Malaguti PHANTOM F 12 MAX 125, PHANTOM F 12 MAX 200 Workshop Manual

PHANTOM F 12 MAX
A
WORKSHOP MANUAL
CHASSIS
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SP
INTRODUCTION 1 44
Notes for easy consultation 1 5
Abbreviations 1 6
General work procedures 1 6
Editing symbols 1 9
GETTING TO KNOW YOUR VEHICLE 2 10
Specifications 2 10
Unpacking 2 12
Appearance check 2 12 Registration data 2 12
VIN Label 2 12
Anti-tampering label 2 12
Main components 2 13 Controls 2 14
Start switch/keys 2 14
Stands 2 15
Display 2 15 Tires 2 16
Fuel tank 2 16
Coolant 2 17
Engine oil 2 17 Transmission oil 2 19
Brake fluid 2 20
Adjustment of engine idling speed 2 20 Shock absorber adjustment 2 21
Fuses 2 21
Checking the shape of the chassis 2 22
DISASSEMBLY 3 23
Front handlebar cover 3 23
Instrument board 3 24
Handlebar upper fairing 3 25
Left control 3 25 Right control 3 26
Front wing 3 27
Speedometer sensor 3 27
Front brake calipers 3 27 Front wheel 3 29
Front brake disc 3 29
Front fairing 3 30
Headlights 3 31 Front indicators 3 32
Headlight guard 3 33
Horn 3 34
Coolant container 3 34 Seat 3 34
Passenger’s seat 3 35
Seat lock 3 35
TABLE OF CONTENTS
SP
DISASSEMBLY 3 23
Battery 3 36
Helmet compartment 3 36 Handle cover 3 38
Rear handle 3 38
Seat lock 3 38
Tail lamps 3 39 Rear indicators 3 39
Number plate light 3 40
Nameplate holder 3 40
Side casings 3 40 Rear cowling 3 41
Rear reflector 3 42
Tail section 3 42
Starter relays 1/2 3 43 Flashlight (125 cc only) 3 44
Regulator 3 44
Control unit 3 45
Fuel probe 3 46 Strut 3 47
Footboard 3 48
Lower fairing 3 49
Fuel filter 3 52 Fuel pump 3 52
Fuel tank 3 52
Radiator 3 53
Radiator fan 3 56 Rear shock absorbers 3 57
Air filter box 3 58
Muffler 3 60
Rear wing 3 62 Transmission cooling sleeve 3 63
Rear calipers 3 63
Rear wheel 3 65
Rear disc 3 66 Engine 3 66
Centre stand 3 72
Side stand 3 73
Side stand switch 3 73 Engine fixing plate 3 74
Switch with key 3 75
Handlebar 3 76
Fork 3 76 Stem-wheel holder assembly 3 77 ASSEMBLY 4 79
Chassis torque wrench settings 4 79
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INTRODUCTION
This Workshop Manual describes the main electrical/mechanical checks, the essential checks and the as-
sembly of components supplied disassembled in order to deliver a brand new motorcycle (the sequence of operations is not binding).
It is essential to follow the instructions with great care. Work carried out carelessly or, worse still, work that has
not been accomplished, can cause injuries and damage or, in the less serious cases, tiresome complaints.
Note:
These manuals provide the necessary information and instructions for routine maintenance and servicing. Some information has been given to us by the engine manufacturers. We therefore decline all responsibility for any error, omission or misrepresentation. MALAGUTI reserves the right to make any changes and modifications hereto it deems necessary without prior notice. For further information and details, please contact the Malaguti S.p.A. Service Division.
MANUAL UPDATES
Updated pages of this publication will be delivered by us (in a reasonable time) already punched and therefore
ready to be incorporated in the Manual. The superseded sheets should not be removed from the manual as they remain applicable to the servicing of pre-modified vehicles.
The table of contents will be duly updated in the event that new pages are inserted, which render the consulta-
tion of the manual difficult.
• IMPORTANT! The Workshop Manuals are to be considered as essential tools to be properly kept up-to-date so
as to maintain their “validity” over time.
