Malaguti PHANTHOM F12R Sevice Manual

1 07/07

MALAGUTI S.p.A.

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

Tel. [phone] - F ax 051.69.47.782

e-mail: [e-mail] - 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 P ARTS CAT ALOGUES 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 e xpert 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 pro vided by the manufacturer.

• It is important to adhere strictly to the following instructions. Any oper ation 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 T orque wrench setting

D Nut

Dx Right

F Picture
G Gasket
P Page
R Washer

Sx Left

T Table
V Screw

TECHNICAL DICTIONARY

V = (DC) Direct current (battery supply)
V ~ (A C) Alternating current (flywheel supply)
A : Ampere Unit of measurement of the electrical current
W : Watt Unit of measurement of the electrical power (product of V olts 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 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” SER VICE
MANUAL

Indicates information which
may be obtained by
referring to said catalogue

SP ARE P ARTS
CATALOGUE

Indicates information which
may be obtained by
referring to said catalogue

DISASSEMBL Y
OPERATIONS

ASSEMBL Y
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 ha ve a complete understanding of

all the symptoms and identify with good approximation the real causes of the trouble. The present man ual provides the technical information and the basic indications on the
intervention procedures but these have to be integrated with the personal e xpertise.

• 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 progressiv e “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 sa y when the right size wrench is not av ailable .

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 f or 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 se v ere 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 D A T A: 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 INDICAT ORS 15

ACCESSES (after removing the shield) 16
LOWER SIDE P ANELS 17
FLOORBOARDS 17
BA TTERY SE A T COVER 17

BA TTERY 17
FUSE DESCRIPTION 18
FUSE REPLACEMENT 18

SEA T COVER ST ORAGE COMPARTMENT 18
ACCESSES 19
LEG SHIELD 19

SEAT 20
SEAT LOCKING DEVICE 20

HELMET COMP ARTMENT 21
ACCESSES (after removing the helmet compartment) 21

FUEL LEVEL PROBE 22

COVER 22
ACCESSES (after removing the cover) 22
REAR FAIRING 23
NUMBER PLA TE HOLDER 24

DESCRIPTION P.

CENTRAL TUNNEL 24

OIL TANK 25
FUEL TANK 25
GAS PEDAL CABLE SPLITTER 27

REAR MUDGUARD 2 8
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 3 2
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 3 6

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

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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

CAP ACITY

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

SP ARK PLUG

Type............................................................................................... NGK BR7 ES

TRANSMISSION

Automatic speed variator with expandable pulle ys, V­belt, automatic dry centrifuge clutch, reduction gear.

FUEL SYSTEM

Carburettor make / type: GUR TNER PY 12 automatic starter.
Fuel: unleaded petrol.

IGNITION

Electronic.

BRAKES

Front brak e: 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

Fr o nt : hydraulically controlled fork with two Ø 30 mm rods. Stroke: 88 mm.
Rear: hydraulic shock absorber. Stroke: 60 mm.

BA TTER Y

T ype 12V, 5Ah.

TYRES

Fro nt: 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: T ubeless

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 b y technicians not authorised by MALA GUTI, b ut 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

• T o fill up the oil tank, remov e the cover (A) b y 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

DASHBO ARD HOLDER

• V3 -

V3

V4

V3

1 ± 10%

DASHBOARD

• V4 -

F. 1 0

V3

V3

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. 1 3

F. 14

FRONT SHIELD

• Position adequate support beneath the scooter.

NOTE - Remove:

- Front mudguard (p. 28)

- Front wheel (p. 31).

F. 1 5

V

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. 1 7

F. 16

• V6 -

V6

2 ± 10%

V6

F. 1 8

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. 1 9

V2a

F. 2 0

B

C

V2

A DD

B

F. 2 1

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. 2 2

B A

5

8

2

3

1

F. 1 2

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 P ANELS

• V2 -

• V3 - (F. 24)

F. 2 5 F. 26

V2
V3

2 ± 10%

V

FLOORBOARDS
(after removing the
lower side panels)

•V -

• V2 -

V2

V3

V2V

F. 24

V2

5 ± 20%

BA TTERY 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. 2 3

V2

18 07/07

F. 2 9

F. 3 0

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. 2 7 F. 2 8

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 illu­strated in the figure; connect
the positive cable first.

