MO Centro 125-160 Frame ENG

125 i.e. - 160 i.e.
FOREWORD
• The present manual specifically addresses to specialised technical personnel (MALAGUTI authorised service centres and single motor mechanics) and contains all the
service interventions indicated by the Manufacturer until the publishing of this document.
• Some basic technical information has been intentionally omitted as it is considered to be common knowledge.
• Additional information is available in the SPARE PARTS CATALOGUES of each model.
• It is important to read all the general information before going through the manual to the specific topics and the maintenance operations to be carried out on the motor-bike in
order to make sure the topics, the technical and safety concepts are clearly understood and the manual can be used as a sure reference text.
• All checks, maintenance, repairs or replacements of spare parts in our motor-bikes are to be performed by skilled and expert technical personnel with specific experience
in state-of-the-art technology and full knowledge of the quickest and most rational procedures, technical characteristics, setting values, tightening torques and information as
to which may only be properly and exhaustively provided by the manufacturer.
• It is important to adhere strictly to the following instructions. Any operation carried out carelessly or not carried out at all may lead to personal injury, damage to the motorcycle
or simply to complaints.
MALAGUTI S.p.A. reserves the right to make any changes and modifications hereto it deems necessary without prior notice.
For further information and details, please contact MALAGUTI S.p.A. Servicing or Engineering Division.
MALAGUTI S.p.A.
Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY
Tel. 051.62.24.811 - Fax 051.69.47.782
e-mail: [email protected] - http: // www.malaguti.com
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NOTES FOR EASY CONSULTATION
ABBREVIATIONS
Cs
TECHNICAL DICTIONARY
Torque wrench setting
V = (DC)
Direct current (battery supply)
Nut
V ~ (AC)
Alternating current (flywheel supply)
Right
A : Ampere
Unit of measurement of the electrical current
F
Picture
W : Watt
Unit of measurement of the electrical power (product of Volts and Amperes; A x V = W)
G
Gasket
Ω : OHM
Unit of measurement of the electrical resistance
P
Page
<
Lower
R
Washer
≤
Lower or equal
Sx
Left
>
Higher
T
Table
Screw
≥
Higher or equal
V
bar
Unit of measurement of pressure
N*m
Newton/metre Unit of measurement of the tightening torque
D
Dx
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.
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SYMBOL LIST
DISASSEMBLY
OPERATIONS
CAUTION!
Recommendations and
precautions regarding rider
safety and motor vehicle
integrity.
ASSEMBLY
OPERATIONS
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
SYMMETRICAL
OPERATIONS
Operations that must be
carried out also on the other
side of the unit or
component.
FIRE HAZARD.
Indicates operations which
may constitute a fire
hazard
GENERAL SERVICE
PERSONNEL
RISK OF
EXPLOSION
Indicates operations
which may constitute a
risk of explosion
MECHANICAL
MAINTENANCE
Operations to be
performed only by an
expert mechanic
TOXIC FUMES
Indicates a possibility of
intoxication or inflammation
of the upper respiratory
tract
ELECTRICAL
MAINTENANCE
Operations be performed
only by an expert electrical/
electronic technician
PRESENT MANUAL
Information on the
present manual
“ENGINE” SERVICE
MANUAL
M
R
Indicates information which
may be obtained by
referring to said catalogue
SPARE PARTS
CATALOGUE
Indicates information which
may be obtained by
referring to said catalogue
SAFETY GLOVES
IDLING ENGINE
These operations require
the use of safety gloves
Switch on the engine, at
idling speed, to perfom
these interventions.
IMPORTANT
ENGINE OFF
Indicates operations to
be performed with
engine off
This topic requires special
attention
Skilled electronic or
mechanical technician.
WARNING!
IGNITION KEY ON
(ON position)
Danger of crashing
arms
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POWER OFF
Indicates that negative
pole is to be disconnected
from the battery before
performing the operation
NO!
Operations to be
absolutely avoided
EMPTY THE CIRCUIT
OIL
COOLANT
FUEL
REPLACE WITH NEW,
ORIGINAL SPARE
PARTS
125 i.e. - 160 i.e.
