Malaguti CENTRO SO 4T Service Manual

Download

1 07/08

50 cc - 4 T

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: info@malaguti.com - http: // www.malaguti.com

FOREWORD

• This 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 07/08

50 cc - 4 T

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 b l 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 07/08

50 cc - 4 T

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)

THIS 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 PAR T S

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 07/08

50 cc - 4 T

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.

5 07/08

50 cc - 4 T

• 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 07/08

50 cc - 4 T

CONTENTS

DESCRIPTION P.

ACCESS (after removing the front cover) 28 SEAT 28 HELMET CASE 28

SEAT BLOCKING DEVICE 29

ACCESS (after removing the helmet compartment) 30 FUEL LEVEL SENSOR - FUEL TANK 31 CENTRAL BAR 32 ACCESS 32 SIDE STRUTS 33 PASSANGER LEVERS 33 FOOTBAR 34 REAR FAIRING 35

REAR HANDLE 35 NUMBER PLATE LIGHT HOUSING 35 REAR LIGHTS ASSEMBLY 35 FULL REAR FAIRING 36 ACCESS (RIGHT SIDE) (LEFT SIDE) 37 REAR FAIRING BREAKDOWN 38

LEGSHIELD 39 ACCESS (after the legshield is removed) 40 KEYSWITCH 41 HORN 41 FRONT MUD GUARD 41 FRONT WHEEL 42 FRONT BRAKE DISC 42 SEQUENCE OF FRONT WHEEL REASSEMBLY 43 FRONT BRAKE CALIPER 43 FRONT SHIELD 44 HANDLEBAR 44 FORK -FORK LEG - COMPLETE FORK 45 MUFFLER 46 REAR WHEEL 46 REAR MUDGUARD - AIR INTAKE ASSEMBLY 47 MANIFOLD EXHAUST 47 SHOCK ABSORBER 48 REMOUNTING THE SHOCK ABSORBER 48 ENGINE 48 FRAME SIZE CHECK 51 CABLE POSITIONING, "PIPE SYSTEM" AND POSITION OF CLAMPS 52

DESCRIPTION P.

TECHNICAL DATA 7 IDENTIFICATION INFORMATION: FRAME N°/ ENGINE N° 8 TIRES 9 MAINTENANCE CHART 10 LUBRICANT CHART 11 FUEL TANK 12 MOTOR OIL 12 TRANSMISSION OIL 13 FRONT BRAKE FLUID 13 BLEEDING THE BRAKE SYSTEM 14 CHECK FRONT/BACK BRAKE PAD AND DISK 14 REPLACE PADS 14 CHECK REAR BRAKE 15 FORK 15

CHECK OIL LEVEL IN THE FORK LEG 15 CHANGE FORK OIL 15

DASHBOARD 16

DIGITAL CLOCK 16

KEY SWITCH 17 ENGINE STARTER 17 HANDLEBAR CONTROLS - LEFT CONTROL - RIGHT CONTROL 17 LIGHTS 18

HEADLIGHT 18 LIGHT BEAM ADJUSTMENT 18 TURN SIGNALS FRONT 18 TAIL-LIGHT 19 NUMBER PLATE LIGHT 20

FUSES 21 BATTERY 22

BATTERY ASSEMBLY 22 CHARGE BATTERY 23

SPARK PLUG 24 DISMANTLING AND REMOVAL PROCEDURES FOR COMPONENTS 25 REASSEMBLY NOTES 25 REAR-VIEW MIRROR (left) 25 REAR-VIEW MIRROR (right) (optional) 25 UPPER COVER 25 FRONT HANDLEBAR COVERS 26 FRONT COVER 27

7 07/08

50 cc - 4 T

DIMENSIONS

Wheel base (A) m .......................................................................................1,340

Max. length (B) m........................................................................................ 2,000

Max. width (C) m .........................................................................................0,730

Max. height (D) m ......................................................................................1,150

Kerb weight kg ...............................................................................................115

Max. load with rider, passenger and luggage kg ..............................................165

CAPACITY

Engine oil cm3 ............................................................................................. 850*

Transmission oil cm3 ................................................................................... 150*

Fuel tank (total) l .................................................................................... 6* (1,7*)

ENGINE: 2 valve - 4 stroke single cylinder:

Type ......................................................................................... PIAGGIO C432M

n° Cylinders ...................................................................................................... 1

Bore x stroke mm ............................................................................. Ø 39 x 41,8

Capacity cm3 ............................................................................................... 49,9

Compression Ratio ...................................................................................11,7 : 1

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

Starting system ........................................................ electrical and/or kickstarter

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

SPARK PLUG

Type ........................................................................... NGK CR8E - NGK CR8EB

TRANSMISSION

Primary drive: automatic transmission by V-belt speed change gear Final: by gears. Automatic centrifugal dry clutch.

