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PIAGGIO
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Fly 150 4T
PIAGGIO Fly 150 4T User Manual
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Handlebar covers
HANDLEBAR COVERS
Code
Action
Duration
1
004019
Handlebar rear section - Re-
placement
2
004018
Handlebar front section - Re-
placement
3
005078
Odometer glass - Replace-
ment
4
005076
Clock / Cell - Replacement
5
005014
Odometer - Replacement
6
005038
Instrument panel warning
light bulbs - Replacement
Fly 125 - 150 4T
Time
TIME - 213
212
214
Table of Contents
Index of Topics
5
Characteristics
6
Safety Rules
7
Maintenance Rules
7
Vehicle Identification
8
Dimensions and Mass
8
Vehicle View
9
Engine Data
9
Transmission Data
10
Capacities
10
Electrical System Data
10
Frame and Suspension Data
10
Wheels and Tyres Data
11
Carburetor Data
12
Tightening Torques
13
Overhaul Data
14
Assembly Clearances
14
Cylinder - Piston Assy Data
15
Piston Rings Data
17
Crankcase - Crankshaft - Connecting Rod Data
18
Fly 125 - 150 4T
19
Slot Packing System
19
Products
20
Tooling
21
Tools View and Identification
22
Maintenance
31
Maintenance Chart
32
Checking the Spark Advance
35
Spark Advance Variation
36
Braking System
38
Level Check
38
Top-Up
38
Headlight Adjustment
39
CO Check
40
SAS Filters Inspection and Cleaning
42
Troubleshooting
44
Engine Troubleshooting
45
Poor Engine Performance
45
Rear Wheel Spins at Idle
45
Starting Difficulties
46
Excessive Oil Consumptions/Exhaust Smoke
46
Insufficient Lubrication Pressure
47
Engine Tends to be Cut-Off at Full Throttle
47
Engine Tends to Cut-Off at Idle
47
High Fuel Consumption
47
Transmission and Brakes Troubleshooting
48
Clutch Grabbing or Performing Inadequately
48
Insufficient Braking
48
Brakes Overheating
48
Electrical System Troubleshooting
49
Battery Troubleshooting
49
Turn Signal Lights Malfunction
49
Steering and Suspensions Troubleshooting
49
Excessive Steering Play
50
Noisy Suspension
50
Suspension Oil Leakage
50
Electrical System
51
Electrical System Diagram
52
Front Side Diagram
55
Front Installation
55
Back Side Diagram
58
Rear Installation
58
Conceptual Diagrams
60
Ignition Diagram
61
Headlights and Automatic Starter Section Diagram
62
Battery Recharge and Starting Diagram
63
Level Indicators and Enable Signals Section
64
Turn Signal Lights Diagram
65
Instruments and Warning Lights Control Board Diagram
66
Checks and Inspections
66
Immobiliser
67
Virgin Circuit
68
Diagnostic Codes
69
Diagnostic Code - 2 Flashes
69
Diagnostic Code - 3 Flashes
70
Ignition Circuit
70
No Spark Plug
71
- Pick-Up
72
- H.V. Coil
72
Battery Recharge Circuit
73
Stator Check
73
Voltage Regulator Check
74
Recharge System Voltage Check
74
Choke Inspection
74
Turn Signals System Check
75
Sealed Battery
76
Dry-Charge Battery
76
Engine from Vehicle
79
Exhaust Assy. Removal
80
Removal of the Engine from the Vehicle
80
Engine
83
Automatic Transmission
84
Transmission Cover
84
Air Duct
85
Removing the Driven Pulley Shaft Bearing
85
Refitting the Driven Pulley Shaft Bearing
86
Removing the Driven Pulley
86
Inspecting the Clutch Drum
86
Removing the Clutch
87
Inspecting the Clutch
88
Pin Retaining Collar
89
Removing the Driven Half-Pulley Bearing
89
Inspecting the Driven Fixed Half-Pulley
90
Inspecting the Driven Sliding Half-Pulley
90
Refitting the Driven Half-Pulley Bearing
90
Refitting the Driven Pulley
91
Inspecting the Clutch Spring
92
Refitting the Clutch
92
To Refit the Driven Pulley
94
Drive-Belt
94
Removing the Driving Pulley
95
Inspecting the Rollers Case
95
Refitting the Driving Pulley
96
Refitting the Transmission Cover
97
End Gear
97
Removing the Hub Cover
97
Removing the Wheel Axle
98
Removing the Hub Bearings
98
Removing the Wheel Axle Bearings
98
To Remove the Driven Pulley Shaft Bearing
99
Inspecting the Hub Shaft
99
Inspecting the Hub Cover
100
Refitting Driven Pulley Shaft Bearing
100
Refitting the Wheel Axle Bearing
100
Refitting the Hub Cover Bearings
101
Refitting the Hub Bearings
101
Refitting the Ub Cover
102
Flywheel Cover
102
Cooling Hood
102
Cooling Fan
103
Removing the Stator
103
Refitting the Stator
104
Flywheel and Starting
104
Removing the Flywheel Magneto
104
Inspecting the Flywheel Components
105
Refitting the Flywheel Magneto
105
Refitting the Starter Motor
105
Cylinder Assy. and Timing System
105
Removing the Timing System Drive
106
Removing the Cam Shaft
107
Removing the Cylinder Head
107
Removing the Valves
108
Removing the Cylinder - Piston Assy.
