Piaggio Fly 125 i.e - 150 i.e Leader MY 2011 (EN)

s3074"> - Resistance of the primary =0.5 Ohm ±8% - Resistance between primary and ground =infinite - Resistance between primary and HV output =3.1 KOhm ±9% - P resence of battery battery voltage voltage between pins 1 and 9 of the interface cable harness upon shifting to ON and for 2 sec.

CHAR - 12

Fly 125 i.e - 150 i.e Leader (2011)

Characteristics

STATOR 

Power: 450 W Resistance between terminals: 0.2 - 1 Ohm terminal insulation from ground

Frame Frame and sus pensions FRAME AND SUSPENSION  Sp ec i f i c at i o n F rame Fro Front suspension Rea Rear suspension

Des c ./Qu an t i t y   Tubular steel frame Hydraulic telescopic fork with Ø 32-mm stem, 76 mm travel. Adjustable 4-position spring preloading single shock absorber, 73 mm travel

Brakes BRAKES Sp ec i f i c at i o n F ront brake

Rear brake

Des c ./Qu an t i t y   Disc brake (Ø 220 mm) with hydraulic control (lever on the far right of the handlebar) and floating calliper. Ø 140-mm drum brake with mechanical control activated by the handlebar left-side lever.

Wheels Wheels and tyres tyr es WHEELS AND TYRES Sp ec i f i c at i o n Wheel rim type F ront wheel rim R ear wheel rim F ront tyre R ear tyre F ront tyre pressure Rear tyre pressure

Des c ./Qu an t i t y   Light alloy wheel rims. 12'' x 3.00 12" x 3.00 Tubeless 120/70-12" Tubeless 120/70 - 12" 1.8 bar 2 bar

CHAR - 13

Fly 125 i.e - 150 i.e Leader (2011)

Characteristics

Sp ec i f i c at i o n Rear wheel pressure (rider and passenger):

Des c ./Qu an t i t y   2.3 bar

Tightening Torques ENGINE  N am e Ignition spark plug Head cover screws Head-cylinder stud bolt nuts S crews fixing head and cylinder to crankcase  Tensio  Tensione nerr fast fasten enin ing g screw screws: s:  Timin  Timing g chai chain n tensi ension oner er cen central ral screw screw C amshaft pulley screw Valve clearance adjustment lock nuts E ngine oil pre-filter cover: E ngine oil drainage cap Alternator flywheel nut S tator screws P ick-up screws Oil pump bulkhead screw Oil pump sprocket gear screw Screws fixing oil pump to the crankcase Oil pump coupling screws Oil sump screws Inlet manifold screw  Throt  Throtttle bod body/m y/manif anifol old d clam clamp p screw screws s S crews fixing cables to starter motor S tarter motor screws  Trans  Transm missio ission n cov cover screw screws s C amshaft retention plate screw P ressure reducer counterweight retainer F lywheel air duct screw Oil filter on crankcase fitting Nut fixing muffler to cylinder head Minimum oil pressure switch Nut locking clutch unit on pulley Drive pulley nut (°) Driven pulley shaft nut Hub oil drainage screw R ear hub cap screws Wheel axle nut Crankcase half union screw

To r q u e i n Nm 10 - 15 Nm 11 - 13 6 to 7 +90° +90° * 8 - 10 8 - 10 10 Nm 5- 6 12 - 14 7 - 9 Nm 25 - 28 Nm 25 - 28 52 - 58 Nm 3- 4 3- 4 4- 5 8 - 10 5- 6 7 - 9 Nm 8 - 10 Nm 7- 9 1.2 - 1.5 1.5 Nm 1.5 - 2.5 11 - 13 11 - 13 13 Nm 5- 6 7 - 8.5 3- 4 27 - 33 16 - 18 12 - 14 55 - 60 Nm 75 - 83 54 - 60 3 - 5 Nm 24 - 26 Nm 115 - 125 8 - 10

In order to ensure an adequate locking torque, lubricate the nuts before fitting them. * When fitting the new stud bolts, nut tightening involves 3 turns of 90° each after the first locking at 6 - 7 Nm, consequently: 6 7 Nm + 90° + 90° + 90° at crossed passages. (°) Apply LOCTITE 243 type threadlock.

GRUPPO STERZO N am e Steering upper ring nut Steering lower ring nut Handlebar fixing screw

To r q u e i n Nm 34.3 - 39.2 11.7 - 13.7 60 - 65

GRUPPO TELAIO N am e E ngine arm bolt - frame arm E ngine-swinging arm bolt F rame-swinging arm bolt Silent block support to chassis bracket fastener bolts S ide stand bolt C entre stand pin

CHAR - 14

To r q u e i n Nm 40 to 45 40 to 45 50 to 55 20 ÷25 12 - 16 39.2 - 44.1

Fly 125 i.e - 150 i.e Leader (2011)

Characteristics

SOSPENSIONE ANTERIORE  Nam e F ork bottom screw Screws fastening stem to fork plate F ront wheel axle F ront wheel axle screw on fork leg F ront mudguard to plate fixing screw

To r q u e i n Nm 20 ÷25 36 to 44 45 ÷50 8 - 8.5 4.5 to 7

REAR SUSPENSION  Nam e R ear wheel axle Lower shock absorber clamp S hock absorber/C hassis nut: S hock absorber to crankcase bracket fastener

To r q u e i n Nm 104 ÷126 40 to 45 20 ÷25 20 ÷25

FRONT FRONT AND REAR BRAK E  Nam e Brake fluid pump-hose fitting Brake fluid pipe-calliper fitting C alliper tightening screw Disc tightening screw (Apply LOCTITE 243 medium-strength threadlock) Oil bleeding valve R ear brake adjustment nut

To r q u e i n Nm 20 ÷25 20 ÷25 24.5 to 27.5 8 - 12 Nm

8 - 12 5

Overhaul data  As sembl sem bl y cl c l earances earan ces Cylinder - piston assy. PISTON TO CAST IRON CYLINDER CYL INDER COUPLING (125) Nam e C oupling C oupling C oupling C oupling coupling 1st oversize coupling 1st oversize coupling 1st oversize coupling 1st oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize C oupling 3rd oversize C oupling 3rd oversize C oupling 3rd oversize C oupling 3rd oversize

