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Haynes repair torrent piaggio zip scooter

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WORKSHOP MANUAL NRG Power Purejet This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. Piaggio Vespa Px Manual Taller Reference Manual. We promise that many of us at piaggio xevo service manual have an MANUAL TALLER PIAGGIO X7EVO IE. View and Download Piaggio Fly 4T workshop manual online. Fly 4T Scooter pdf manual download. Also for: Fly Free Piaggio and Vespa Motorcycle Service Manuals for download. Lots of people charge for motorcycle service and workshop manuals online which is a bit cheeky I reckon as they are freely available all over the internet. £5 each online or download your Piaggio or Vespa manual here for free!! This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics 5/5(4).

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Haynes repair torrent piaggio zip scooter Fly - 4T Engine from vehicle - Remove the protection sheath indicated in the figure and disconnect the automatic starter and carburettor heater connections - Unscrew the engine pin-swinging arm nut on the right-hand side of the vehicle and slide off the pin on the left hand side - Support the vehicle adequately with a jack and remove the shock absorber lower clamping. Fly - 4T Engine Refitting the ub cover - Fit a new gasket together with the centring dow- els, haynes repair torrent piaggio zip scooter . Fly - 4T Engine - Introduce the float with the rod on the fuel feeding tube side, haynes repair torrent piaggio zip scooter . Workshop Manual Scooter pages. If it is necessary to add water too frequently, check the vehicle electrical system: To do this, use a plate and a support with specific tool dial gauge. Non-original or non-conforming spares may damage the vehicle. Fly - 4T Engine - Remove the sprayer. Page Fly - 4T Engine - Fit the automatic valve-lifter retaining dish, using the counterweight screw fastener as a reference. Inspecting The Piston Fly - 4T Engine - The pistons are oversized due to cylinder rectifi- cation and are subdivided into three categories 1st, 2nd, 3rd with 0. Headlamp warning light Keeping the zero setting position, fit the tool on the cylinder and haynes repair torrent piaggio zip scooter it with 2 nuts, as shown in the figure. Fly - 4T Electrical system To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient. Fly - 4T Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. Page 48 Fly - 4T Troubleshooting Possible Cause Operation Loose nozzles Check the maximum and minimum nozzles are adequately fixed in their fittings Incorrect float level Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted. Fly - 4T Electrical system Legend: Never mistake the codes movement sen- sor replacement and tone wheel replace- ment in the event of noise of the indicated components. Page Fly - 4T Engine Removal - First remove the transmission cover and the com- plete driving pulley - Install the base of the appropriate tool on the oil guard using the screws provided.
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Page Fly - 4T Engine Measure the distance between the outer rotor and the pump body; see figure. Electronic ignition device with choke and turn signal controls haynes repair torrent piaggio zip scooter . Page 70 Fly - 4T Electrical system If it does not work, replace the aerial. Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves, haynes repair torrent piaggio zip scooter . Fly - 4T Time Final gear assy. Page Fly - 4T Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. Fly - 4T Engine - To assemble the new ball bearing insert it com- pletely down in its housing with the specific punch and finally assemble the Seeger ring. Page Fly - 4T Suspensions - Check that the bearings do not show flaws or jamming. Removing The Clutch Fly - 4T Engine Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings inner diameter 15 and 17 mm. Fly - 4T Engine - A wrong installation of a cap can seriously affect the bushing lubrication pressure. Fly - 4T Time Rocker arms support assy. Fly - 4T Haynes repair torrent piaggio zip scooter system Labofuge 400 torrent Rear drum brake Once the muffler and the wheel have been re- moved, follow these steps: Page Fly - 4T Engine - Remove the chamber with the accelerating pump, its control and gasket. Fly - 4T Engine - Check the guide shoes for the variator back-plate are not worn. Page Fly - 4T Engine Insert a transparent rubber pipe to the bleeding intake of the fuel tank. If battery potential is found, repeat the inspection from the connector to the ECU. Fly - 4T Engine Specification Desc. Low-fuel warning light Fly - 4T Engine Refitting the driven pulley shaft bearing - Heat up the crankcase inside with the hot air gun. Fly - 4T Engine - Remove the central screw with Belleville washer, as shown in the diagram. Fly - 4T Engine - Check that the coupling surfaces, the tank and the diaphragm are not dented. Specific tooling Y Digital multimeter Electric characteristic The ignition system consists of: Removing The Front Wheel Fly - 4T Suspensions Sospensioni anteriore This section is devoted to operations that can be carried out on the suspension. Page 93 Fly - 4T Engine - Insert the driving belt into the pulley unit accord- ing to their direction of rotation. Keihin maximum time 5 min Adjusting the idle - The engine does not require frequent adjustment of the idle, however it is important that this adjust Fly - 4T Engine - Calculate the piston pin coupling clearance. Page of Go. Dashboard light bulbs