Do not invert cable
connection.

+

SEAT CO VER
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. 3 2

F. 3 3

F. 34

B

F. 3 1

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).

20 07/07

F. 38

F. 3 5 F. 36

V2

F. 3 7

D2

SEAT

• D2 -

D2

3 ± 20%

• D2 (F . 40)

• R2 (F . 40)

V2

3 ± 20%

SEAT LOCKING
DEVICE

• V2 -

D

• Remove the cables
from the battery,
from the front part.

• Gently separate the
leg shield and
disconnect the
connector (D) of the
recharge socket.

• D2 -

21 07/07

ACCESSES

(after removing the helmet compartment)

• Fuel level probe (A)

• Engine oil probe (B)

• Low fuel warning light (C)

• Engine oil probe connector (D)

• Low fuel warning light sensor connector (E)

• Fuel level probe connector (F)

• Rear light connector (G)

HELMET COMP ARTMENT

•V -

• V4 -

• Cover (A).

• Gasket (B).

• Cover (C).

• Gasket (D).

V

V4

5 ± 20%

F. 3 9

V4

C

D

B

V4

A

V

F. 4 0

R2

D2

B

E

C

B

V4

F

A

G

D

F. 4 1

22 07/07

F. 4 2

F. 43

F. 4 4

ACCESSES

(after removing the cover)

• CDI unit (A)

• T ension regulator (B)

• Flasher relays (C)

• Start relay (D)

• Mass rope (E)

COVER

•V -

FUEL LEVEL
PROBE

• V4 - (F. 41)

NOTE - During reassembly , insert the

float (1) so that the probe con­nector is turned as shown in
F. 42.

V4

2 ± 10%

V

D

B

A

1

C

F. 45

E

23 07/07

F. 4 6

F. 4 8

F. 47

F. 49

A

V2

V

REAR FAIRING

• V2 -

• Rear light frame (A).

NOTE - In these conditions,

the lamp can be
replaced. T o replace
the lamp of the
indicators, loosen
the screws (V).

• V2 -

V2

5 ± 20%

• Remove the side
flanks by sliding
them towards the
rear part of the
scooter.

• (Gently) separate the side
flanks.

V2

24 07/07

F. 5 2

• Disconnect the connector
(B) and definitely remove
the fairing, including the
number plate holder.

NUMBER PLATE HOLDER

• V2 -

B

F. 5 1F. 5 0

•V -

V

5 ± 20%

• Free the anchoring notches
(A) of the fairing. Gently
remove the fairing itself,
being careful with the
cabling of the rear lights.

F. 5 4

V4

V4

A

V

A

F. 5 3

CENTRAL TUNNEL

• V4 -

• Release the tunnel (A) from
the hooks and let it slide in
the direction indicated by
the arrow.

V2

25 07/07

• Use pincers to release the strap (A) and discon­nect the pipe (B).

• Insert a screw, which shall function as tap, in
the tank exit connection.

• Disconnect the connector (C).

• V3 -

V3

2 ± 20%

OIL TANK

F. 5 6

E

V4

F. 55

V3

C

B

A

D

FUEL TANK

After removing the oil tank:

• Disconnect the connector (D - F. 55).

• Disconnect the connector (E).

• Disconnect the fuel supply pipe.

• V4 -

V4

5 ± 20%

NOTE - In order to reach the oil tank and the fuel

tank, it is necessary to remove the rear
fairing.

26 07/07

NOTE - Should you need to replace the pipe (B) of the mixer oil, (pointed out in yellow) position and anchor it according to the illustrations below . If not properly fixed, the pipe

may interfere with the exhaust gas pipe.

F. 57

F. 58

F. 5 9

B

27 07/07

GAS PEDAL CABLE SPLITTER

•V -

• Disconnect the clamp cables (A).