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X
W
Z
Y
(RH PAGE)
P A GE LA Y OUT
Y Chapter
X Section title
W Page N°
Z Date of issue
NOTES FOR EASY CONSULTATION
MODIFIED PAGES
• Modified pages shall bear the same number as those in the previous edition /pre-modified ones, followed by the
letter M, with the date of issue appearing in the appropriate box.
• Modified pages may contain new illustrations; in this case, the added illustration (or illustrations) will bear the number of the illustration on the former page, followed by a letter.
ADDITIONAL PAGES
• Any additional pages shall bear the last number of the section to which they belong, followed by the letter A and the date of issue.
ILLUSTRATIONS
• This manual describes disassembly of 125 cc and 200 cc versions; the illustrations will bear indications as to which version of the vehicle is illustrated, in order to dis­tinguish the sequences.
Illustration n°
Version
ILLUSTRATIONS
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F Figure
Cs Tightening torque
P Page
Pr Paragraph
S Section
Sc Diagram
T Table V Screw
EDITING SYMBOLS
• Symbols have been provided for quick and easy reference (see page 9), identifying situations requiring
utmost attention or providing practical suggestions or simple information.
These symbols may appear next to a text (in which case they refer solely to the text itself), next to a figure (in which case they refer to the topic illustrated in the figure and to the relative text), or at the top of the page (in which case they refer to all the topics dealt with in the page).
Note:
The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations. They are therefore to be considered as veritable “memory tags”. In case of any doubt as to their meaning, consult the page in which they are fully described.
ABBREVIATIONS
Note:
the letter V in the illustrations refers to retaining or adjusting screws. The number following this letter refers to the number of the same type of screw in the unit or component described and illustrated. Letters not followed by a number indicate a single screw. In case of different screws being referred to in the illustration, the letter V is followed by a number and a small letter. For instance: (V4a). Unless otherwise specified, units and components are reassembled by proceeding in the reverse order of remov­al.
GENERAL WORK PROCEDURES
• The advice, recommendations and warnings given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment damage and idle times. They should therefore be strictly adhered to.
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F. 1
F. 3
F. 2
ADVICE:
• Only use quality tools and equipment.
Only use equipment conforming to EU Directives for lifting the vehicle.
• During operations, always keep tools and equipment at hand, possibly laying them out according to the 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 clean and tidy.
• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progres­sive “pulls” in accordance to a “criss-cross” pattern.
• Preferably use open-end box wrenches by “pulling” and not “pushing”.
• Adjustable wrenches (F. 1) should only be used in case of emergency, i.e. when a properly sized wrench is not available. they should preferably not be used as the movable jaw tends to open thus risking damaging or not properly tightening the bolt to the correct torque. In any case, when using an adjustable wrench, take care to proceed as shown in Figure 1.
• Except for occasional customers, always make out and deliver to the customer a work sheet specifying the operations performed, with notes as to any future checks eventually required.
RECOMMENDATIONS:
Before carrying out any operation on the vehicle, wait for all parts to cool down.
• For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and coordinated beforehand.
• Make sure that each component has been properly fitted before proceeding with the next one.
• Lubricate all parts (where applicable) before reinstalling them.
• Gaskets, O-rings, circlips and split pins must be replaced at every refitting.
• The torque settings specified in the manuals refer to the “final torque”, which must be attained progressively by steps.
• Loosen and tighten aluminium alloy parts (covers) only after the engine has fully cooled down.
• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.
• Work in a comfortable position and ensure that the vehicle is stable.
• Never use a screwdriver as a lever or chisel.
• Never use pincers to loosen or tighten screws or nuts because, in addition to not providing a sufficient clamping force, they may also damage the screw head or nut hexagon.
Never tap the wrench with a hammer or other similar tools to loosen or tighten screws and nuts (F. 2).
Never attempt to increase the lever arm by fitting a tube into the wrench (F. 3).
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F. 4
A
Never use open flames for any reason.
Never leave open containers or containers not suitable for holding fuel in passageways, close to heat
sources, etc
Never use petrol to clean the vehicle or the floor of the workshop. Always use low flash point solvents to
clean the vehicle components.
Never suck from or blow into the fuel pipe.