In i t i al s M N O P M1 N1 O1 P1 M2 N2 O2 P2 M3 N3 O3 P3

Cy l i n d er 56.997 - 57.004 57.004 - 57.011 57.011 - 57.018 57.018 - 57.025 57.197 - 57.204 57.204 - 57.211 57.211 - 57.218 57.218 - 57.225 57.397 - 57.404 57.404 - 57.411 57.411 - 57.418 57.418 - 57.425 57.597 - 57.604 57.604 - 57.611 57.611 - 57.618 57.618 - 57.625

Pi s t o n 56.944 - 56.951 56.951 - 56.958 56.958 - 56.965 56.965 - 56.972 57.144 - 57.151 57.151 - 57.158 57.158 - 57.165 57.165 - 57.172 57.344 - 57.351 57.351 - 57.358 57.358 - 57.365 57.365 - 57.372 57.544 - 57.551 57.551 - 57.558 57.558 - 57.565 57.565 - 57.572

Pl ay o n f i t t i n g   0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060

COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER  (125) Nam e C oupling C oupling C oupling C oupling

In i t i al s A B D C

Cy l i n d er 56.980 - 56.987 56.987 - 56.994 57.001 - 57.008 56.994 - 57.001

Pi s t o n 56.933 - 56.940 56.940 - 56.947 56.954 - 56.961 56.947 - 56.954

Pl ay o n f i t t i n g   0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054

CHAR - 15

Fly 125 i.e - 150 i.e Leader (2011)

Characteristics

Nam e coupling 1st oversize coupling 1st oversize coupling 1st oversize coupling 1st oversize C oupling 2nd oversize C oupling 2nd oversize C oupling 2nd oversize C oupling 2nd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize

In i t i al s A1 B1 D1 C1 A2 B2 C2 D2 A3 B3 C3 D3

Cy l i n d er 57.180 - 57.187 57.187 - 57.194 57.201 - 57.208 57.194 - 57.201 57.380 - 57.387 57.387 - 57.394 57.394 - 57.401 57.401 - 57.408 57.580 - 57.587 57.587 - 57.594 57.594 - 57.601 57.601 - 57.608

Pi s t o n 57.133 - 57.140 57.140 - 57.147 57.154 - 57.161 57.147 - 57.154 57.333 - 57.340 57.340 - 57.347 57.347 - 57.354 57.354 - 57.361 57.533 - 57.540 57.540 - 57.547 57.547 - 57.554 57.554 - 57.561

Pl ay o n f i t t i n g   0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054

ERKE  COUPLING BETWEEN (A SSO-W ERKE   ) PISTON AND CYLINDER (150)

Nam e C oupling C oupling C oupling C oupling coupling 1st oversize coupling 1st oversize coupling 1st oversize coupling 1st oversize C oupling 2nd oversize C oupling 2nd oversize C oupling 2nd oversize C oupling 2nd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize

In i t i al s A B C D A1 B1 C1 D1 A2 B2 C2 D2 A3 B3 C3 D3

Cy l i n d er 62.580 - 62.587 62.587 - 62.594 62.594 - 62.601 62.601 - 62.608 62.780 - 62.787 62.787 - 62.794 62.794 - 62.801 62.801 - 62.808 62.980 - 62.987 62.987 - 62.994 62.994 - 63.001 63.001 - 63.008 63.180 - 63.187 63.187 - 63.194 63.194 - 63.201 63.201 - 63.208

Pi s t o n 62.533 - 62.540 62.540 - 62.547 62.547 - 62.554 62.554 - 62.561 62.733 - 62.740 62.740 - 62.747 62.747 - 62.754 62.754 - 62.761 62.933 - 62.940 62.940 - 62.947 62.947 - 62.954 62.954 - 62.961 63.133 - 63.140 63.140 - 63.147 63.147 - 63.154 63.154 - 63.161

Pl ay o n f i t t i n g   0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054

IGHT  WAY  COUPLING BETWEEN (R IGHT   ) PISTON AND CYLINDER (150)

Nam e C oupling C oupling C oupling C oupling

In i t i al s A B C D

Cy l i n d er 62.580 - 62.587 62.587 - 62.594 62.594 - 62.601 62.601 - 62.608

Pi s t o n 62.541 - 62.548 62.548 - 62.555 62.555 - 62.562 62.562 - 62.569

Pl ay o n f i t t i n g   0.032 - 0.046 0.032 - 0.046 0.032 - 0.046 0.032 - 0.046

In i t i al s A A A A

Qu an t i t y   0.15 - 0.30 0.10 - 0.30 0.10 - 0.35 0.15 - 0.30

Piston rings

SEALING RINGS (125) Nam e C ompression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize

CHAR - 16

Des c r i p t i o n

Di m en s i o n s 57 x 1 57x1 57x2.5 57.2 x 1

Fly 125 i.e - 150 i.e Leader (2011)

Nam e Oil scraper ring 1st oversize Oil scraper ring 1st oversize Compression ring 2nd oversize Oil scraper ring 2nd oversize Oil scraper ring 2nd oversize Compression ring 3rd oversize Oil scraper ring 3rd oversize Oil scraper ring 3rd oversize

Des c r i p t i o n

Characteristics

Di m en s i o n s 57.2x1

In i t i al s A

Qu an t i t y   0.10 - 0.30

57.2x2.5

A

0.10 - 0.35

57.4x1

A

0.15 - 0.30

57.4x1

A

0.10 - 0.30

57.4x2.5

A

0.10 - 0.35

57.6x1

A

0.15 - 0.30

57.6x1

A

0.10 - 0.30

57.6x2.5

A

0.10 - 0.35

Di m en s i o n s 62.6x1 62.6x1 62.6x2.5 62.8x1

In i t i al s A A A A

Qu an t i t y   0.15 - 0.30 0.20 - 0.40 0.20 - 0.40 0.15 - 0.30

62.8x1

A

0.20 - 0.40

62.8x2.5

A

0.20 - 0.40

63.0 x 1

A

0.15 - 0.30

63.0 x 1

A

0.20 - 0.40

63.0 x 2.5

A

0.20 - 0.40

63.2 x 1

A

0.15 - 0.30

63.2 x 1

A

0.20 - 0.40

63.2 x 2.5

A

0.20 - 0.40

Maximum clearance after use: 1 mm

SEALING RINGS (150) Nam e C ompression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize Oil scraper ring 1st oversize Oil scraper ring 1st oversize Compression ring 2nd oversize Oil scraper ring 2nd oversize Oil scraper ring 2nd oversize Compression ring 3rd oversize Oil scraper ring 3rd oversize Oil scraper ring 3rd oversize

