Malaguti F10 User manual

1 03/08

125 i.e. - 160 i.e.

MALAGUTI S.p.A.

Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY

Tel. 051.62.24.811 - Fax 051.69.47.782

e-mail: [email protected] - http: // www.malaguti.com

FOREWORD

• The present manual specifically addresses to specialised technical personnel (MALAGUTI authorised service centres and single motor mechanics) and contains all the

service interventions indicated by the Manufacturer until the publishing of this document.

• Some basic technical information has been intentionally omitted as it is considered to be common knowledge.

• Additional information is available in the SPARE PARTS CATALOGUES of each model.

• It is important to read all the general information before going through the manual to the specific topics and the maintenance operations to be carried out on the motor-bike in

order to make sure the topics, the technical and safety concepts are clearly understood and the manual can be used as a sure reference text.

• All checks, maintenance, repairs or replacements of spare parts in our motor-bikes are to be performed by skilled and expert technical personnel with specific experience

in state-of-the-art technology and full knowledge of the quickest and most rational procedures, technical characteristics, setting values, tightening torques and information as

to which may only be properly and exhaustively provided by the manufacturer.

• It is important to adhere strictly to the following instructions. Any operation carried out carelessly or not carried out at all may lead to personal injury, damage to the motorcycle

or simply to complaints.

MALAGUTI S.p.A. reserves the right to make any changes and modifications hereto it deems necessary without prior notice.

For further information and details, please contact MALAGUTI S.p.A. Servicing or Engineering Division.

2 03/08

125 i.e. - 160 i.e.

NOTES FOR EASY CONSULTATION

ABBREVIATIONS

EDITING SYMBOLS:

• Symbols have been provided for quick and easy reference, 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.

Cs Torque wrench setting

D Nut

Dx Right

F Picture

G Gasket

P Page

R Washer

Sx Left

T Ta bl e

V Screw

TECHNICAL DICTIONARY

V = (DC) Direct current (battery supply)

V ~ (AC) Alternating current (flywheel supply)

A : Ampere Unit of measurement of the electrical current

W : Watt Unit of measurement of the electrical power (product of Volts and Amperes; A x V = W)

ΩΩ

Ω : OHM Unit of measurement of the electrical resistance

< Lower

≤≤

≤ Lower or equal

> Higher

≥≥

≥ Higher or equal

bar Unit of measurement of pressure

N * m Newton/metre Unit of measurement of the tightening torque

3 03/08

M

R

SYMBOL LIST

CAUTION!

Recommendations and

precautions regarding rider

safety and motor vehicle

integrity.

WARNING! Situations

entailing the risk of personal

injury to maintenance or repair

mechanics, other workshop

personnel or third parties, or

damage to environment,

vehicle or equipment

FIRE HAZARD.

Indicates operations which

may constitute a fire

hazard

RISK OF

EXPLOSION

Indicates operations

which may constitute a

risk of explosion

TOXIC FUMES

Indicates a possibility of

intoxication or inflammation

of the upper respiratory

tract

WARNING!

Danger of crashing

arms

SAFETY GLOVES

These operations require

the use of safety gloves

IMPORTANT

This topic requires special

attention

GENERAL SERVICE

PERSONNEL

Skilled electronic or

mechanical technician.

MECHANICAL

MAINTENANCE

Operations to be

performed only by an

expert mechanic

ELECTRICAL

MAINTENANCE

Operations be performed

only by an expert electrical/

electronic technician

IGNITION KEY ON

(ON position)

PRESENT MANUAL

Information on the

present manual

“ENGINE” SERVICE

MANUAL

Indicates information which

may be obtained by

referring to said catalogue

SPARE PARTS

CATALOGUE

Indicates information which

may be obtained by

referring to said catalogue

DISASSEMBLY

OPERATIONS

ASSEMBLY

OPERATIONS

SYMMETRICAL

OPERATIONS

Operations that must be

carried out also on the other

side of the unit or

component.

EMPTY THE CIRCUIT

REPLACE WITH NEW,

ORIGINAL SPARE

PARTS

IDLING ENGINE

Switch on the engine, at

idling speed, to perfom

these interventions.

ENGINE OFF

Indicates operations to

be performed with

engine off

POWER OFF

Indicates that negative

pole is to be disconnected

from the battery before

performing the operation

NO!

Operations to be

absolutely avoided

OIL

COOLANT

FUEL

4 03/08

125 i.e. - 160 i.e.

GENERAL WORK PROCEDURES

• The recommendations 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, and should therefore be strictly adhered to.

• Always listen with attention to the Customer’s opinion and complaints about the motor-bike operation, asking specific questions in order to have a complete understanding of

all the symptoms and identify with good approximation the real causes of the trouble. The present manual provides the technical information and the basic indications on the

intervention procedures but these have to be integrated with the personal expertise.

• We suggest planning the service interventions in order to avoid any waste of time or downtime. Try to reduce as much as possible the operations necessary to reach the

components that needs repairing.

• Prepare the components that are likely to be replaced.

• Use only the original spare parts.

• Mark the components that may be mis-placed during re-assembly operations.

• Only use quality tools and equipment.

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

• During operations, always keep tools and equipment at hand, possibly laying them out according to the sequence in which they are to be used. Absolutely avoid putting them on the

vehicle itself, out-of-sight or in poorly accessible places.

• Always keep the work area neat and clean.

• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progressive “pulls” using a “criss-cross” pattern.

• The torque settings specified in the manual refer to the “final torque”, which must be attained progressively by steps.

• Preferably use open-end box wrenches by “pulling” and not “pushing”.

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

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

5 03/08

125 i.e. - 160 i.e.

• Before carrying out any operation, wait for all parts to cool down.

• For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and co-ordinated beforehand.

• Make sure that each component has been properly mounted before proceeding with assembling the next one.

• Always replace gaskets, O-rings, circlips and split pins at every refitting.

• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.

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 floor of the workshop. Always use low flash point solvents to clean the vehicle components.

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

Never suck from or blow into the fuel pipe.

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

Do not use fuses with a higher rated capacity than indicated: this may cause severe damages to the electrical system and burn a fire as a conse-quence of short circuit.

• Make sure that the vehicle is stable and not to have to take on awkward working positions.

• Never reuse old gaskets or circlips.

• Never use a screwdriver as a lever or chisel.

• Never use pincers 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 hexagon.

• Never tap the wrench with a hammer or other similar tool to loosen or tighten screws and nuts.

• Never attempt to increase the lever arm by fitting a tube into the wrench.

03/086

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.

It is absolutely forbidden to walk on the lifting device.

F.3

03/087

INDEX

DESCRIZIONE P

SPECIFICATIONS 8

IDENTIFICATION DATA: FRAME N° / ENGINE N° 9

TYRES 9

MAINTENANCE TABLE 10

LUBRICANT TABLE 11

REAR MIRRORS 12

FAIRING 12

UPPER HANDLEBAR COVER 12

DASH WIRING 12

INSTRUMENTS 12

ACCESSES 13

FRONT SHIELD 13

GRUPPO FARI 14

DIRECTION INDICATORS 14

ACCESSES 15

LOWER SIDE PANELS 16

ACCESSES 16

COIL 17

FUSE DESCRIPTION 17

FUSE REPLACEMENT 17

BATTERY 17

LEG SHIELD 18

SEAT 18

INSPECTION LID 18

REAR LIGHT 19

REAR FAIRING 19

ACCESSES 20

HELMET COMPARTMENT 21

SEAT LOCKING DEVICE 21

PEDANA POGGIAPIEDI 21

ACCESSES 22

FUEL LEVEL PROBE 22

OIL TANK 23

FUEL TANK 23

RIGHT AND LEFT SWITCH UNIT 24

KEY SWITCH 25

HORN 25

REPLACING THE LININGS 26

BRAKE CALIPER 26

FORK 27

OIL REPLACEMENT 28

FORK ASSY 28

SUSPENSION 29

CENTRAL KICK STAND 30

FOOT REST RODS 30

REAR WHEEL 31

REAR DRUM BRAKE 31

CHECKING 32

BRAKE LEVER ADJUSTMENT 32

AIR FILTER 33

ENGINE 34

FRAME DIMENSION CHECK 36

CABLE POSITIONING, “PIPE SYSTEM” AND LOCATION OF

ANCHORING STRAPS

37

DESCRIZIONE P

03/088

SPECIFICATIONS

DIMENSIONS

Wheel base (A) m ........................................................................................ 1,175

