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PIAGGIO Fly 150 4T User Manual

PIAGGIO Fly 150 4T
223 pages
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- Remove the upper screw (2).
- Add 30 cc ±1 "Fork PG" oil (SAE 20W oil for
forks).
- Refit all components.
Locking torques (N*m)
Upper screw tightening torque 20 to 25 Nm
Lower screw tightening torque: 20 to 25 Nm
Refitting
When fitting the fork, lubricate with the steering
bearing tracks with the recommended grease.
Tighten the lower ring nut "A" and the upper ring
nut "B" to the specified torque
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 C
and +120 C; NLGI 2; ISO-L-XBCIB2.
Locking torques (N*m)
Steering lower ring nut 8 ÷ 10 Steering upper
ring nut 35 ÷ 40
Fly 125 - 150 4T Suspensions
SUSP - 161

Table of Contents

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PIAGGIO Fly 150 4T Specifications

General IconGeneral
BrandPIAGGIO
ModelFly 150 4T
CategoryScooter
LanguageEnglish

Summary

Rules

Safety Rules

General safety precautions for vehicle maintenance operations.

Maintenance Rules

Guidelines for performing maintenance operations, including using genuine parts and tools.

Vehicle Identification

Dimensions and Mass

Technical specifications for the vehicle's dimensions and weight.

Engine Specifications

Engine Details

Detailed specifications for the engine, including bore, stroke, and power.

Transmission System

Transmission Components

Details of the transmission system, including variator, belt, and clutch.

Brakes

Specifications for the front and rear braking systems.

Wheels and Tyres

Secondary Air System

Explanation of the secondary air system for emission control.

Carburettor Settings

125cc Version Carburettor

Specific carburettor settings for the 125cc model.

150cc Version Carburettor

Specific carburettor settings for the 150cc model.

Tightening Torques

Lubrication Torques

Specified torque values for lubrication system components.

Head and Cylinder Torques

Specified torque values for engine head and cylinder components.

Crankcase and Crankshaft Torques

Specified torque values for crankcase and crankshaft components.

Cylinder-Piston Assembly

Piston and Cylinder Coupling (150cc)

Specifications for piston and cylinder coupling for the 150cc model.

Piston and Cylinder Coupling (125cc)

Specifications for piston and cylinder coupling for the 125cc model.

Piston Rings

Sealing Rings (125cc)

Specifications for sealing rings for the 125cc model.

Sealing Rings (150cc)

Specifications for sealing rings for the 150cc model.

Crankcase, Crankshaft, and Connecting Rod

Axial Clearance: Crankshaft & Connecting Rod

Measurement specifications for axial clearance between crankshaft and connecting rod.

Axial Clearance: Crankshaft & Bearings

Measurement specifications for axial clearance between crankshaft and its bearings.

Slot Packing System

Shimming System (125cc)

Procedure and specifications for the shimming system on the 125cc model.

Recommended Products

Shimming System (150cc)

Procedure and specifications for the shimming system on the 150cc model.

Tooling

Specialized Tools List

A catalog of specialized tools with their codes and descriptions.

Maintenance Procedures

Maintenance Chart

Schedule and tasks for regular vehicle maintenance.

Spark Advance Check

Procedure for checking and adjusting spark advance timing.

Braking System Maintenance

Brake Fluid Level and Top-up

Procedure for checking and topping up brake fluid.

Headlight Adjustment

Steps for adjusting the vehicle's headlights.

CO Check

Procedure for checking and adjusting carbon monoxide levels.

SAS Filter Inspection and Cleaning

SAS Filter Maintenance

Instructions for inspecting and cleaning the secondary air system filter.

Troubleshooting Guide

Engine Issues

Common engine problems like poor performance and rear wheel spin at idle.

Starting and Fuel System Issues

Diagnosing difficulties with starting, fuel supply, and carburettor.

Braking and Clutch Issues

Diagnosing and resolving issues with brakes and clutch performance.

Steering and Suspension Issues

Troubleshooting problems related to steering hardening, play, and noisy suspension.

Electrical System Issues

Diagnosing battery and turn signal light malfunctions.

Electrical System

Wiring Diagrams and Legends

Schematics and component identification for the electrical system.

