Page 1
PHANTOM F 12 MAX
A
WORKSHOP MANUAL
CHASSIS
Page 2
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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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SECTION 2
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
GETTING TO KNOW YOUR VEHICLE
A - CHASSIS
CHASSIS
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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ENGLISH
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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ENGLISH
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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DISASSEMBLY
A - CHASSIS
SECTION 3
F. 7
F. 6
V5
V
V2
A
B
V2a
REMOVING THE HANDLEBAR UPPER FAIRING
• (Remove front handlebar cover)
Undo the screws (V5 - F.6).
REMOVING THE LEFT CONTROL
• (Remove front handlebar cover)
Undo the screw (V - F.7) and remove the counterweight.
Undo the screws (V2 - F.7) and remove the left
control.
Caution!!! To reduce friction during
knob removal and refitting, use compressed air.
Detach the fast-ons of the stop switch wiring (A F.7).
Undo the hydraulic transmission screw (B - F.7),
paying attention to oil leaks.
Loosen the screws (V2a - F.7) and remove the rear
brake pump.
Caution!!! When refitting, remember
to replace the copper gaskets and to
bleed using the relevant equipment.
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ENGLISH
DISASSEMBLY
A - CHASSIS
SECTION 3
F. 8
F. 9
V
V2a
V2
A
B
C
D
V
V2a
V2
A
B
C
200 cc
125 cc
REMOVING THE RIGHT CONTROL
125 cc VERSION
• (Remove front handlebar cover)
Disconnect the opening (A - F.8) and closing (B. F.8) of the throttle cable.
Undo the screw (V - F.8) and remove the counterweight.
Undo the screws (V2 - F.8) and remove the throttle
control.
Caution!!! To reduce friction during
knob removal and refitting, use compressed air.
Detach the fast-ons of the stop switch wiring (C F.8).
Undo the hydraulic transmission screw (D - F.8),
paying attention to oil leaks.
Loosen the screws (V2a - F.8) and remove the front
brake pump.
Caution!!! When refitting, remember
to replace the copper gaskets and to
bleed using the relevant equipment.
REMOVING THE RIGHT CONTROL
200 cc VERSION
• (Remove front handlebar cover)
Disconnect the throttle cable (A - F.9).
Undo the screw (V - F.9) and remove the counterweight.
Undo the screws (V2 - F.9) and remove the throttle
control.
Caution!!! To reduce friction during
knob removal and refitting, use compressed air.
Detach the fast-ons of the stop switch wiring (B F.9).
Undo the hydraulic transmission screw (C - F.9),
paying attention to oil leaks.
Loosen the screws (V2a - F.9) and remove the front
brake pump.
Caution!!! When refitting, remember
to replace the copper gaskets and to
bleed using the relevant equipment.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.10
F. 11
F.12
V
V2
V2
V2a
V
REMOVING THE FRONT WING
Undo the front (V2 - F.10) and rear (V2a - F.10)
screws and remove the wing by pulling it through
the fork, taking care to prevent it getting scratched.
Caution!!! This operation is symmetrical.
REMOVING THE SPEEDOMETER SENSOR
Undo the screw (V - F.11), paying attention not to
lose the spacer.
Caution!!! When refitting, use a thickness gage to make sure that the gap
between the sensor and disc is 1÷2
mm; on the contrary, provide a shim
near the spacer.
REMOVING THE FRONT CALIPERS
Undo the screws (V2 - F.12), undo the hydraulic
transmission screw (V - F.12) and detach the hydraulic transmission from the pliers.
Caution!!! When refitting, put the long
screw in the top fitting and replace
the gasket of the hydraulic transmission screw.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.13
2 mm
CHECKING THE FRONT BRAKE PADS FOR
WEAR
• Check the discs for wear. If they are worn or
scratched, have them ground.
If they are particularly damaged or a thinner
than 2 mm, replace them.
REPLACING THE FRONT CALIPERS
Empty the hydraulic circuit and drain fluid into a
special container so that it may be disposed of in
accordance to the laws in force concerning waste
disposal.
Caution!!! When removing the calipers,
pay special attention to prevent damage to the oil duct, disc and brake pads.
Caution!!! Minimum thickness of the
pads is 2 mm (F. 13).
After working on the braking system, make sure
that the brake fluid pipe is not twisted, that the
discs and pads are not soiled with oil or grease
and that all screws and fittings are firmly wrenched
in place.
Caution!!! A spongy feeling in the brake
lever or a change in its free play mean
that the braking circuit is faulty.
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ENGLISH
DISASSEMBLY
A - CHASSIS
SECTION 3
F.16
F.14
F.15
V6
A
A
B
B
C
REMOVING THE FRONT WHEEL
• (Remove speedometer sensor and front cali-
pers)
CAUTION!!!
Before disassembly, hold the centre
chassis section to prevent the vehicle
falling over.
Unscrew the lock nut (A - F.14) fastening the wheel
pin, whilst holding the pin head in place with an
Allen wrench.
