Malaguti Madison3 250ie Workshop Manual

WORKSHOP MANUAL

FRAME AND RUNNING GEAR

3 05/06

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FRAME AND RUNNING GEAR

INTRODUCTIONINDEX

1 - INTRODUCTION

INTRODUCTION..................................................... 5

Manual updates ................................................................ 5

NOTES FOR EASY CONSULTATION..................... 5

Modified pages ................................................................. 5

Additional pages ............................................................... 5

Configuration of the pages................................................ 5

Symbols ............................................................................ 6

Abbreviations .................................................................... 6

Units of measurement....................................................... 6

Recommendations ............................................................ 7

GENERAL WORK PROCEDURES......................... 7

Suggestions ...................................................................... 7

OPERATING SYMBOLS......................................... 9

2 - GETTING TO KNOW YOUR SCOOTER

TECHNICAL DATA.................................................. 10

Dimensions ....................................................................... 10

Capacity ............................................................................ 10

Engine: 4-valve single-cylinder Piaggio............................ 10

Spark plug......................................................................... 10

Transmission..................................................................... 10

Fuel system....................................................................... 10

Electronic ignition.............................................................. 10

Brakes............................................................................... 10

Frame................................................................................ 10

Suspension ....................................................................... 10

Battery............................................................................... 10

Tyres ................................................................................. 10

DIMENSIONAL CHECK OF FRAME. ..................... 11

3 - MAINTENANCE

MAINTENANCE TABLE.......................................... 12

4 - DISASSEMBLY

REAR-VIEW MIRRORS. ......................................... 13

CENTRAL FAIRING................................................ 13

CHANGING THE FRONT TURN INDICATOR BULB.14

WINDSHIELD.......................................................... 15

UPPER HANDLEBAR COVER. .............................. 16

ACCESSIBILITY. .................................................... 16

RIGHT-HAND CONTROL. ...................................... 17

LEFT-HAND CONTROL.......................................... 17

AMBIENT TEMPERATURE SENSOR..................... 18

HANDLEBAR LOWER COVER. ............................. 19

SUB PANEL . .......................................................... 20

ACCESSIBILITY. .................................................... 21

SPEEDOMETER SENSOR. .................................... 22

FRONT BRAKE CALIPER...................................... 22

Checking front brake wear................................................ 22

FRONT WHEEL . .................................................... 23

FRONT BRAKE DISC ............................................ 25

FRONT MUDGUARD. ............................................. 25

FRONT FAIRING .................................................... 26

ACCESSIBILITY. .................................................... 28

MAIN SWITCH. ....................................................... 29

REPLACING THE HEADLIGHT BULBS................. 30

Low beam / high beam bulbs (A) ...................................... 30

Parking light (B) ................................................................ 30

SIDE COVERS. ....................................................... 30

RIDER SEAT. .......................................................... 31

PILLION SEAT . ...................................................... 31

ACCESSIBILITY. .................................................... 32

BATTERY................................................................ 32

SEAT LOCK. ........................................................... 33

HELMET COMPARTMENT . ................................... 34

ACCESSIBILITY. .................................................... 35

REPLACING THE TAILLIGHT BULBS.................... 36

Turn indicator bulb ............................................................ 36

Rear taillight bulb .............................................................. 36

PILLION GRAB HANDLE....................................... 36

REAR FAIRING....................................................... 37

ACCESSIBILITY. .................................................... 38

INSTRUMENT PANEL. ........................................... 39

LOWER FAIRING AND FOOTBOARD. .................. 40

ACCESSIBILITY. .................................................... 43

MUFFLER. .............................................................. 43

EXHAUST MANIFOLD............................................ 44

REAR SHOCK ABSORBERS................................. 45

REAR BRAKE CALIPER. ....................................... 45

Check the disc and pads of the rear brake for wear......... 46

REAR WHEEL......................................................... 46

REAR DISC............................................................. 48

FILTER BOX............................................................ 49

ENGINE................................................................... 50

SIDE STAND. .......................................................... 54

Side stand switch .............................................................. 54

