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1 11/07
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: 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.
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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
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
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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
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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”.
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.
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• 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.
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CONTENTS
DESCRIPTION P.
ACCESS- SEAT- HELMET CASE 30
SEAT LOCKING DEVICE 31
ACCESS 32
FUEL LEVEL SENSOR - FUEL PUMP SENSOR 33
FUEL TANK 34
BATTERY CASE COVER - ACCESS- SIDE STRUTS 35
ACCESS 36
REAR FAIRING 37
REAR HANDLE 38
NUMBER PLATE LIGHT HOUSING- REAR LIGHTS ASSEMBLY 39
FULL REAR FAIRING 40
ACCESS (RIGHT SIDE) 41
(LEFT SIDE) 42
ELECTRONIC CONTROL UNIT- VOLTAGE REGULATOR 43
IGNITION COIL - ROLLOVER SENSOR 43
REAR FAIRING BREAKDOWN 44
LEGSHIELD 45
ACCESS 46
KEYSWITCH - HORN 47
FRONT WHEEL - FRONT BRAKE DISC 47
SEQUENCE OF FRONT WHEEL REASSEMBLY 48
FRONT BRAKE CALIPER 48
FRONT MUD GUARD - FRONT SHIELD 49
BACK HANDLEBAR COVER - HANDELBAR CONTROL - BRAKE PUMP 50
HANDLEBAR - ELECTRIC FAN AND RADIATOR 51
EXPANSION TANK 53
FORK -FORK LEG - COMPLETE FORK 54
MUFFLER - OXYGEN SENSOR 55
MANIFOLD EXHAUST - REASSEMBLY OF EXHAUST SYSTEM 56
SHOCK ABSORBERS- REMOUNTING THE SHOCK ABSORBERS 56
REAR MUDGUARD 57
AIR INTAKE ASSEMBLY 58
AIR FILTER 59
AIR FILTER MAINTENANCE - STARTER 60
REAR BRAKE CALIPER 61
REAR WHEEL 62
REAR BRAKE DISK - REAR WHEEL- ENGINE 63
FRAME SIZE CHECK 64
CABLE POSITIONING, "PIPE SYSTEM" AND POSITION OF CLAMPS 65
DESCRIPTION P.
TECHNICAL DATA 7
IDENTIFICATION INFORMATION: FRAME N°/ ENGINE N° - TIRES 8
MAINTENANCE CHART 9
LUBRICANT CHART 10
FUEL TANK - COOLANT RESERVOIR 11
MOTOR OIL 12
LEVEL CHECK/ CHANGE 12
TRANSMISSION OIL 13
CHECK LEVEL/ TOPPING UP - CHANGE 13
BRAKE FLUID 13
CHECK- CHANGE 13
BLEEDING THE BRAKE SYSTEM 14
FRONT CALIPER - REAR CALIPER 14
CHECK FRONT/BACK BRAKE PADS AND DISKS 15
REPLACE PADS 15
FRONT BRAKES - REAR BRAKES 15
FORK 16
CHECK OIL LEVEL IN THE FORK LEG 16
CHANGE FORK OIL 16
SHOCK ABSORBER ADJUSTMENTS 16
LOCATION OF THE MAIN ELECTRICAL AND ELECTRONIC ELEMENTS 17
DASHBOARD 19
ELECTRIC/ SERVICE WARNING LIGHT- DIGITAL CLOCK 19
KEY SWITCH - HANDLEBAR CONTROLS 20
LEFT CONTROL - RIGHT CONTROL 20
ENGINE STARTER 20
LIGHTS 21
HEADLIGHT - LIGHT BEAM ADJUSTMENT- TURN SIGNALS 21
TAIL-LIGHT - NUMBER PLATE LIGHT 22
FUSES - FUSE REPLACEMENT 23
BATTERY 24
BATTERY ASSEMBLY - CHARGE BATTERY 24
SPARK PLUG 25
REPLACEMENT 25
DISMANTLING AND REMOVAL PROCEDURES FOR COMPONENTS 26
REASSEMBLY NOTES - REAR-VIEW MIRROR- UPPER COVER 26
FRONT HANDLEBAR COVERS 27
ACCESS 28
FRONT SHIELD 29
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DIMENSIONS
Wheel base (A) m .......................................................................................1,360
Max. length (B) m........................................................................................2,050
Max. width (C) m .........................................................................................0,735
Max. height (D) m ......................................................................................1,180
Kerb weight kg ...............................................................................................140
Max. load with rider, passenger and luggage kg..............................................180
CAPACITY
Engine oil cm3 ........................................................................................... 1000*
Transmission oil cm3 ................................................................................... 150*
Fuel tank (total) l ................................................................................. 8,2* (3,0*)
ENGINE: 2 valve - 4 stroke single cylinder:
Type .............................................................................................. MALAGUTI 01
MALAGUTI 02
n° Cylinders ...................................................................................................... 1
Bore x stroke mm .......................................................................... Ø 52,4 x 57,8
Ø 58,0 x 57,8
Capacity cm3.................................................................................................125
153
Compression Ratio .................................................................................. 10,6 : 1
11,3 : 1
Cooling........................................................................................................ liquid
Starting system............................................................................. electric starter
lubrication system................................................................................ wet sump
SPARK PLUG
Type ............................................................................................NGK DPR7EA9
TRANSMISSION
Primary drive: automatic transmission by V-belt speed change gear
Final: by gears. Automatic centrifugal dry clutch.