Max. length (B) m......................................................................................... 1,640

Max. width (C) m .......................................................................................... 0,660

Max. height (D) m ........................................................................................ 1,040

Kerb weight kg .................................................................................................. 82

Max. load with rider, passenger and luggage kg ............................................ 170

CAPACITY

Engine oil cm3 ............................................................................................. 1400*

Transmission oil cm3 ..................................................................................... 100*

Fuel tank (total) ............................................................................................... 8,0*

TWO-STROKE ENGINE

Type ........................................................................................................ CMA03C

Cylinders ............................................................................................................. 1

Bore x stroke mm................................................................................ Ø 40 x 39,2

Capacity cm3

................................................................................................... 49

Cooling ................................................................................................... forced air

Starting system.................................................. electric starter and/or kick starter

SPARK PLUG

Type ........................................................................NGK BR8 ES - NGK BR7 ES

TRANSMISSION

Automatic speed variator with expandable pulleys, V-

belt, automatic dry centrifuge clutch, reduction gear.

FUEL SYSTEM

Carburettor make / type: GURTNER PY 12 automatic starter.

Fuel: unleaded petrol.

IGNITION

Electronic.

BRAKES

Front brake: disk type, Ø 155 mm with transmission and hydraulic calipers

Rear brake:drum type, Ø 110 mm with mechanical transmission.

CHASSIS

Steel tube single beam, split at the footrest.

SUSPENSIONS

Front: hydraulically controlled fork with two Ø 26 mm rods. Stroke: 53 mm.

Rear: hydraulic shock absorber. Stroke: 60 mm.

BATTERY

Type 12V, 4Ah.

TYRES

Front:100/80 - 10 - 52 J

Rear: 100/80 - 10 - 52 J

* Indicative Value

F.4

03/089

IDENTIFICATION DATA: FRAME N° / ENGINE N°

• The body number (A) is stamped on the central body tube and can be viewed by

removing the cover (B).

• Engine identification data are located on the left-hand engine crankcase (C).

Any alteration to the vehicle identification data is pursued by the Law.

TYRES

Type: Tubeless

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

than or identical to those indicated.

It is however necessary for speed indexes to be identical for both

tyres. Use only tyres with the relevant type approval.

Minimum tread depth is 2 mm.

• There are T.W.I. marks all around the tyre sides. These correspond to tyre wear

indicators situated in the tyre’s tread; if there is no difference between the

thickness of the tyre wear indicators and the tread depth, the tyre must be

replaced.

Tyre inflation pressure must be adjusted while the tyre is at ambient

temperature.

F.5

F.6

F.7

100/80 - 10” 52J 100/80 - 10” 52J

03/0810

MAINTENANCE TABLE

NOTE -Maintenance operations should be performed more frequently if the vehicle is used in rainy weather, in dusty places or on rough

terrain.

Due to their simplicity, checks with no asterisk CAN also be carried out by technicians not authorised by MALAGUTI, but

under their direct responsibility.

03/0811

LUBRICANT TABLE

NOTE -Use only recommended products.

• To fill, remove the inspection cover, unscrewing the screw

(V) and cap (A), pulling outwards.

• Pour in oil.

1.4

0.4

F.8

03/0812

REAR MIRRORS

• Uncover and loosen the

nut (D).

• Unscrew the arm holding

the mirror.

FAIRING

UPPER HANDLEBAR

COVER

•V3

• Remove the upper

handlebar cover by lighting

hitting it upwards.

V3

Cs - N

*

m

0,5 ± 20 %

DASH WIRING

• Disconnect the dash

connector.

• Disconnect the odometer

transmission by pressing

the two tabs and

simultaneously rotating the

connector to remove it

from its housing.

• Remove the "fastom" (A)

and all the light bulb

sockets (B) from the fuel

indicator and odometer

instruments.