NOTE - Selective transmissions (cables C): one is connected to the carburetor and

the other to the oil pump.

F. 61

F. 60

V

C

A

NOTE - The ignition coil (B) is positioned under the left footbord.

CB

28 07/07

REAR MUDGUARD

• V2 -

V2

5 ± 20%

• V2 - and relative bushs.

V2

3 ± 20%

During re-assembly
insert the removed
parts, both outside
and inside the fender.

FRONT MUDGUARD

• V2 -

V2

3 ± 20%

F. 6 4

F. 6 2

V2

F. 6 3

V2

V2

29 07/07

FRONT BRAKE PUMP

• V2/a -

• U-bolt (B).

• Screw/connection (V).

• Disconnect the Fastons (C).

HANDLEBAR COMMANDS

• V2 -

• Disconnect the connectors (A).

• Disconnect the accelerator transmission (T).

V2

1,6 ± 20%

V2/a

28 ± 20%

V

20 ± 20%

D

50 ± 20%

HANDLEBAR

• Remove:

- Front handlebar cover (p . 12)

- Front shield (p. 13).

• V2/b -

• V1 -

• Loosen nut (D) and slide the handlebar off,
being careful not to damage cables or
pipes.

V2/b

10 ± 10%

F . 65/aF. 6 5

V2/a

B

V

AV

V2

A V2

C

V1TV2/b

D

30 07/07

V3

F. 66

HORN

• Disconnect the Fastons

(A).

•V -

F. 6 7

KEY SWITCH

• Separate the front shield (p. 13).

• Disconnect the connector.

• V3 - (foolproof screws).

V3

10 ± 15%

ODOMETER
SENSOR

• V1 (F. 74).

• Connector (C).

A

V

V1

10 ± 20%

V

7 ± 10%

F. 6 8

C

31 07/07

FRONT WHEEL

F. 6 9

F. 7 0

P

D

Make sure the scooter is perfectly stable and insert a suitable support beneath the lower side panels.

• When reassembling the wheel pin, insert
the spacers (A - B).

F. 7 2

B

F. 7 1

A

• Slide the wheel pin off (P).

Do not activate the
brake lever while the
wheel is off.

• Remove the front mudguard
(p. 28).

• Unscrew the nut (D),
preventing it from falling by
using a wrench for the
wheel pin.

D

45 ± 15%

32 07/07

REPLACING THE LININGS

• Remove the cover (A).

• Remove the seeger (B).

• Remove the pin (C) and the spring (D).

• Operate in the opposite direction to remount the components.

BRAKE CALIPER

• V2 -

•R -

FRONT BRAKE

CHECKING LINING WEAR AND BRAKE DISC

• Check the wear of the linings by looking from the front part of the fork. In case of doubt regarding their “v alidity”,
remove them and replace them.

• Check also the state of the brake disc. In case of excessive wear or anomaly, replace it.

Minimum thickness of linings should be 2 mm. Minimum thickness of disc should be 3,5 mm.

F. 73

F. 7 4

V1

R

V2

30 ± 20%

R

20 ± 20%

V2

every 2,000 km (approx. 1,205 miles)

33 07/07

F. 75

V

A

B

FORK

WHEEL SHAFT

• Remove:

- Front mudguard (p. 28)

- Front wheel (p. 31)

- Brake caliper (for left shaft)
(p. 32)

- Odometer sensor (for left shaft) (p. 30).

• Loosen (V)

• Lift the shaft a few millimeters (A).

• Remove the spring ring (B).

• Slide the shaft downwards (A).

OIL LEVEL CHECK

• Block the wheel shaft in a clamp, in vertical
position.

• Remove:

- Cover (A)

- Seeger ring (B)

- Propeller nut (C), complete with O-Ring (D)

- Spring (E) (let oil drip off it)

• Bring the shaft (F) to its end-of-travel position.

F. 7 6

F. 77

• Insert a measuring pin or a caliber and make
sure the oil is at a depth of 110 mm (approx.
3,93 inches) from the upper rim of the shaft.