When welding, make sure that there are no flammable liquids in the vicinity. Always remove the tank, even
if completely empty, and disconnect the negative cable (-) from the battery.
Never leave the engine running in closed or poorly ventilated areas.
Before any servicing, make sure that the motorbike is perfectly stable. The front wheel should preferably be anchored to the equipment (A - F 4) integral with the lifting board.
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R
M
L
H
F
A
B
D
C
I
G
E
EDITING SYMBOLS
A) CAUTION! Recommendations and precautions regarding rider
safety and motor vehicle integrity.
B) WARNING! Situations entailing the risk of personal injury to
maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment, vehicle or equipment.
C) FIRE HAZARD
Indicates operations which may constitute a fire hazard.
D) RISK OF EXPLOSION
Indicates operations which may constitute a risk of explosion.
E) TOXIC FUMES
Indicates a possibility of intoxication, inflammation or corrosion.
F) MECHANICAL MAINTENANCE
Operations to be performed only by an expert mechanic.
G) ELECTRICAL MAINTENANCE
Operations be performed only by an expert electrical/electronic technician.
H) NO! Operations to be absolutely avoided.
I) ENGINE WORKSHOP MANUAL
Indicates information which may be obtained by referring to said catalogue.
L) SPARE PARTS CATALOGUE
Indicates information which may be obtained by referring to said catalogue.
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SPECIFICATIONS
125 cc
200 cc
Dimensions:
Max. length Max. width Max. height 1210 mm 1280 mm Wheel base 1400 mm 1410 mm
Weight:
kerb weight 139 kg 143 kg maximum load
Engine:
Type single cylinder, 2 valves single cylinder, 4 valves Cylinder type 3M5 M244M Displacement 124 cm
3
198 cm
3
Bore x stroke 53.7 x 54.8 mm 72.0 x 48.6 mm Compression ratio 11: 1 11.5: 1 Starting system Lubricating system Ignition system
Type of oil:
Engine oil Total amount 1.4 L 1000 cc Transmission oil Total amount 0.14 L 150 cc Brake fluid
Fuel:
Type Fuel tank capacity Reserve amount
Carburettor:
Type 5XL WVF7 - KEI HIN/CVK30 Manufacturer TEIKEI Walbro
Chassis:
Frame
Spark plug:
Type NGK CR8EB NGK CR8EB
CHAMPION RG6YC Manufacturer Electrode gap
Cooling system
Type Recommended fluid
Mode:
1980 mm
760 mm
170 kg
electrical starter
wet sump electronic
Q8 CLASS 10W-40
Q8 T35 - 80W
Q8 BRAKE FLUID DOT 4
unleaded petrol
9.5 L 3 L
single tubular steel frame split at
the footboard level
NGK
0.6 ~ 0.7 mm
liquid cooled
Q8 TOP FLUID
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Transmission:
Type
Primary reduction system Clutch
Tires:
Type Front 130/70-13 57P 130/70-13 57S Rear 130/60-18 63P 140/60-13 63S
Tire pressure (ambient temperature):
Front 0 ~ 90 kg Rear 0 ~ 90 kg Front 90 kg ~ max. load Rear 90 kg ~ max. load
Brakes:
Front Calipers Operation Rear Calipers Operation
Suspensions:
Front Max. stroke Rear Max. stroke
Electrical equipment:
Battery capacity Horn
Lights
Low beam High beam Front parking light Front/rear - right/left turn indicators Instrument board lights Stop light Rear parking light Number plate
125 cc 200 cc
automatic speed variator, by V-belt,
one speed
gear type
dry, centrifugal and automatic
tubeless
2.3 bar
2.3 bar
2.3 bar
2.3 bar
hydraulic disk type, Ø220 mm
hydraulic
right hand
hydraulic disk type, Ø220 mm
hydraulic
left hand
telescopic-hydraulic fork with two stanchions Ø 33
90 mm
2 hydraulic shock absorbers with adjustable spring preload
82 mm
12V 9 Ah
12V
halogen, 12V - 65W HB3
halogen, 12V - 55W H3
12V - 3W 12V 10W
LED
12V - 16W - 2 Pcs
12V - 2.3W - 10 Pcs
12V - 5 W
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SECTION 2
F.1i
F.2i
A
A
125 cc200 cc
B
C
MARCHIO DI FABBRICA: MALAGUTI S.P.A.
CATEGORIA DEL VEICOLO: (*)
1 -
---------------------
2 -
---------------------
3 -
---------------------
4 -
----------------------
5 -
----------------------
6 -
-----------------------
7 -
-----------------------
8 -
-----------------------
9 -
------------------------
10 -
---------------------
11 -
----------------------
12 - ----------------------
F.3i
F.4i
UNPACKING
• Unpack the motorcycle following the instructions printed on the pack, which must be disposed of in accordance to the laws in force.
APPEARANCE CHECK
• Make sure all plastic components have been correctly fitted. In particular check the vehicle for scratches, marks, etc.
REGISTRATION DATA
ENGINE REGISTRATION NUMBER
Engine registration data (A - F.1i) are on the left engine crankcase.
VEHICLE REGISTRATION NUMBER
To access the vehicle registration number, open the centre hatch, using the ignition keys, and remove the cover (B - F. 2i).
VIN LABEL
The vehicle’s VIN label is applied to the front of the vehicle, on the right hand side, under the upper fairing
(C - F.3i)
ANTI-TAMPERING LABEL
Anti-tampering label (only for version 125 cc.) - (F. 4i). The anti-tampering label is located inside the
helmet holder. It bears all the registration data requested by Directive 97/24/CE.
If you have replaced your helmet holder, make sure the new component features this label.
When ordering spare parts, also quote the vehicle or engine registration data.
This label must be neither removed nor changed.
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F.5i
F.6i
15a
24
22
14
20
17
16
25
21
23
1819
15b
4
1
2
7
8
13
9
5
11
10
12
3
6
MAIN COMPONENTS (Left hand side)
1. Digital instrument board
2. Switch with key
3. Front ticket holder
4. Front disc brake calipers
5. Carburettor
6. Rear turn indicators
7. Tail light
8. Nameplate holder
9. Air filter
10. Seat lock
11. Left hand rear view mirror
12. Passenger’s handle
13. Adjustable shock absorbers
MAIN COMPONENTS (Right hand side)
14. Right hand mirror
15a. High beam headlight
15b. Low beam headlight
16. Front turn indicators
17. Helmet holder
18. Fork
19. Fuel tank cap
20. Muffler
21. Battery
22. Anti-theft hook
23. Centre stand
24. Spark plug
25. Seat
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F.9i
26
29
27
28
30
31
32
33
40
39
38
36
37
35
34
F.7i
F.8i
CONTROLS
Right hand controls
26. Front brake lever
27. Counterweight
28. Throttle grip
29. MODE button
30. Front brake oil tank
31. Electrical starter button
32. Light switch
33. Emergency switch, engine
stop
Left hand controls
34. Rear brake oil tank
35. “Flash” lever, high beam lights
36. Rear brake lever
37. Counterweight
38. Light switch
39. Turn indicator switch
40. Horn button
START SWITCH/KEYS
• The main switch controls the ignition circuit and steering lock.
: all electrical contacts are disconnected.
: contacts are connected. The engine can start.
: the steering lock is on.
KEYS The vehicle is supplied with two keys featuring a code number, which have the following functions:
Providing the ignition contact
Turning the lights on.
Locking the steering system.
Opening the hatch of the fuel cap compartment.
STEERING LOCK Locking: turn the handlebar all the way to the right or left, push the key in and turn it counter-clockwise. Disengaging: turn the key clockwise.
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F.10i
F.11i
B
A
C
2
B
1
A
6
4
73
5
STANDS
Make sure the centre stand (A - F. 10i) and the side stand (B - F. 10i) are correctly fitted and that they move correctly. Check the spring holding the side stand in place on a regular basis.
DISPLAY
1- Coolant temperature indicator
The red notch (A) and the activation of the red warning light (B) mean that the liquid is too hot, owing to a fault in the cooling circuit or to a shortage of coolant. Bring the vehicle to an immediate stop.
2- Fuel level indicator
The warning light (C) comes on to indicate that the reserve amount has been reached.