Des c r i p t i o n

Crankcase Crankcase - crankshaft - connecting rod   AXIA L CLEARA CL EARANCE NCE BETWEEN CRANKSHA FT AND CONNECTING ROD Nam e Half-shaft, transmission side F lywheel-side half shaft C onnecting rod with P P Crank pin width

Des c r i p t i o n

Di m en s i o n s 16.6 +0-0.05

In i t i al s A

Qu an t i t y   D = 0.20 - 0.50

16.6 +0-0.05 18 -0.10 -0.15 51.400

B C E

D = 0.20 - 0.50 0.20 to 0.50

 AXIA L CLEARA CL EARANCE NCE BETWEEN CRANKSHAFT CRANK SHAFT AND A ND CRANKSHAFT CRANKSHA FT HALF-BEA HAL F-BEA RINGS Nam e C rankshaft C rankshaft Crankcase Crankcase Crankshaft half-bearing Crankshaft half-bearing Crankshaft half-bearing Crankshaft category 1 Crankcase category 1

Des c r i p t i o n

Di m en s i o n s

In i t i al s C ategory 1 C ategory 2 C ategory 1 C ategory 2 Category B - blue C ategory C - yellow C ategory E - green E-E

Qu an t i t y   28.998 - 29.004 29.004 - 29.010 32.953 - 32.959 32.959 - 32.965 1.973 - 1.976 1.976 - 1.979 1.979 - 1.982

CHAR - 17

Fly 125 i.e - 150 i.e Leader (2011)

Characteristics

Nam e Crankshaft category 1 Crankcase category 2 Crankshaft category 2 Crankcase category 1 Crankshaft category 2 Crankcase category 2

Des c r i p t i o n

Di m en s i o n s

In i t i al s C-C

Qu an t i t y  

C-C B -B

Characteristic  Crankshaft/crankcase axial clearance «A»:

0.15 - 0.40

Slot packing system - Provisionally fit the piston into the cylinder, without any base gasket. - Assemble a dial gauge on the specific tool - Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure. - Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation)

CHAR - 18

Fly 125 i.e - 150 i.e Leader (2011)

Characteristics

- Calculate the difference between the two measurements: use the chart below to identify the thickness of the cylinder base gasket gas ket to to be used used for refitting. refitting. Correctly C orrectly identify identify the cylinder base gasket thickness to keep the correct compression ratio. - Remove the special tool and the cylinder.

Specific Specific tooling  020428Y Piston 020428Y Piston position check mounting 

Characteristic  Compression ratio (125/150)

10.6 ±0.5 to 1

SHIMMING SYSTEM (125) Sp ec i f i c at i o n Value measured  Thick  Thickne ness ss Value measured  Thick  Thickne ness ss Value measured  Thick  Thickne ness ss

Des c ./Qu an t i t y   0 - 0.1 0.8 ±0.0 ±0.05 5 0.1 - 0.3 0.6 ±0.0 ±0.05 5 0.3 - 0.4 0.4 ±0.0 ±0.05 5

SHIMMING SYSTEM (150) Sp ec i f i c at i o n Value measured  Thick  Thickne ness ss Value measured  Thick  Thickne ness ss Value measured  Thick  Thickne ness ss

Des c ./Qu an t i t y   1 - 1.1 0.8 ±0.0 ±0.05 5 1.1 - 1.3 0.6 ±0.0 ±0.05 5 1.3 - 1.4 0.4 ±0.0 ±0.05 5

Products RECOMMENDED PRODUCTS TABLE  Pr o d u c t Lubricant for gearboxes and transmissions Brake fluid

Stand, Stand, throt throttl tle, e, brak brake e leve leverr lub lubrica ricati tion on Oil Oil for for air air fil filtter spon spong ge

Des c r i p t i o n Lubricant for gearboxes and transmissions. Brake fluid.

Sp ec i f i c at i o n s SAE 80W/90, API GL4 - API GL5

Synthetic fluid S AE J 1703 -F MVS S 116 - DOT 3/4 - ISO IS O 4925 4925 - CUNA CU NA NC 956 956 DOT 4 Grease for brake brake levers, levers, throt throttl tle, e, stand stand White White calciu calcium m comple complex x soap-based soap-based spray grease with with NLGI NLG I 2; ISO-L-XB ISO- L-XBCI CIB2 B2 Spec Specia iall pro prod duct for for the tr treat eatment ent of foam foam filters.

CHAR - 19

Characteristics

Pr o d u c t Synthet Synthetic ic oil oil for for 4-str 4-stroke oke engine engines s

Fly 125 i.e - 150 i.e Leader (2011)

Des c r i p t i o n Sp ec i f i c at i o n s Synthet Synthetic-ba ic-based sed lub lubrica ricant nt for four four strok stroke e SAE 5W-40, 5W-40, API SL, SL , ACEA A3, J ASO MA engines. Grease Y ellow-brown, lilithium-base, me medium-fi- ISO L-X-BCHA L-X-BC HA 3 - DIN 51 825 825 K3K -20 bre multi-purpose multi-purpose grease. greas e.  Tran  Transmiss smissio ion n flex flexib ible le hoses hoses - lub lubri rica cattion ion Synt Synthetic etic-b -base ased d lubr lubric ican antt for for four four stro stroke ke SAE 5W-40, 5W-40, API SL, SL , ACEA A3, J ASO MA engines.

