Scooter Fly 50 4t 4v Workshop Manual
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Scooter Fly 50 4t 4v Workshop Manual

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WORKSHOP MANUAL
677586 EN
Fly 50 4t 4v

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  • Page 1 WORKSHOP MANUAL 677586 EN Fly 50 4t 4v...
  • Page 2 WORKSHOP MANUAL 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.
  • Page 3 WORKSHOP MANUAL Fly 50 4t 4v This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggio dealers and sub-agents. It is assumed that the person utilizing this manual for servicing or repairing Piaggio vehicles has knowledge of the principles of mechanics and standard procedures required for general vehicle repair.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Fly 50 4t 4v Characteristics 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;...

  • Page 8: Vehicle Identification

    Fly 50 4t 4v Characteristics Vehicle identification The chassis prefix is stamped on the right strut. The engine prefix is stamped on the rear wall of the transmission crankcase. VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix RP8C52 Engine prefix C522M Dimensions and mass...
  • Page 9 Fly 50 4t 4v Characteristics EIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 117 kg Wheelbase 1345 mm Length 1,870 mm Width (handlebar) 705 mm Height (without mirrors) 1150 mm Engine ENGINE Specification Desc./Quantity Type single-cylinder, four-stroke and four-valve, air-cooled engine...
  • Page 10 Fly 50 4t 4v Characteristics Capacities CAPACITY Specification Desc./Quantity Fuel tank 7±0.5 lt Rear hub 85 cm³ Engine oil ~ 850 cc Electrical system When the advance check is carried out with a stroboscopic gun, add 10° flywheel keying to the table below.
  • Page 11 Fly 50 4t 4v Characteristics TURN INDICATOR SWITCH IGNITION KEY LIGHT SWITCH STARTER BUTTON CHAR - 11...
  • Page 12 Fly 50 4t 4v Characteristics 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...
  • Page 13 Fly 50 4t 4v Characteristics - Power: 120 W - resistance between BLUE cable and GROUND CONNECTION: 1 Ohm Frame and suspensions FRAME AND SUSPENSION Specification Desc./Quantity Frame Tubular steel frame Front suspension Hydraulic telescopic fork with Ø 32-mm stem, 76 mm travel.

  • Page 14: Front Suspension

    Fly 50 4t 4v Characteristics Name Torque in Nm Camshaft pulley screw 12 - 14 Rocking lever axle and camshaft bearing screw 3 to 4 Nm Rocking levers adjusting nuts: 7 to 9 Nm Engine oil pre-filter cover: 25 - 28 Nm...

  • Page 15: Assembly Clearances

    Fly 50 4t 4v Characteristics Name Torque in Nm Disc tightening screw (Apply LOCTITE 243 medium-strength 8 - 12 Nm threadlock) Oil bleeding valve 8 - 12 Rear brake adjustment nut Overhaul data Assembly clearances Cylinder - piston assy. COUPLING BETWEEN PISTON AND CYLINDER...
  • Page 16 Fly 50 4t 4v Characteristics - Measure the outer diameter of the gudgeon pin. Characteristic Pin outside diameter 13 +0 -0.004 mm Minimum admissible diameter gudgeon pin 12.990 mm - Measure the diameter of the bearings on the pis- ton.
  • Page 17 Fly 50 4t 4v Characteristics ring - maximum clearance allowed after use 0.17 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.
  • Page 18 Fly 50 4t 4v Characteristics SEALING RINGS Name Description Dimensions Initials Quantity 1st Compression ring 39 x 1 0.08 to 0.20 2nd Compression ring 39 x 1 0.05 to 0.20 Oil scraper ring 39 x 2 0.20 to 0.70 1st Compression ring 39.2 x 1...
  • Page 19 Fly 50 4t 4v Characteristics Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE Name Description Dimensions Initials Quantity Half-shaft, transmission 14 +0 -0.005 side Flywheel-side half shaft 16 +0 -0.005 Connecting rod 14.8 +0.05 -0 Spacer tool 45.00 / Fits and clearan-...
  • Page 20 Fly 50 4t 4v Characteristics Measure the bearings along X and Y axes Characteristic Crankshaft bearing, transmission side 20 -0.012 -0.025 mm Crankshaft bearing, flywheel side 17 +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.

  • Page 21: Cylinder Head

    Fly 50 4t 4v Characteristics 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-...
  • Page 22 Fly 50 4t 4v Characteristics - 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.
  • Page 23 Fly 50 4t 4v Characteristics 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»...
  • Page 24 Fly 50 4t 4v Characteristics - Measure the diameter of the valve stems in the three positions indicated in the diagram. TANDARD DIAMETER Specification Desc./Quantity Intake 3.970 to 3.985 mm Exhaust 3.960 to 3.975 mm INIMUM DIAMETER PERMITTED Specification Desc./Quantity Intake 3.958 mm...
  • Page 25 Fly 50 4t 4v Characteristics Measure the valve guides ALVE GUIDE DIAMETER Specification Desc./Quantity Valve guide Standard diameter: 4 + 0.012 mm Valve 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.
  • Page 26 Fly 50 4t 4v Characteristics - Inspect the camshaft for signs of abnormal wear on the cams. Characteristic Standard diameter - Bearing A: Ø 12 +0.002 +0.010 Standard diameter - Bearing B: Ø 16-0.015 -0.023 mm Minimum diameter allowed - Bearing A: Ø...
  • Page 27 Fly 50 4t 4v Characteristics Slot packing system Characteristic Compression ratio 11.5 to 12 : 1 PISTON PROTRUSION CHECK Name Measure A Thickness shimming_1 1.7 to 1.95 0.25 shimming_2 1.95 to 2.2 0.35 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications...
  • Page 28 INDEX OF TOPICS TOOL OOLING...
  • Page 29 Fly 50 4t 4v Tooling SPECIFIC TOOLS Stores 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, 2...
  • Page 30 Fly 50 4t 4v Tooling Stores code Description 008119Y009 Tube to assemble shafts and axles 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for Ø...
  • Page 31 Fly 50 4t 4v Tooling Stores code Description 020193Y 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...
  • Page 32 Fly 50 4t 4v Tooling Stores code Description 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator 020334Y Multiple battery charger TOOL - 32...
  • Page 33 Fly 50 4t 4v Tooling Stores code Description 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020359Y 42x47-mm Adaptor 020360Y 52x55-mm Adaptor 020363Y 20-mm guide TOOL - 33...
  • Page 34 Fly 50 4t 4v Tooling Stores code Description 020364Y 25-mm guide 020376Y Adaptor handle 020431Y Valve oil seal extractor 020432Y Tool to fit the start-up sector spring 020439Y 17-mm guide 020444Y Tool for fitting/ removing the driven pulley clutch TOOL - 34...
  • Page 35 Fly 50 4t 4v Tooling Stores code Description 020448Y 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 driven pulley shaft 020456Y Ø 24-mm adaptor...
  • Page 36 Fly 50 4t 4v Tooling Stores code Description 020480Y Petrol pressure check kit 020565Y Flywheel lock calliper spanner 020683Y Valve pressing member TOOL - 36...
  • Page 37 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 38: Maintenance Chart

    Fly 50 4t 4v Maintenance Maintenance chart SCHEDULED MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R:REPLACE, A: ADJUST, L:LUBRICATE * Replace every 2 years Km x 1000 Safety fasteners Spark plug Drive belt...

  • Page 39: Spark Plug

    Fly 50 4t 4v Maintenance - 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.
  • Page 40 Fly 50 4t 4v Maintenance - 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.
  • Page 41 Fly 50 4t 4v Maintenance 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.
  • Page 42 Fly 50 4t 4v Maintenance - Remove the rear wheel. - Prepare an adequately sized container. - Unscrew the oil drainage plug and drain out all the oil. See also Removing the rear wheel - Screw in the drainage cap again and fill the hub with the prescribed oil.

  • Page 43: Engine Oil

    Fly 50 4t 4v Maintenance DO NOT RUN THE ENGINE WITH THE AIR FILTER DISAS- SEMBLED OR EXCESS WEAR OF CYLINDER AND PISTON WILL RESULT. Recommended products AGIP 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.
  • Page 44 Fly 50 4t 4v Maintenance 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.

