction is kept stable and that

and that there are no fuel leaks.

- Reconnect the vacuum pipe to the manifold.

- Position the fuel pipe with the outlet at the point

of the tap.

Engine Fly 50 4t 4v

ENG - 146

- Turn the engine by using the starter motor for five

seconds with the carburettor at minimum.

- Take up the fuel by means of a graded burette.N.B.THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-RECT NUMBER OF REVS OR BY THE WRONG POSITIONOF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB-TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-LET ON THE MANIFOLD HAS A SECTION INTENTIONALLYREDUCED FOR THE PURPOSE OF ENHANCING THE SUC-TION PULSATION AND THEREBY GUARANTEE A CON-STANT TAP FLOW RATE.

Specific tooling020329Y Mity-Vac vacuum-operated pump

CharacteristicMinimum flow rate20 cc

- Completely empty the fuel tank.

- Remove the petrol delivery pipe and the low-

pressure pipe.

- Loosen the clip and remove the cock.

- Clean the tank and the filter of the cock with a

specific solvent.

- Refit the cock making sure that there is an O-

Ring.

- Turn the cock to the direction it had before it was

removed and block the clip.N.B.THE FILTER CAN BE UNSCREWED FROM THE COCK TOFACILITATE CLEANING.

Removing the carburettor

- To detach the carburettor from the engine, re-

move the two clamps anchoring the carburettor to

the inlet manifold and the air intake coupling to the

filter.

- Remove the fuel supply pipe.

- Disconnect the starter connection.

- Detach the accelerator cable with the sheath that

connects the plate and the support.

- Remove the carburettor.

Fly 50 4t 4v Engine

ENG - 147

- Remove the protection, the bracket and the start-

er undoing the screw shown in the figure.CAUTIONTHE CARBURETTOR FEATURES AN ANTI-VIBRATIONRUBBER BUFFER FITTED ON THE LOWER SUPPLEMENTOF THE ACCELERATING PUMP BODY. UPON REFITTINGTHE CARBURETTOR ON THE ENGINE, MAKE SURE THISBUFFER IS PRESENT SO THAT THE PETROL IN THE TANKDOES NOT EMULSIFY.

- Remove the 2 fixing screws indicated in the fig-

ure, the vacuum chamber cover and the spring.

- Remove the vacuum valve together with the di-

aphragm; the pin, the spring and its plastic guide.WARNINGDURING THE REMOVAL OF THE COVER TAKE SPECIALCARE NOT TO RELEASE THE SPRING ACCIDENTALLY.

- Remove the 3 fixing screws and the chamber with

the gasket.

- Remove the chamber components following the

procedure below.

- Undo the 2 screws fixing the intake pump dia-

phragm cover.

Engine Fly 50 4t 4v

ENG - 148

- Remove the cover being careful with the spring

below, then remove the spring, take out the rubber

protection and the diaphragm together with the

pipe O-Ring.

-Remove the accelerating pump jet together with

the ball spring.

- Remove the screw indicated in the figure fixing

the float pin.

- Remove the float and the plunger.

-Remove the maximum nozzle.

-Remove diffuser.

-Remove the minimum nozzle.

Fly 50 4t 4v Engine

ENG - 149

- Remove the sprayer tilting the carburettor body.N.B.THIS OPERATION IS NECESSARY TO AVOID LOSINGSPRAYER PARTS WHEN CLEANING THE CARBURETTORBODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DONOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM-AGE IT.

- Remove the idle flow screw with the O-ring and

the spring.

CAUTION

DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS:FUEL SUPPLY PIPE, PIN SEATING, STARTER NOZZLE, THROTTLE VALVE CONTROL VALVESHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWSARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT.

Engine Fly 50 4t 4v

ENG - 150

Refitting the carburettor

- Before refitting, wash the carburettor body accu-

rately with a degreasing solvent and compressed

air.

- Pay special attention to the fuel supply pipe and

the plunger seat.

- For the minimum circuit, make sure the following

points are properly cleaned: air gauging, exhaust

section controlled by flow screw, progression

holes near the throttle valve.