GENERAL WORK PROCEDURES
• The recommendations given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment
damage and idle times, and should therefore be strictly adhered to.
• Always listen with attention to the customer’s opinion and complaints about the motor-bike operation, asking specific questions in order to have a complete understanding of
all the symptoms and identify with good approximation the real causes of the trouble. The present manual provides the technical information and the basic indications on the
intervention procedures but these have to be integrated with the personal expertise.
• We suggest planning the service interventions in order to avoid any waste of time or downtime. Try to reduce as much as possible the operations necessary to reach the
components that needs repairing.
• Prepare the components that are likely to be replaced and all the original spare parts you may need.
• Use only the original spare parts.
• Mark the components that may be mis-placed during re-assembly operations.
• Only use quality tools and equipment.
• Only use equipment conforming to EU Directives for lifting the vehicle.
• During operations, always keep tools and equipment at hand, possibly laying them out according to the sequence in which they are to be used. Absolutely avoid putting them on the
vehicle itself, out-of-sight or in poorly accessible places.
• Always keep the work area neat and clean.
• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progressive “pulls” using a “criss-cross” pattern.
• The torque settings specified in the manual refer to the “final torque”, which must be attained progressively by steps.
• Preferably use open-end box wrenches by “pulling” and not “pushing”.
Before any servicing, make sure that the vehicle is perfectly stable.
The front wheel should be anchored to fixture, which is integral with the lift platform.
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• Before carrying out any operation, wait for all parts to cool down.
• For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and co-ordinated beforehand.
• Make sure that each component has been properly mounted before proceeding with assembling the next one.
• Always replace gaskets, O-rings, circlips and split pins at every refitting.
• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.
Do not use fuses with a higher rated capacity than indicated: this may cause severe damages to the electrical system and burn a fire as a conse-quence of short circuit.
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.
• Make sure that the vehicle is stable and not to have to take on awkward working positions.
• Never reuse old gaskets or circlips.
• Never use a screwdriver as a lever or chisel.
• Never use pincers to loosen or tighten screws or nuts because, in addition to not providing a sufficient clamping force, they may also damage the screw head or nut hexagon.
• Never tap the wrench with a hammer or other similar tool to loosen or tighten screws and nuts.
• Never attempt to increase the lever arm by fitting a tube into the wrench.
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CONTENTS
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DESCRIPTION
TECHNICAL DATA
IDENTIFICATION INFORMATION: FRAME N°/ ENGINE N° -TIRES
MAINTENANCE CHART
LUBRICANT CHART
FUEL TANK - COOLANT RESERVOIR
MOTOR OIL
LEVEL CHECK/ CHANGE
TRANSMISSION OIL
CHECK LEVEL/ TOPPING UP - CHANGE
BRAKE FLUID
CHECK- CHANGE
BLEEDING THE BRAKE SYSTEM
FRONT CALIPER - REAR CALIPER
CHECK FRONT/BACK BRAKE PADS AND DISKS
REPLACE PADS
FRONT BRAKES - REAR BRAKES
FORK
CHECK OIL LEVEL IN THE FORK LEG
CHANGE FORK OIL
SHOCK ABSORBER ADJUSTMENTS
LOCATION OFTHE MAIN ELECTRICAL AND ELECTRONIC ELEMENTS
DASHBOARD
ELECTRIC/ SERVICE WARNING LIGHT- DIGITAL CLOCK
KEY SWITCH - HANDLEBAR CONTROLS
LEFT CONTROL - RIGHT CONTROL
ENGINE STARTER
LIGHTS
HEADLIGHT - LIGHT BEAM ADJUSTMENT-TURN SIGNALS
TAIL-LIGHT - NUMBER PLATE LIGHT
FUSES - FUSE REPLACEMENT
BATTERY
