Malaguti PHANTOM F 12 MAX 200 Workshop Manual

Brand: Malaguti

Model: PHANTOM F 12 MAX 200

Category: Motorcycles

Type: Workshop Manual

This manual is also suitable for

PHANTOM F 12 MAX 125

PHANTOM F 12 MAX

WORKSHOP MANUAL

CHASSIS

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INTRODUCTION 1 44

Notes for easy consultation 1 5

Abbreviations 1 6

General work procedures 1 6

Editing symbols 1 9

GETTING TO KNOW YOUR VEHICLE 2 10

Specifications 2 10

Unpacking 2 12

Appearance check 2 12

Registration data 2 12

VIN Label 2 12

Anti-tampering label 2 12

Main components 2 13

Controls 2 14

Start switch/keys 2 14

Stands 2 15

Display 2 15

Tires 2 16

Fuel tank 2 16

Coolant 2 17

Engine oil 2 17

Transmission oil 2 19

Brake fluid 2 20

Adjustment of engine idling speed 2 20

Shock absorber adjustment 2 21

Fuses 2 21

Checking the shape of the chassis 2 22

DISASSEMBLY 3 23

Front handlebar cover 3 23

Instrument board 3 24

Handlebar upper fairing 3 25

Left control 3 25

Right control 3 26

Front wing 3 27

Speedometer sensor 3 27

Front brake calipers 3 27

Front wheel 3 29

Front brake disc 3 29

Front fairing 3 30

Headlights 3 31

Front indicators 3 32

Headlight guard 3 33

Horn 3 34

Coolant container 3 34

Seat 3 34

Passenger’s seat 3 35

Seat lock 3 35

TABLE OF CONTENTS

DISASSEMBLY 3 23

Battery 3 36

Helmet compartment 3 36

Handle cover 3 38

Rear handle 3 38

Seat lock 3 38

Tail lamps 3 39

Rear indicators 3 39

Number plate light 3 40

Nameplate holder 3 40

Side casings 3 40

Rear cowling 3 41

Rear reflector 3 42

Tail section 3 42

Starter relays 1/2 3 43

Flashlight (125 cc only) 3 44

Regulator 3 44

Control unit 3 45

Fuel probe 3 46

Strut 3 47

Footboard 3 48

Lower fairing 3 49

Fuel filter 3 52

Fuel pump 3 52

Fuel tank 3 52

Radiator 3 53

Radiator fan 3 56

Rear shock absorbers 3 57

Air filter box 3 58

Muffler 3 60

Rear wing 3 62

Transmission cooling sleeve 3 63

Rear calipers 3 63

Rear wheel 3 65

Rear disc 3 66

Engine 3 66

Centre stand 3 72

Side stand 3 73

Side stand switch 3 73

Engine fixing plate 3 74

Switch with key 3 75

Handlebar 3 76

Fork 3 76

Stem-wheel holder assembly 3 77

ASSEMBLY 4 79

Chassis torque wrench settings 4 79

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INTRODUCTION

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

sembly of components supplied disassembled in order to deliver a brand new motorcycle (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, tiresome complaints.

Note:

These manuals provide the necessary information and instructions for routine maintenance and servicing. Some

information has been given to us by the engine manufacturers. We therefore decline all responsibility for any error,

omission or misrepresentation.

MALAGUTI reserves the right to make any changes and modifications hereto it deems necessary without prior

notice.

For further information and details, please contact the Malaguti S.p.A. Service Division.

MANUAL UPDATES

• Updated pages of this publication will be delivered by us (in a reasonable time) already punched and therefore

ready to be incorporated in the Manual. The superseded sheets should not be removed from the manual as they

remain applicable to the servicing of pre-modified vehicles.

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

tion 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.

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(RH PAGE)

PAGE LAYOUT

Y Chapter

X Section title

W Page N°

Z Date of issue

NOTES FOR EASY CONSULTATION

MODIFIED PAGES

• Modified pages shall bear the same number as those in the previous edition /pre-modified ones, followed by the

letter M, with the date of issue appearing in the appropriate box.

