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Scooter Fly 50 4t 4v User Manual

Scooter Fly 50 4t 4v
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WORKSHOP MANUAL
677586 EN
Fly 50 4t 4v

Table of Contents

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Scooter Fly 50 4t 4v Specifications

General IconGeneral
Fuel SystemCarburetor
IgnitionCDI
Rear BrakeDrum
Tires Front120/70-12
Tires Rear130/70-12
CoolingAir
TransmissionAutomatic
Front SuspensionTelescopic fork
Rear SuspensionSingle shock absorber
Front BrakeDisc

Summary

Rules

Safety rules

General safety precautions for vehicle maintenance operations.

Maintenance rules

Guidelines for using appropriate parts, tools, and procedures during maintenance.

Vehicle identification

Dimensions and mass

Specifies the physical dimensions and weight of the vehicle.

Engine

Transmission

Details the components and function of the vehicle's transmission system.

Electrical system

Components arrangement

Illustrates the location of various electrical system components on the vehicle.

Ground points

Identifies chassis and voltage regulator ground points for electrical system checks.

Electrical system installation

Provides guidance on connecting electrical system components on the front and back sides.

Conceptual diagrams

Presents schematic diagrams illustrating the vehicle's electrical system layout.

Ignition

Details the vehicle's ignition system, including components and operation.

Instruments and warning lights control board

Explains the layout and function of the instrument panel and warning lights.

Checks and inspections

Describes checks and inspections for the ignition system, including control unit testing.

Ignition circuit

Covers the procedures for checking and maintaining the vehicle's ignition circuit.

Voltage regulator check

Outlines methods for checking the voltage regulator's functionality and common faults.

Turn signals system check

Details how to troubleshoot issues with the vehicle's turn signal system.

Dry-charge battery

Provides instructions and warnings for handling and preparing dry-charge batteries.

Battery maintenance

Explains essential battery checks and maintenance procedures.

Battery installation

Guides on the correct procedure for installing and preparing a VRLA battery.

Connectors

Identifies and describes various electrical connectors used in the system.

Engine from vehicle

Exhaust assy. Removal

Details the steps for removing the exhaust assembly from the vehicle.

Removal of the engine from the vehicle

Provides a step-by-step guide for safely removing the engine from the vehicle.

Engine

Automatic transmission

Covers the removal and inspection of the automatic transmission cover, kickstart, and air duct.

Removing the driven pulley shaft bearing

Explains the process of removing and refitting the driven pulley shaft bearing.

Inspecting the clutch drum

Details the inspection of the clutch drum, including diameter and eccentricity checks.

Inspecting the clutch

Guides on checking the clutch friction material thickness and general condition.

Removing the driven half-pulley bearing

Outlines the procedure for removing the driven half-pulley bearing.

Inspecting the driven fixed half-pulley

Describes how to inspect the driven fixed half-pulley for wear and proper condition.

Inspecting the driven sliding half-pulley

Covers the inspection of the driven sliding half-pulley, including diameter measurements.

Inspecting the clutch spring

Details the inspection of the clutch spring, including free length and thickness checks.

Refitting the driven pulley

Provides instructions for refitting the driven pulley assembly and related components.

Drive-belt

Explains how to check the drive belt for damage and measure its width.

Removing the driving pulley

Outlines the steps for removing the driving pulley and its associated parts.

Inspecting the rollers case

Guides on inspecting the rollers case, bushings, and sliding shoes for wear.

Refitting the driving pulley

Details the procedure for refitting the driving pulley assembly, including belt installation.

Refitting the transmission cover

Explains the steps for refitting the transmission cover and associated components.

End gear

Covers the procedure for removing and refitting the end gear components.

Removing the hub cover

Details the process of removing the hub cover and associated parts.

Removing the wheel axle

Outlines the removal of the intermediate gear and the complete gear wheel axle.

Removing the wheel axle bearings

Explains the procedure for removing wheel axle bearings.

Removing the driven pulley shaft bearing

Details the process for removing the driven pulley shaft bearing.

Inspecting the hub shaft

Guides on inspecting the hub shaft for wear, distortion, and capacity.

Inspecting the hub cover

Explains how to inspect the hub cover for dents or distortion.

Refitting the driven pulley shaft bearing

Details the procedure for refitting the driven pulley shaft bearing.