- For the starter circuit, blow the connection pipe

properly with the jet. This is necessary because

the nozzle support hides other inaccessible inter-

nal calibrations.

- Blow the intake nozzle properly.

The acceleration nozzle outlet is extremely small

and is oriented to the throttle valve.

- Check that the carburettor body has the closing ball for the idle circuit pipe.

- Check that the coupling surfaces, the chamber and the diaphragm are not dented.

-Check that the depression valve housing pipe is not scratched.

- Check that the throttle valve and the shaft do not show abnormal wear.

- Check that the plunger seat does not show abnormal wear.

- Replace the carburettor in case of irregularities.N.B.

TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.

Fly 50 4t 4v Engine

ENG - 151

- Wash and blow the minimum nozzle properly and

reassemble it.

- Accurately wash and blow the components of the

maximum circuit, the sprayer, the diffuser and the

nozzle.

- Introduce the sprayer in the carburettor body with

the bigger cylindrical part directed to the diffuser.

- Fit the diffuser.

-Assemble the maximum nozzle.

- Check that the tapered pin does not show signs

of wear on the sealing surfaces of the shock ab-

sorber pin and the return clamp.

- Replace the rod if worn out.

- Check that the float is not worn on the pin housing

or on the contact plate with the rod and that there

are no fuel infiltrations.

- Replace it in case of failures.

- Fit the float together with the pin and rod in its

position and lock it with its screw.N.B.INTRODUCE THE RETURN SPRING ON THE FLOATPLATE ADEQUATELY

- Insert the ball in the corresponding accelerating

pump.

- Fit the spring.

- Fit the accelerating pump nozzle.WARNINGWHEN REFITTING, PAY SPECIAL ATTENTION TO THECOMPONENTS AS THEY ARE SMALL.

Engine Fly 50 4t 4v

ENG - 152

- Check the diaphragm is in good conditions and

remove the remaining components of the acceler-

ating pump following these steps:

- Insert the O-Ring in the pipe.

- Insert the diaphragm together with the pin and its

spring.N.B.REPLACE THE DIAPHRAGM IF THERE ARE SIGNS OF UN-DULATIONS, CRACKS OR HARDENING.

- Fit the accelerating pump diaphragm cover and

tighten the 2 fixing screws making sure the spring

below is correctly positioned.

- Fit the rubber bellows protecting the pin in the

upper part of the accelerating pump.

Level check

- Tilt the carburettor so that the needle valve at the

fuel supply is closed and the float weight does not

affect it.

- Check that the diaphragm closing line and the

float central line are parallel as shown in the figure.

- Blow air in to the tank and then assembly it and

its gasket on the carburettor body with the 3 fixing

screws.N.B.-ALWAYS USE NEW RINGS AND GASKETS FOR REFIT-TING.WARNINGTHE SCREW IN THE TANK BOTTOM IS A BLEEDING ONEAND CONSEQUENTLY IT ONLY REQUIRES CLEANING.

Fly 50 4t 4v Engine

ENG - 153

- Insert the diaphragm into the throttle valve.

- Insert the tapered pin together with the plastic

support and the contrast spring into the throttle

valve.N.B.PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETHFACING THE INNER SIDE OF THE MEMBRANE TO BEABLE TO FIT THE LOWER END OF THE THROTTLE VALVESPRING.

- Fit the vacuum chamber cover with the 2 fixing

screws paying special attention to the spring.

Inspecting the automatic choke device

- Check that the automatic starter piston is not de-

formed or rusty.

- Check that the piston slides freely in its seating.

- Check that the piston sealing O-Ring is not de-

formed.

- The starter must be more or less functional de-

pending on the ambient temperature.

- Measure the protrusion of the piston as shown in

the figure and check its corresponding value.

- Make sure that the starter is adjusted for the am-

bient temperature.

CharacteristicProtrusion value11.5 mm

ambient temperature24° C

Engine Fly 50 4t 4v

ENG - 154

- The starter should disconnect progressively by

means of electric heating.

- Check the starter resistance when adjusted to the

ambient temperature.

Characteristicambient temperature24° C

Electric characteristicAutomatic starter resistance20 Ω ± 5 %

- Use battery to power the automatic starter and

check that piston protrudes as much as possible.