FUEL TANK............................................................. 55

FUEL LEVEL SENSOR. ......................................... 56

HANDLEBAR.......................................................... 56

SUB-FAIRING. ........................................................ 57

FRONT FORK......................................................... 58

FRONT DAMPER.................................................... 59

Right.................................................................................. 59

Left .................................................................................... 59

Checking the oil level in the damper................................. 60

Changing the fork oil ......................................................... 61

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INDEX

RADIATOR.............................................................. 62

RADIATOR (assembly) . ........................................ 64

HORN ..................................................................... 65

BRAKE CALIPERS OVERHAUL. ........................... 65

Overhaul of rear caliper .................................................... 65

Overhaul of front caliper ................................................... 67

BRAKE MASTER CYLINDERS . ............................ 69

BLEEDING THE BRAKE SYSTEM......................... 70

Rear brake caliper ............................................................ 70

Front brake caliper............................................................ 70

SECURING CLAMPS. ............................................ 71

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INTRODUCTION

• This Workshop Manual describes the main electrical/mechanical checks, the essential checks and the assembly

of components supplied disassembled in order to deliver a brand new vehicle (the sequence of operations is not

binding).

• It is essential to follow the instructions with great care. Work carried out carelessly or, worse still, work that has not

been accomplished, can cause injuries and damage or, in the less serious cases, complaints.

NOTE These manuals provide the necessary information and instructions for routine maintenance and serv-

icing.

Some information has been given to us by the engine manufacturers. We therefore decline all respon-

sibility for any error, omission or misrepresentation.

MALAGUTI reserves the right to make any changes and modifications hereto it deems necessary

without prior notice.

MANUAL UPDATES

• The updates will be sent by us (in a reasonable time). Every CD-Rom you receive will supersede the one already in

your possession.

• The table of contents will be duly updated in the event that new pages are inserted, which render the consultation

of the manual difficult.

• IMPORTANT! The Workshop Manuals are to be considered as essential tools to be properly kept up-to-date so as

to maintain their validity over time.

NOTES FOR EASY CONSULTATION

CONFIGURATION OF THE PAGES

MODIFIED PAGES

• Pages that have been modified will bear the same number as the same page of the previous edition, followed by a

letter M and, in the relative box, the new date of issue.

ADDITIONAL PAGES

• Any additional pages shall bear the last number of the section to which they belong, followed by the letter A and the

new edition date.

INTRODUCTION

Y

X

W

Z

Chapter

Section title

Page N°

Date of issue

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INTRODUCTION

SYMBOLS

• Symbols are provided for quick and easy reference (see the relevant heading), identifying situations requiring

utmost attention or providing practical suggestions or simple information.

• These symbols may appear next to a text (in which case they refer solely to the text itself), next to a figure (in

which case they refer to the topic illustrated in the figure and to the relative text), or at the top of the page (in which

case they refer to all the topics dealt with in the page).

NOTE The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat

basic technical concepts or safety recommendations. They are therefore to be considered as “me-

mory tags”. In case of any doubt as to their meaning, consult the page in which they are fully descri-

bed.

UNITS OF MEASUREMENT

All the dimensions in this Manual are shown in mm.

NOTE The letter V in the illustrations refers to fixing or adjusting screws. The number following this letter

refers to the number of the same type of screw in the unit or component described and illustrated. A

letter without a number indicates quantity 1. In case of different screws being referred to in the illus-

tration, the letter V is followed by a number and a lower case letter. Example: (V4a).

Unless otherwise specified, units and components are reassembled by proceeding in the reverse

order of removal.

F

Cs

P

Pr

S

Sc

T

V

Figure

Tightening torque

Page

Paragraph

Section

Diagram

Table

Screw

F

Cs

P

Pr

S

Sc

T

V

ABBREVIATIONS

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INTRODUCTION

GENERAL WORK PROCEDURES

• The advice, recommendations and warnings given hereafter are aimed at ensuring maximum work safety as well

as at considerably reducing the risk of accidents, personal injury, equipment damage and idle times. We therefore

recommend observing such advice, recommendations and warnings scrupulously.

SUGGESTIONS

• Only use top quality tools and equipment.

• Only use equipment conforming to EU Directives for lifting the vehicle.

• During all operations keep tools close at hand, ideally in accordance with a predetermined sequence of use, and

anyway never leave tools on the vehicle or in concealed or hard to reach positions.