• Modified pages may contain new illustrations; in this case, the added illustration (or illustrations) will bear the

number of the illustration on the former page, followed by a letter.

ADDITIONAL PAGES

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

the date of issue.

ILLUSTRATIONS

• This manual describes disassembly of 125 cc and 200

cc versions; the illustrations will bear indications as to

which version of the vehicle is illustrated, in order to dis-

tinguish the sequences.

Illustration n°

Version

ILLUSTRATIONS

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F Figure

Cs Tightening torque

P Page

Pr Paragraph

S Section

Sc Diagram

T Table

V Screw

EDITING SYMBOLS

• Symbols have been provided for quick and easy reference (see page 9), 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 veritable “memory tags”. In case of

any doubt as to their meaning, consult the page in which they are fully described.

ABBREVIATIONS

Note:

the letter V in the illustrations refers to retaining 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. Letters not followed by a

number indicate a single screw. In case of different screws being referred to in the illustration, the letter V is

followed by a number and a small letter. For instance: (V4a).

Unless otherwise specified, units and components are reassembled by proceeding in the reverse order of remov-

al.

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. They

should therefore be strictly adhered to.

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F. 1

F. 3

F. 2

ADVICE:

• 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 se-

quence 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 clean and tidy.

• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progres-

sive “pulls” in accordance to a “criss-cross” pattern.

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

• Adjustable wrenches (F. 1) should only be used in case of emergency, i.e. when a properly sized wrench is not

available. they should preferably not be used as the movable jaw tends to open thus risking damaging or not

properly tightening the bolt to the correct torque. In any case, when using an adjustable wrench, take care to

proceed as shown in Figure 1.

• Except for occasional customers, always make out and deliver to the customer a work sheet specifying the

operations performed, with notes as to any future checks eventually required.

RECOMMENDATIONS:

• Before carrying out any operation on the vehicle, 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 coordinated beforehand.

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

• Lubricate all parts (where applicable) before reinstalling them.

• Gaskets, O-rings, circlips and split pins must be replaced at every refitting.

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

steps.

• Loosen and tighten aluminium alloy parts (covers) only after the engine has fully cooled down.

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

• Work in a comfortable position and ensure that the vehicle is stable.

• 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 tools to loosen or tighten screws and nuts (F. 2).

• Never attempt to increase the lever arm by fitting a tube into the wrench (F. 3).

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F. 4

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.

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 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 motorbike is perfectly stable.

The front wheel should preferably be anchored to the equipment (A - F 4) integral with the lifting board.

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EDITING SYMBOLS

A) CAUTION! Recommendations and precautions regarding rider

safety and motor vehicle integrity.

B) 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.

C) FIRE HAZARD

Indicates operations which may constitute a fire hazard.

D) RISK OF EXPLOSION

Indicates operations which may constitute a risk of explosion.

E) TOXIC FUMES

Indicates a possibility of intoxication, inflammation or corrosion.

F) MECHANICAL MAINTENANCE

Operations to be performed only by an expert mechanic.

G) ELECTRICAL MAINTENANCE

Operations be performed only by an expert electrical/electronic

technician.

H) NO! Operations to be absolutely avoided.

I) ENGINE WORKSHOP MANUAL

Indicates information which may be obtained by referring to said

catalogue.

L) SPARE PARTS CATALOGUE

Indicates information which may be obtained by referring to said

catalogue.

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SPECIFICATIONS

125 cc

200 cc

Dimensions:

Max. length

Max. width

Max. height 1210 mm 1280 mm

Wheel base 1400 mm 1410 mm

Weight:

kerb weight 139 kg 143 kg

maximum load

Engine:

Type single cylinder, 2 valves single cylinder, 4 valves

Cylinder type 3M5 M244M

Displacement 124 cm

198 cm

Bore x stroke 53.7 x 54.8 mm 72.0 x 48.6 mm

Compression ratio 11: 1 11.5: 1

Starting system

Lubricating system

Ignition system

Type of oil:

Engine oil

Total amount 1.4 L 1000 cc

Transmission oil

Total amount 0.14 L 150 cc

Brake fluid

Fuel:

Type

Fuel tank capacity

Reserve amount

Carburettor:

Type 5XL WVF7 - KEI HIN/CVK30

Manufacturer TEIKEI Walbro

Chassis:

Frame

Spark plug:

Type NGK CR8EB NGK CR8EB

CHAMPION RG6YC

Manufacturer

Electrode gap

Cooling system

Type

Recommended fluid

Mode:

1980 mm

760 mm

170 kg

electrical starter

wet sump

electronic

Q8 CLASS 10W-40

Q8 T35 - 80W

Q8 BRAKE FLUID DOT 4

unleaded petrol

9.5 L

3 L

single tubular steel frame split at

the footboard level

NGK

0.6 ~ 0.7 mm

liquid cooled

Q8 TOP FLUID

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Transmission:

Type

Primary reduction system

Clutch

Tires:

Type

Front 130/70-13 57P 130/70-13 57S

Rear 130/60-18 63P 140/60-13 63S

Tire pressure (ambient temperature):

Front 0 ~ 90 kg

Rear 0 ~ 90 kg

Front 90 kg ~ max. load

Rear 90 kg ~ max. load

Brakes:

Front

Calipers

Operation

Rear

Calipers

Operation

Suspensions:

Front

Max. stroke

Rear

Max. stroke

Electrical equipment:

Battery capacity

Horn

Lights

Low beam

High beam

Front parking light

Front/rear - right/left turn indicators

Instrument board lights

Stop light

Rear parking light

Number plate

125 cc 200 cc

automatic speed variator, by V-belt,

one speed

gear type

dry, centrifugal and automatic

tubeless

2.3 bar

hydraulic disk type, Ø220 mm

hydraulic

right hand

hydraulic disk type, Ø220 mm

hydraulic

left hand

telescopic-hydraulic fork with two stanchions Ø 33

90 mm

2 hydraulic shock absorbers with adjustable spring preload

82 mm

12V 9 Ah

12V

halogen, 12V - 65W HB3

halogen, 12V - 55W H3

12V - 3W

12V 10W

LED

12V - 16W - 2 Pcs

12V - 2.3W - 10 Pcs

12V - 5 W

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F.1i

F.2i

125 cc200 cc

MARCHIO DI FABBRICA: MALAGUTI S.P.A.

CATEGORIA DEL VEICOLO: (*)

---------------------

----------------------

-----------------------

------------------------

---------------------

----------------------

F.3i

F.4i

UNPACKING

• Unpack the motorcycle following the instructions printed on the pack, which must be disposed of in accordance

to the laws in force.

APPEARANCE CHECK

• Make sure all plastic components have been correctly fitted. In particular check the vehicle for scratches, marks,

etc.

REGISTRATION DATA

ENGINE REGISTRATION NUMBER

Engine registration data (A - F.1i) are on the left engine crankcase.

VEHICLE REGISTRATION NUMBER

To access the vehicle registration number, open the centre hatch, using the ignition keys, and remove the

cover (B - F. 2i).

VIN LABEL

The vehicle’s VIN label is applied to the front of the vehicle, on the right hand side, under the upper fairing

(C - F.3i)

ANTI-TAMPERING LABEL

Anti-tampering label (only for version 125 cc.) - (F. 4i). The anti-tampering label is located inside the

helmet holder. It bears all the registration data requested by Directive 97/24/CE.

If you have replaced your helmet holder, make sure the new component features this label.

When ordering spare parts, also quote the vehicle or engine registration data.

This label must be neither removed nor changed.