Refitting the wheel axle bearing

Outlines the steps for refitting the wheel axle bearing.

Refitting the ub cover

Provides instructions for refitting the hub cover and associated components.

Flywheel cover

Explains the removal and refitting of the flywheel cover.

Cooling hood

Details the removal and refitting of the cooling hood and related parts.

Cooling fan

Explains the procedure for removing and refitting the cooling fan.

Removing the stator

Guides on how to remove the stator and its wiring.

Refitting the stator

Details the procedure for refitting the stator and flywheel assembly.

Flywheel and starting

Covers procedures related to the flywheel and engine starting system.

Removing the starter motor

Explains the steps for removing the starter motor from the engine.

Removing the flywheel magneto

Details the process of removing the flywheel magneto assembly.

Inspecting the flywheel components

Guides on inspecting flywheel components for wear and damage.

Starter gear rim

Explains how to check the starter gear rim's condition.

Intermediate gear

Guides on inspecting the intermediate gear and Bendix mechanism.

Refitting the flywheel magneto

Details the procedure for refitting the flywheel magneto assembly.

Refitting the starter motor

Explains the steps for refitting the starter motor to the engine.

Cylinder assy. and timing system

Covers procedures for cylinder assembly and timing system components.

Removing the rocker-arms cover

Details the removal of the rocker-arms cover and related parts.

Removing the timing system drive

Outlines the process for removing the timing system drive components.

Removing the cam shaft

Explains the procedure for removing the camshaft and its related parts.

Removing the cylinder head

Details the steps for removing the cylinder head and associated components.

Removing the valves

Guides on how to remove the valves, springs, and seals from the cylinder head.

Removing the cylinder - piston assy.

Explains the process of removing the cylinder and piston assembly.

Inspecting the small end

Details how to inspect the connecting rod's small end diameter and condition.

Inspecting the wrist pin

Guides on measuring the wrist pin's diameter and admissible limits.

Inspecting the piston

Explains how to inspect the piston's bearing diameter and clearances.

Inspecting the cylinder

Details how to measure the cylinder's inner diameter and check for run-out.

Inspecting the piston rings

Guides on inspecting piston rings, their openings, and fitting procedures.

Removing the piston

Explains the procedure for removing the piston from the cylinder.

Refitting the piston rings

Details the correct procedure for refitting piston rings onto the piston.

Refitting the cylinder

Guides on refitting the cylinder assembly and associated components.

Inspecting the cylinder head

Outlines checks for cylinder head surface wear, distortion, and bearing condition.

Inspecting the timing system components

Details inspection of timing system parts like sliders, pulleys, and chains.

Inspecting the valve sealings

Explains how to inspect valve sealings and check valve seat condition.

Inspecting the valves

Guides on inspecting valve length, stem diameter, and guide clearances.

Inspecting the cam shaft

Details inspection of the camshaft for wear, diameter, and axial clearance.

Refitting the head and timing system components

Outlines the procedure for refitting the cylinder head and timing system components.

Refitting the timing chain

Explains the steps for refitting the timing chain and tensioner.

Refitting the rocker-arms cover

Guides on refitting the rocker-arms cover after maintenance.

Refitting the intake manifold

Details the procedure for refitting the intake manifold and carburettor.

Crankcase - crankshaft

Covers the disassembly and inspection of the crankcase and crankshaft.

Splitting the crankcase halves

Explains the process of splitting the crankcase halves and removing the crankshaft.

Removing the crankshaft bearings

Guides on removing the crankshaft bearings using specialized tools.

Refitting the crankshaft bearings

Details the procedure for refitting crankshaft bearings.

Inspecting the crankshaft alignment

Outlines how to check the crankshaft alignment and maximum admitted run-out.

Refitting the crankcase halves

Explains the steps for refitting the crankcase halves and securing them.

Lubrication

Provides details on lubrication procedures for engine components.

Crankshaft oil seals

Details the removal and refitting of crankshaft oil seals.

Oil pump

Covers the removal, inspection, and refitting of the oil pump assembly.

Fuel supply

Details procedures related to fuel supply, including tank removal and carburettor checks.

Removing the carburettor

Explains the procedure for detaching and removing the carburettor from the engine.

Refitting the carburettor

Details the process of refitting the carburettor and its components.

Inspecting the automatic choke device

Guides on inspecting the automatic choke device for proper function and protrusion.