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Refitting The Driven Pulley Fly - 4T Engine - To assemble the new ball bearing insert it com- pletely down in its housing with the specific punch and finally assemble the Seeger ring. Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves. Fly - 4T Pre-delivery Static test Static control after the test ride: Fly - 4T Engine Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings inner diameter 15 and 17 mm, haynes repair torrent piaggio zip scooter . If faults are de- tected, do the following. Page 81 Fly - 4T Engine from vehicle - Remove the fuel supply pipe from the carburettor - Remove the fuel valve low-pressure pipe from the manifold as shown in the photograph - Remove the flywheel wiring connector, the earth terminal and the starter motor positive cable indi- cated in the figure - Remove the clamp retaining the starter wiring Page Fly - 4T Engine - On the flywheel side crankcase half, take partic- ular care cleaning the oil ducts for the main bush- ings, the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the fly- wheel side oil seal. Headlamp warning light Keep the pipe up so that the ends are higher than the venturi haynes repair torrent piaggio zip scooter . Fly - 4T Engine from vehicle Exhaust assy. Fly - 4T Maintenance - Operating on the flash bulb phase difference cal- ibrator, make the reference on the flywheel cover coincide with the fan reference as shown in the photograph. Page 96 Fly - 4T Engine - Check the guide shoes for the variator back-plate are not worn. Page Fly - 4T Engine Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate, haynes repair torrent piaggio zip scooter . Fly - 4T Engine - Remove the central screw with Belleville washer, as shown in the diagram. Fly - 4T Time Final gear assy.

Not all versions shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. Reproduction of this publication in whole or in part is prohibited. 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.

Even though the latter contains no asbestos, inhaling dust is harmful. Non-original or non-conforming spares may damage the vehicle. To ensure the best functioning of the SAS system, every 12, km the scooter should be taken to an Authorised Piaggio Service Centre to have the filter cleaned Scheduled maintenance operations section.

The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air. Fly - 4T Characteristics Specification Desc. Fly - 4T Characteristics Cylinder - piston assy. Fly - 4T Characteristics Slot packing system - Provisionally fit the piston into the cylinder, without any base gasket. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.

Fly - 4T Maintenance - Operating on the flash bulb phase difference cal- ibrator, make the reference on the flywheel cover coincide with the fan reference as shown in the photograph. Read the advance degrees indicated by the stroboscopic light and compare them with those specified. A certain lowering of the level is caused by wear on the pads. Fly - 4T Maintenance CO check - Remove the exhaust gases outlet cap on the ex- haust pipe - Using the supplied washer, install the exhaust gases collection kit fitting onto the pipe, as shown in the figure.

Fly - 4T Maintenance SAS filters inspection and cleaning - Remove the shock absorber lower retainer from the engine. Fly - 4T Maintenance - Remove the 4 flywheel cover screws indicated in the photograph and remove the flywheel cover.

Care- fully clean the By-Pass area. Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Fly - 4T Troubleshooting Possible Cause Operation Loose nozzles Check the maximum and minimum nozzles are adequately fixed in their fittings Incorrect float level Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted.

If irregu- larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: Fly - 4T Electrical system Legend: Electronic ignition device with choke and turn signal controls 4. Turn signal switch 6. Stop switch on rear brake 8. Fly - 4T Electrical system Low-fuel warning light Turn signal warning light R. Dashboard light bulbs Headlamp warning light Fly - 4T Electrical system Specification Desc.

Fly - 4T Electrical system Immobiliser The electric ignition system is fed with direct cur- rent and is protected by an anti-theft immobilizer integrated to the control unit. The ignition system consists of: This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stor- ed one is deleted.

Fly - 4T Electrical system If it does not work, replace the aerial. If no faults are found, replace the control unit. Specific tooling Y Digital multimeter Electric characteristic Fly - 4T Electrical system To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.