- The correct warm up time depends on the ambi-

ent temperature.

- If protrusion, resistance or timing values are dif-

ferent from the ones prescribed, replace the start-

er.

CharacteristicBattery12V-9Ah

max. protrusion15 mm

max. time15 min

- Fit the starter, the support bracket and the pro-

tection with the screw indicated in the figure.

Fly 50 4t 4v Engine

ENG - 155

- Insert rubber pipes for chamber ventilation.

- Insert the O-Ring, the washer, the spring and the

idle flow screw in their seats.

- Refit the carburettor on the engine and connect

again the accelerator cable with the sheath and the

support plate and the electrical connection of the

starter.

- Reconnect the fuel supply pipe and tighten the 2

clamping screw fixing the carburettor to the inlet

manifold and the air inlet coupling to the filter.

Adjusting the idle

- The engine does not require frequent idle speed adjustments, but it is essential to strictly follow certain

rules when adjusting the idle speed.

- Before adjusting the carburettor make sure to respect requirements on lubrication, valve clearance,

and complying timing; spark plug should be in optimum conditions, air filter clean and sealed, and the

exhaust system tight.

- Connect the tester thermometer to the sump, us-

ing a cover with oil expressly prepared for probes.

- Start the engine and before adjusting the idle

speed, make sure that the oil temperature is be-

tween 70÷80 °C.


Engine Fly 50 4t 4v

ENG - 156

- Using the rpm indicator in the analyser or a sep-

arate one, adjust the idle screw.N.B.THE WASTED SPARK IGNITION SYSTEM OFFERS RE-MARKABLE POWER. READINGS MAY NOT BE ACCU-RATE IF INADEQUATE RPM INDICATORS ARE USED.

Specific tooling020332Y Digital rpm indicator

CharacteristicIdle speedabout 1900/2000 rpm

Fly 50 4t 4v Engine

ENG - 157

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 overhaulCuscinetti a sfere sul mozzo ruota

- 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

Fly 50 4t 4v Suspensions

SUSP - 159

- 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

001467Y014 Pliers to extract ø 15-mm bearings



020412Y 15-mm guide


Suspensions Fly 50 4t 4v

SUSP - 160

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.

- Insert the wheel axle after greasing it from the

brake disc opposite side, centring the retainer on

the fork leg onto the projecting parts of the odom-

eter drive.

- Make the fork travel to adjust the fork legs on the

wheel axle.

- Holding the wheel axle, lock the nut on the op-

posite side to the specified torque.

- Tighten the two safety screw on the fork leg to

the specified torque.

Locking torques (N*m)Front wheel axle nut 45 - 50 Safety screw on forkleg 6 ÷ 7

Handlebar


SUSP - 161

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

- Install the handlebars on the steering tube, pay-

ing attention to the centring, aligning the recess on

the handlebar with that on the steering tube as

shown in the figure.

- Tighten the handlebar fixing screw on the steer-

ing tube to the specified torque.

- Lubricate the nut with engine oil before installa-

tion.

Locking torques (N*m)Handlebar fixing screw 50 to 55

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 - 162

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

OverhaulSostituzione anello di tenuta e smontaggio stelo

- 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

To refit the fork, carry out the removal operations but in reverse order, observing the prescribed tight-

ening torques of the steering fifth wheels.

Locking torques (N*m)Steering lower ring nut 8 ÷ 10 Steering upper ring nut 35 - 40

Steering column


SUSP - 163

Removal

- Position the vehicle on the centre stand.

- Set a support under the vehicle in such a way that

the wheel is able to move freely and the vehicle

does not fall.

- Remove the handlebar.

- Remove the front brake calliper.

- Free the fork from the odometer cable and the

front brake calliper pipe.

- Loosen the upper ring nut «1» and collect the

shim washer «2».

Specific tooling020055Y Wrench for steering tube ring nut

Locking torques (N*m)Steering upper ring nut 35 - 40


SUSP - 164

- Remove the upper ring (or lower ring nut) «3» of

the upper bearing «A».

- Slide the fork and collect the cage with the balls

«4» of the upper bearing «A».