108
Inspecting the Small End
109
Inspecting the Wrist Pin
109
Inspecting the Piston
111
Removing the Piston
111
Refitting the Piston Rings
112
Refitting the Cylinder
113
Inspecting the Cylinder Head
113
Inspecting the Timing System Components
114
Inspecting the Valve Sealings
114
Inspecting the Valve Housings
114
Inspecting the Valves
115
Inspecting the Springs and Half-Cones
117
Refitting the Valves
117
Inspecting the Cam Shaft
117
Refitting the Head and Timing System Components
119
Crankcase - Crankshaft
122
Splitting the Crankcase Halves
123
Inspecting the Crankshaft Alignment
125
Inspecting the Crankcase Halves
126
Inspecting the Crankshaft Plain Bearings
128
Refitting the Crankcase Halves
129
Lubrication
130
Lubrication - Conceptual Diagrams
131
Oil Pressure Check
132
Crankshaft Oil Seals
132
Removal
133
Refitting
133
Oil Pump Removal
135
Oil Pump Inspection
136
Oil Pump Refitting
137
Removing the Oil Sump
138
Inspecting the By-Pass Valve
138
Refitting the Oil Sump
139
Fuel Supply
139
Removing the Carburettor
140
Refitting the Carburettor
146
Level Check (Carburetor)
149
Inspecting the Valve and Needle
151
Inspecting the Automatic Choke Device
153
Adjusting the Idle
154
Suspensions
157
Front Suspension
158
Removing the Front Wheel
158
Front Wheel Hub Overhaul
158
Refitting the Front Wheel
159
Handlebar Removal
160
Handlebar Refitting
160
Front Fork Overhaul
160
Replacement of Seal Ring Rod Disassembly
160
Front Fork Refitting
161
Steering Column Refitting
162
Steering Bearing Removal
162
Removing the Rear Wheel
163
Refitting the Rear Wheel
163
Shock Absorbers Removal
163
Centre-Stand
164
Braking System Section
165
Front Brake Caliper Removal
166
Front Brake Caliper Overhaul
166
Front Brake Caliper Refitting
168
Front Brake Disc Removal
168
Front Brake Disc Refitting
168
Disc Inspection
169
Front Brake Pads Removal
169
Front Brake Pads Refitting
169
Fill - Front
170
Front Brake Pump
171
Front Brake Pump Removal
172
Front Brake Pump Refitting
172
Rear Drum Brake
173
Chassis
174
Removing the Ignition Key-Switch When on *Off*
175
Removing the Ignition Key-Switch When on *Lock*
175
Footrest
175
Air Filter
176
Rear Mudguard
176
Helmet Bay
177
Fuel Tank
177
Pre-Delivery
178
Aesthetic Inspection
179
Tightening Torques Inspection
179
Electrical System Inspection
179
Levels Check
180
Road Test
180
Static Test
181
Functional Inspection
181
Time
182
Engine View
183
Crankcase View
184
Crankshaft View
185
Cylinder Assy.
186
Cylinder Head Assy. View
187
Rocker Arms Support Assy.view
188
Cylinder Head Cover View
189
Chain Tensioner View
190
Oil Filter View
191
Flywheel Cover View
192
Driven Pulley View
193
Oil Pump View
194
Final Gear Assy. View
195
Driving Pulley View
196
Transmission Cover View
197
Starter Motor View
198
Flywheel Magneto View
199
Belt Cooling Duct
199
Carburetor View
200
Exhaust Pipe View
201
Air Cleaner View
202
Frame View
203
Legshield Spoiler View
204
Rear Cover View
205
Central Cover View
206
Underseat Compartment
207
Plate Holder View
208
Mudguard View
209
Fuel Tank View
210
Rear Shock-Absorber View
211
Steering Column Bearings View
212
Handlebar Covers View
213
Handlebar Components View
214
Swing-Arm View
215
Brake Hoses View
216
Seat View
217
Turn Signal Lights Exploded View
218
Front Wheel View
219
Rear Wheel View
220
Electric Devices View
221
Electronic Controls
222
Transmissions - Diagram
222
Front Suspension View
223
5
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PIAGGIO Fly 150 4T Specifications
General
Brand
PIAGGIO
Model
Fly 150 4T
Category
Scooter
Language
English
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