No spark plug When noticing no spark plug proceded as follows: Fly - 4T Electrical system Y Multimeter adaptor - Peak voltage detection Electric characteristic High voltage coil secondary resistance value High voltage coil secondary resistance value: Fly - 4T Electrical system Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel.

The alternator is directly connected to the voltage regulator. In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety fuse. Fly - 4T Electrical system Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed In case higher voltages are detected, replace the regulator.

Fly - 4T Electrical system with the key switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the key switch.

If battery potential is found, repeat the inspection from the connector to the ECU. Fly - 4T Electrical system Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit.

Fly - 4T Electrical system Commissioning dry-charged batteries: Fly - 4T Electrical system The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle electrical system: Fly - 4T Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Unscrew the 2 screws fixing the muffler to the housing; then remove the whole muffler paying at- tention to the interference between its supporting bracket and the cooling cover.

Fly - 4T Engine from vehicle - Remove the fuel supply pipe from the carburettor - Remove the fuel valve low-pressure pipe from the manifold as shown in the photograph - Remove the flywheel wiring connector, the earth terminal and the starter motor positive cable indi- cated in the figure - Remove the clamp retaining the starter wiring Fly - 4T Engine from vehicle - Remove the protection sheath indicated in the figure and disconnect the automatic starter and carburettor heater connections - Unscrew the engine pin-swinging arm nut on the right-hand side of the vehicle and slide off the pin on the left hand side - Support the vehicle adequately with a jack and remove the shock absorber lower clamping.

Fly - 4T Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the rear plastic cover first by inserting a screwdriver in the corresponding slotted holes. Fly - 4T Engine Air duct - Unscrew the Torx screws fixing the air manifold bulkhead and remove the bulkhead.

Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. Fly - 4T Engine Refitting the driven pulley shaft bearing - Heat up the crankcase inside with the hot air gun.

Fly - 4T Engine Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings inner diameter 15 and 17 mm. Fly - 4T Engine - Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes. After- wards make the support screw make contact with a minimum force. Fly - 4T Engine Pin retaining collar - Remove the collar with the aid of 2 screwdrivers.

Removing the driven half-pulley bearing - Remove the retaining ring using two flat blade screwdrivers. Fly - 4T Engine Inspecting the driven fixed half-pulley - Measure the external diameter of the pulley bush- ing. Fly - 4T Engine - To assemble the new ball bearing insert it com- pletely down in its housing with the specific punch and finally assemble the Seeger ring. Specific tooling Y Adaptor 28 x 30 mm Y Adaptor handle Y 17 mm guide Refitting the driven pulley - Check that the faying surfaces between the Fly - 4T Engine Inspecting the clutch spring - Measure the unloaded length of the spring of the movable driven half-pulley.

Fly - 4T Engine - Insert the driving belt into the pulley unit accord- ing to their direction of rotation. Fly - 4T Engine Refitting the driven pulley - Reassemble the clutch bell and spacer. Drive-belt During the wear checks foreseen in the scheduled maintenance services at 6, km; 18, km; etc.

The rim bottom of the tooth must not have incisions or cracking; Fly - 4T Engine Removing the driving pulley - Lock the driving pulley with the specific tool as shown in the figure. Fly - 4T Engine - Check the guide shoes for the variator back-plate are not worn. Fly - 4T Engine Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover.

Fly - 4T Engine Removing the wheel axle Remove the intermediate gear and the complete hub cover. Removing the hub bearings - Check the state of the bearings being examined wear, clearance and noisiness. If faults are de- tected, do the following. Fly - 4T Engine With the appropriate tools, remove the oil seal as shown in the figure.

Specific tooling Y Adaptor handle Y 42xmm adaptor Removing the driven pulley shaft bearing If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven pulley. Fly - 4T Engine Inspecting the hub cover - Check that the fitting surface is not dented or distorted. Refitting the driven pulley shaft bearing - Heat up the parts using the specific heat gun Specific tooling Fly - 4T Engine Assemble the Seeger ring.

Assemble the oil seal flush with the in- ternal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub. Fly - 4T Engine Refitting the ub cover - Fit a new gasket together with the centring dow- els. On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggest to intervene on the vacuum socket inserting on the inlet manifold widening the hole from 0.

Fly - 4T 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. Fly - 4T Engine Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.

Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly. Fly - 4T Engine Removing the timing system drive - Remove the parts listed below first: Fly - 4T Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram.

Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves.

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