Front and Rear Electrical Installation

Guides for installing electrical components on the front and rear of the vehicle.

Ignition System

Components and troubleshooting for the ignition system.

Battery Maintenance and Charging

Instructions for maintaining and charging sealed and dry-charge batteries.

Immobiliser System

Operation, troubleshooting, and diagnostic codes for the immobiliser.

Engine Operations

Engine Removal and Installation

Procedures for removing the engine from the motorcycle frame.

Automatic Transmission

Detailed information on the automatic transmission system.

Carburettor Overhaul and Adjustment

Procedures for removing, cleaning, and adjusting the carburettor.

Idle Speed Adjustment

Procedure for adjusting the engine's idle speed and CO levels.

Crankcase and Crankshaft

Procedures for splitting crankcase halves and checking crankshaft clearances.

Cylinder and Piston Assembly

Steps for removing and inspecting the cylinder-piston assembly.

Valve and Camshaft Maintenance

Procedures for inspecting and refitting valves and camshafts.

Oil Pump and Sump Operations

Procedures for removing, inspecting, and refitting the oil pump and sump.

Suspension System

Front Suspension Overhaul

Procedures for front wheel and hub overhaul.

Handlebar and Steering Column

Procedures for handlebar removal, refitting, and steering column maintenance.

Front Fork Overhaul

Detailed overhaul procedures for the front fork.

Rear Wheel and Shock Absorbers

Procedures for rear wheel and shock absorber removal and refitting.

Centre Stand Replacement

Instructions for replacing the vehicle's centre stand.

Braking System

Front Brake Calliper Overhaul

Detailed overhaul and reassembly procedures for the front brake calliper.

Front Brake Disc and Pads

Procedures for front brake disc inspection and pad replacement.

Brake System Filling and Bleeding

Procedure for filling and bleeding the front brake system.

Chassis Components

Ignition Key-Switch and Footrest

Procedures for removing the ignition key-switch and footrest.

Air Filter and Rear Mudguard

Steps for removing the air filter housing and rear mudguard.

Helmet Bay and Fuel Tank

Procedures for removing the helmet bay and fuel tank.

Pre-Delivery Checks

Aesthetic and Torque Inspection

Visual checks of appearance and tightening torques.

Electrical System and Fluid Levels

Checks on electrical system, fluid levels, and battery condition.

Road Test and Functional Checks

Procedures for road testing and functional inspection of vehicle systems.

Service Operations - Engine

Engine Removal and Refitting

Time estimate for removing and refitting the engine.

Crankcase Operations

Time estimates for crankcase and gasket replacement.

Crankshaft Operations

Time estimates for crankshaft and oil seal replacement.

Cylinder Head Operations

Time estimates for cylinder head and valve replacement.

Oil Filter Operations

Time estimates for oil filter and sensor replacement.

Carburettor Operations

Time estimates for carburettor heating, manifold, and choke replacement.

Service Operations - Chassis and Bodywork

Frame Replacement

Time estimates for frame and stand replacement.

Legshield Spoiler Components

Time estimates for legshield spoiler and footrest replacement.

Fuel Tank Operations

Time estimates for fuel tank cap, float, valve, and fuel tank replacement.

Mudguard Replacement

Time estimates for front and rear mudguard replacement.

Service Operations - Suspension and Steering

Steering Column Bearing Operations

Time estimates for steering fifth wheel replacement and clearance adjustment.

Handlebar Component Replacement

Time estimates for handlebar components like levers, grips, and mirrors.

Brake Hose Operations

Time estimates for brake shoes/pads, brake line, and brake fluid bleeding.

Service Operations - Lighting and Signaling

Turn Signal Lights Operations

Time estimates for headlamp, turn indicator bulbs, and taillight replacement.

Front Wheel Operations

Time estimates for front wheel axle, bearings, tyre, and brake disc replacement.

Rear Wheel Operations

Time estimates for rear brake pads/shoes and tyre replacement.

Service Operations - Electrical System

Electric Device Replacement

Time estimates for control unit, HV coil, and battery replacement.

Electronic Control Replacement

Time estimates for headlight switch, horn button, and starter button replacement.

Service Operations - Front Suspension

Fork Component Replacement

Time estimates for fork oil seal, fork leg, and fork oil replacement.

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