• If necessary, fill up with oil:

FORK OIL ~ 90 cc per shaft

V

30 ± 20%

34 07/07

Upper balls 22 (Ø 3/16”)

Lower balls 19 (Ø 1/4”)

OIL REPLACEMENT
(wheel shafts)

• With the shaft blocked in a clamp, in vertical
position, place a container beneath the screw (V).

•V -

• Let the oil flow for a few minutes.

• Remove the wheel shaft as described above.

• T urn the shaft upside down and let any residual oil
drip out.

Do not disperse oil in the environment. Make sure
it is eliminated according to local norms regarding

special garbage disposal.

• Tighten the screw (V) with its relative gasket.

• Carefully pour new oil in the shaft:

~ 90 cc (right - left)

• Check oil level as described above.

• Reassemble the parts.

V

24 ± 10%

FORK ASSY

To remo ve the complete fork,
remove:

• Shield (p. 13).

• Front mudguard (p . 28).

• Front wheel (p. 31).

• Brake caliper (p. 32).

• Odometer sensor (p. 30).

• Handlebar (p. 29).

To release the f ork:

• Upper lock-nut (A)

• Lower lock-nut (B).

F. 7 8

F. 7 9

F. 8 0

NOTE - While removing the fork group, be careful not to

let the balls (S) out.

• Clean the cap seats (C). Check them for wear and replace
them if necessary.

Grease and reassemble the fork unit.

A
B

V

35 07/07

F. 81 F. 82

•D -

• Carefully remove the wheel,
making sure the vehicle is
stable.

D

100 ± 20%

REAR DRUM
BRAKE

• Remove the rear wheel.

• Unscrew and remove the

adjustung nut (D).

F. 83

F. 8 4

D1

E

D

C

E

A

B

A

A

D

REAR
WHEEL

NOTE - To remove the rear

wheel, you must remove the
exhaust system (p. 37).

• Position the scooter on the
stand and insert a suitable
support beneath the engine.

• Remove the cover (A).

• Grasp (with both hands) the
two sectors of the rear brake
shoes (A), open them out
vigorously , in order to separate
them from cam/pin (E).

The high strength of
the springs (B) may
cause the crushing of
your fingers.

• Loosen the nut (D1- F . 83)
and remove the lev er (C - F.

83), paying attention to the
torsion spring with which is
connected.

• Extract the cam/pin (E).

Clean and grease only the central part of the cam/pin. During re-assembly, the
cam/pin should be inserted in its seat and free from any frictions. Do not use
any tools to insert the cam/pin. Control the correct hooking of the springs (B).

36 07/07

F. 85

F. 8 6

F. 8 8

V

D

BRAKE LEVER ADJUSTMENT

• Pull the lever verifying that the brake begins working, after
an idle stroke of the lever of about 10 mm.

• If necessary, carry out adjustment by acting on the
adjustment nut (D).

• Rotate the wheel manually , operating f or different times the
brake lever verifying the idle stroke, the braking efficacy
and the free rotation of the wheel, after having released the
lever itself.

F. 8 7

After the adjustment, verify that the adjustment nut thread is not completely employed up to the
end of the thread itself (that would mean that the brake shoes are completely worn out).

NOTE - Rear brake
transmission is secured
in the lower part of the
motorcycle, by the
screw (V).

CHECKING

Friction material

• Control the conditions of the brake shoes, verify
the minimum thickness of the friction material,
which should’t be thinner then mm 2, otherwise,
replace the shoes.

Drum

• Clean carefully the inner part of the drum,
verifying that there are no clearly visible scores
or damages. Otherwise proceed with the
replacement of the rear rim.

37 07/07

D

40 ± 20%

SUSPENSION

•D -

•V -

V

24 ± 20%

• V2/a -

• Gasket (replace it with
a new one).

V2/a

8 ± 15%

F. 91

EXHAUST SYSTEM

The operations described
below should be carried
out only when the exhaust
system has cooled down.