Locking torques (N*m)Steering lower ring nut 8 ÷ 10

When the specified torque of the lower ring nut is reached, loosen by 90°.

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 - 165

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 - 166

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:


- 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.

- Check clearance as described above. Make sure the front fork can move all long its stroke, from left

to right or vice versa, rotating freely and smoothly.

- Keep the lower ring nut «3» in position, by using a specific wrench and tighten the upper ring nut «1»

to the specified torque. Check again the bearings clearance.

Specific tooling020055Y Wrench for steering tube ring nut

Locking torques (N*m)Steering lower ring nut 8 ÷ 10 Steering upper ring nut 35 - 40When the specified torque of the lower ring nut is reached, loosen by 90°.

See also


SUSP - 167

Handlebar

Rear

Removing the rear wheel


- 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 - 168

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 - 169

Overhaul

Regularly check the clearance of the swinging arm retainer pins. To carry out these operations, proceed

as follows:


- Hold the rear wheel firmly and try to move it perpendicularly to the travel direction.

- If there is any clearance, check all the fastening elements that connect the swinging arm to the engine

and chassis as well as the condition of the silent block.

- Grease the points indicated in the drawing during the refit.

Locking torques (N*m)Silent-block swinging arm retaining bolts 36 to 44 Engine-swinging arm bolt 40 to 45 Frame-swinging arm bolt 50 to 55

Shock absorbers


SUSP - 170

Removal

- Adequately support the rear part of the vehicle.

- Remove the side fairings.

- 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 - 171

Centre-stand

REMOVAL

- Use a jack to support the vehicle properly.

- Remove the two return springs from the centre

stand.

- Undo the nut shown in the figure.

- Remove the pin from the right side.

- Remove the centre stand.

FITTING

- On refitting tighten the nut to the specified torque.

Locking torques (N*m)Centre stand pin 40 to 45

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 - 172

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.

Braking system Fly 50 4t 4v

BRAK SYS - 174

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

Fly 50 4t 4v Braking system

BRAK SYS - 175

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 - 176

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 - 177

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 - 178

Front brake pump

- Remove the front and rear handlebar cover.

- Disconnect the tube, collecting the brake oil in a

container.

- Operate on the two U bolt clamps (see figure).

- On refitting, perform the operation in reverse.

- Tighten the hydraulic line to the prescribed torque and then fill and purge the system.

Locking torques (N*m)Brake fluid hose-pump fitting 20 - 25 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 alsoRemoving the rear wheel


BRAK SYS - 179

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 - 180


BRAK SYS - 181

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

Fly 50 4t 4v Chassis

CHAS - 183

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

Chassis Fly 50 4t 4v

CHAS - 184

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 - 185

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 - 186

• 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 - 187

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 - 188

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 - 189

• 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 - 190

• 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 - 191

• 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 - 192

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 - 193

• 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 - 194

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 - 195

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 - 196

- 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 - 197

• 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


- Remove the footrest.

- Remove the spoilers.

- Unscrew the two clamps holding the filter housing

to the crankcase.

- Loosen the two clamps indicated.

- Remove the filter housing.

See alsoSide fairingsFootrestspoiler


CHAS - 198

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 - 199

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 spoilers.

- 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 - 200

- 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 - 201

• 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 - 202

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

Pre-delivery Fly 50 4t 4v

PRE DE - 204

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

Fly 50 4t 4v Pre-delivery

PRE DE - 205

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

Pre-delivery Fly 50 4t 4v

PRE DE - 206

AAir filter: 42, 198

BBattery: 52, 85, 87, 192, 202Brake: 162, 163, 174, 176, 179

CCarburettor: 38, 147, 151Checks: 78

EEngine oil: 43

FFuel: 146, 200

HHeadlight: 48, 187Hub oil: 41

IIdentification: 8Instrument panel: 186

MMaintenance: 7, 38Mirrors: 184

OOil filter: 45

RRecommended products:

SShock absorbers: 170Spark plug: 39, 79Stand: 172Suspension: 52

TTank: 200Transmission: 9, 51, 100, 110Tyres: 13

VVehicle: 8, 94, 169

Documents

Piaggio Fly 50 4t 4v (EN)