Adjusting the idle

Explains how to adjust the engine's idle speed according to specific procedures.

Suspensions

Front

Covers the removal and overhaul of the front wheel and hub assembly.

Refitting the front wheel

Details the correct procedure for refitting the front wheel assembly.

Handlebar

Explains the removal and refitting of the handlebar and associated components.

Front fork

Guides on the removal and overhaul of the front fork assembly.

Steering column

Covers the removal and adjustment of the steering column bearings.

BEARING SEAT REPLACEMENT ON CHASSIS

Details the replacement procedure for bearing seats on the chassis.

LOWER BEARING SEAT REPLACEMENT ON FORK

Explains how to replace the bearing seat on the front fork.

Steering bearing

Guides on checking and adjusting steering bearing clearance.

Rear

Covers the removal and refitting of the rear wheel.

Swing-arm

Details the removal and overhaul procedures for the swing-arm.

Shock absorbers

Explains the removal and refitting procedures for the shock absorbers.

Centre-stand

Guides on the removal and fitting of the centre stand.

Side stand

Details the removal and fitting of the side stand.

Braking system

Front brake calliper

Explains the removal and refitting of the front brake calliper.

Front brake disc

Guides on the removal and inspection of the front brake disc.

Disc Inspection

Details how to inspect the brake disc thickness and run-out.

Front brake pads

Explains the removal, replacement, and checking of front brake pads.

Fill

Provides instructions for filling and bleeding the front hydraulic brake system.

Front brake pump

Guides on the removal and refitting of the front brake pump.

Rear drum brake

Explains the adjustment, removal, and fitting of the rear drum brake.

Transmission replacement

Details the procedure for replacing the transmission system.

Chassis

Seat

Explains how to remove and access the seat and helmet compartment.

Side fairings

Guides on removing the legshield and associated fairing components.

Rear rack

Details the removal of the grab handle and rear rack components.

Driving mirrors

Explains how to adjust and tighten the driving mirrors.

Rear handlebar cover

Guides on removing the rear handlebar cover and instrument panel assembly.

Instrument panel

Details the removal of the instrument panel and its related covers.

Front handlebar cover

Explains how to remove the front handlebar cover and access the headlight assembly.

Headlight assy.

Guides on removing the headlight assembly and replacing bulbs.

Daylight running light

Details the procedure for replacing the daylight running light bulb.

Front turn indicators

Explains how to replace the front turn indicator bulbs.

Legshield

Guides on removing the legshield, front mudguard, and associated parts.

Knee-guard

Details the removal of the knee-guard and glove-box components.

Removing the ignition key-switch when on *off*

Explains the procedure for removing the ignition key-switch in the 'off' position.

Removing the ignition key-switch when on *lock*

Guides on removing the ignition key-switch when in the 'lock' position.

Taillight assy.

Details the removal of the taillight assembly and associated components.

License plate light

Explains how to remove the license plate light bulb and holder.

Footrest

Guides on removing the footrest and related parts like side fairings.

Side fairings

Details the removal of side fairings, including covers and headlights.

License plate holder

Explains how to remove the license plate holder and rear light unit.

Air filter

Guides on removing the air filter housing and associated components.

Rear mudguard

Details the removal of the rear mudguard and associated retainers.

Helmet bay

Explains how to lift the saddle and remove the helmet bay.

spoiler

Guides on removing the spoiler and footrest components.

Fuel tank

Details the removal of the fuel tank and its related pipes and connectors.

Front mudguard

Explains how to remove the front mudguard and its fixing screws.

Front central cover

Guides on removing the front central cover and its lower fixing screws.

Battery

Details the procedure for removing the battery and its compartment cover.

Lower cover

Explains how to remove the lower cover and its fixing screws.

Pre-delivery

Aesthetic inspection

Covers visual checks of paintwork, plastics, scratches, and dirt.

Tightening torques inspection

Details checks for safety fasteners and specific tightening torques.

Electrical system

Outlines pre-delivery checks for the vehicle's electrical system components.

Levels check

Guides on checking essential fluid levels like brake fluid, hub oil, and engine coolant.

Road test

Describes checks performed during a road test, including starting, throttle response, and braking.

Static test

Covers static checks after a test ride, including starter operation and steering.

Functional inspection

Lists functional checks for braking, clutch, engine, and other systems.