3- Green low beam indicator light
4- Blue high beam indicator light
5- Green turn indicator light
6- Multifunction digital instrument board
7- Not controlled
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bar
(psi)
2,3 2,3
(33,4) (33,4)
2,3 2,3
(33,4) (33,4)
X
Y
X
Y
F.13i
F.12i
B
A
TIRE PRESSURE CHECK
Tire pressure must be checked when the tires are cold.
FUEL TANK
Open the hatch (A - F. 13i) with the starter key, unscrew the cap (B ­F. 13i) and fill the tank. Immediately wipe off spilled fuel.
Use unleaded petrol.
Fuel tank capacity: Total: 9.5 L Reserve amount: 3 L
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F.14i
F.15i
1
A
Max Min
A
F.16i
1 2
3
A
COOLANT
CHECK
To gain access to the coolant tank (1 - F. 14i), for engine cooling, remove the cover by loosening the screw (A - F. 14i). The coolant level must be checked on a cold engine since the level varies with engine temperature. The level of coolant must fall within the maximum and minimum notches on the tank. If the level is low, add coolant.
ENGINE OIL, 125 cc
CHECK
Put the scooter on its centre stand and warm up the engine. Stop the engine and wait a few minutes for the oil level to stabilise before checking. Unscrew the dipstick from the engine crankcase (A ­F. 15i). Clean the dipstick and put it back into its seat but do not screw it in place. By means of this operation, you will check the oil level. The level must be between the MIN and MAX marks on the dipstick (F. 15i). If the level is low, add oil. Put the dipstick back into its seat and screw it in place.
REPLACEMENT
Warm the engine up for a few minutes. Stop the engine, put an oil pan under it and remove the dipstick; remove the drainage cap (A - F. 16i), and let the oil flow out. Clean the oil filtering net (1 - F. 16i) with solvent. Check the “O-ring” (3 - F. 16i) and replace it if it is damaged; refit the “O-ring”, the compression spring (2 - F. 16i), the oil filter and the drainage cap.
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A
Max Min
F.17i
A
B
F.18i
ENGINE OIL, 200 cc
CHECK
Park the scooter on flat ground and place it on its centre stand. Start the engine and let it run until it reaches oper­ating temperature; turn off the engine and wait 5-10 min­utes to enable the oil to flow into the sump. Unscrew the dipstick (A - F. 17i) from the engine crank­case and clean it; now fit it back into its seat and screw it firmly in place. Remove the cap-dipstick and make sure the oil level falls within the MIN and MAX marks illustrated in F.17i. If the level is low, add oil. After checking, refit the cap and dipstick and screw firmly in place.
REPLACEMENT
Warm up the engine for a few minutes; stop the engine and put an oil pan under the casing in correspondence with the cap (A-F. 18i). Remove the drainage cap and the dipstick and let the oil flow out. Clean the filtering net with compressed air, check the state of the cap’s O-ring and, if damaged, replace it. Remove the cartridge filter with O-ring (B-F. 18i) and re­place it with a new one. Before fitting the new cartridge filter, lubricate the relative O-ring and screw in place, tightening by hand. Refit the filtering net and the cap with O-ring. Fill the engine with oil, refit the cap-dipstick and screw firmly in place. Run the engine to charge the new filter and lubricating circuit. Stop the engine and, after 5 minutes, check the oil level. If necessary, fill up to the MAX level mark.
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F.19i
A
B
B
F.20i
A
MIN
MAX
F.21i
B
F.22i
TRANSMISSION OIL, 125 cc
CHECK
Place the scooter on its stand. Put a container under the engine crankcase, remove the oil filling bolt (A - F. 19i) and the drainage cap to drain out the oil (B - F. 20i); refit the drainage cap and fill the crankcase with the recommended type of oil.
Start the engine and let it warm up for a few minutes. While it is warming up, check for oil leakage. If oil is leaking, immediately turn off the engine and locate the cause.
REPLACEMENT
Place the scooter on its stand. Put a container under the engine crankcase, remove the oil filling bolt (A - F. 19i) and the drainage cap to drain out the oil (B - F. 20i); let the oil flow into a suita­ble container (pay attention to avoid scorching). Close the drainage cap and add new oil. You can now close the filling cap.
