PIAGGIO Fly Manuel d'instructions

WORKSHOP MANUAL

633204

Fly

WORKSHOP

MANUAL

Fly

The descriptions and illustrations given in this publication are not binding. While the basic specifications

as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA 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.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

WORKSHOP MANUAL

Fly

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-

Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a

basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important

changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this

manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are

unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along

with the specific tool catalogue.

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

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

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

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

injury.

Safeguarding the environment Sectionsmarked with this symbol indicatethe correct use of thevehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage 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

TIME TIME

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 spare parts 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.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English measurement. 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 electric connections have been done properly, particularly the ground and battery connections.

Fly Characteristics

CHAR - 7

Vehicle identification

VEHICLE IDENTIFICATION

Specification Desc./Quantity

Frame prefix ZAPM44100 ÷ 1001

Engine prefix C441M ÷ 1001

Dimensions and mass

DIMENSIONS AND MASS

Specification Desc./Quantity

Dry weight 97 Kg

Length 1,880

Maximum height 1150 mm

Seat height 785

Width 735

Wheelbase 1,340

Characteristics Fly

CHAR - 8

Engine

ENGINE

Specification Desc./Quantity

Engine type Two-stroke, single cylinder Piaggio Hi-PER2

Bore x stroke 40 X 39.3 mm

Cubic capacity 49.40 cc

Compression ratio 10,3 :1

Carburettor DELL'ORTO PHVA 17.5

CO adjustment 3.5% ± 0.5

Engine idle speed 1800 to 2000 r.p.m.

Air filter Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and

50% unleaded petrol).

Starting system electric starter/kick-starter

Lubrication With blend and variable oil variable according to the engine

revolutions and the throttle valve opening by means of a pump

controlled by the driving shaft with toothed belt.

Fuel supply Gravity feed, with unleaded petrol (with a minimum octane rat-

ing of 95) with carburettor.

Cooling system forced coolant circulation system

Fly Characteristics

CHAR - 9

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator, torque server, V-

belt, automatic clutch, gear reduction unit.

Capacities

CAPACITIES

Specification Desc./Quantity

Rear hub oil Quantity: approx. 85 cc

oil mixer tank Plastic, capacity ~ 1.2 l

Fuel tank capacity approx. 7.2 litres (of which 1.5 l is reserve)

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

Type of ignition Capacitive discharge type electronic ignition, with incorporated

high voltage coil

Ignition advance (before TDC) Fixed 17° ± 1

Recommended spark plug CHAMPION RN2C

Battery 12V-4Ah

Main fuse 7.5 A

Generator In alternate current with three output sections

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Type of chassis Welded tubular steel chassis with stamped sheet reinforce-

ments.

Front suspension Telescopic mechanical fork, 76mm travel.

Rear suspension Single hydraulic shock absorber, 72.5-mm travel

Brakes

FRENI

Specification Desc./Quantity

Front brake Disc brake (Ø 200 mm) with hydraulic control (lever on the right

end of the handlebar) and floating calliper.

Rear brake drum brake (Ø 140 mm) with mechanical linkage.(l.h. brake

lever).

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheel rim Die-cast aluminium alloy 3.50 x 12"

Front tyre Tubeless, 120/70-12"

Characteristics Fly

CHAR - 10

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