CHAR - 20

INDEX OF TOPICS

T OOLING OOLING

TOOL

Fly 125 i.e - 150 i.e Leader (2011)

 Tool  Toolin ing g

SPECIFIC TOOLS

 TOOL - 22 22

St o r es c o d e 001330Y

Des c r i p t i o n Tool for fitting steering seats

001467Y 009

Bell for OD 42-mm bearings

001467Y 01 013

P liers to extract ø 15-mm bearings

002465Y

P liers for circlips

005095Y

E ngine support

006029Y

P un unch for fitting fifth steering bearing on steering tube

008564Y

F lywheel extractor

Fly 125 i.e - 150 i.e Leader (2011)

St o r es c o d e 020004Y

Des c r i p t i o n P unch for removing fifth wheels from headstock

020055Y

Wrench for steering tube ring nut

020074Y

Support base for checking crankshaft alignment

020150Y

Air heater support

020151Y

Air heater

020193Y

Oil pressure check gauge

 Tooli  Toolin ng

 TOOL - 23 23

Fly 125 i.e - 150 i.e Leader (2011)

 Tool  Toolin ing g

 TOOL - 24 24

St o r es c o d e 020262Y

Des c r i p t i o n C rankcase splitting plate

020263Y

Driven pulley assembly sheath

020271Y

Tool for removing-fitting silent bloc

020306Y

P un unch for assembling valve seal rings

020329Y

Mity-Vac vacuum-operated pump

020330Y

S troboscopic light to check timing

Fly 125 i.e - 150 i.e Leader (2011)

St o r es c o d e 020331Y

Des c r i p t i o n Digital multimeter

020332Y

Digital rpm indicator

020334Y

Multiple battery charger

020335Y

Magnetic support for dial gauge

020359Y

42x47-mm Adaptor

 Tooli  Toolin ng

 TOOL - 25 25

Fly 125 i.e - 150 i.e Leader (2011)

 Tool  Toolin ing g

 TOOL - 26 26

St o r es c o d e 020360Y

Des c r i p t i o n 52x55-mm Adaptor

020363Y

20-mm guide

020364Y

25-mm guide

020368Y

driving pulley lock wrench

020375Y

28 x 30 mm adaptor

020376Y

Adaptor handle

Fly 125 i.e - 150 i.e Leader (2011)

St o r es c o d e 020382Y

Des c r i p t i o n Valve cotters equipped with part 012 removal tool

020382Y 011

adapter for valve removal tool

020412Y

15-mm guide

020423Y

Driven pulley lock wrench

020424Y

Driven pulley roller casing fitting punch

020425Y

P unch for flywheel-side oil seal

 Tooli  Toolin ng

 TOOL - 27 27

Fly 125 i.e - 150 i.e Leader (2011)

 Tool  Toolin ing g

 TOOL - 28 28

St o r es c o d e 020426Y

Des c r i p t i o n P iston fitting fork

020427Y

P iston assembly band

020428Y

P iston position check mounting

020430Y

P in lock fitting tool

020431Y

Valve oil seal extractor

020434Y

Oil pressure check fitting

Fly 125 i.e - 150 i.e Leader (2011)

St o r es c o d e 020439Y

Des c r i p t i o n 17-mm guide

020444Y

Tool for fitting/ removing the driven pulley clutch

020480Y

P etrol pressure check kit

020565Y

F lywheel lock calliper spanner

020622Y

Transmission-side oil seal punch

020922Y

Diagnosis Tool

 Tooli  Toolin ng

 TOOL - 29 29

INDEX OF TOPICS

M  AINTENANCE 

MAIN 

Fly 125 i.e - 150 i.e Leader (2011)

Maintenance

Maint Maintenance enance chart  MAINTENANCE TABLE  I :

INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY  CLEAN, R : REPLACE,  A : ADJUST, L : LUBRICATE  * Check every 3,000 km ** Replace every 2 years

C :

k m x 1,000

S afety fasteners S park plug C entre stand / Side stand Drive belt  Throt  Throtttle cont control rol Air filter * Oil filter Mesh oil filter Valve clearance E lectrical system and battery C ylinder ventilation system Brake levers Brake fluid ** E ngine oil * Hub oil Headlight direction adjustment Brake pads S liding shoes / C VT rollers  Tyre  Tyre pre pressu ssure re and and wear ear Vehicle road test Odometer gear S uspension S teering  Trans  Transm missio ission n Operation time

1 I

6

I L I A

C I L I R R I I I

A 80'

C R C A I

12 I R L R A C R C

I

18

I L I C R C A I

24 I R L R A C R C

30

I L I C R C

36 I R L R A C R C A I

42

I L I C R C

48 I R L R A C R C

54

I L I C R C A I

60 I R L R A C R C

 

I I I I I C C L L L L L I I I I I I I I I I R R R R R R R R R R R R R R R R R R R R A A A A A I I I I I I I I I I I R I R I R I R I R I I I I I I I I I I I I I I I I I I I I L L L L L I I I I I A A A A A L L L L L 170' 180' 170' 195' 115' 290' 115' 195' 170' 180'

Spark Spark pl ug  - P osition the vehicle vehicle on the stand - Remove the external engine inspection panel, unscrewing the indicated screws.

MAIN - 31

Maintenance

Fly 125 i.e - 150 i.e Leader (2011)

- Disconnect the spark plug H.V. cable cap. - Slide the internal cover upwards.

- 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 s ooty,, the conditions of the washer, and measure the distance between the electrodes using the appropriate feeler gauge. -Adjust the distance, if necessary, by bending the side electrode very carefully. In case of anomaly (as described before), replace the spark plug with another of the recommended type.

- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it. - Refit the cover. MAIN - 32

Fly 125 i.e - 150 i.e Leader (2011)

Maintenance

- Fit the cap on the spark plug as far as it will go. - Carry out refit operations. CAUTION 

THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD.THE SPARK PLUG MUST  BE REPLACED EVERY 12,000 KM. THE USE OF NON CONFORMING ELECTRONIC IGNITION  CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY  DAMAGE THE ENGINE.

Characteristic  Electrode gap

0.7 to 0.8 mm Spark plug (125 (125 cc)

NGK CR8 CR 8EB - DENSO U24ES U24ESR-NB R-NB Spark plug (150 (150 cc)

NGK CR7 CR 7EB - DENSO U22ES U22ESR-NB R-NB

Locki ng torq ues (N* (N*m) m) Ignition spark plug 10 plug 10 - 15 Nm

Hub oil  Check  - P ark the vehicle vehicle on flat ground and rest it on the the centre stand. - Unscrew the oil dipstick/cover, dry it with a cloth and reinsert it screwing it in thoroughly.

- Remove emove the dipstick/cover and check that the the oil level is between between MIN and MAX. - If the level is below the MIN value, restore the proper amount of oil in the hub. - Screw S crew the the oil dipstick back and check it is locked. locked.