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F.5i

F.6i

15a

1819

15b

MAIN COMPONENTS

(Left hand side)

1. Digital instrument board

2. Switch with key

3. Front ticket holder

4. Front disc brake calipers

5. Carburettor

6. Rear turn indicators

7. Tail light

8. Nameplate holder

9. Air filter

10. Seat lock

11. Left hand rear view mirror

12. Passenger’s handle

13. Adjustable shock absorbers

MAIN COMPONENTS

(Right hand side)

14. Right hand mirror

15a. High beam headlight

15b. Low beam headlight

16. Front turn indicators

17. Helmet holder

18. Fork

19. Fuel tank cap

20. Muffler

21. Battery

22. Anti-theft hook

23. Centre stand

24. Spark plug

25. Seat

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F.9i

F.7i

F.8i

CONTROLS

Right hand controls

26. Front brake lever

27. Counterweight

28. Throttle grip

29. MODE button

30. Front brake oil tank

31. Electrical starter button

32. Light switch

33. Emergency switch, engine

stop

Left hand controls

34. Rear brake oil tank

35. “Flash” lever, high beam lights

36. Rear brake lever

37. Counterweight

38. Light switch

39. Turn indicator switch

40. Horn button

START SWITCH/KEYS

• The main switch controls the ignition circuit and steering lock.

: all electrical contacts are disconnected.

: contacts are connected. The engine can start.

: the steering lock is on.

KEYS

The vehicle is supplied with two keys featuring a code number, which have the following functions:

• Providing the ignition contact

• Turning the lights on.

• Locking the steering system.

• Opening the hatch of the fuel cap compartment.

STEERING LOCK

Locking: turn the handlebar all the way to the right or left, push the key in and turn it counter-clockwise.

Disengaging: turn the key clockwise.

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F.10i

F.11i

STANDS

Make sure the centre stand (A - F. 10i) and the side

stand (B - F. 10i) are correctly fitted and that they move

correctly. Check the spring holding the side stand in

place on a regular basis.

DISPLAY

1- Coolant temperature indicator

The red notch (A) and the activation of the red warning light (B) mean that the liquid is too hot, owing to a fault

in the cooling circuit or to a shortage of coolant. Bring the vehicle to an immediate stop.

2- Fuel level indicator

The warning light (C) comes on to indicate that the reserve amount has been reached.

3- Green low beam indicator light

4- Blue high beam indicator light

5- Green turn indicator light

6- Multifunction digital instrument board

7- Not controlled

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bar

(psi)

2,3 2,3

(33,4) (33,4)

2,3 2,3

(33,4) (33,4)

F.13i

F.12i

TIRE PRESSURE CHECK

Tire pressure must be checked when the tires are cold.

FUEL TANK

Open the hatch (A - F. 13i) with the starter key, unscrew the cap (B -

F. 13i) and fill the tank. Immediately wipe off spilled fuel.

Use unleaded petrol.

Fuel tank capacity:

Total: 9.5 L

Reserve amount: 3 L

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F.14i

F.15i

Max

Min

F.16i

COOLANT

CHECK

To gain access to the coolant tank (1 - F. 14i), for

engine cooling, remove the cover by loosening the

screw (A - F. 14i).

The coolant level must be checked on a cold engine

since the level varies with engine temperature. The

level of coolant must fall within the maximum and

minimum notches on the tank.

If the level is low, add coolant.

ENGINE OIL, 125 cc

CHECK

Put the scooter on its centre stand and warm up the

engine. Stop the engine and wait a few minutes for

the oil level to stabilise before checking.

Unscrew the dipstick from the engine crankcase (A -

F. 15i).

Clean the dipstick and put it back into its seat but do

not screw it in place.

By means of this operation, you will check the

oil level.

The level must be between the MIN and MAX marks

on the dipstick (F. 15i). If the level is low, add oil.

Put the dipstick back into its seat and screw it in

place.

REPLACEMENT

Warm the engine up for a few minutes.

Stop the engine, put an oil pan under it and remove

the dipstick; remove the drainage cap (A - F. 16i),

and let the oil flow out.

Clean the oil filtering net (1 - F. 16i) with solvent.

Check the “O-ring” (3 - F. 16i) and replace it if it is

damaged; refit the “O-ring”, the compression

spring (2 - F. 16i), the oil filter and the drainage cap.

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Max

Min

F.17i

F.18i

ENGINE OIL, 200 cc

CHECK

Park the scooter on flat ground and place it on its centre

stand. Start the engine and let it run until it reaches oper-

ating temperature; turn off the engine and wait 5-10 min-

utes to enable the oil to flow into the sump.