• V2 - (see “removing the rear
mudguard”, p. 28).

F. 9 0

• Remove the strap (A)
and disconnect the
secondary air emission
pipe (B).

• V2/b -

V2/b

30 ± 20%

F. 9 2

F. 8 9

D

V

V2

V2/a

V2/b

B

A

38 07/07

F. 93

AIR FILTER
(Maintenance)

• The air filter can be
reached by removing the
lower side panels (p. 17).

• Release the spring (A) on
the carburetor.

• V3 -

• Remove:

- Cover (A)

- Filtering element (B).

• Immerge the filtering element
in a solution: solvent for
filters, for a few minutes.

• Squeeze the filter (wearing
rubber gloves) until all solvent
is eliminated.

• Spread oil for air filter on the
entire surface of the filter,
eliminating any excessive
material; in fact, the filter
must be uniformly
impregnated, without dripping.

• In case the filtering element is
damaged, replace with a new,
original one.

When reassembling the air filter unit, make sure the container contact
surfaces are perfectly adherent, to av oid aspiration of non-filtered air .

F. 94

V2

10 ± 15%

V2

F. 95

C

(Removing)

• V2 -

• Release the spring (A) on the
carburetor.

• Remove the filter case (C).

39 07/07

F. 9 6 F. 9 7

ENGINE

• Remove the rear fairing (p. 23) and the lower
side panels (p. 17).

• Disconnect the connector (A) of the start
engine.

• Disconnect the mass pipe (B) of the start
engine.

• Disconnect the flywheel connector (C) and
the three “faston” connectors (F).

Engine oil tank (p. 25).

• Disconnect the engine oil outlet pipe (C) and
use a screw to close it.

• Pull off the spark plug lead (D).

• Use the spring (E) to release the air filter from
the carburetor.

Remove the air filter unit (p. 38).

F. 9 8 F. 9 9

B

A

C

D

E

F . 97/a

C

F

40 07/07

F. 1 00

F. 101

During the re­connection of the
cable, verify that the
side (C) of the cam, is
aligned with the notch
on the fixed point of
reference.

F. 102

V

D

A

CB

F . 99/a

•V -

• V2 -

• Lateral air convey or, pa ying
attention to the hook
element positioned in the
lower part of the conveyor
itself.

V

V2

• Disconnect the first
accelerator cable, from the
carburetor.

• Disconnect the second
accelerator cable (A) from
the cam (B) which operates
on the oil mixer.

• Disconnect the carburetor
starter connector (C) (page
41 F. 103).

• Remove the muffler
(p. 37).

• Release the rear brake
transmission cable by
operating on the nut (D).

• Remove the rear wheel p.

35.

• Unscrew the lower locking screw (V) of
the shock absorber.

• Rotate the suspension upwards and
anchor it to the scooter frame.

• Remove the stand.

41 07/07

D

62 ± 15%

• Unscrew the locking nut (D) and slide the
pin out (A).

F. 1 03 F. 1 04

A

F. 105

FRAME DIMENSION CHECK

• In case of presumed deformation, however slight, of the frame after an
accident, check the dimensions of the frame.

Check value A = 1026 mm (tolerance ± 2 mm)

• In case the values found are out of the tolerance range, replace the frame.

It is absolutely forbidden to deform the frame in order to reset value
(A) as in its original configuration.

Before removing the engine shaft, you must
lift the scooter from its rear part. For this
operation it is advisable to have another
operator help you.

Removing the engine from the frame is a
dangerous operation, and should be carried out
with maximum care and attention in order to
avoid crushing arms and legs and to protect the
engine itself.

Removing the pieces and parts which allow the engine to be
separated from the frame means that a certain number of straps
must be cut. These must be replaced and positioned as in the
original configuration. Check the illustrations on the upcoming pages.

D

C

42 07/07

F. 106

F. 108F. 107

CABLE POSITIONING, “PIPE SYSTEM” AND
LOCATION OF ANCHORING STRAPS

43 07/07

F. 109

44 07/07

F. 110