MAIN - 33

Maintenance

Fly 125 i.e - 150 i.e Leader (2011)

Replacement  - Remove the oil dipstick/cover.

- 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.

Recommended Recommen ded products Lubricant for gearboxes gearboxes and transmissions Lubricant for gearboxes gearboxes and transmissions.

SAE 80W/90, API GL4 - API GL5

Characteristic  Rear Rear hub o il 

~200 cm³

Lockin g torq ues (N*m) (N*m) Hub oil drainage screw 3 screw 3 - 5 Nm

MAIN - 34

Fly 125 i.e - 150 i.e Leader (2011)

Maintenance

 Ai r f il ter  - Remove R emove the saddle and the helmet compartment. compartment. - Remove the lower cover. - Remove the front central cover. - Remove the grab handle. - Remove the side fairings. - Remove the footrest. - Remove the spoilers. - Remove the air duct. - Loosen the 6 screws and remove the air filter cover. - Remove the filtering element and clean it with water and shampoo; then dry it with a clean cloth and short blasts of compressed air. Finally, immerse it in a mixture of 50% oil of the recommended type and 50% petrol. Then gently squeeze the filter element between your hands, allow it to drip and then refit it. CAUTION 

IF THE VEHICLE IS USED USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF  THE AIR FILTER MORE OFTEN MORE OFTEN TO AV OID OID DAMAGING THE  ENGINE.

Recommended Recommended produc ts Oil for air filter sponge Special Special product for the treatment of foam filters.

-

See also Helmet bay Lower cover Front central cover Rear rack S ide fairings fairings Footrest spoiler

Engine oil  In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the thermal group. An in su ff ic ien t q uan ti ty of oi l c an c aus e ser io us dam age t o t he en gi ne.

MAIN - 35

Maintenance

Fly 125 i.e - 150 i.e Leader (2011)

In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement  Change oil and replace filter as indicated in the scheduled maintenance maintenance table. The engine must be emptied emptied by draining draining off the oil through the drainage plug of the mesh pre-filter, flywheel side; furthermore to facilitate oil drainage, loosen or remove the cap/dipstick. Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter and remove it. To carry out this operation, it is not necessary to remove the whole silencer. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from oil dipstick/cover.  Then  Then star startt up the vehic ehicle le,, leav leave e it run running ing for a few minutes and switch it off: After about five minutes, check the level and, if necessary, neces sary, top-up but never exceeding the MAX level reference mark. mark. The The cartridge 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.

Recommended Recommended produc ts Engine oil Synthetic-based oil Synthetic-based lubricant for four  stroke engines.

SAE 5W-40 W-40, API SL, SL , ACEA A3, J ASO MA MAIN - 36

Fly 125 i.e - 150 i.e Leader (2011)

Maintenance

Characteristic  Engine oil  1100 1100 cm ³ 

Lockin g torqu es (N* (N*m) m) Engine oil dr ainage cap cap 25 - 28 

Check   This  This oper operat atio ion n must ust be car carried ied out out with ith the eng engine ine cold cold and and follo ollow wing ing the proced ocedu ure below elow:: - Place the vehicle on its centre stand and on flat ground. completely . - Undo cap/dipstick, dry it off with a clean cloth and reinsert it, screwing down completely 

- Rem R emove ove the cap/dipstick again and check that that the the level is between between the MIN and MAX reference marks; marks; top up if necessary.  The  The MAX lev level mark ark ind indicat icates es a quant antity ity of arou aroun nd 1100 cc of oil oil in the eng engine. ine. If the chec check k is car carried ied out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level. Engine oil top-up

 The  The oil oil shou should ld be topp opped up aft after hav having ing chec check ked the level and in any case by adding oil without  ever exceeding the MAX. level .

Restoration of the the level from MIN to MAX requires approximately 200 cc .

Engine oil filter   The  The oil oil filt ilter must be rep replace laced d ever every y time ime the oil oil is chan chang ged. ed. Use new oil of the recommended type for topping up and changing purposes and comply with the regulations regarding timing timing and mileage, as described in in the periodic maintenance table. Make sure the pre-filter and drainage plug O-rings are in good conditions. MAIN - 37

Maintenance

Fly 125 i.e - 150 i.e Leader (2011)

Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new oil filter being careful to lubricate the O-ring before fitting it. Change the engine oil. WARNING

IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF  GREASE, WE RECOMMEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH.

Recommended Recommended produc ts Engine oil Synthetic-based oil Synthetic-based lubricant for four stroke engines.

SAE 5W-40 5W-40, API SL, SL , ACEA A3, J ASO MA

Oil pressure warning warning l ight   The  The vehic ehicle le is equi equip pped ped with ith a tellt elltal ale e lig light on the dashboard that lights up when the key is turned to the «ON » position. However, this light should switch off once the engine has started. If the light turns on during braking, at idling  speed or while turni ng a corner, it is necessary  to check the oil level and and the lubric ation system.

Checking Checking the ignitio n 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. If I f the reference mark mark is opposite opposite the the indicator on the head, make the crankshaft turn once more. -The TDC reference mark is repeated also between the flywheel cooling fan and the flywheel cover.  To use this refer eferen ence ce mark ark, remove ove the spar spark k plug lug and turn the engine in the opposite direction to the normal normal direction of rotation using a compass compass spanMAIN - 38

Fly 125 i.e - 150 i.e Leader (2011)

Maintenance

ner applied to the camshaft drive sprocket housing. N.B. TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.

Checking th e valve valve clearance -To check valve clearance, centre the reference marks of the timing system. - Use a feeler gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve clearance values, intake and exhaust respectively, are different from the ones indicated below, adjust them by loosening the lock nut and operate on the set screw with a screwdriver.

Characteristic  Valve clearance

Intake: 0.10 mm (when cold) Exhaust: 0.15 mm (when cold)

Locki ng torq ues (N* (N*m) m) Valve Valve clearance clearance adjustment lo ck nut s 7 - 9 Nm

Braking system Level check  Proceed as follows: - Rest R est the vehicle on its centre centre stand with with the handlebars perfectly horizontal; - Check C heck the level of liquid with with the related warning warning light « A ». A certain lowering of the level is caused by wear on the brake pads.

MAIN - 39

Maintenance

Top-up Proceed as follows: - Remove the front handlebar cover. - Remove the reservoir cap by loosening the two screws, remove the gasket and top-up using only the fluid specifie specified d without exceeding exceeding the maximum maximum level. CAUTION  ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION 

 AVOID CONTACT OF THE BRAKE FLUID WITH YOUR  EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WA SH WITH WATER. CAUTION  BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS. CAUTION  BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY  USED CONTAINERS. UNDER NORMAL CLIMA TIC CONDITIONS, CONDITIONS, REPLACE FLUID AS INDICATED IN THE SCHEDULED MAINTENANCE  TABLE. N.B. SEE THE BRAK ING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.

Recommended Recommended produc ts  AGIP BRAK B RAKE E 4 Brake fluid.

S ynt ynthetic hetic fluid fluid SAE J 1703 1703 -FMVS -F MVSS S 116 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4

Locki ng torq ues (N* (N*m) m) Brake pump reservoir screws 15 to 20 

See also Front handlebar cover

MAIN - 40

Fly 125 i.e - 150 i.e Leader (2011)

Fly 125 i.e - 150 i.e Leader (2011)

Maintenance

Headlight Headlight adjustment  Proceed as follows: vehicle in running order and with with 1. P osition the vehicle the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit white screen; ensure ensure that the the longitudinal axis of the vehicle is perpendicular to the screen; 2 . Turn on the headlight and check that the boun-

dary of the light beam projected onto the screen is not higher than 9/10 or lower than 7/10 of the distance between the centre of the headlight and the ground; case, ase, adjust adjust the headlight by 3. If this is not the c operating the screw indicated. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEA MS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY  WHERE THE VEHICLE IS USED.

 An ti -evap or ati on syst sy st em  The  The fuel tank ank vapou apours rs breat eather is reali ealise sed d throu rough a valve fixed on the left strut of the chassis.  To acce access ss the valv alve it is neces ecessa sarry to remove ove the legshield.

See also Legshield

MAIN - 41

INDEX OF TOPICS

ROUBLESHOOTING T ROUBLESHOOTING

TROUBL

Fly 125 i.e - 150 i.e Leader (2011)

 Trou  Troubl bles esh hoot ooting ing

Engine Poor performance POOR PERFORMANCE  Po s s i b l e Cau s e Air filter blocked or dirty

E xcessive drive belt wear Lack of compression: parts, cylinder and valves worn Oil level exceeds maximum Excess Excess of scale scales s in the com combust bustio ion n cha cham mber ber Inco Incorr rrec ectt timing ing or or wor worn n tim timing ing sy system stem elem elemen entts Muffler obstructed Inef Ineffficie icien nt aut automatic atic transm ansmis issi sion on

Wrong valve adjustment Overheated valves Valve seat distorted Worn Worn cylin cylinde der, r, Worn Worn or brok broken en pist piston on ring rings s

Op er at i o n Rem Remove the sp sponge, wa wash with water and car shampoo, th then soak it in a mixture mixture of 50% petrol and 50% 50% specific oil. P ress with your hand without squeezing, allow it to drip dry and refit. C heck it and replace, if necessary Replace the worn parts Che Check for causes and fill to reach the correct level Desca Descale le the cyli cylin nder, der, the pis pistton, on, the the head head and and the the valv alves Tim Time th the syst system em agai again n or or rep repla lace ce the wor worn n par partts R eplace Chec Check k th the rol rolle lerrs an and th the pu pulley lley movem ovement ent, rep repla lace ce the dam dam-aged parts and lubricate the movable guide of the driven pulley with grease. Adjust the valve clearance properly Rem Remove the head and the valves, gr grind or replace the valves R eplace the head unit Replace Replace the pist piston on cylin cylinde derr assembly bly or just just the pist piston on ring rings s

Starting difficulties DIFFICULTY STARTING UP  Po s s i b l e Cau s e F la lat battery

F aulty spark plug Inco Incorr rrec ectt valv alve seal sealin ing g or or val valv ve ad adjust justm ment ent Starter motor and start-up system fault Altered fuel ch characteristics Air Air fifilter ob obstr structed or or di dirty. F uel pump fault

Op er at i o n C he heck the state of the battery. If it shows signs of sulphation, replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1/10 of the capacity of the battery itself. R eplace the spark plug Insp Inspec ectt the hea head d an and/or /or res resttore ore th the cor corrrect ect clea clearrance ance Check starter motor. Drain off the fu fuel no longer up to standard; th then, re refill Rem Remove th the sp sponge, wa wash with water an and car sh shampoo, th then soak it in a mixture mixture of 50% petrol and 50% 50% specific oil. P ress with your hand without squeezing, allow it to drip dry and refit. C heck the pump.

Excessive Excessive oil cons umptio n/Exhaust n/Exhaust smoke EXCESSIVE CONSUMPTION  Po s s i b l e Cau s e Op er at i o n Wrong valve adjustment Adjust the valve clearance properly Overheated valves Rem Remove the head and the valves, gr grind or replace the valves Misshapen/worn valve seats R eplace the head unit Wor Worn cyli cylin nder, er, Wor Worn n or broke roken n pist iston rin rings Repla Replace ce the pis pistton cyli cylin nder asse assem mbly or pist iston ring ings Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings fitted properly Oil leak leaks s from from the coupl couplin ings gs or or fro from m the gask gasket ets s Check and and rep replac lace e the the gaske gasketts or rest restor ore e the the coupl couplin ing g seal seal Worn valve oil guard Replace the valve oil seal Worn valve guides Check and replace the head unit if required

 TROUBL - 43 43

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 Trou  Troub blesh leshoo ootting ing

Insufficient lubrication pressure POOR LUBRICATION PRESSURE  Po s s i b l e Cau s e By-Pas Pass re remains op open

Oil Oil pu pump with ith exce excessi ssiv ve cle clear aran ance ce Oil filter too dirty Oil level too low

Op er at i o n Che Check the By-Pas Pass an and replace ifif required. Ca Carefully clean the By-Pass area. area. Perfo Perforrm the dim dimensi ension onal al chec check ks on on the oil oil pump com componen onentts Replace the cartridge filter R estore the level adding the recommended oil type

Transmiss Transmiss ion and brakes Clutch grabbing or p erforming in adequately  adequately  IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE  Po s s i b l e Cau s e Sli Slippage or irregular functioning

Op er at i o n Che Check that there is no grease on the masses. Check that the faying surface between the clutch masses and the clutch housing is mainly in the middle and with equivalent specifications on the three masses. Check Check that the the clutch housing is not scored or worn abnormally abnormally

Insufficient braking  INEFFICIENT OR NOISY BRAKING Po s s i b l e Cau s e Worn brake pads or or sho shoes

Fron Front brake ake dis disk k loos loose e or or defor eform med Air bubb bubbles les insid inside e the the hydr hydraul aulic ic brak braking ing system system Fluid Fluid leak leakag age e in hydr hydrau auli lic c bra braki kin ng syst system em Excessive Excessive clearance clearance in the the rear rear brak brake e contr control ol cable cable

Op er at i o n Rep Replace the brake pads or or shoes an and check for brake disk or drum wear conditions. Chec Check k the brake ake dis disc c scr screw ews s ar are lock locked ed;; use a dial ial gau gaug ge an and a wheel mounted on the vehicle to measure the axial shift of  the disc. Carefully Carefully bleed bleed the the hyd hydrau raulic lic braki braking ng system system,, (ther (there e must must be no flexible movement of the brake lever). Failin Failing g ela elast stic ic fit fittting ings, plu plung nger er or brak brake e pum pump sea seals, ls, repl replac ace e Adjust Adjust the the clear clearance ance wit with h the the appr appropr opriat iate e adjust adjuster er locat located ed on the back part of the crankcase.

Brakes overheating  BRAK ES OVERHEATING OVERHEATING Po s s i b l e Cau s e Rubber gaskets swollen or stuck Com Compensat sation holes on on the pump clogged Bra Brake di disc sla slack or or disto storted

Defective piston sliding

Electrical Electrical system

 TROUBL - 44 44

Op er at i o n R eplace gaskets. Cle Clean carefully and blast with compresse ssed air Che Check the brake di disc scr screws ar are locked; use a dial ga gauge an and a wheel mounted on the vehicle to measure the axial shift of  the disc. C heck calliper and replace any damaged part.

Fly 125 i.e - 150 i.e Leader (2011)

 Trou  Troubl bles esh hoot ooting ing

Battery  BATTERY  Po s s i b l e Cau s e Battery

Op er at i o n 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. The battery runs down completely in the course of 5 to 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keeping in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+ marked+. Follow the the instruct instructions ions in the the ELEC EL EC TRIC TR ICAL AL SY S Y STEM ST EM chapter for the recharging of the batteries. batteries.

Steering Steering and su spensions Heavy Heavy st eerin eerin g  STEERING HARDENING Po s s i b l e Cau s e Ste Steering hardening

Op er at i o n Che Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: if they they are recessed or if the balls are squashed, s quashed, replace them.

Excessive steering play  EXCESSIVE STEERING CLEARANCE  Po s s i b l e Cau s e Exce Excess ssiv ive e stee steerring ing clea clearrance

Op er at i o n Chec Check k th the tig tigh htenin ening g of of th the top top ring nu nut. If irregulari arities ies con continu inue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.

Noisy suspension NOISY SUSPENSION  Po s s i b l e Cau s e NOISY SUS SUSPEN PENSI SIO ON

Op er at i o n If the front suspension is noisy, check: Tha That the shock absorber works properly inside the stanchions and that the steering ball bearings are in good condition. Finally, F inally, check the locking torque of the wheel axle nut, the brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly.

Suspension Suspension oil leakage leakage OIL Po s s i b l e Cau s e Fau Faulty or broken seals

LEAKAGE FROM  LEAKAGE  FROM  SUSPENSION 

Op er at i o n Rep Replace the shock absorber Che Check the condition of wear of the steering covers and the adjustments. adjustments.

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 TROUBL - 46 46

Fly 125 i.e - 150 i.e Leader (2011)

INDEX OF TOPICS

LECTRICAL E LECTRICAL

SYSTEM 

ELE SYS

Electrical system

1 Ignition switch 2 Fuses N. 3 - 7.5A 3 Fuses N. 6 - 5A 4 Fuses N. 4 - 7.5A 5 Fuses N. 5 - 7.5A 6 Fuses N. 1 - 10A 7 Fuses N. 2 - 7.5A 8 Starter remote control contact 9 Starter relay coil 10 Battery 11 Chassis ground

engine ground 12 Chassis engine 13 Chassis engine earth braid 14 Voltage regulator 15 Flywheel 16 Front ground node 17 Rear ground node 18 Rear left turn indicator 19 Front left turn indicator 20 Front right turn indicator 21 Rear right turn indicator 22 Turn indicator warning light 23 Turn indicators control device 24 High beam warning light 25 Complete front headlamp 26 Light switch 27 Horn

ELE SY S - 48 48

Fly 125 i.e - 150 i.e Leader (2011)

Fly 125 i.e - 150 i.e Leader (2011)

Electrical system

28 C.D.I. control unit 29 Lights logic relay 30 Starter button 31 Stop light bulbs 32 Stop switch 33 Fuel injector 34 Injection relay 35 Light switch 36 Horn button 37 Rear daylight running light

running light 38 Front daylight running 39 License plate bulb 40 Panel lighting bulb 41 Daylight running light warning light

Immobilizer LED LE D 42 Immobilizer 43 Injection warning light 44 Oil pressure warning light 45 Oil pressure sensor

gauge 46 Fuel gauge 47 Immobilizer antenna 48 Engine temperature sensor 49 Stand button 50 Pickup 51 Lambda probe 52 HV coil 53 Diagnostics socket 54 Fuel pump 55 Starter motor 56 Engine stop switch 57 Fuses N. 7 - 30A KEY   Ar : Orange Az: Sky Blue Bi : White Bl : Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

ELE SY S - 49 49

Electrical system

Components arrangement 

ELE SY S - 50 50

Fly 125 i.e - 150 i.e Leader (2011)

Fly 125 i.e - 150 i.e Leader (2011)

Electrical system

1. Horn - For access remove the leg shield back

plate as described in the «Bodywork» chapter.

2. Voltage regulator - remove the front shield to

reach it.

3. Battery, Battery, 4. Main fuse, 5. Diagnost Diagnost ics connecto r  - For access, remove the battery inspection

cover inside the compartment in the leg shield back plate.

6. Starter Starter r elay - Remove the legshield, as de-

scribed in chap. «Bodywork» to reach it.

ELE SY S - 51 51

Electrical system

7. Fuse Fuse box, 8. Injection l oad and headlight 

elays - F or access remove remove the the central cover of tthe he r elays front shield.

9. Turn indicator int ermittence - It is fixed within

the front shield.

10. Fuel pum p - 11. 11. Fuel level transm itt er - They

are mounted on the tank, remove the footrest, as described in chap «Bodywork» to reach it.

12. Flywh eel, 13. 13. Oil press ure sen sor , 14. 14. Engine speed sensor (Pick-up) - remove the fan

cover cap, as described in the chap. «Engine» to reach it. To access the connectors of the flywheel stator and engine speed sensor, you must remove the right spoiler as described in the chap. «Bodywork».

ELE SY S - 52 52

Fly 125 i.e - 150 i.e Leader (2011)

Fly 125 i.e - 150 i.e Leader (2011)

Electrical system

15. 15. Immobil izer antenna - Remove the front

shield to reach it, as described in the «Bodywork» chapter.

16. Injecti on ECU - Remove the helmet compart-

ment to reach it.

17. 17. Side stand swit ch - The connector is located

behind the left spoiler.

ELE SY S - 53 53

Electrical system

18. Engin e temperatur e sensor - 19. Fuel injecto r - For access remove the helmet compartment.

20. H.V. H.V. coil - 21. Oxygen s ensor . - To T o access access

the coil and the connector of the oxygen sensor, remove remove the right spoiler. The sensor s ensor is fixed on the exhaust pipe.

ELE SY S - 54 54

Fly 125 i.e - 150 i.e Leader (2011)

Fly 125 i.e - 150 i.e Leader (2011)

Electrical system

Ground poi nts  Ther  There e is a chas chassi sis s groun ound point oint on the vehic ehicle le,, on the front side of the steering tube. Remove the legshield to reach it.

On the engine there is a ground point on the starter motor.

On the left side of the frame, under the spoiler, there is the engine ground - frame cable.

Electrical Electrical sy stem installation

ELE SY S - 55 55

Electrical system

Front side 1. Immobilizer LED connector

Instrument ent panel connector (A) (A) 2. Instrum 3. Instrum Instrument ent panel connector (B) (B)

4. Headlight connector 5. Front stop button connector 6 . Rear stop button connector

7. Light switch 8. Tur  Turn ind indicat icator or con connect nector or 9. Horn button

10.Engine stop switch connector 11. Light switch connector 12. Starter button

ELE SY S - 56 56

Fly 125 i.e - 150 i.e Leader (2011)

Fly 125 i.e - 150 i.e Leader (2011)

Electrical system

13. Instruments and controls branch of the main

wiring 14. Start-up solenoid

15. Battery positive cable 16. Battery negative cable 17. Main fuse box 1 18. Branch of the fuse box connection connection main main wiring

and diagnostics socket

19. Branch of the turn indicators connection main

wiring 20. Front right turn indicator connector

turn indicator connector 21. Front left turn 22. Regulator 23. Regulator / flywheel connector 24. Main regulator / wiring connector 25.Front and rear ground point connectors

Immobilizer antenna antenna connector 26. Immobilizer 27 . Ignition switch 28. Turn  Turn ind indicat icator or int interm ermitt ittence ence cab cable 29.Injection and lighting loads relay connection

cables 30. Fuse box

ELE SY S - 57 57

Electrical system

31.Branch of the antenna connection main wiring,

ignition switch and injection load relay and lights 32. Front branch of the main wiring 33. Horn connectors

34.Side stand / main wiring button connector

35.Centre branch of the main wiring 36.Fuel pump connector

transmitter ter connector 37.F uel level transmit

Back side 1. Centre branch of the main wiring 2. Rear branches of the main wiring 3. Lambda probe cable 4. Coil / spark plug cable

ELE SY S - 58 58

Fly 125 i.e - 150 i.e Leader (2011)

Fly 125 i.e - 150 i.e Leader (2011)

Electrical system

5. Starter motor positive cable 6. Starter motor negative cable 7.Engine and injector temperature sensor cables

8. Main control unit / wiring connector 9. E ngine temperatu temperature re sensor sensor connector 10. Injector connector

11.Coil connector 12. P ick-up connector / m main ain wiring 13. Regulator / flywheel connector

14. License plate light cable 15. Taillight connector 16.Left rear indicator connector 17. Right rear indicator connector

ELE SY S - 59 59

Electrical system

Ignition

1 Ignition switch 3 Fuses N. 6 - 5A 7 Fuses N. 2 - 7.5A 10 Battery 11 Chassis ground 16 Front ground node 28 C.D.I. control unit 34 Injection relay

Immobilizer LED LE D 42 Immobilizer 47 Immobilizer antenna 49 Stand button 52 HV coil 56 Engine stop switch 57 Fuses N. 7 - 30A

ELE SY S - 60 60

Fly 125 i.e - 150 i.e Leader (2011)

Fly 125 i.e - 150 i.e Leader (2011)

Electrical system

Battery Battery recharge and and starting 

1 Ignition switch 2 Fuses N. 3 - 7.5A 8 Starter remote control contact 9 Starter relay coil 10 Battery 11 Chassis ground 13 Chassis engine earth braid 14 Voltage regulator regulator 15 Flywheel 23 Turn indicators control device 28 C.D.I. control unit 30 Starter button 31 Stop light bulbs 32 Stop switch 55 Starter motor 57 Fuses N. 7 - 30A

ELE SY S - 61 61

Electrical system

Fly 125 i.e - 150 i.e Leader (2011)

Level Level in dicators and enable signals section

1 Ignition switch 2 Fuses N. 3 - 7.5A 3 Fuses N. 6 - 5A 7 Fuses N. 2 - 7.5A 10 Battery 11 Chassis ground

engine ground 12 Chassis engine 16 Front ground node 28 C.D.I. control unit 33 Fuel injector 34 Injection relay 41 Daylight running light warning light

Immobilizer LED LE D 42 Immobilizer 43 Injection warning light 44 Oil pressure warning light 45 Oil pressure sensor

gauge 46 Fuel gauge 47 Immobilizer antenna 48 Engine temperature sensor 49 Stand button 50 Pickup 51 Lambda probe 56 Engine stop switch 57 Fuses N. 7 - 30A

ELE SY S - 62 62