  • Page 45: Engine Oil Filter

    Fly 50 4t 4v Maintenance 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.

  • Page 46: Checking The Ignition Timing

    Fly 50 4t 4v Maintenance 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.
  • Page 47 Fly 50 4t 4v Maintenance 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.

  • Page 48: Headlight Adjustment

    Fly 50 4t 4v Maintenance Locking torques (N*m) Brake pump reservoir screws 15 to 20 See also Front 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;...
  • Page 49 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 50: Troubleshooting

    Fly 50 4t 4v Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter blocked or dirty Remove the sponge, wash with water and car shampoo, then soak it in a mixture of 50% petrol and 50% specific oil. Press with your hand without squeezing, allow it to drip dry and refit.
  • Page 51 Fly 50 4t 4v Troubleshooting Insufficient lubrication pressure POOR LUBRICATION PRESSURE Possible Cause Operation By-Pass remains open Check the By-Pass and replace if required. Carefully clean the By-Pass area. Oil pump with excessive clearance Perform the dimensional checks on the oil pump components...
  • Page 52 Fly 50 4t 4v Troubleshooting Battery BATTERY Possible Cause Operation Battery The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically.
  • Page 53 Fly 50 4t 4v Troubleshooting TROUBL - 53...
  • Page 54 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 55 Fly 50 4t 4v Electrical system 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...
  • Page 56 Fly 50 4t 4v Electrical system 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...
  • Page 57 Fly 50 4t 4v Electrical system 1. Battery: to access open the front panel. 2. Diagnostic socket: to access open the front pan- 3. Fuses: remove the legshield to reach it. 4. Fuse for electronic starter device: remove the legshield to reach it.
  • Page 58 Fly 50 4t 4v Electrical system 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.
  • Page 59 Fly 50 4t 4v Electrical system 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.
  • Page 60 Fly 50 4t 4v Electrical system 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.
  • Page 61 Fly 50 4t 4v Electrical system 34. Side stand sensor: remove the footrest to reach it. 35. S.I.S. Valve: remove the central cover to reach 36. Ambient temperature sensor: remove the cen- tral cover to reach it 37. Taillight: remove the rear light assembly to reach it.
  • Page 62 Fly 50 4t 4v Electrical system 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.
  • Page 63 Fly 50 4t 4v Electrical system 7. Start-up solenoid 8. At the battery connections ELE SYS - 63...
  • Page 64 Fly 50 4t 4v Electrical system 9. Battery negative terminal connection 10. Positive battery pole connection 11. Main fuse 12.Diagnostics connection ELE SYS - 64...
  • Page 65 Fly 50 4t 4v Electrical system 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...
  • Page 66 Fly 50 4t 4v Electrical system 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...
  • Page 67 Fly 50 4t 4v Electrical system 24. Starter motor connection branch 25. Solenoid switches and fuses branch 26. Side stand sensor connection 27. Side stand sensor ELE SYS - 67...
  • Page 68 Fly 50 4t 4v Electrical system 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...
  • Page 69 Fly 50 4t 4v Electrical system Back side 1. High voltage coil connection 2. Voltage regulator 3. Ambient temperature sensor connection 4. S.I.S. valve connection ELE SYS - 69...
  • Page 70 Fly 50 4t 4v Electrical system 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...
  • Page 71 Fly 50 4t 4v Electrical system 11. P.T.C. connection Conceptual diagrams 1. External temperature sensor 2. Front and rear brake light 3. Fuel reserve sensor 4. Starter motor 5. Start-up solenoid ELE SYS - 71...
  • Page 72 Fly 50 4t 4v Electrical system 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.
  • Page 73 Fly 50 4t 4v Electrical system Ignition Ignition 3. Fuel reserve sensor 6. 12v-6Ah battery 7. 15a Fuse 9. Low fuel warning light 12V - 1.7W 13. Fuel gauge 14. Fuel level transmitter 17. Fuse 7.5A 18. Ignition switch contacts...
  • Page 74 Fly 50 4t 4v Electrical system Lights and turn indicators 2. Front and rear brake light 6. 12v-6Ah battery 7. 15a Fuse 15. 21W filament for brake light in bulb 12V - 5/21W 17. Fuse 7.5A 18. Ignition switch contacts 20.
  • Page 75 Fly 50 4t 4v Electrical system 7. 15a Fuse 9. Low fuel warning light 12V - 1.7W 13. Fuel gauge 14. Fuel level transmitter 17. Fuse 7.5A 18. Ignition switch contacts Enabling buttons and level indicators Battery recharge and start up 2.
  • Page 76 Fly 50 4t 4v Electrical system 5. Start-up solenoid 6. 12v-6Ah battery 7. 15a Fuse 8. Starter button 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.
  • Page 77 Fly 50 4t 4v Electrical system 18. Ignition switch contacts 20. Voltage regulator 21. S.I.S. Valve 22. PTC 38. Light relay 39. Automatic starter 40. NTC temperature sensor 41. Electronic ignition device 42. Fuse 10A 43. Diagnostics socket Instruments and warning lights control board...
  • Page 78 Fly 50 4t 4v Electrical system INSTRUMENT BOARD - WARNING LIGHTS AND INSTRUMENT PANEL Specification Desc./Quantity Instrument panel bulb 12V-1.7W Instrument panel bulb 12V-1.7W Headlight warning light 12V-1.7W Left turn indicator warning light 12V-1.7W Right turn indicator warning light 12V-1.7W...
  • Page 79 Fly 50 4t 4v Electrical system If the failure persists, check the generator and the stator components as follows: After visually checking the electrical connections, use a specific tester to measurement the stator winding and the pickup (see table). If any failure is found after checking the loading coil and the pick-up, replace the stator and the dam- aged parts.
  • Page 80 Fly 50 4t 4v Electrical system conforming values are measured, replace the Pick-Up; otherwise, repair the cable harness. Electric characteristic Pick - up resistance approx. 170 Ohm - HV primary coil check Disconnect the electronic starter connector and check continuity between terminal No. 3 (purple) and terminal No.
  • Page 81 Fly 50 4t 4v Electrical system - 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.
  • Page 82 Fly 50 4t 4v Electrical system ~ 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).
  • Page 83 Fly 50 4t 4v Electrical system - 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 ANALOGUE...
  • Page 84 Fly 50 4t 4v Electrical system 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.
  • Page 85 Fly 50 4t 4v Electrical system - 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).
  • Page 86 Fly 50 4t 4v Electrical system 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.

  • Page 87: Battery Installation

    Fly 50 4t 4v Electrical system 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 -).
  • Page 88 Fly 50 4t 4v Electrical system 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.
  • Page 89 Fly 50 4t 4v Electrical system 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.
  • Page 90 Fly 50 4t 4v Electrical system 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.
  • Page 91 Fly 50 4t 4v Electrical system 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.
  • Page 92 Fly 50 4t 4v Electrical system 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.
  • Page 93 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 94 Fly 50 4t 4v Engine from vehicle 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 vehicle CAUTION SUPPORT THE VEHICLE ADEQUATELY.
  • Page 95 Fly 50 4t 4v Engine from vehicle - 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.
  • Page 96 Fly 50 4t 4v Engine from vehicle - 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.
  • Page 97 Fly 50 4t 4v Engine from vehicle - 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.
  • Page 98 Fly 50 4t 4v Engine from vehicle - 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.
  • Page 99 INDEX OF TOPICS NGINE...

  • Page 100: Automatic Transmission

    Fly 50 4t 4v Engine 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.

  • Page 101: Removing The Driven Pulley

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

  • Page 102: Inspecting The Clutch Drum

    Fly 50 4t 4v Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. Characteristic clutch housing diameter/standard value Ø 107+0.2 +0 mm clutch housing diameter/max. value allowed after use Ø...
  • Page 103 Fly 50 4t 4v Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
  • Page 104 Fly 50 4t 4v Engine Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEAL RING.
  • Page 105 Fly 50 4t 4v Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings. - Measure the inside diameter of the mobile half- pulley bushing. Characteristic Mobile driven half-pulley/ Maximum diameter allowed Ø...
  • Page 106 Fly 50 4t 4v Engine 020456Y Ø 24-mm adaptor 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...