Remove the wheel pin, whilst paying attention to
the spacers:
- the long one (A - F.15).
- two short ones (B - F.15).
Remove the wheel assembly.
Caution!!! Do not operate the brake
lever after removing the wheel, since
the pads would come into contact with
each other.
Caution!!! When refitting, make sure
to refit the spacers and grease the
wheel pin (C - F.15).
REMOVING THE FRONT DISC
• (Remove speedometer sensor, front calipers
and front wheel)
Loosen the screws (V6 - F.16)
Caution!!! When reassembling, replace the screws and apply a high
strength thread locker.
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ENGLISH
DISASSEMBLY
A - CHASSIS
SECTION 3
F.18
F.19
F.17
V10V10
F.19/a
V
REMOVING THE FRONT UPPER FAIRING
• (Remove front wheel and front wing)
Remove the centre foot rest fitted to the lower fairing (paying attention not to damage the tabs).
Caution!!! This operation is symmetrical.
Undo the screws (V10 - F.18).
Undo the screw (V - F.19/a) under the strut.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.20
B
A
F.22
F.21
V4
A
V4
A
B
C
Disconnect the two connectors (A-B - F.20) of the
front light cables.
Remove the upper fairing by pulling it through the
fork, taking care to prevent it getting scratched.
Position the upper fairing upside down, with its
painted side facing upwards.
REMOVING THE HEADLIGHTS
Caution!!! There is no need to remove
the upper fairing; it can be placed on
the front wing covered beforehand
with scratch-proof material.
To remove the low beam headlight, undo the screws
(V4 - F.21).
To gain access to the light bulb, remove the lamp
socket (A - F.21), by turning it 15° anti-clockwise.
To remove the high beam headlight, undo the screws
(V4 - F.22).
To access the bulb, remove the rubber cap (A F.22), disconnect the cable (B - F.22) and act on
the clips (C - F.22).
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.23
F.24
F.25
A
V2
V2
A
A
To access the parking light bulbs, remove the
lamp sockets (A - F.23).
To remove the entire headlight assembly, undo the
screws (V2 - F.24) and unscrew the light adjustment knob (A - F.24).
Caution!!! When refitting the adjustment knob, install all parts in the right
sequence.
To adjust the beam, act on the knob (A) as follows:
- tighten to raise the beam
- loosen to lower the beam
REMOVING THE FRONT INDICATORS
Caution!!! There is no need to remove
the upper fairing; it can be placed on
the front wing covered beforehand
with scratch-proof material.
Undo the screws (V2 - F.25).
To gain access to the light bulb, remove the lamp
socket (A - F.25), by turning it 15° anti-clockwise.
Caution!!! This operation is symmetrical.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.26
F.27
V4
A
B
C
D
E
F
G
H
REMOVING THE HEADLIGHT GUARD
Caution!!! There is no need to remove
the upper fairing; it can be placed on
the front wing covered beforehand
with scratch-proof material.
Loosen the screws (V4 - F.26) and remove the
guard.
COMPONENTS THAT CAN BE ACCESSED BY REMOVING THE UPPER FAIRING
By removing the upper fairing, you can gain access to the following components:
• Horn (A)
• Fuse carrier (B)
• Coolant container (C)
• Fork (D)
• Radiator (E)
• Switch with key (F)
• The fan’s thermal switch (G)
• Ring nuts of the steering system (H)
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.30
A
F.28
F.29
V
V2
A
B
HORN
Caution!!! There is no need to remove
the upper fairing; it can be placed on
the front wing covered beforehand
with scratch-proof material.
Undo the screw (V - F.28) and disconnect the cables.
Caution!!! Refit components in the
right sequence.
COOLANT CONTAINER
• (Remove upper fairing)
Undo the screws (V2 - F.29).
Loosen the clamp (A - F.29) and remove the pipe.
Loosen the clamp (B - F.29) and remove the pipe.
REMOVING THE SEAT
Release the seat with a wrench (A - F.30) and tip
it over.
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DISASSEMBLY
A - CHASSIS
SECTION 3
D2
F.32
V2
F.31
F.33
A
V2
Unscrew the nuts (D2 - F.31), remove the seat
and position it with the stuffing facing upwards.
REMOVING THE PASSENGER’S SEAT
Undo the screws (V2 - F.32) and remove the passenger’s seat by pulling it out from the front side.
Caution!!! The level of electrolyte in
the battery can be checked through
the sight glass under the passenger’s
seat, thus avoiding removal.
REMOVING THE SEAT LOCK
• (Remove passenger’s seat)
Remove the nut covers (A - F.33) and undo the
screws (V2 - F.33).
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.36
V2
A
F.34
F.35
A
B
C
A
Release the cable from the lock by unhooking
the spring (A - F.34).
REMOVING THE BATTERY
• (Remove passenger’s seat)
Detach the cables (A-B - F.35) from their terminals.
Carefully lift the battery and before actually pulling
it out of its compartment, release it from the exhaust pipe (C - F.35).
Caution!!! Refit the battery, making
sure that the exhaust pipe is connected, that it is coming out of the battery
compartment and that is not bent,
clogged or twisted.
REMOVING THE HELMET HOLDER
• (Remove battery, seat and passenger’s seat)
Undo the screws (V2 - F.36).
Caution!!! With the helmet holder fitted, the carburettor can be adjusted
through the hole (A - F.36).
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.37
V2
A
B
C
A
C
B
F.38
Undo the screws (V2 - F.37).
Raise the helmet holder and pull out battery cables (A-B - F.37), exhaust pipe (C - F.37) and seat
lock cable.
Caution!!! When refitting, take care to
put the exhaust pipe, battery cables
and seat lock cable back into their
openings.
COMPONENTS THAT CAN BE ACCESSED BY REMOVING THE HELMET HOLDER
By removing the helmet holder, you can gain access to the following components:
• Fuel probe (A)
• Carburettor (B)
• Control unit connector (C)
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.40
F.41
V2
V3
L
A
B
F.39
V2
REMOVING THE HANDLE COVER
• (Remove seat, passenger’s seat and helmet
holder)
Undo the screws (V2 - F.39), remove the cover and
pull it out from the rear side after disengaging its
hooks.
REMOVING THE REAR HANDLE
• (Remove seat, passenger’s seat, helmet hold-
er and handle cover)
Undo the screws (V3 - F.40).
Undo the screws (V2 - F.40).
Remove the rear handle.
Caution!!! The handle features four
threaded holes for fastening the luggage container or rack.
REMOVING THE SEAT LOCK
• (Remove seat, passenger’s seat and helmet
holder)
Remove the spring (A - F.41) and pull out the cable
(B - F.41).
Pull the tab (L - F-41) downwards and remove the
barrel.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.42
V2
A
B
F.43
F.44
V3
V
V1
A
REMOVING THE TAIL LAMPS
• (Remove seat, passenger’s seat, helmet hol-
der, handle cover and rear handle)
Undo the screws (V2 - F.42).
Remove the clamp (A - F.42) and detach the connector (B - F.42).
Undo the screws (V3 - F.43) and release the snap
locks.
To access the bulb of the stop light, remove the
centre lamp socket by turning it 45° clockwise.
To access the 5 bulbs of the parking lights, remove the relative lamp sockets.
Caution!!! Test operation, before refitting removed parts.
REMOVING THE REAR INDICATORS
Undo the screw (V - F.44).
Remove the glass cover and detach the lamp socket cables.
Undo the fixing screw (V1 - F.44).
Remove the cover (A - F.44) and take out the lamp.
Caution!!! This operation is symmetrical.
Caution!!! Test operation, before refitting removed parts.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.47
F.46
V
V3
F.45
V
REMOVING THE NUMBER PLATE LIGHT
Undo the screw (V - F.45).
To access the light bulb, remove the lamp socket
whilst paying attention not to damage the cables.
Caution!!! Test operation, before refitting removed parts.
REMOVING THE NUMBER PLATE HOLDER
Remove the number plate by undoing the four
screws or rivets.
Undo the screws (V3 - F.46).
Caution!!! Do not use glue, two-sided
adhesive tape, etc. to refit the number
plate.
REMOVING THE SIDE CASINGS
Undo the screw (V - F.47).
Remove the side casing by pulling out from the
front so that it detaches from its snap locks.
Caution!!! This operation is symmetrical.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.48
C
A
B
F.49
V4
F.50
V
COMPONENTS THAT ARE ACCESSED BY REMOVING THE RIGHT SIDE CASING
By removing the side casing, you can gain access to the following components:
• Regulator (A)
• Control unit (B)
• Weights (C)
REMOVING THE REAR COWLING
• (Remove seat, passenger’s seat, helmet hol-
der, handle cover, rear handle and side casings)
Detach the cable of the tail lamp.
Undo the screws (V4 - F.49) on the right and left.
Undo the screw (V - F.50), by releasing the shock
absorber plaque.
Caution!!! This operation is symmetrical.
Raise and release the rear cowling from its hooks
by pulling its front side open. Pay attention not to
scratch the plastic.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.53
V2
F.51
F.52
V2
V2
REMOVING THE REAR REFLECTOR
Undo the screws (V2 - F.51) and remove the reflector by pulling it outwards.
REMOVING THE TAIL SECTION
• (Remove seat, passenger’s seat, helmet hol-
der, handle cover and rear handle)
Undo the screws (V2 - F.52) on both sides.
Undo the screws (V2 - F.53), release the snap locks
on the top side of the tail and remove the tail section.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.55
B
A
F.54
B
A
C
D
P
C
COMPONENTS THAT ARE ACCESSED BY REMOVING THE REAR COWLING
By removing the rear cowling, you can gain access to the following components:
• Starter relay 1 (A)
• Starter relay 2 (B)
• Flashlight (C - 125 cc only)
• Fuel pump (D)
REMOVING STARTER RELAYS 1/2
• (Remove side casings and rear cowling)
- 1st relay (A - F.55): release from the chassis by
pulling upwards, then detach the connector (C F.55).
- 2nd relay (B - F.55): take out of the relay holder (P
- F.55).
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.56
A
125 cc
F.57
V2
125 cc
A
F.58
200 cc
A
V2
F
M
M
REMOVING THE FLASHLIGHT
125 cc VERSION ONLY
• (Remove side casings and rear cowling)
Disconnect the connector (A - F.56) and release
the flashlight from the chassis.
REMOVING THE REGULATOR
125 cc VERSION
• (Remove side casings and rear cowling)
Detach the connector (A - F.57)
Undo the screws (V2 - F.57).
Caution!!! When refitting, fasten the
weights (M - F.57) firmly in place.
REMOVING THE REGULATOR
200 cc VERSION
• (Remove side casings and rear cowling)
Detach the connector (A - F.58)
Undo the screws (V2 - F.58).
Caution!!! When refitting, fasten the
weights (M - F.58) firmly in place and
check the condition of the 15 A fuse (F
- F.58).
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.61
200 cc
B
F.59
A
125 cc
F.60
125 cc
F.57
G
A
REMOVING THE CONTROL UNIT
125 cc VERSION
• (Remove side casings and rear cowling)
Remove the clamps and detach the connector (A F.59).
Take the control unit out of its rubber protection (G
- F.60).
REMOVING THE CONTROL UNIT
200 cc VERSION
• (Remove side casings and rear cowling)
Remove the rubber protection (A - F.61), release
the connector (B - F.61) and cut the clamps holding the wires in place.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.63
A
200 cc
V2
F.62
F.64
V4
Undo the screws (V2 - F.62).
Caution!!! The flashlight is built into
the control unit.
REMOVING THE FUEL PROBE
• (Remove seat, passenger’s seat and helmet
holder)
Detach the connector (A - F.63) and cut the clamps
that hold the wires in place.
Undo the screws (V4 - F.64) and remove the probe.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.65
F.66
F.67
F.65/b
A
V2
V
V
REMOVING THE STRUT
Place the scooter on its centre stand.
Remove the rubber mat on the footboard (A - F.65).
Undo the screws (V2 - F.65/b).
Undo the screw (V - F.66).
Undo the screw (V - F.67).
Carefully pull the strut towards the front.
Caution!!! When refitting remember
that the V - F.66/67 screws are longer
than the V2 - F.65/b screws.
These operations are symmetrical.
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DISASSEMBLY
A - CHASSIS
SECTION 3
A
T
B
V2
V3
125 cc
125 cc
125 cc
F.68
F.69
F.70
REMOVING THE FOOTBOARD
125 cc VERSION
• (Remove side casings, rear cowling and strut)
Undo the screws (V3 - F.68) on both sides.
Undo the screws (V2 - F.69) to release the footboard from the secondary air valve.
Open the tank’s hatch (A - F.70), unscrew the cap
(T - F.70) and remove the gasket (B - F.70).
Pull the footboard upwards.
Caution!!! After removing the footboard, screw the tank’s cap back on.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.73
A
A
T
B
V3
200 cc
F.71
200 cc
F.72
REMOVING THE FOOTBOARD
200 cc VERSION
• (Remove side casings, rear cowling and strut)
Undo the screws (V3 - F.71) on both sides.
Open the tank’s hatch (A - F.72), unscrew the cap
(T - F.72) and remove the gasket (B - F.72).
Pull the footboard upwards.
Caution!!! After removing the footboard, screw the tank’s cap back on.
REMOVING THE LOWER FAIRING
• (Remove side casings, rear cowling, strut, foot-
board and upper fairing)
Detach cables (A - F.73) from fuses.
Caution!!! When reassembling, fasten
the fast-ons as follows:
- 15 A fuse BLUE/RED - LIGHT BLUE
- 7.5 A fuse YELLOW-BLUE
- 7.5 A fuse WHITE/GREY - BLUE
- 10 A fuse GREEN/RED - BLUE
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.76
F.75
V2
A
F.74
V
Undo the screw (V - F.74) under the footrest.
Caution!!! This operation is symmetrcal.
Undo the screws (V2 - F.75) of the luggage hook.
Remove the cover (A - F.76) of the switch with key
by turning it 1/4 of a turn clockwise.
Remove the lower fairing, by pulling it carefully
downwards.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.77
A
B
C
E
D
COMPONENTS THAT ARE ACCESSED BY REMOVING THE STRUT, FOOTBOARD AND THE LOWER FAIRING
By removing the strut, footboard and lower fairing, you can gain access to the following components:
• 15 A recharge fuse (A)
• Side stand switch (B)
• Radiator fan (C)
• Tank (D)
• Petrol filter (E)
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ENGLISH
DISASSEMBLY
A - CHASSIS
SECTION 3
F.79
A
B
C
V2
F.78
B
A
F.80
V2
REMOVING THE FUEL FILTER
• (Remove side casings, rear cowling, strut and
footboard)
CAUTION!!!
Make sure the tank is empty.
Loosen clamp A (F.78), clamp B (F.78) and take
the petrol filter off its support.
Caution!!! When refitting, avoid narrow bends of the pipes.
REMOVING THE FUEL PUMP
• (Remove side casings, rear cowling, strut and
footboard)
Detach the fuel inlet pipe (A - F.79), the fuel outlet
pipe (B - F.79) and the vacuum pipe (C - F.79).
Undo the screws (V2 - F.79).
Caution!!! When refitting, connect the
pipes in their correct position.
REMOVING THE FUEL TANK
• (Remove side casings, rear cowling, strut, foot-
board and lower fairing)
CAUTION!!!
Make sure the tank is empty.
Before emptying the tank, wait for the
engine to cool down. Use a manual
pump.
Release the petrol filter and disconnect the probe
connector.
Undo the screws (V2 - F.80) on both sides.
Shift the tank towards the rear side to enable the
front fixing tabs to move beyond the coupling. You
can now pull the tank out from the front side.
Caution!!! When refitting, perform
above operations in reverse order.
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F.83
B
A
F.81
F.82
A
A
125 cc
125 cc
125 cc
REMOVING THE RADIATOR
125 cc VERSION
• (Remove upper fairing)
CAUTION!!!
Empty the radiator by putting a suitable container under it. Now open the
pipe clamp (A - F.81) and detach the
pipe from its coupling.
The radiator is installed on a Silentblock; to remove this, proceed as follows.
Disconnect the fan connector (A - F.82).
Disconnect the cables of the thermostatic fan (A F.83) and of the thermal switch when these are
warm (B - F.83).
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DISASSEMBLY
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SECTION 3
F.84
A
B
F.85
125 cc
125 cc
V2
Remove the two pipes, by unscrewing the clamps
(A/B - F.84).
Disengage and remove the radiator support plate
by loosening the screws (V2 - F.85).
Remove the radiator by pulling it downwards.
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DISASSEMBLY
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SECTION 3
F.88
A
F.86
F.87
A
A
200 cc
200 cc
200 cc
B
REMOVING THE RADIATOR
200 cc VERSION
• (Remove upper fairing)
CAUTION!!!
Empty the radiator by putting a suitable container under it. Now open the
pipe clamp (A - F.86) and detach the
pipe from its coupling.
The radiator is installed on a Silentblock; to remove this, proceed as follows.
Disconnect the fan connector (A - F.87).
Disconnect the cables of the thermostatic fan (A F.88).
Caution!!! Do not remove the drainage cap (B - F.88).
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SECTION 3
F.89
A
B
F.90
200cc
F.91
V3
V2
200cc
A
Remove the two pipes, by unscrewing the clamps
(A/B - F.89).
Disengage and remove the radiator support plate
by loosening the screws (V2 - F.90).
Remove the radiator by pulling it downwards.
RADIATOR FAN
• (Remove radiator)
Detach the connector (A - F.90).
Undo the screws (V3 - F.91).
Remove fan by pulling it sideways.
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A - CHASSIS
SECTION 3
F.92
A
125 cc
F.93
F.94
200 cc
A
B
200 cc
B
A
B
F.94/b
REMOVING THE FRONT SHOCK ABSORBERS
125 cc VERSION
CAUTION!!!
Before disassembly, hold the centre
chassis section to prevent the vehicle
falling over.
To remove the left shock absorber, unscrew the
top bolt (A - F.92) and the bottom bolt (B - F.92)
and remove the shock absorber by pulling it towards the rear side.
Caution!!! This operation is symmetrical.
REMOVING THE REAR SHOCK ABSORBERS
200 cc VERSION
• (Remove filter box and muffler)
CAUTION!!!
Before disassembly, hold the centre
chassis section to prevent the vehicle
falling over.
To remove the right shock absorber, unscrew the
top bolt (A - F.93) and the bottom nut (B - F.93)
and remove the shock absorber by pulling it towards the rear side.
Undo the nut (B) and pull the shock absorber outwards, without moving the arm.
To remove the left shock absorber, unscrew the
top bolt (A - F.94) and the bottom bolt (B - F.94)
and remove the shock absorber by pulling it towards the rear side.
Caution!!! When refitting, check the
direction in which the shock absorb-
ers are fitted (F.94 /b).
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SECTION 3
F.97
V2
F.96
A
A
B
F.95
125 cc
125 cc
125 cc
REMOVING THE AIR FILTER BOX
125 cc VERSION
• (Remove helmet holder)
Open the clamp (A - F.95) and disconnect the steam
recycling pipe (B - F.95).
Unscrew the clamp (A - F.96) and disconnect the
suction pipe.
Undo the screws (V2 - F.97).
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SECTION 3
F.98
V
125 cc
F.99
F.100
200 cc
200 cc
A
B
A
Undo the screw (V - F.98) and remove the filter box
assembly, complete with its coupling.
REMOVING THE AIR FILTER BOX
200 cc VERSION
• (Remove helmet holder)
Open the clamp (A - F.99) and disconnect the
steam recycling pipe (B - F.99).
Unscrew the clamp (A - F.100) and disconnect the
suction pipe.
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V3
V2
F.103
F.102
F.101
125 cc
125 cc
200 cc
V2
Undo the screws (V2 - F.101) and remove the filter
box.
REMOVING THE MUFFLER
125 cc VERSION
CAUTION!!!
Before removing, make sure the muffler has cooled down.
Undo the screws (V2 - F.102) securing the exhaust
manifold in place.
Undo the screws (V3 - F.103) and remove the muffler with its guard.
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SECTION 3
F.105
F.106
F.104
125 cc
G
200 cc
V2
200 cc
V3
The parts composing the exhaust assembly must
be disassembled as illustrated in F.104.
Caution!!! When refitting the muffler,
remember to replace part G.
REMOVING THE MUFFLER
200 cc VERSION
CAUTION!!!
Before removing, make sure the muffler has cooled down.
Undo the screws (V2 - F.105) securing the exhaust
manifold in place.
Undo the screws (V3 - F.106) and remove the muffler with its guard.
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SECTION 3
F.107
200 cc
F.108
V2
125 cc
F.109
200 cc
V2
G
The parts composing the exhaust assembly must
be disassembled as illustrated in F.107.
Caution!!! When refitting the muffler,
remember to replace part G.
REMOVING THE REAR WING
125 cc VERSION
• (Remove muffler compartment)
Undo the screws (V2 - F.108).
Undo the screws (V2 - F.97- page 57), the screw
(V - F.98- page 58) and push the filter box aside to
enable removal of the wing.
REMOVING THE REAR WING
200 cc VERSION
• (Remove muffler compartment)
Undo the screws (V2 - F.109).
Undo the screws (V2 - F.101- page 59) and push
the filter box aside to enable removal of the wing.
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F. 11 0
V3
A
F. 11 2
V2
V
125 cc
F. 111
125 cc
200 cc
A
V3
REMOVING THE TRANSMISSION COOLING
SLEEVE
125 cc VERSION
• (Remove strut)
Undo the screws (V3 - F.110).
Cut the clamp (A - F.110) and pull out the sleeve.
REMOVING THE TRANSMISSION COOLING
SLEEVE
200 cc VERSION
• (Remove strut)
Undo the screws (V3 - F.111).
Cut the clamp (A - F.111) and pull out the sleeve.
REMOVING THE REAR CALIPERS
125 cc VERSION
• (Remove muffler)
Undo the screws (V2 - F.112).
Loosen the hydraulic transmission screw (V - F.112)
and detach the pipe from the calipers.
Caution!!! When refitting, replace the
gasket of the hydraulic screw.
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SECTION 3
F.113
F.114
2 mm
200 cc
V2
V
REMOVING THE REAR CALIPERS
200 cc VERSION
• (Remove muffler)
Undo the screws (V2 - F.113).
Loosen the hydraulic transmission screw (V - F.113)
and detach the pipe from the calipers.
Caution!!! When refitting, replace the
gasket of the hydraulic screw.
CHECKING THE REAR BRAKE PADS FOR
WEAR
• Check the discs for wear. If they are worn or
scratched, have them ground.
If they are particularly damaged or are thinner
than 2 mm, replace them.
Caution!!! Minimum thickness of the
pads is 2 mm (F. 114).
REPLACING THE REAR CALIPERS
Empty the hydraulic circuit and drain fluid into a
special container so that it may be disposed of in
accordance to the laws in force concerning waste
disposal.
Caution!!! When removing the calipers,
pay special attention to prevent damage to the oil duct, disc and brake pads.
After working on the braking system, make sure
that the brake fluid pipe is not twisted, that the
discs and pads are not soiled with oil or grease
and that all screws and fittings are firmly wrenched
in place.
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F. 11 5
V2
A
125 cc
F. 11 6
200 cc
V1
A
V
V2
V
REMOVING THE REAR WHEEL
125 cc VERSION
• (Remove muffler, rear wing and rear calipers)
CAUTION!!!
Before disassembly, hold the centre
chassis section to prevent the vehicle
falling over.
Disassemble the arm as follows:
Undo the bottom screw (V - F.115) of the right shock
absorber and turn it towards the rear side.
Undo the screws (V2 - F.115).
Caution!!! When refitting, put the long
screw in the top section and the short
screw in the bottom section (F.115).
Undo the nut (A - F.115) and remove the wheel.
Caution!!! When refitting, insert all
parts in the right order and grease
them.
REMOVING THE REAR WHEEL
200 cc VERSION
• (Remove muffler, rear wing and rear calipers)
CAUTION!!!
Before disassembly, hold the centre
chassis section to prevent the vehicle
falling over.
Disassemble the arm as follows:
Undo the bottom screw of the right shock absorber (V - F.116) and turn it towards the rear side.
Undo the screws (V2 - F.116).
Undo the screw (V1 - F.116) and remove the support of the hydraulic transmission pipe.
Remove the split pin (A - F.116), remove the protection, unscrew the nut and remove the wheel.
Caution!!! When refitting, insert all
parts in the right order and grease
them.
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DISASSEMBLY
A - CHASSIS
SECTION 3
F.117
V6
F. 11 9
125 cc
A
F.118
125 cc
V
REMOVING THE REAR DISC
• (Remove rear wheel)
Undo the screws (V6 - F.117).
Caution!!! When reassembling, replace the
screws and apply a high strength thread locker.
ENGINE REMOVAL
125 cc VERSION
• (Remove seat, passenger’s seat, helmet hold-
er, air filter box, muffler, rear wing, rear calipers
and rear wheel)
CAUTION!!!
Before disassembly, hold the centre
chassis section to prevent the vehicle
falling over.
Disengage the rear left shock absorber by undoing
the screw (V - F.118).
Disengage the transmission cooling sleeve (A F.119).
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B
A
A
F.121
F.122
125 cc
125 cc
F.120
B
A
125 cc
Remove the pipe for delivery to the radiator (A F.120), by unscrewing the clamp (B - F.120).
Remove the return pipe of the radiator (A - F.121)
by unscrewing the clamp (B - F.121).
Detach the flywheel connectors (A - F.122) and
cut all the cable fixing clamps.
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F.123
F.124
F.125
125 cc
A
B
125 cc
V2
125 cc
V
Detach the fast-on (A - F.123) and the pipe of the
fuel pump (B - F.123).
Disengage the carburettor from the engine by undoing the screws (V2 - F.124) and secure the carburettor to the chassis.
Undo the screw (V - F.125) and remove the support of the hydraulic transmission pipe.
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SECTION 3
F.126
B
125 cc
F.127
F.128
200 cc
A
A
125 cc
Unscrew the nut (A - F.126).
Remove the pin (B - F.127).
Pull the engine out from the rear side.
ENGINE REMOVAL
200 cc VERSION
• (Remove seat, passenger’s seat, helmet hold-
er, air filter box, muffler, rear wing, rear calipers
and rear wheel)
CAUTION!!!
Before disassembly, hold the centre
chassis section to prevent the vehicle
falling over.
Disengage the transmission cooling sleeve (A F.128).
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SECTION 3
F.129
F.130
F.131
200 cc
A
200 cc
A
B
V2
200 cc
A
C
B
Remove the connector (A - F.129) from the flywheel
cover.
Disengage the rear shock absorber by unscrewing
the bolt (A - F.130).
The shock absorber can also be disengaged by
removing the screws (V2 - F.130) that secure the
support (B - F.130) to the engine.
Remove the pipe for delivery to the radiator (A F.131), by unscrewing the clamp (B - F.131).
Detach the fast-on (C - F.131).
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SECTION 3
F.132
F.133
F.134
200 cc
200 cc
200 cc
V
A
B
A
V2
A
Remove the pipe (A - F.132) .
Disengage the carburettor from the engine by undoing the screws (V3 - F.132) and secure the carburettor to the chassis.
Remove the radiator return pipe (A - F.133), by
unscrewing the clamp (B - F.133).
Undo the screw (V - F.133) and remove the support of the hydraulic transmission pipe.
Unscrew the nut (A - F.134).
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B
V
V
F.135
200 cc
F.136
125 cc
F.137
125 cc
A
Remove the pin (B - F.135) and pull the engine out
from the rear side of the vehicle.
REMOVING THE CENTRE STAND
125 cc VERSION
CAUTION!!!
Before disassembly, hold the vehicle
in place to prevent it falling over.
Undo the screw (V - F.136).
Undo the screw (V - F.137).
Remove the double spring (A - F.137) and hence
the stand.
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F.139
A
V
F.138
F.140
V2
200 cc
B
A
REMOVING THE CENTRE STAND
200 cc VERSION
CAUTION!!!
Before disassembly, hold the vehicle
in place to prevent it falling over.
Remove the double spring (A - F.138).
Unscrew the nut (B - F.138), remove the pin and
hence the stand.
REMOVING THE SIDE STAND
Remove the double spring (A - F.139).
Undo the screw (V - F.139).
Furthermore, check correct operation of the switch,
which should prevent engine ignition if the stand is
operated.
Caution!!! Do not tamper with this
safety device!
REMOVING THE SIDE STAND SWITCH
• (Remove seat, passenger’s seat and helmet
holder)
Undo the screws (V2 - F.140).
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SECTION 3
F.143/b
F.141
A
F.142
A
125 cc
F.143
A
C
125 cc
V
B
125 cc
D
Disconnect the cables (A - F.141) and cut the cable clamps.
REMOVING THE ENGINE FIXING PLATE
125 cc VERSION
• (Remove seat, passenger’s seat, helmet hold-
er, handle cover, rear handle, side casings, tail
section and strut)
CAUTION!!!
Before disassembly, hold the vehicle
in place to prevent it falling over.
Remove the spring (A - F.142).
Undo the screw (V - F.143).
Remove the pin (A - F.143), by unscrewing the nut
(B - F.143/b).
Remove the pin (C - F.143), by unscrewing the nut
(D - F.143/b).
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F.146
A
V2
F.145
F.145/b
F.144
200 cc
A
200 cc
200 cc
A
V
B
C
D
REMOVING THE ENGINE FIXING PLATE
200 cc VERSION
• (Remove seat, passenger’s seat, helmet hold-
er, handle cover, rear handle, side casings, tail
section and strut)
CAUTION!!!
Before disassembly, hold the vehicle
in place to prevent it falling over.
Remove the spring (A - F.144).
Undo the screw (V - F.145).
Remove the pin (A - F.145), by unscrewing the nut
(B - F.145/b).
Remove the pin (C - F.145), by unscrewing the nut
(D - F.145/b).
REMOVING THE SWITCH WITH KEY
• (Remove handlebar cover, upper fairing and low-
er fairing)
Undo the screws (V2 - F.146) and disconnect the
cables (A - F.146).
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SECTION 3
F.148
V
F.147
A
B
F.149
A
REMOVING THE HANDLEBAR
• (Remove the handlebar cover, upper fairing and
right/left controls)
Undo the screw (V - F.147) and cut the cable
clamps.
Pull the handlebar upwards.
REMOVING THE FORK
• (Remove handlebar, upper fairing, front wheel,
front wing and front calipers)
Unscrew and remove the ring nut (A - F.148).
Unscrew and remove the underlying ring nut (B F.148).
Remove the fork assembly by pulling it outwards.
CAUTION!!!
Support the fork to prevent it falling.
Pay attention as the bottom balls (A - F.149) may
come out.
Clean away any grease, including the grease in
the seats. Check for wear and make the necessary replacements.
Grease and refit.
Caution!!!
There are 22 top balls (Ø 3/16”)
There are 19 bottom balls (Ø 1/4”)
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F.150
F.151
V
A
C
B
E
D
F
65 mm
F.152
A
REMOVING THE STANCHION-WHEEL HOLDER
ASSEMBLY
• (Remove upper fairing, front wheel, front wing
and front calipers)
Loosen the screw (V - F.150) and raise the stanchion by a few millimetres.
Using a screwdriver, remove the snap ring (A F.150) fitted to the top side of the stanchion and
remove the stanchion-wheel holder assembly by
pulling it downwards.
Caution!!! This operation is symmetrical.
CHECK THE OIL LEVEL OF THE FORKS.
Caution!!! When disassembling the
stanchion-wheel holder assembly secure it in place in a vise, taking care
to put soft protective material between the jaws and the components
in order to prevent crushing or
scratches.
If the fork has reached its travel end position or is
making too much noise, check the oil level inside
the stanchions, as follows:
remove the top cap (A - F.151) and the snap ring
(B- F.151) by pressing the cap (C- F.151) complete
with its “O-ring” (D- F.151) down with a screwdriver.
Remove the spring (E- F.151) with care, and let its
oil drip off.
Move the stanchion (F - F.151) to its travel end
position.
Whilst keeping the stanchion-wheel holder assembly upright, insert a ruler (or the rod of a gage) and
check the oil level, which must be at 65 mm (F.152)
from the top edge of the stanchion.
Top up if necessary.
Caution!!! This operation is symmetrical.
Before refitting the stanchion assembly, apply grease to the “O-ring” (D F.151), or replace the latter.
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SECTION 3
F.153
V
V
CHANGE THE OIL IN THE FORK
Put the scooter on its centre stand.
Put a container under the wheel holder, remove
the screw (V - F.153) and let as much oil as possible flow out.
Disassemble the stanchions-wheel holders and tip
them over to drain out any residual oil.
Oil wastes must be disposed of correctly.
Refit the drainage screw (V - F.153).
Carefully pour new oil into the stanchion (100 cc.
both for the right and left stanchions).
Check the oil level as described above.
Reassemble the stanchions and refit the assembly on the scooter.
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ASSEMBLY
A - CHASSIS
SECTION 4
CHASSIS TORQUE WRENCH SETTINGS
125 cc
200 cc
N*m Kg*m
N*m Kg*m
85 8.5 85 8.5
30 3.0 30 3.0
50 5.0 50 5.0
140 14.0 140 14.0
24 2.4 24 2.4
23 2.3 23 2.3
68 6.8 68 6.8
37 3.7 37 3.7
30 3.0 30 3.0
100 10.0 100 10.0
45 4.5 45 4.5
24 2.4 40 4.0
- - 30 3.0
35 3.5 35 3.5
38 3.8 38 3.8
TORQUE WRENCH SETTINGS
Front wheel pin
Front brake calipers
Handlebar clamp
Steering lock
Muffler-arm coupling
Rear arm
Engine pin
Engine fixing pin
Rear brake calipers
Rear wheel
Top shock absorber
Bottom shock absorber
Bottom shock absorber coupler
Top handlebar clamp
Rocker assembly
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ASSEMBLY
A - CHASSIS
SECTION 4
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