• Always keep the work area clean and tidy.

• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in a “crosswise

pattern” in successive “torquing steps”.

• Preferably use open-end wrenches and tighten by exerting “pulling force” rather than “pushing force”.

• Adjustable wrenches should only be used in case of

emergency, i.e. when a properly sized wrench is not

available. During the torquing stage the movable jaw

tends to open thus risking damaging the screw head or

achieving unreliable tightening torque values. In any

case, when using an adjustable wrench, take care to

proceed as shown in the figure.

• Except in the case of occasional services, prepare a

work sheet for the customer, on which to take a note

of all the work performed and write memos relating to

any future checks that may be required.

RECOMMENDATIONS

• Before carrying out any work on the vehicle wait for

all the parts to cool down completely.

• For operations requiring two mechanics, make sure that

the various steps to be performed by each of them are

clearly defined and coordinated beforehand.

• Make sure that each component has been properly fit-

ted before proceeding with the next one.

• Lubricate all parts (where applicable) before reinstall-

ing them.

• Gaskets, oil seals, snap rings and cotters must be re-

newed at every refitting.

• The torque settings specified in the manuals refer to

the “final torque”, which must be reached progressively

by steps.

• Loosen and tighten aluminium alloy parts (covers) only

after the engine has cooled down fully.

• Only use screwdrivers of suitable sizes in relation to

the screws to be loosened or tightened.

• Work in a comfortable position and ensure that the ve-

hicle is stable.

• Never use a screwdriver as a lever or chisel.

• Never use pliers to loosen or tighten screws or nuts because, in addition to not providing a sufficient clamping force,

they may also damage the screw head or nut hex.

• Never tap wrenches with a hammer (or other similar tools) to loosen or tighten screws and nuts.

• Never attempt to increase leverage by attaching tubes, etc. to wrenches.

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INTRODUCTION

A

Never use open flames for any reason.

Never leave open containers or containers not suitable for holding fuel in passageways, close to

heat sources. etc.

Never use petrol to clean the vehicle or the workshop floor. Always use low flash point solvents to

clean the vehicle components.

Never suck from or blow into the fuel pipe.

When welding, make sure that there are no flammable liquids in the vicinity. Always remove the fuel

tank, even if completely empty, and disconnect the negative cable (-) from the battery.

Never leave the engine running in closed or poorly ventilated areas.

Before any servicing, make sure that the vehicle is perfectly stable.

The front wheel should preferably be anchored to fixture (A), which is integral with the lift platform.

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INTRODUCTION

OPERATING SYMBOLS

IMPORTANT!

CAUTION! - Descriptions concerning operations that are potentially hazardous for the maintenance

mechanic or repairman, other workshop personnel or extraneous persons, for the environment, for the

vehicle, and for the tools and equipment.

DISCONNECT POWER - Before performing the work described, disconnect the battery negative cable.

RISK OF FIRE - Indicates operations that may constitute a fire hazard.

EXPLOSION HAZARD - Indicates operations that may constitute a risk of explosion.

TOXIC FUMES - Indicates the risk of intoxication or inflammation of the respiratory tract.

NO! - Operations to be absolutely avoided.

SYMMETRICAL OPERATIONS - Operations to repeat on both sides of the unit or component in question.

ENGINE WORKSHOP MANUAL - Information that can be found in the engine workshop manual.

FITTING AND ASSEMBLY OPERATIONS

REMOVAL AND DISASSEMBLY OPERATIONS

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B

D

06039483

TECHNICAL DATA

MALAGUTI SpA reserves the right to modify technical data at any time without prior notice.