  • Page 107: Refitting The Driven Pulley

    Fly 50 4t 4v Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE...

  • Page 108: Removing The Driving Pulley

    Fly 50 4t 4v Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley.
  • Page 109 Fly 50 4t 4v Engine 20.12 mm Driving pulley/ Standard diameter: 20.021 mm Driving pulley bushing/ Diameter maximum: XXX mm Driving pulley bushing/ Standard diameter: 20 -0.020/-0.041mm Refitting the driving pulley - Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.
  • Page 110 Fly 50 4t 4v Engine Refitting the transmission cover - Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and its seating in the crankcase and the re- turn spring. - Remove the damaged components.
  • Page 111 Fly 50 4t 4v Engine 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.
  • Page 112 Fly 50 4t 4v Engine 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.
  • Page 113 Fly 50 4t 4v Engine 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.
  • Page 114 Fly 50 4t 4v Engine 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.

  • Page 115: Removing The Stator

    Fly 50 4t 4v Engine Cooling fan - Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.
  • Page 116 Fly 50 4t 4v Engine 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 ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COV- ER ASSEMBLY.
  • Page 117 Fly 50 4t 4v Engine Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS - Extract the flywheel with the extractor.
  • Page 118 Fly 50 4t 4v Engine 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.
  • Page 119 Fly 50 4t 4v Engine 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.
  • Page 120 Fly 50 4t 4v Engine 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.
  • Page 121 Fly 50 4t 4v Engine 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 pads N.B.

  • Page 122: Removing The Cylinder Head

    Fly 50 4t 4v Engine 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.

  • Page 123: Inspecting The Small End

    Fly 50 4t 4v Engine 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.

  • Page 124: Inspecting The Piston

    Fly 50 4t 4v Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. Characteristic Standard diameter: gudgeon pin 13 -0 -0.004mm Minimum admissible diameter gudgeon pin 12.990 mm Inspecting the piston - Measure the diameter of the bearings on the pis- ton.
  • Page 125 Fly 50 4t 4v Engine 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.

  • Page 126: Removing The Piston

    Fly 50 4t 4v Engine SEALING RINGS Name Description Dimensions Initials Quantity 1st Compression ring 39 x 1 0.08 to 0.20 2nd Compression ring 39 x 1 0.05 to 0.20 Oil scraper ring 39 x 2 0.20 to 0.70 1st Compression ring 39.2 x 1...
  • Page 127 Fly 50 4t 4v Engine - 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.

  • Page 128: Inspecting The Cylinder Head

    Fly 50 4t 4v Engine 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 BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER LINER.
  • Page 129 Fly 50 4t 4v Engine Measure the camshaft bearing seats and rocking lever support pins with a bore meter HEAD CHECK Specification Desc./Quantity Standard diameter (mm) A Ø 32.015 to 32.025 Standard diameter (mm) B Ø 16.0 to 16.018 Standard diameter (mm) C Ø...
  • Page 130 Fly 50 4t 4v Engine 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. Characteristic Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm...
  • Page 131 Fly 50 4t 4v Engine - Measure the diameter of the valve stems in the three positions indicated in the diagram. TANDARD DIAMETER Specification Desc./Quantity Intake 3.970 to 3.985 mm Exhaust 3.960 to 3.975 mm INIMUM DIAMETER PERMITTED Specification Desc./Quantity Intake 3.958 mm...
  • Page 132 Fly 50 4t 4v Engine Inspecting the valve stem guide clearance Measure the valve guides ALVE GUIDE DIAMETER Specification Desc./Quantity Valve guide Standard diameter: 4 + 0.012 mm Valve 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.
  • Page 133 Fly 50 4t 4v Engine 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.
  • Page 134 Fly 50 4t 4v Engine - 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»...
  • Page 135 Fly 50 4t 4v Engine - Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque. Specific tooling 020450Y Camshaft fitting/removal tool - Fit pins, inlet rocking lever and discharge rocking lever.
  • Page 136 Fly 50 4t 4v Engine 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.
  • Page 137 Fly 50 4t 4v Engine Camshaft pulley screw Head cover 12 - 14 screw 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.
  • Page 138 Fly 50 4t 4v Engine 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.
  • Page 139 Fly 50 4t 4v Engine - 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.
  • Page 140 Fly 50 4t 4v Engine -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 tooling 020359Y 42x47-mm Adaptor 020364Y 25-mm guide...
  • Page 141 Fly 50 4t 4v Engine Off-line maximum admitted - D 0.10 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.
  • Page 142 Fly 50 4t 4v Engine - 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)
  • Page 143 Fly 50 4t 4v Engine 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.
  • Page 144 Fly 50 4t 4v Engine - 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.
  • Page 145 Fly 50 4t 4v Engine Measure the distance between the outer rotor and the pump body (see figure). Characteristic Admissible maximum clearance 2 0.20 mm - Check the axial clearance of the rotors using a trued bar as reference as shown in the figure.