TRANSMISSION OIL, 200 cc
CHECK
Park the scooter on flat ground and place it on its cen­tre stand. Unscrew the dipstick (A- F. 21i), clean it and screw it back into place. Take it out again and make sure the oil level is between the MAX and MIN notches. If the level is low, top up to the MAX notch.
REPLACEMENT
Park the scooter on flat ground and place it on its cen­tre stand. Unscrew the dipstick (A- F. 21i), clean it, screw it back into place then put a container under the engine crank­case and unscrew the drainage screw (B-F.22i), paying attention to the gasket. Let the oil flow into the container (pay attention to avoid scorching). Refit the drainage cap and gasket and fill with new oil. Refit the cap and dipstick (A-F.21i).
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F.23i
MIN
A
S
F.24i
B
S
BRAKE FLUID
CHECK
The visual check should be made through the sight glass (S) of the tanks: (A - F.23i - front brake) (B - F.24i - rear brake), with the scooter parked on flat ground and per­fectly upright. The oil should be at 3 mm from the bottom edge of the sight glass. Top up by removing the covers (A - B), after loosening the fixing screws.
REPLACEMENT
If the fluid features traces of dirt, debris or water, it must be replaced. A soft and spongy feeling in the brake lever can indicate the presence of air in the circuit. Contact an authorised service centre at once.
ADJUSTMENT OF ENGINE IDLING SPEED
Engine idling speed must be adjusted every time it seems irregular. To perform a correct check, start the engine and warm it up to its operating temperature. Let it run idle and check speed. Open and close the throttle several times to make sure that idling speed is maintained stable.
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F.25i
3
2
1
A
A
F
P
F.26i
SHOCK ABSORBER ADJUSTMENT
The shock absorbers are equipped with a spring preload ring nut, with which it is possible to adjust the scooter’s behaviour depending on the load carried, how the scooter is driven and where. The adjustment is made by means of the key fitted to the ring nut (A - F. 25i); turn it clockwise to increase the spring preload.
FUSES
The electrical equipment includes four fuses protecting the main components against faults. These are located in the glove compartment (Fig. 26i). An illustration of the protected component is placed next to each fuse. To replace a fuse, remove the screw (A) to open the left hand hatch; using the pliers supplied (P- F.26i) remove the blown fuse and replace with another having the same capacity. Spare fuses (F - F.26i) are under the pliers (P). If you have used the spare fuse, provide another spare of identical capacity.
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SECTION 2
F.27i
A
A= 1220mm 2mm
+
-
CHECKING THE SHAPE OF THE CHASSIS
If your scooter has had an accident and you believe that the chassis is deformed, it is essential to perform a check on its shape before providing any further repair and setting up work. The checking value (A - F.27i) must be 1220 mm with a tolerance of ± 2 mm.
Never deform the chassis to obtain the original “A” measure.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F. 1
F. 2
F. 3
F. 1/b
V1
V4
A
B
A
REMOVING THE FRONT HANDLEBAR COVER
Undo the centre screw (V1 - F.1) which is ac­cessed by removing the cover (A - F.1b).
Undo the side screws (V4 - F.2).
Pull the handlebar cover up (A - F. 3) along with the instrument board. Pay attention in order not to damage the instrument board connector cable (B ­F.3).
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DISASSEMBLY
A - CHASSIS
SECTION 3
F. 4
F. 5
A
B
B
A
C
D
E
F
V4
REMOVING THE INSTRUMENT BOARD
(Remove front handlebar cover)
Pull out the connector (B - F. 4), by pressing the tab (A - F. 4).
Undo the screws (V4 - F.4) and detach the in­strument board from the front handlebar cover.
COMPONENTS ACCESSED BY REMOVING THE FRONT HANDLEBAR COVER
By removing the front handlebar cover, you gain access to the following components:
• Instrument board cables (A)
• Connector for the handlebar controls (right/left) (B)
• STOP switch, right hand control (C)
• STOP switch, left hand control (D)
• Coupling for the rear brake pump (E)
• Coupling for the front brake pump (F).
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