DIMENSIONS

wheel base (A), m .................................................1.410

max. length (B), m .................................................1.980

max. width (C), m ..................................................0.790

max. height (D), m .................................................1.640

kerbside weight, Kg ..................................................165

max. load with rider, pillion and luggage, Kg .............185

CAPACITY

engine oil, cc ........................................................ 1300*

transmission oil cc .................................................. 250*

fuel tank (reserve), l...........................................8.5* (3*)

* Guideline value

ENGINE: 4-VALVE SINGLE-CYLINDER PIAGGIO

type ....................................................................M366M

n° of cylinders...............................................................1

bore x stroke, mm........................................... Ø 72 x 60

displacement, cm

3

....................................................244

compression ratio ...........................................11±0.5 : 1

cooling................................................................... liquid

starting system ........................................ electric starter

lubrication system........................................... wet sump

SPARK PLUG

type: .............................................CHAMPION RG4 HP

...........................................................NGK CR8EB

TRANSMISSION

Expandable pulley automatic variator, V-belt, automatic dry

centrifugal clutch, secondary drive gearbox and transmis-

sion housing with forced circulation cooling system.

FUEL SYSTEM

Electronic injection with electric fuel pump.

Fuel: unleaded petrol.

ELECTRONIC IGNITION

High efficiency inductive coil integrated with injection, va-

riable ignition advance and separate H.T. coil.

BRAKES

Front: 240 mm disk with hydraulic transmission and

calliper with two pistons

Rear: 240 mm disk with hydraulic transmission and

calliper

FRAME

Frame made with single steel tube split at footboard level.

SUSPENSION

Front: Hydraulic fork Ø 36 mm - travel: 130 mm

Rear: N.2 hydraulic shock absorbers with adjusta-

ble spring preload - travel: 75 mm.

BATTERY

Type: 12V, 12Ah; sealed unit.

TYRES

Front: ————— 120/70 - 14 55P

Rear: ————— 140/60 - 14 64P

It is possible to use tyres with load and speed indexes that

are higher than or identical to those indicated. It is howe-

ver necessary for speed indexes to be identical for both

tyres.

GETTING TO KNOW

YOUR SCOOTER

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GETTING TO KNOW

YOUR SCOOTER

FRAME AND RUNNING GEAR

A = 1220 ± 2 mm

A

06039484

DIMENSIONAL CHECK OF FRAME

If the scooter has been involved in an accident and you suspect even slight distortion of the frame it is essential to

perform the dimensional checking procedure before any further “repair or set-up” work.

Control dimension (A) must be 1220 mm with a tolerance of ± 2 mm.

Do not attempt to bend the frame to restore the original “A” measurement.

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1

2

3

4

**

*

5

6

7

8

9

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

**

*

MAINTENANCE TABLE

= first service

= change

= adjustment

= clean = inspection

CHECKS AND REPLACEMENT OPERATIONS

FIRST 1000

km

5000 km

or

10 months

10000 km

or

20 months

15000 km

or

30 months

20000 km

or

40 months

25000 km

or

50 months

30000 km

or

60 months

35000 km

or

70 months

40000 km

or

80 months

45000 km

or

90 months

50000 km

or

100 months

55000 km

or

110 months

60000 km

or

120 months

65000 km

or

130 months

70000 km

or

140 months

75000 km

or

150 months

80000 km

or

160 months

Spark plug

Engine oil and oil filter

Gearbox oil

Valves

Drive belt

Variator shoes / rollers

Tightness of brake lines - Injection system

Fuel pump filter

Air filter

Drive belt housing air filter

Electrical system, battery and charge level

Brake pads - condition and wear

Level and density of coolant (change every 2 years) –

Correct fitting and tightness of hoses

Brake fluid circuit

Wheel bearings

Frame linkages

Steering operation and play (lubricate if necessary)

Operation and oil-tightness of fork and shock absorbers

Tightness of nuts and bolts

Tightness of side and centre stands – Pivot lubrication

Operation of side stand switch - Lubrication

Throttle control

Tyre pressure – Tread wear

Final check:

Condition of tyres - Pressure – Lights -

Indicators - Switch functions - Road test

If the periodic drive belt inspection (every 10000 km) reveals excessive wear in relation to the conditions of use,

reduce the intervals between future services.

The maintenance schedule is based on average riding conditions. Machines subject to severe use or ridden in unu-

sually wet or dusty conditions or off the road require more frequent servicing.

Certain simple checks, i. e. those marked with an asterisk, MAY be performed under the direct re-

sponsibility of technicians not specifically authorised by MALAGUTI.

Every 2000 km

Every 20 months or 10000 km

MAINTENANCE

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06039057_1

06039029_1

06039035_1

A

V2

D

A

REAR-VIEW MIRRORS

• Lift rubber boot then undo nut (D) and mirror (A).