Unscrew the dipstick (A - F. 17i) from the engine crank-

case and clean it; now fit it back into its seat and screw

it firmly in place.

Remove the cap-dipstick and make sure the oil level falls

within the MIN and MAX marks illustrated in F.17i.

If the level is low, add oil.

After checking, refit the cap and dipstick and screw firmly

in place.

REPLACEMENT

Warm up the engine for a few minutes; stop the engine

and put an oil pan under the casing in correspondence

with the cap (A-F. 18i).

Remove the drainage cap and the dipstick and let the oil

flow out.

Clean the filtering net with compressed air, check the state

of the cap’s O-ring and, if damaged, replace it.

Remove the cartridge filter with O-ring (B-F. 18i) and re-

place it with a new one.

Before fitting the new cartridge filter, lubricate the relative

O-ring and screw in place, tightening by hand.

Refit the filtering net and the cap with O-ring.

Fill the engine with oil, refit the cap-dipstick and screw

firmly in place.

Run the engine to charge the new filter and lubricating

circuit. Stop the engine and, after 5 minutes, check the oil

level. If necessary, fill up to the MAX level mark.

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F.19i

F.20i

MIN

MAX

F.21i

F.22i

TRANSMISSION OIL, 125 cc

CHECK

Place the scooter on its stand.

Put a container under the engine crankcase, remove

the oil filling bolt (A - F. 19i) and the drainage cap to

drain out the oil (B - F. 20i); refit the drainage cap and fill

the crankcase with the recommended type of oil.

Start the engine and let it warm up for a few minutes.

While it is warming up, check for oil leakage. If oil is

leaking, immediately turn off the engine and locate the

cause.

REPLACEMENT

Place the scooter on its stand.

Put a container under the engine crankcase, remove

the oil filling bolt (A - F. 19i) and the drainage cap to

drain out the oil (B - F. 20i); let the oil flow into a suita-

ble container (pay attention to avoid scorching).

Close the drainage cap and add new oil. You can now

close the filling cap.

TRANSMISSION OIL, 200 cc

CHECK

Park the scooter on flat ground and place it on its cen-

tre stand.

Unscrew the dipstick (A- F. 21i), clean it and screw it

back into place. Take it out again and make sure the oil

level is between the MAX and MIN notches.

If the level is low, top up to the MAX notch.

REPLACEMENT

Park the scooter on flat ground and place it on its cen-

tre stand.

Unscrew the dipstick (A- F. 21i), clean it, screw it back

into place then put a container under the engine crank-

case and unscrew the drainage screw (B-F.22i), paying

attention to the gasket.

Let the oil flow into the container (pay attention to avoid

scorching).

Refit the drainage cap and gasket and fill with new oil.

Refit the cap and dipstick (A-F.21i).

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F.23i

MIN

F.24i

BRAKE FLUID

CHECK

The visual check should be made through the sight glass

(S) of the tanks: (A - F.23i - front brake) (B - F.24i - rear

brake), with the scooter parked on flat ground and per-

fectly upright.

The oil should be at 3 mm from the bottom edge of the

sight glass.

Top up by removing the covers (A - B), after loosening

the fixing screws.

REPLACEMENT

If the fluid features traces of dirt, debris or water, it must

be replaced.

A soft and spongy feeling in the brake lever can indicate

the presence of air in the circuit. Contact an authorised

service centre at once.

ADJUSTMENT OF ENGINE IDLING SPEED

Engine idling speed must be adjusted every time it

seems irregular.

To perform a correct check, start the engine and warm

it up to its operating temperature. Let it run idle and

check speed.

Open and close the throttle several times to make sure

that idling speed is maintained stable.

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Malaguti PHANTOM F 12 MAX 200 Workshop Manual

Brand: Malaguti

Model: PHANTOM F 12 MAX 200

Category: Motorcycles

Type: Workshop Manual

This manual is also suitable for

PHANTOM F 12 MAX 125

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Malaguti PHANTOM F 12 MAX 200 Workshop Manual

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Malaguti PHANTOM F 12 MAX 200 Workshop Manual

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