INSTRUMENTS

• The odometer and fuel

indicator are pressure

inserted; to remove them,

press as shown being

careful to hold the front

part of the instrument with

your fingers.

F.9

F.10

F.11 F.12

03/0813

ACCESSES

(after removing the front handlebar cover)

(1) Blinking

(2) Dashboard connector

(3) Front brake “stop” switch

(4) Rear brake “stop” switch

(5) Right switch connector

(6) Left switch connector

(7) Front brake pump oil connection

(8) Rear brake transmission

(9) Dashboard protection condenser

FRONT SHIELD

• Remove the foot rest mat.

•V4 -

•V2

• Lighting hit upwards to

release the shield.

V4

Cs - N

*

m

2 ± 10 %

V2

Cs - N

*

m

2 ± 10 %

F.14

F.15

F.13

03/0814

• Slightly spread the shield

and disconnect the

connector (A).

• Remove the shield

including the headlights

and blinkers.

GRUPPO FARI

•V3

• V (Vite regolazione fascio

luminoso).

When reassembling,

check correct OR

positioning.

• C (Plexiglas).

Always replace the

gasket before

reassembling.

•V2

• Faston (A).

DIRECTION

INDICATORS

•V1

• Faston (B).

F.16

F.17

F.18

F.19

03/0815

ACCESSES

(after removing the shield)

(1) Regulator

(2) Key switch connector

(3) Connector for anti-theft device

(4) Headlights connector

(5) Handlebar nut and bult

(6) 7.5 A light protection fuse

(7) Horn

(8) Twin gas mixer

After removing the cables, reposition and anchor the cables

with new straps, as described in the figure.

F.20

03/0816

LOWER SIDE PANELS

•V2

• Foot rest mat (A).

•V2 -

•V1 -

V2

Cs - N

*

m

2 ± 10 %

V2

Cs - N

*

m

2 ± 10 %

V1

Cs - N

*

m

2 ± 10 %

• Release the strut (B) from the rear

hood and foot rest, being careful not to

break the fastening hooks

• Release the rear brake cable (C).

ACCESSES

(after removing the lower

side panels)

(1) A.T. coil

F.21

F.22

F.23

F.24

03/0817

COIL

NOTE - Remove:

- Lower Side Panels

(p.16).

•V2

• Faston (A).

FUSE DESCRIPTION

B) 10 A - General protection/Recharge

C) 7,5 A - Lights protection/Starter

FUSE REPLACEMENT

Always replace a fuse with another of same

capacity. Higher capacity may result in

serious damage to the electric system,

including the risk of fire.

BATTERY

• Battery cover (A).

• Remove battery

• Disconnect the vent pipe

(D)

• Disconnect the cables;

firstly the cable connected

to mass (-).

BATTERY

• Connect the cables as illustrated in the figure;

connect the positive cable (+) first. .

Do not invert cable connection.

When reassembling

the battery, do not

forget to insert the

vent pipe. Make sure

it exits the battery

seat without bending

or strangling.

F.25

F.27

F.28

F.26

03/0818

LEG SHIELD

NOTE - Remove:

- Front Shield (p.13).

- Battery (p.17).

• Unscrew the ring nut (A).

•V3

• Remove the wiring.

• Remove the leg guard (B)

as indicated.

V3

Cs - N

*

m

5 ± 20 %

SEAT

• Open the seat (A).

•D2

INSPECTION LID

•V1

• Be careful to correctly

insert the reference tabs

when reassembling.

D2

Cs - N

*

m

3 ± 10 %

F.29

F.30

F.31

F.32

03/0819

REAR LIGHT

•V2

• Faston (A), (B), (C), (D).

When reassembling,

the faston (B), pink

wire, must be

connected on the

same side as the

faston (D), black

grounding wire.

REAR FAIRING

NOTE - Remove:

- Rear light (p.19).

- Seat (p.18).

- Inspection lid (p.18).

•V2

• V (Fig. 33)

• Carefully remove the

rear hood (A)

slighting spreading

the sides.

V2

Cs - N

*

m

2 ± 10 %

F.34

F.35

F.36

F.33

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Malaguti F10 User manual

Malaguti F10 User manual

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