  • Page 146: Fuel Supply

    Fly 50 4t 4v Engine Central screw Cover screws 12 to 14 Nm 0.7 to 0.9 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.

  • Page 147: Removing The Carburettor

    Fly 50 4t 4v Engine - 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 POSITION OF THE TUBE.
  • Page 148 Fly 50 4t 4v Engine - Remove the protection, the bracket and the start- er undoing the screw shown in the figure. CAUTION THE CARBURETTOR FEATURES AN ANTI-VIBRATION RUBBER BUFFER FITTED ON THE LOWER SUPPLEMENT OF THE ACCELERATING PUMP BODY. UPON REFITTING...
  • Page 149 Fly 50 4t 4v Engine - Remove the cover being careful with the spring below, then remove the spring, take out the rubber protection and the diaphragm together with the pipe O-Ring. -Remove the accelerating pump jet together with the ball spring.
  • Page 150 Fly 50 4t 4v Engine - Remove the sprayer tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM- AGE IT.
  • Page 151 Fly 50 4t 4v Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with a degreasing solvent and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For the minimum circuit, make sure the following...
  • Page 152 Fly 50 4t 4v Engine - Wash and blow the minimum nozzle properly and reassemble it. - Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindrical part directed to the diffuser.
  • Page 153 Fly 50 4t 4v Engine - Check the diaphragm is in good conditions and remove the remaining components of the acceler- ating pump following these steps: - Insert the O-Ring in the pipe. - Insert the diaphragm together with the pin and its spring.
  • Page 154 Fly 50 4t 4v Engine - Insert the diaphragm into the throttle valve. - Insert the tapered pin together with the plastic support and the contrast spring into the throttle valve. N.B. PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH...
  • Page 155 Fly 50 4t 4v Engine - The starter should disconnect progressively by means of electric heating. - Check the starter resistance when adjusted to the ambient temperature. Characteristic ambient temperature 24° C Electric characteristic Automatic starter resistance 20 Ω ± 5 % - Use battery to power the automatic starter and check that piston protrudes as much as possible.
  • Page 156 Fly 50 4t 4v Engine - 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.
  • Page 157 Fly 50 4t 4v Engine - 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.
  • Page 158 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 159: Removing The Front Wheel

    Fly 50 4t 4v Suspensions 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.
  • Page 160 Fly 50 4t 4v Suspensions - 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-...
  • Page 161 Fly 50 4t 4v Suspensions 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...

  • Page 162: Front Fork

    Fly 50 4t 4v Suspensions 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.

  • Page 163: Steering Column

    Fly 50 4t 4v Suspensions 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 also Front handlebar cover Rear handlebar cover Handlebar...
  • Page 164 Fly 50 4t 4v Suspensions 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.
  • Page 165 Fly 50 4t 4v Suspensions - 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 ÷...
  • Page 166 Fly 50 4t 4v Suspensions 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.
  • Page 167 Fly 50 4t 4v Suspensions 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.

  • Page 168: Removing The Rear Wheel

    Fly 50 4t 4v Suspensions Handlebar Rear Removing the rear wheel - Position the vehicle on the centre stand. - Remove the silencer. - Use a screwdriver to remove the plastic cap. - Remove the cotter pin. - Remove the cap.
  • Page 169 Fly 50 4t 4v Suspensions 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.

  • Page 170: Shock Absorbers

    Fly 50 4t 4v Suspensions Overhaul Regularly check the clearance of the swinging arm retainer pins. To carry out these operations, proceed as follows: - Position the vehicle on the centre stand. - Hold the rear wheel firmly and try to move it perpendicularly to the travel direction.
  • Page 171 Fly 50 4t 4v Suspensions 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.

  • Page 172: Side Stand

    Fly 50 4t 4v Suspensions 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.
  • Page 173 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 174: Front Brake Disc

    Fly 50 4t 4v Braking system 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.
  • Page 175 Fly 50 4t 4v Braking system See also Removing the front wheel Refitting When refitting, position the disc correctly making sure that it rotates in the direction indicated on the disc itself. Recommended products Loctite 243 Medium-strength threadlock Medium Loctite 243 threadlock...

  • Page 176: Front Brake Pads

    Fly 50 4t 4v Braking system See also Removing 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 CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.
  • Page 177 Fly 50 4t 4v Braking system 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...

  • Page 178: Recommended Products

    Fly 50 4t 4v Braking system 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.

  • Page 179: Rear Drum Brake

    Fly 50 4t 4v Braking system 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.
  • Page 180 Fly 50 4t 4v Braking system 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 also...
  • Page 181 Fly 50 4t 4v Braking system BRAK SYS - 181...
  • Page 182 INDEX OF TOPICS CHAS HASSIS...
  • Page 183 Fly 50 4t 4v Chassis Seat - Unscrew the 2 fixing screws and remove the sad- 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.

  • Page 184: Rear Rack

    Fly 50 4t 4v Chassis See also Legshield 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 also Helmet bay Driving mirrors •...
  • Page 185 Fly 50 4t 4v Chassis 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.

  • Page 186: Instrument Panel

    Fly 50 4t 4v Chassis Instrument panel • Remove the rear handlebar cover • Unscrew the 4 fixing screws and remove the in- strument panel See also Rear handlebar cover Front handlebar cover • Remove the 2 screws in the rear handlebar cover and the screw under the headlamp.
  • Page 187 Fly 50 4t 4v Chassis • 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.
  • Page 188 Fly 50 4t 4v Chassis 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;...
  • Page 189 Fly 50 4t 4v Chassis 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.
  • Page 190 Fly 50 4t 4v Chassis • 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 also Footrest...
  • Page 191 Fly 50 4t 4v Chassis • 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.
  • Page 192 Fly 50 4t 4v Chassis • Remove the screw fixing the leg shield back plate from the front. • Remove the shield back plate. See also Legshield Battery Removing the ignition key-switch when on *off* • Remove the shield back plate.
  • Page 193 Fly 50 4t 4v Chassis See also Knee-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.
  • Page 194 Fly 50 4t 4v Chassis • 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.

  • Page 195: License Plate Light

    Fly 50 4t 4v Chassis 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.
  • Page 196 Fly 50 4t 4v Chassis 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.
  • Page 197 Fly 50 4t 4v Chassis - 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 also Helmet bay Front central cover Rear rack Taillight assy.
  • Page 198 Fly 50 4t 4v Chassis • 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 also Side fairings Taillight assy. Air filter - Remove the side fairings.

  • Page 199: Rear Mudguard

    Fly 50 4t 4v Chassis 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.

  • Page 200: Fuel Tank

    Fly 50 4t 4v Chassis spoiler - Remove the footrest. - 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.

  • Page 201: Front Mudguard

    Fly 50 4t 4v Chassis - 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.

  • Page 202: Lower Cover

    Fly 50 4t 4v Chassis • 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.
  • Page 203 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 204 Fly 50 4t 4v Pre-delivery 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...
  • Page 205 Fly 50 4t 4v Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
  • Page 206 Fly 50 4t 4v Pre-delivery Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 207 Air filter: 42, 198 Battery: 52, 85, 87, 192, 202 Brake: 162, 163, 174, 176, 179 Carburettor: 38, 147, 151 Checks: 78 Engine oil: 43 Fuel: 146, 200 Headlight: 48, 187 Hub oil: 41 Identification: 8 Instrument panel: 186 Maintenance: 7, 38 Mirrors: 184 Oil filter: 45 Recommended products:...
  • Page 208 Vehicle: 8, 94, 169...

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