Malaguti PHANTHOM F12R Sevice Manual

1 07/07

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: inf[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 07/07

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 Unit of measurement of the tightening torque

3 07/07

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.

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

FUEL

EMPTY THE CIRCUIT

4 07/07

F. 1

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 and all the original spare parts you may need.

• 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”.

• The roller adjustable wrenches must be used only in case of emergency, that is to say when the right size wrench is not available.

In fact, when force is applied, the mobile vice tends to open and this may cause damage to the bolts and also result in a scarcely

reliable tightening torque. Always use the wrenches as indicated in Figure.

5 07/07

F. 2

• 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.

6 07/07

A

F. 3

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.

7 07/07

CONTENTS

DESCRIPTION P.

SPECIFICATIONS 8

IDENTIFICATION DATA: FRAME N° / ENGINE N° 9

TYRES 9

MAINTENANCE TABLE 10

LUBRICANT TABLE 11

REAR MIRRORS 12

FAIRING 12

FRONT HANDLEBAR COVER 12

DASHBOARD HOLDER 12

DASHBOARD 12

ACCESSES (after removing the front handlebar cover) 13

FRONT SHIELD 13

HEADLIGHTS 15

DIRECTION INDICATORS 15

ACCESSES (after removing the shield) 16

LOWER SIDE PANELS 17

FLOORBOARDS 17

BATTERY SEAT COVER 17

BATTERY 17

FUSE DESCRIPTION 18

FUSE REPLACEMENT 18

SEAT COVER STORAGE COMPARTMENT 18

ACCESSES 19

LEG SHIELD 19

SEAT 20

SEAT LOCKING DEVICE 20

HELMET COMPARTMENT 21

ACCESSES (after removing the helmet compartment) 21

FUEL LEVEL PROBE 22

COVER 22

ACCESSES (after removing the cover) 22

REAR FAIRING 23

NUMBER PLATE HOLDER 24

DESCRIPTION P.

CENTRAL TUNNEL 24

OIL TANK 25

FUEL TANK 25

GAS PEDAL CABLE SPLITTER 27

REAR MUDGUARD 28

FRONT MUDGUARD 28

HANDLEBAR COMMANDS 29

BRAKE PUMPS 29

HANDLEBAR 29

KEY SWITCH 30

HORN 30

ODOMETER SENSOR 30

FRONT WHEEL 31

FRONT BRAKE 32

CHECKING LINING WEAR AND BRAKE DISC 32

REPLACING THE LININGS 32

BRAKE CALIPER 32

FORK 33

WHEEL SHAFT 33

OIL LEVEL CHECK 33

OIL REPLACEMENT (wheel shafts) 34

FORK ASSY 34

REAR WHEEL 35

REAR DRUM BRAKE 35

CHECKING 36

BRAKE LEVER ADJUSTMENT 36

EXHAUST SYSTEM 37

RADIATOR 37

AIR FILTER (Maintenance) (Removing) 38

ENGINE 39

FRAME DIMENSION CHECK 41

CABLE POSITIONING, “PIPE SYSTEM” AND 42

LOCATION OF ANCHORING STRAPS

8 07/07

SPECIFICATIONS

DIMENSIONS

Wheel base (A) m .......................................................................................1,300

Max. length (B) m........................................................................................1,830

Max. width (C) m .........................................................................................0,705

Max. height (D) m........................................................................................1,160

Kerb weight kg ...............................................................................................105

Max. load with rider, passenger and luggage kg..............................................175

CAPACITY

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

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

Fuel tank (total)........................................................................................... l 9.5*

TWO-STROKE ENGINE

Type...................................................................................................... CMA02C

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

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

Capacity cm3.................................................................................................. 49

Cooling............................................................................................................ air

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

SPARK PLUG

Type............................................................................................... 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 190 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 30 mm rods. Stroke: 88 mm.

Rear: hydraulic shock absorber. Stroke: 60 mm.

BATTERY

Type 12V, 5Ah.

TYRES

Front: 130/60 - 13 53 J

Rear: 130/60 - 13 53 J

* Indicative Value

F. 4

9 07/07

F. 5 F. 6

F. 7

130/60 13”53J 130/60 13”53J

TYRES

Type: Tubeless

IDENTIFICATION DATA: FRAME N° / ENGINE N°

• The vehicle’s identification number (VIN) (A) is located on the rear side of the

chassis, under the helmet compartment.

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

Any alteration to the vehicle identification data is pursued by the

Law.

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.

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.

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

10 07/07

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.