FUEL SYSTEM

Carburettor KEIHIN CVK Automatic starter Fuel: unleaded petrol.

IGNITION

Electronic.

BRAKES

Front brake: disk type Ø 225 mm transmission and hydraulic calipers. Rear brake: drum Ø 139 mm, mechanical transmission

CHASSIS

Made of steel pipes with a high resistance.

SUSPENSIONS

Front: hydraulically controlled fork Ø 28 mm - stroke 80 mm. Rear: Swinging engine with hydraulic shock absorber featuring helical spring;

Stroke: 68 mm.

BATTERY

Type 12V, 9Ah, no maintenance.

TIRES

Front: 90/80 - 16 52P (tubeless) Rear: 100/80 - 16 52P (tubeless)

* Indicative Value

F. 1

A B

SPECIFICATIONS

8 07/08

50 cc - 4 T

IDENTIFICATION DATA: FRAME N° / ENGINE N°

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

sis, 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.

F. 3

• When ordering spare parts, also quote the vehicle identification data.

ANTI-TAMPERING PLATE

• An anti-tampering plate, bearing all vehicle identification data required by Directive 97/24/CE, is fitted inside the helmet compartment. If you have the helmet compartment replaced, make sure the plate is fitted too.

This label must be neither removed nor changed.

F. 4

F. 2

9 07/08

50 cc - 4 T

TYRES

Type: Tubeless (wiithout inner tube)

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.

The pressure of tires must be adjusted while the tire is at ambient temperature. Pressure differing from that indicated can lead to higher fuel consumption, irregular wear of the tire, impaired vehicle performance and riding conditions.

F. 5

Check the tire conditions (before every journey): if they are broken (cracked) or cut, have them replaced as soon as possible.

• “T.W.I.” marks are provided all around the tire side walls. These correspond to tire wear indicators, which are situated in the tire’s tread; if there is no difference between the thickness of these indicators and the tread depth itself, the tire must be replaced.

Minimum tread depth (front and rear) is 2 mm (F. 6).

F. 6

PRESSURE

2.0 2.0 2.1

(29.0) (29.0) (30.5)

2.2 2.3 2.3

(31.9) (33.4) (33.4)

10 07/08

50 cc - 4 T

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 07/08

50 cc - 4 T

LUBRICANT TABLE

NOTE - Use only recommended products.

LUBRICANTS

ENGINE OIL (4 STROKE) FORMULA EXCEL SAE 5W40

ENGINE TRANSMISSION OIL T35 - 80W

AIR FILTER LUBRICANT AIR FILTER OIL

RADIATOR FLUID TOP FLUID

BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4

FORK ROD OIL FORK OIL

12 07/08

50 cc - 4 T

FUEL TANK

• The fuel tank cap (A) is accessible by raising the seat, using the ignition key (B) and turning it clockwise.

Use unleaded gas.

F. 7

F. 8

• 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 drain plug (F) and the mesh filter (C).

• Wash the filter (C) with solvent.

• Check the wear conditions of the O-Ring (3) and replace if necessary.

• Reassembly: O-Ring (B) e the filter (C).

• Screw on and tighten the drain plug (F).

• Top up the engine of oil specified and replace the cap/ dipstick (A).

Start the engine; leave it running for a few minutes, and check that there are no leaks.

• Turn the engine off and check the oil level.

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 6,000 KM

F B

F. 9/a

Top with the oil Q8 FORMULA EXCEL SAE 5W 40

F. 9

every 3.000 km

CHECK LEVEL

• The engine must be cold and the vehicle on level ground.

• The level is shown on the cap/ dipstick (A), in order to check level, screw the cap back.

ENGINE OIL

850

6,0 1,7

13 07/08

50 cc - 4 T

CHECK LEVEL/ TOP UP

• Cold engine

• Vehicle on level ground.

• Place a drip pan under the engine.

• Unscrew the oil dipstick (A), dry it and put it back.

• Then extract again the dipstick, and check that the oil level reaches the mark half way between the “MIN.” and “MAX” marks.

• If necessary, top up with oil specified.

• Screw the oil dipstick (A) back.

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 dipstick (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.

• Screw the oil dipstick (A) back.

CHECK

• Visually check by way of the warning signal (S) located on the front 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.

FRONT BRAKE FLUID

Do not mix different oil types when topping off.

every 30 days

Every 12,000 Km or 24 months

F. 1 1

F. 1 0

14 07/08

50 cc - 4 T

BLEED BRAKE SYSTEM

FRONT CALIPER

NOTE - Position the vehicle in a stabile manner and

perfectly on level ground.