RIGHT-HAND MIRROR is fitted by screwing

it COUNTER-CLOCKWISE.

LEFT-HAND MIRROR is fitted by screwing it

CLOCKWISE.

CENTRAL FAIRING

• Remove panels (A) by prising with a screwdriver.

• Undo screws (V2).

DISASSEMBLY

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DISASSEMBLY

06039041_1

06039032_1

06039029_1

B

A

B

• Disengage central fairing (B) and remove it from sco-

oter, rotating it forwards.

CHANGING THE FRONT TURN INDICATOR

BULB

• Remove panels (A) by prising with a screwdriver.

• Turn bulb-holder ringnut (B) counter-clockwise and

remove.

• Extract bulb by pulling it.

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DISASSEMBLY

06039045_1

V6

A

WINDSHIELD

• (Remove central fairing).

• Undo screws (V6).

• Remove windshield (A).

• Recover the rubber grommets under the screws.

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DISASSEMBLY

06039048_1

06039059_1

06039060_1

V2a

A

V2b

G

F

D

A

E

C

H

S

B

UPPER HANDLEBAR COVER

• (Remove rear-view mirrors).

• Undo screws (V2a) and (V2b).

• Remove upper handlebar cover (A).

ACCESSIBILITY

Removing the front handlebar cover provides access to

the following components:

• Handlebar screw (A);

• connector for LH handlebar control (B);

• ambient temperature sensor connector (C);

• RH control STOP switch (D);

• LH control STOP switch (E);

• rear brake master cylinder union (F);

• front brake master cylinder union (G);

• resistance connector (H);

• steering adjustment ringnuts (S).

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DISASSEMBLY

06039385

06039386

V2

V

A

B

V

V2

RIGHT-HAND CONTROL

• (Remove rear-view mirrors).

• (Remove upper handlebar cover).

• Unscrew union (B).

• Undo screw (V) and remove counterweight.

• Disconnect wiring connectors.

• Undo screws (V2) and remove throttle control.

• Disconnect throttle opening (A) cables.

Use compressed air to reduce friction when

removing and refitting the twist grip.

At time of reassembly shorter screw (V2)

must be located in UPPER part of control.

LEFT-HAND CONTROL

• (Remove rear-view mirrors).

• (Remove upper handlebar cover).

• Disconnect switch connector.

• Undo screw (V) and remove counterweight.

• Undo screws (V2) and remove LH control.

Use compressed air to reduce friction when

removing and refitting the twist grip.

At time of reassembly shorter screw (V2)

must be located in UPPER part of control.

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DISASSEMBLY

06039021_1

06039060_1

A

B

C

AMBIENT TEMPERATURE SENSOR

• (Remove rear-view mirrors).

• (Remove upper handlebar cover).

• Detach the connector (A).

• Remove sensor (B) from lower handlebar cover (C).

The sensor must be mounted EXTERNAL-

LY to the lower handlebar cover, as shown

in the figure.

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DISASSEMBLY

06039061_1

06039062_1

V2

V

HANDLEBAR LOWER COVER

• (Remove rear-view mirrors).

• (Remove upper handlebar cover).

• (Remove right-hand control).

• (Remove ambient temperature sensor).

• Undo screws (V2).

• Undo screw (V).

• Remove lower handlebar cover.

To remove handlebar cover completely, di-

sconnect the two right-hand control con-

nectors.

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DISASSEMBLY

06039085_1

06039082_1

06039086_1

V

V4a

V4b

A

B

SUB PANEL

• Remove footboards (A).

• Undo screw (V).

• Undo screws (V4a) and (V4b).

• Remove sub-panel (B).

Screws (V4a) are longer than screws (V4b).

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DISASSEMBLY

06039090_1

06039088_1

06039227_1

C

D

B

A

ACCESSIBILITY

Removing the sub panel provides access to the following

components:

• Ignition coil (A).

• Bank angle sensor (B).

• Radiator drain plug (C).

• Side stand switch (D).

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Malaguti Madison3 250ie Workshop Manual

Malaguti Madison3 250ie Workshop Manual

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