FUEL SYSTEM
Electronic fuel injection with electric fuel pump.
Fuel: unleaded petrol.
IGNITION
Digital
BRAKES
Front brake: disk type Ø 245 mm double piston hydraulic caliper Ø 25 mm
Rear brake: disk type Ø 220 mm double piston hydraulic caliper Ø 34 mm
CHASSIS
High-tensile steel tubes
SUSPENSIONS
Front: hydraulically fork Ø 33 mm; Stroke: 88 mm.
Rear: Swinging engine with double hydraulic shock absorber. Stroke: 74 mm.
BATTERY
Type 12V, 9Ah, maintenance free.
TYRES
Front: 100/80 - 16 50P (tubeless)
Rear: 120/80 - 16 60P (tubeless)
* Indicative Value
SPECIFICATIONS
F. 1
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F. 2
F. 3
F. 4
120/80 - 16” - 60P 100/80 - 16” - 50P
2.0 2.0 2.1
(29.0) (29.0) (30.5)
2.2 2.3 2.3
(31.9) (33.4) (33.4)
B
A
TYRES
Type: Tubeless (wiithout inner tube)
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.
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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
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LUBRICANT TABLE
NOTE - Use only recommended products.
LUBRICANTS
ENGINE OIL (4 STROKE) CLASS 10W 40
ENGINE TRANSMISSION OIL CLASS 10W 40
AIR FILTER LUBRICANT AIR FILTER OIL
RADIATOR FLUID TOP FLUID
BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4
FORK ROD OIL FORK OIL
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FUEL TANK
• The fuel tank cap (A) is accessible by raising the seat, using
the ignition key and turning it clockwise.
• Check the fluid level in the inspection window (C) found
under the shield.
If it needs to be topped up, use the product
specified in the lubricants chart.
Use unleaded fuel.
A
Do not remove the cap when the motor is hot.
F. 5
F. 6
F. 7
COOLANT TANK
• Open the case with the ignition key.
• Remove the plastic protection piece (B).
B
C
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every 2,000 km
CHECK LEVEL
• The engine must be cold and the vehicle
on level ground.
• The level is shown on the cap/ dipstick
(A).
Top with the oil specified in the
lubricant chart.
F. 8
F. 9 F. 1 0
A
1
3
2
A
S
F
ENGINE OIL
• Place an appropriate drain pan under the engine (with the vehicle on flat
ground).
• Pull out the cap/ dipstick (A).
• Unscrew the drain plug (S) and let all the used oil drain out.
• Remove the filter/plug (F).
• Wash the screen (1) with solvent or if it is damaged, replace it.
• Check the wear conditions of the O-Ring (3) and replace if necessary.
• Reassembly: O-Ring (3)- Spring (2)- Screen (1) and tighten the filter/plug.
• Screw on and tighten the drain plug (S).
• Top up the engine with 800 cc of Q8 CLASS 10W40 oil and replace the cap/
dipstick.
Start the engine; leave it running for a few minutes, and check that there
are no leaks.
Dispose of used oil in accordance with current laws in force.
CHANGE
Warm up the engine for a few minutes and then shut it off.
• After the first 1,000 Km
• Every 4,000 KM
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CHECK LEVEL/ TOP UP
• Cold engine
• Vehicle on level ground.
• Place a drip pan under the engine.
• Unscrew the oil filler screw (A).
• If necessary, top up with oil specified in the lubricant
chart until the oil starts to overflow.
• Screw on the screw (A).
F. 11
TRANSMISSION OIL
CHANGE
If there is any debris or water in the brake fluid, it is essential that it be completely changed and the brake system must be bled. Excessive elasticity in the
brake lever is usually an indication that air is in the system.
CHANGE
• After the first 1,000 Km
• Every 12,000 Km
• Cold engine
• Vehicle on level ground
• Place a drip pan under the engine.
• Unscrew the oil filler screw (A).
• Unscrew the drain screw (B)
• Drain out all the used oil.
• Clean the threads of the drain screw and screw back on.
• Refill the crankcase with oil specified in the lubricant
chart until the oil starts to overflow.
• Screw back on the screw (A).
CHECK
• Visually check by way of the warning signal (S) located on the front and back
brake reservoir, with the vehicle on level ground and perfectly straight.
• The fluid level must be 3mm from the lower limit of the warning signal.
BRAKE FLUID
A
B
S
S
F. 12
every 30 days
Every 12,000 Km or 24 months
Do not mix different oil types when topping off.
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C
V
V
C
• Repeat the operation, until only liquid comes out of
the rubber tube.
BLEED BRAKE SYSTEM
FRONT CALIPER
NOTE - Position the vehicle in a stabile manner and
perfectly on level ground.
• Remove the (right side) oil pump reservoir cover (A),
unscrewing the relative screws (V"), in order to be
able to top off the fluid.
• Fill the right brake fluid reservoir (B) to the highest
level.
• Remove the rubber hood (C) of the bleeder screw
(V) and insert a rubber tube to recover the brake
fluid.
• Pump the right brake lever (D), prime it and bring
the system in pressure.
• Keeping the brake lever pumped, loosen the bleeder
screws (V), to allow air to escape. Then, tighten
the bleeder screw (V)
F. 13 F. 14
F. 1 5
F. 16
V
12 ± 16%
REAR CALIPER
• To bleed the rear caliper, follow the same operation
above, but pump the left brake lever (S).
A
V2
B
S
B
D
V2A
• Top up the brake fluid level in the reservoir (B).
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F. 20
CHECK FRONT/BACK BRAKE PADS AND DISKS
• Check the condition of front and back brake pads and discs
every 2,000 Km.
• Carry out a visual check on the thickness of the brake pads as
shown in the illustration.The minimum thickness of the brake
pad friction material must not be less than 2mm.
• Replace the pads if they are close to the allowed limit, or if they
are damaged.
F. 21
REPLACING PADS
F. 19
REAR BRAKE
F. 17 F. 18
FRONT BRAKE
NOTE - The procedures for replacing front and back brake pads
can be deduced from the illustration shown below.
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FORK
CHECK OIL LEVEL IN THE
FORK LEG
• Remove the fork leg.
If a "limit switch" of the fork is
found, or if they produce
abnormal sounds, the oil level
inside the pins must be
checked. Removal of the legs
can be seen in F. 22.
• Insert a ruler or gauge and
check that the oil is at least
75mm from the upper edge
of the leg.
• If necessary, top up with oil:
FORK OIL
F. 22
Adjust both shock absorbers using these instructions.
Uneven adjustment can compromise the stability of the vehicle.
F. 23
A
V
Perform adjustments using the special key equipped on the ring nut (A), located on the upper part of the shock absorbers;
turning it anti- clockwise will increase the strength of the spring (increase in load)
SHOCK ABSORBER
ADJUSTMENTS
5) adjustment positions are included:
1) driver only (to 75 kg)
2) driver only (over 75 kg)
3) driver and case
4) driver and passenger
5) driver, passenger, and case.
CHANGE FORK OIL
• Place an appropriate drip pan under the slider and remove the screws
(V).
• Drain out as much oil as possible.
• Proceed to dismantle the fork legs, as previously described.
• Turn the fork legs upside-down, to let the remaining oil drain out.
Hydraulic oil is corrosive and may cause personal injury.
Do not improperly dispose of used oil in the environment.
• Remount the drain screw (V).
NOTE - When remounting, replace the copper washer located under the
screw (V).
• Check the oil level, as previously described.
• Reassemble the fork components and the fork on the motorcycle.
• Carefully pour the "new" oil in the fork.
Quantity per fork 90 cc.
V
17 ± 15%
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LOCATION OF THE MAIN ELECTRICAL AND ELECTRONIC ELEMENTS
F. 2 4
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F. 2 5
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ELECTRIC/SERVICE MALFUNCTION WARNING
LIGHT
When the starter key is turned in the switch in the
position, without starting the engine, the
warning light (as well as the warning light )
will remain on for a few seconds to verify the
functioning, and it will normally shut off after this.
If it stays on longer (fully and/or flickering) it means:
• Electrical Malfunction (blinking light): indicates a
malfunction in the electrical system.
• SERVICE (15 short blinking lights): indicates the
need to perform programmed maintenance (see the
Maintenance Chart on page 9).
In both cases, reset the signal after performing the
necessary operations.
The warning light interval of the SERVICE
sign of the may have different
meanings as shown in the Maintenance
Chart, depending on the vehicles conditions
of use.
DIGITAL CLOCK
• Date and month readout
Press the top button once (after a few seconds the clock will automatically reappear).
• Seconds readout
Press the top button twice; to restore the initial configuration, press the button again.
To set the clock and calendar, use the two buttons on the right hand side of the dial, starting with the time display.
• Setting the month
Press the lower button twice; and then with the top button select the exact number.
• Setting the date
Press the lower button three times; and then using the top button select the exact number.
• Setting the time
Press the lower button four times, and then using the top button select the exact number.
• Setting the minutes
Press the lower button four times, and then using the top button select the exact number.
Press the lower button once again to return to the time display. Confirm modifications by pressing the top button.
DASHBOARD
1) Speedometer
2) Odometer
3) Turn signal warning light (green)
4) High beams warning light (blue)
5) Electric/SERVICE Malfunction warning light
(orange)
6) coolant temperature too high warning light
(red)
7) Fuel gauge indicator
8) Coolant temperature indicator (red zone:
temperature too high)
9) Digital clock
F. 26
9
8
7
6
5
4
3
2
1
/