Nr. : coupon

: check

: clean

: adjust

: replace

MAINTENANCE TABLE

11 07/07

LUBRICANTS

ENGINE TRANSMISSION OIL T35 - 80W

OIL FOR MIXING CITY BIKE ULTRA (synthetic)

DAILY SUPER (semi-synthetic)

AIR FILTER LUBRICANT AIR FILTER OIL

BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4

FORK ROD OIL FORK OIL

F. 8

A

OIL TANK Litres

TOTAL TANK CAPACITY

RESERVE

• To fill up the oil tank, remove the cover (A) by pulling

its side flap.

LUBRICANT TABLE

NOTE - Use only recommended products.

12 07/07

REAR MIRRORS

• Uncover and loosen the nut

(D).

• Unscrew the arm holding

the mirror.

• Remove the front handlebar,

including the dashboard.

• Disconnect the dashboard

connector.

D

F. 9

F. 11 F. 12

DASHBOARD HOLDER

• V3 -

V3

V4

V3

1 ± 10%

DASHBOARD

• V4 -

F. 10

V3

1 ± 10%

FAIRING

FRONT HANDLEBAR

COVER

• V3 -

13 07/07

ACCESSES

(after removing the front handlebar cover)

1) Dashboard connector

2) Front brake “stop” switch

3) Rear brake “stop” switch

4) Right switch connector

5) Left switch connector

6) Front brake pump oil connection

7) Rear brake transmission

8) Dashboard protection condenser

F. 13

F. 1 4

FRONT SHIELD

• Position adequate support beneath the scooter.

NOTE - Remove:

- Front mudguard (p. 28)

- Front wheel (p. 31).

F. 15

V

5 ± 20%

V3

2 ± 10%

V3

•V -

• V3 -

6

2

8

7

3

154

14 07/07

• Gently separate the shield and disconnect the connector (A).

• Remove the shield, including the

headlights and the direction indicators.

F. 17

F. 1 6

• V6 -

V6

2 ± 10%

V6

F. 18

A

15 07/07

HEADLIGHTS

•V2

• V2a

• V - (regulation screws for the

beam of light)

• Gutter (A)

• Shell (D)

• Faston (C)

DIRECTION

INDICATORS

• Shell (D)

•V1

F. 19

V2a

F. 20

B

C

V2

A DD

B

F. 21

V

V1

16 07/07

ACCESSES

(after removing the shield)

NOTE - Cut the strap (A - F. 12) and remove the sheath

(B) to access connectors (F.12/a).

1) Odometer transmission connector

2) Key switch connector

3) Connector for anti-theft device

4) Headlights connector

5) Fuse box connections

6) Steering wheel allowance regulation ring nut

7) Horn

8) Fork

F. 22

B A

5

8

2

3

1

F. 12

4 7

6

After removing the cables, reposition and

anchor the cables with new straps, as

described in the figure.

17 07/07

LOWER SIDE PANELS

• V2 -

• V3 - (F. 24)

F. 25 F. 2 6

V2

V3

2 ± 10%

V

FLOORBOARDS

(after removing the

lower side panels)

•V -

• V2 -

V2

V3

V2V

F. 2 4

V2

5 ± 20%

BATTERY SEAT

COVER

•V

• Cover (A)

BATTERY

•V1

• Stop battery (B)

• Remove battery

• Disconnect the vent

pipe (C)

• Disconnect the cables;

firstly the cable

connected to

mass

C

V1

B

A

-

F. 23

V2

18 07/07

F. 29

F. 30

FUSE DESCRIPTION

A) 10 A - General protection/

Recharge

B) 5 A - Stop protection/

Direction indicators/

Horn

C) 7,5 A - Lights protection/

Starter

A

B

C

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.

F. 27 F. 28

When reassembling

the battery, do not

forget to insert the

vent pipe. Make sure

it exits the battery

seat without bending

or strangling.

BATTERY

• Connect the cables as illu-

strated in the figure; connect

the positive cable first.

Do not invert cable

connection.

+

SEAT COVER

STORAGE COMPARTMENT

•V -

• Cover (A).

A

V

19 07/07

LEG SHIELD

• V - (F. 31)

• V1 -

V1

5 ± 20%

• Remove the cover

(A - F. 31) of the key

switch.

F. 32

F. 33

F. 3 4

B

F. 31

ACCESSES

• Socket for battery recharging

(B) (max. 5 Ah).

V

5 ± 20%

V

B

A

V1

C

• Remove the Fastons (B) on

the back of the fuse box.

Write down the

positions of the

Fastons before

disconnecting them.

• Open the two wire

clamps (C).

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Malaguti PHANTHOM F12R Sevice Manual

Malaguti PHANTHOM F12R Sevice Manual

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