• Remove the oil pump reservoir cover (A),

unscrewing the relative screws (V2), in order to be able to top off the fluid.

• Fill the 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. 12 F. 13

12 ± 16%

CHECK FRONT BRAKE PADS AND DISK

• Check the condition of front brake pads and disc every 2,000 Km.

• Carry out a visual check on the thickness of the brake pads. 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. 1 4

REPLACING PADS

V2A

F. 1 5

NOTE - The procedures for replacing front brake pads can be deduced

from the illustration shown below.

15 07/08

50 cc - 4 T

CHECKING THE REAR BRAKE

• Make sure that the idle stroke of the lever is ~ 10 mm.

• Ad just the lever by means of the adjuster (A), if necessary.

F. 1 7

F. 1 6

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. 18.

• Insert a ruler or gauge and check that the oil is at least 75 mm from the upper edge of the leg.

• If necessary, top up with oil:

FORK OIL

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.

17 ± 15%

Quantity per fork 90 cc.

F. 1 8

16 07/08

50 cc - 4 T

DIGITAL CLOCK

• Reading date and month: press top button once (time will appear automatically after a few seconds).

• Reading seconds: press top button twice; to resume the initial configuration, press the button again.

• Setting month: press the bottom button twice and select the correct number with the top button.

• Setting date: press the bottom button 3 times and select the correct number with the top button.

• Setting time: press the bottom button 4 times and select the correct number with the top button.

• Setting minutes: press the bottom button 5 times and select the correct number with the top button.

Press the bottom button again to return to time display mode. If you have changed your settings, save them by pressing the top button.

INSTRUMENT BOARD

1) Analogue instruments, Speedometer

Current speed in kmh or mph.

2) Odometer

Total distance travelled in kmh.

3) Green turn indicator light

4) Blue high beam indicator light

5) Fuel level indicator

Orange zone: approaching reserve. Red zone: reserve - Refuel!!

6) Battery level indicator

This indicates the charge level of the battery and correct operation of the recharging system.

7) Digital clock

F. 1 9

To prevent damage, avoid washing instruments with pressurised system.

17 07/08

50 cc - 4 T

KEY SWITCH

Ignition inhibited (extractable key)

Preset starting position (non extractable key)

Steering lock insert (Ignition inhibited: extractable key).

In case both of the equipped keys are lost the entire locking kit must be replaced.

STARTING THE ENGINE

Before pushing the starter button to start the motor, first pull the front or rear brake lever and keep it pulled.

Do not start the engine in a closed ambient, because the exhaust is highly toxic. To not damage the injection system, never operate the "START" button if the fuel tank is empty, or turn the key switch to "ON".

If the engine does not start, release the starter switch, wait a moment, and then press it again. In order not to drain the battery, do not operate the starter for more than 10 seconds on each try. Do not rev the engine to its limit when it is cold.

Start the engine with the headlights off.

HANDLEBAR CONTROLS

3 2 1

RIGHT HAND CONTROL

1) Counterweight

2) Throttle grip

3) Front brake lever A) Light switch:

right = OFF centre = parking and instrument board lights left = low/high beam lights

B) Electric starter button.

LEFT HAND CONTROL

1) Rear brake lever

2) Counterweight

3) Horn button

4) Turn indicator switch

5) Button for turning off indicator lights

6) Light switch:

high beam low beam

F. 2 0 F. 2 1

18 07/08

50 cc - 4 T

LIGHTS

HEADLIGHT

The headlights are quartz lamps (halogen).

• High/Low beam lights (A). Halogen Bulb 12V - 60/55W (H4).

• Tail lights (B). Bulb 12V - 5W (W5W).

Change light bulb

• To reach the headlight bulbs it is necessary to remove the

front handle cover (see page 26).

LIGHT BEAM ADJUSTMENTS

• Place the vehicle in gear, 10 m from a wall.

• Turn on the low beam and keep the vehicle vertical without the kickstand and without people sitting on it.

• With a Philips screwdriver, adjust the headlight adjustment screws (R), keeping in mind that turning clockwise lowers the light beam and vice versa.

• Adjust the beam so that the lower line of the beam is about 95 cm off the ground when projected on a wall.

F. 2 4

TURN SIGNALS FRONT

• Bulb (C) 12V - 10W (RY 10W).

Light bulb replacement

• To reach the front direction indicators bulbs it is necessary to

remove the front cover and the battery cover (see see page 22).

F. 2 3

F. 2 2

+ 43 hidden pages

Malaguti CENTRO SO 4T Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual