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Piaggio Fly 50 4T Service Repair Manual 2007-2011 – PDF Download
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Piaggio Fly 50 4T Service Repair Manual 2007-2011
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Description
Piaggio Fly 50 4T Service Repair Manual 2007-2011
FILE DETAILS:
Piaggio Fly 50 4T Service Repair Manual 2007-2011
LANGUAGE:ENGLISH
PAGES:270+
DOWNLOADABLE:YES
FILE TYPE:PDF
PIAGGIO FLY 50 4T SERVICE REPAIR MANUAL 2007-2011 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Piaggio Fly 50 4T Service Repair Manual 2007-2011
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
TABLE OF CONTENTS:
Piaggio Fly 50 4T Service Repair Manual 2007-2011
Man: MSS Fly 50 4T............................................. 5 Cap:Characteristics........................................ 6 Sez:Rules.............................................. 7 Sez:Safety rules....................................... 7 Sez:Maintenance rules.................................. 7 Sez:Vehicle identification............................. 7 Sez:Dimensions and mass................................ 8 Sez:Engine............................................. 9 Sez:Transmission....................................... 9 Sez:Capacities......................................... 10 Sez:Electrical system.................................. 10 Sez:Frame and suspensions.............................. 10 Sez:Brakes............................................. 10 Sez:Wheels and tyres................................... 10 Sez:Secondary air...................................... 11 Sez:Carburettor........................................ 11 Sez:50cc Version....................................... 11 Sez:Kehin.............................................. 11 Sez:Tightening Torques................................. 12 Sez:Overhaul data...................................... 12 Sez:Assembly clearances................................ 12 Sez:Cylinder - piston assy............................. 12 Sez:Piston rings....................................... 13 Sez:Crankcase - crankshaft - connecting rod............ 14 Sez:Slot packing system................................ 15 Sez:Products........................................... 16 Cap:Tooling................................................ 17 Cap:Maintenance............................................ 26 Sez:Maintenance chart.................................. 27 Sez:Carburettor........................................ 29 Sez:Checking the spark advance......................... 30 Sez:Spark plug......................................... 31 Sez:Hub oil............................................ 32 Sez:Check.............................................. 32 Sez:Replacement........................................ 32 Sez:Air filter......................................... 32 Sez:Engine oil......................................... 33 Sez:Replacement........................................ 33 Sez:Check.............................................. 34 Sez:Engine oil filter.................................. 34 Sez:Checking the ignition timing....................... 35 Sez:Checking the valve clearance....................... 35 Sez:Headlight adjustment............................... 36 Sez:CO check........................................... 37 Sez:SAS filters inspection and cleaning................ 38 Cap:Troubleshooting........................................ 40 Sez:Engine............................................. 41 Sez:Poor performance................................... 41 Sez:Rear wheel spins at idle........................... 41 Sez:Starting difficulties.............................. 41 Sez:Excessive oil consumption/Exhaust smoke............ 42 Sez:Insufficient lubrication pressure.................. 42 Sez:Engine tends to cut-off at full throttle........... 42 Sez:Engine tends to cut-off at idle.................... 42 Sez:Excessive exhaust noise............................ 43 Sez:High fuel consumption.............................. 43 Sez:SAS malfunctions................................... 43 Sez:Transmission and brakes............................ 43 Sez:Clutch grabbing or performing inadequately......... 43 Sez:Insufficient braking............................... 44 Sez:Brakes overheating................................. 44 Sez:Electrical system.................................. 44 Sez:Battery............................................ 44 Sez:Turn signal lights malfunction..................... 44 Sez:Steering and suspensions........................... 44 Sez:Rear wheel......................................... 44 Sez:Controls........................................... 45 Cap:Electrical system...................................... 0 Sez:Conceptual diagrams................................ 48 Sez:Ignition........................................... 48 Sez:Headlights and automatic starter section........... 49 Sez:Battery recharge and starting...................... 49 Sez:Level indicators and enable signals section........ 50 Sez:Turn signal lights................................. 51 Sez:Checks and inspections............................. 52 Sez:Ignition circuit................................... 53 Sez:Stator check....................................... 53 Sez:Voltage regulator check............................ 54 Sez:Recharge system voltage check...................... 55 Sez:Sealed battery..................................... 57 Sez:Dry-charge battery................................. 58 Cap:Engine from vehicle.................................... 0 Sez:Exhaust assy. Removal.............................. 61 Sez:Removal of the engine from the vehicle............. 61 Cap:Engine................................................. 62 Sez:Automatic transmission............................. 63 Sez:Transmission cover................................. 63 Sez:Kickstart.......................................... 63 Sez:Air duct........................................... 63 Sez:Removing the driven pulley shaft bearing........... 63 Sez:Refitting the driven pulley shaft bearing.......... 64 Sez:Removing the driven pulley......................... 64 Sez:Inspecting the clutch drum......................... 64 Sez:Removing the clutch................................ 65 Sez:Inspecting the clutch.............................. 65 Sez:Pin retaining collar............................... 66 Sez:Removing the driven half-pulley bearing............ 66 Sez:Inspecting the driven fixed half-pulley............ 67 Sez:Inspecting the driven sliding half-pulley.......... 67 Sez:Refitting the driven half-pulley bearing........... 68 Sez:Inspecting the clutch spring....................... 69 Sez:Refitting the clutch............................... 69 Sez:Refitting the driven pulley........................ 70 Sez:Drive-belt......................................... 70 Sez:Removing the driving pulley........................ 70 Sez:Inspecting the rollers case........................ 71 Sez:Refitting the driving pulley....................... 72 Sez:Refitting the transmission cover................... 72 Sez:End gear........................................... 73 Sez:Removing the hub cover............................. 73 Sez:Removing the wheel axle bearings................... 74 Sez:Removing the driven pulley shaft bearing........... 75 Sez:Inspecting the hub shaft........................... 75 Sez:Inspecting the hub cover........................... 76 Sez:Refitting the wheel axle bearing................... 76 Sez:Refitting the hub bearings......................... 77 Sez:Refitting the ub cover............................. 77 Sez:Flywheel cover..................................... 78 Sez:Cooling hood....................................... 78 Sez:Cooling fan........................................ 78 Sez:Removing the stator................................ 79 Sez:Refitting the stator............................... 79 Sez:Flywheel and starting.............................. 79 Sez:Removing the starter motor......................... 79 Sez:Removing the flywheel magneto...................... 80 Sez:Inspecting the flywheel components................. 80 Sez:Starter gear rim................................... 81 Sez:Intermediate gear.................................. 81 Sez:Refitting the flywheel magneto..................... 81 Sez:Refitting the starter motor........................ 82 Sez:Cylinder assy. and timing system................... 82 Sez:Removing the rocker-arms cover..................... 82 Sez:Removing the timing system drive................... 83 Sez:Removing the cam shaft............................. 84 Sez:Removing the cylinder head......................... 85 Sez:Removing the valves................................ 85 Sez:Removing the cylinder - piston assy................ 86 Sez:Inspecting the small end........................... 86 Sez:Inspecting the wrist pin........................... 87 Sez:Inspecting the piston.............................. 87 Sez:Inspecting the cylinder............................ 88 Sez:Inspecting the piston rings........................ 89 Sez:Removing the piston................................ 89 Sez:Choosing the gasket................................ 90 Sez:Refitting the piston rings......................... 92 Sez:Refitting the cylinder............................. 94 Sez:Inspecting the cylinder head....................... 94 Sez:Inspecting the timing system components............ 95 Sez:Inspecting the valve sealings...................... 95 Sez:Inspecting the valve housings...................... 96 Sez:Inspecting the valves.............................. 96 Sez:Inspecting the springs and half-cones.............. 97 Sez:Refitting the valves............................... 98 Sez:Inspecting the cam shaft........................... 98 Sez:Refitting the head and timing system components.... 99 Sez:Refitting the timing chain.........................101 Sez:Refitting the rocker-arms cover....................102 Sez:Refitting the intake manifold......................103 Sez:Crankcase - crankshaft.............................103 Sez:Splitting the crankcase halves.....................104 Sez:Removing the crankshaft bearings...................105 Sez:Refitting the crankshaft bearings..................105 Sez:Inspecting the crankshaft alignment................106 Sez:Refitting the crankcase halves.....................107 Sez:Lubrication........................................107 Sez:Crankshaft oil seals...............................107 Sez:Removal............................................108 Sez:Refitting..........................................108 Sez:Oil pump...........................................109 Sez:Removal............................................109 Sez:Inspection.........................................110 Sez:Refitting..........................................111 Sez:Removing the oil sump..............................111 Sez:Refitting the oil sump.............................112 Sez:Fuel supply........................................112 Sez:Removing the carburettor...........................113 Sez:Refitting the carburettor..........................116 Sez:Level check........................................119 Sez:Inspecting the automatic choke device..............120 Sez:Adjusting the idle.................................122 Cap:Suspensions............................................125 Sez:Front..............................................126 Sez:Removing the front wheel...........................126 Sez:Front wheel hub overhaul...........................126 Sez:Refitting the front wheel..........................127 Sez:Handlebar..........................................127 Sez:Removal............................................128 Sez:Refitting..........................................128 Sez:Front fork.........................................128 Sez:Overhaul...........................................128 Sez:Refitting..........................................129 Sez:Steering column....................................129 Sez:Refitting..........................................130 Sez:Removal............................................130 Sez:Rear...............................................130 Sez:Removing the rear wheel............................130 Sez:Refitting the rear wheel...........................131 Sez:Shock absorbers....................................131 Sez:Removal............................................131 Sez:Refitting..........................................132 Sez:Centre-stand.......................................132 Cap:Braking system......................................... 0 Sez:Front brake calliper...............................134 Sez:Removal............................................134 Sez:Overhaul...........................................134 Sez:Refitting..........................................135 Sez:Front brake disc...................................136 Sez:Removal............................................136 Sez:Refitting..........................................136 Sez:Disc Inspection....................................136 Sez:Front brake pads...................................137 Sez:Removal............................................137 Sez:Refitting..........................................137 Sez:Fill...............................................138 Sez:Front..............................................138 Sez:Front brake pump...................................139 Sez:Removal............................................139 Sez:Refitting..........................................140 Sez:Rear drum brake....................................140 Cap:Chassis................................................142 Sez:Removing the ignition key-switch when on *off*.....143 Sez:Removing the ignition key-switch when on *lock*....143 Sez:Footrest...........................................143 Sez:Air filter.........................................144 Sez:Rear mudguard......................................144 Sez:Helmet bay.........................................144 Sez:Fuel tank..........................................145 Cap:Pre-delivery........................................... 0 Sez:Aesthetic inspection...............................147 Sez:Tightening torques inspection......................147 Sez:Electrical system..................................147 Sez:Levels check.......................................148 Sez:Road test..........................................148 Sez:Static test........................................148 Sez:Functional inspection..............................149 Cap:Time...................................................150 Sez:Engine.............................................151 Sez:Crankcase..........................................151 Sez:Crankshaft.........................................152 Sez:Cylinder assy......................................153 Sez:Cylinder head assy.................................153 Sez:Rocker arms support assy...........................154 Sez:Cylinder head cover................................155 Sez:Driven pulley......................................156 Sez:Oil pump...........................................157 Sez:Driving pulley.....................................158 Sez:Transmission cover.................................159 Sez:Starter motor......................................160 Sez:Flywheel magneto...................................161 Sez:Carburettor........................................162 Sez:Exhaust pipe.......................................162 Sez:Air cleaner........................................163 Sez:Frame..............................................164 Sez:Legshield spoiler..................................165 Sez:Rear cover.........................................166 Sez:Central cover......................................167 Sez:Mudguard...........................................168 Sez:Fuel tank..........................................169 Sez:Rear shock-absorber................................170 Sez:Steering column bearings...........................171 Sez:Handlebar covers...................................172 Sez:Handlebar components...............................173 Sez:Swing-arm..........................................174 Sez:Seat...............................................175 Sez:Turn signal lights.................................176 Sez:Front wheel........................................177 Sez:Rear wheel.........................................179 Sez:Electric devices...................................179 Sez:Electronic controls................................181 Sez:Transmissions......................................182 Sez:Brake callipers....................................183 Sez:Steering column....................................184 Sez:Helmet bay.........................................185 Sez:Rear wheel axle....................................186 Sez:Secondary air box..................................187
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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