BATTERY ASSEMBLY - CHARGE BATTERY
SPARK PLUG
REPLACEMENT
DISMANTLING AND REMOVAL PROCEDURES FOR COMPONENTS
REASSEMBLY NOTES - REAR-VIEW MIRROR- UPPER COVER
FRONT HANDLEBAR COVERS
ACCESS
FRONT SHIELD
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DESCRIPTION
ACCESS- SEAT- HELMET CASE
SEAT LOCKING DEVICE
ACCESS
FUEL LEVEL SENSOR - FUEL PUMP SENSOR
FUELTANK
BATTERY CASE COVER - ACCESS- SIDE STRUTS
ACCESS
REAR FAIRING
REAR HANDLE
NUMBER PLATE LIGHT HOUSING- REAR LIGHTS ASSEMBLY
FULL REAR FAIRING
ACCESS (RIGHT SIDE)
(LEFT SIDE)
ELECTRONIC CONTROL UNIT- VOLTAGE REGULATOR
IGNITION COIL - ROLLOVER SENSOR
REAR FAIRING BREAKDOWN
LEGSHIELD
ACCESS
KEYSWITCH - HORN
FRONT WHEEL - FRONT BRAKE DISC
SEQUENCE OF FRONTWHEEL REASSEMBLY
FRONT BRAKE CALIPER
FRONT MUD GUARD - FRONT SHIELD
BACK HANDLEBAR COVER - HANDELBAR CONTROL - BRAKE PUMP
HANDLEBAR - ELECTRIC FAN AND RADIATOR
EXPANSIONTANK
FORK -FORK LEG - COMPLETE FORK
MUFFLER - OXYGEN SENSOR
MANIFOLD EXHAUST - REASSEMBLY OF EXHAUST SYSTEM
SHOCK ABSORBERS- REMOUNTING THE SHOCK ABSORBERS
REAR MUDGUARD
AIR INTAKE ASSEMBLY
AIR FILTER
AIR FILTER MAINTENANCE - STARTER
REAR BRAKE CALIPER
REAR WHEEL
REAR BRAKE DISK - REAR WHEEL- ENGINE
FRAME SIZE CHECK
CABLE POSITIONING, "PIPE SYSTEM" AND POSITION OF CLAMPS
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Compression Ratio .................................................................................. 10,6 : 1
11,3 : 1
Cooling ........................................................................................................ liquid
Starting system. ............................................................................ electric starter
lubrication system ................................................................................ wet sump
SPECIFICATIONS
SPARK PLUG
Type ............................................................................................ NGK DPR7EA9
TRANSMISSION
Primary drive: automatic transmission by V-belt speed change gear
Final: by gears. Automatic centrifugal dry clutch.
FUEL SYSTEM
Electronic fuel injection with electric fuel pump.
Fuel: unleaded petrol.
F. 1
IGNITION
Digital
DIMENSIONS
Wheel base (A) m ....................................................................................... 1,360
Max. length (B) m ........................................................................................ 2,050
Max. width (C) m ......................................................................................... 0,735
Max. height (D) m ...................................................................................... 1,180
Kerb weight kg ............................................................................................... 140
Max. load with rider, passenger and luggage kg .............................................. 180
BRAKES
Front brake: disk type Ø 245 mm double piston hydraulic caliper Ø 25 mm
Rear brake: disk type Ø 220 mm double piston hydraulic caliper Ø 34 mm
CHASSIS
High-tensile steel tubes
CAPACITY
Engine oil cm3 ........................................................................................... 1000*
Transmission oil cm3 ................................................................................... 150*
Fuel tank (total) l ................................................................................. 8,2* (3,0*)
SUSPENSIONS
Front:
hydraulically fork Ø 33 mm; Stroke: 88 mm.
Rear:
Swinging engine with double hydraulic shock absorber. Stroke: 74 mm.
ENGINE: 2 valve - 4 stroke single cylinder:
Type .............................................................................................. MALAGUTI 01
MALAGUTI 02
n° Cylinders ...................................................................................................... 1
Bore x stroke mm .......................................................................... Ø 52,4 x 57,8
Ø 58,0 x 57,8
Capacity cm3 ................................................................................................. 125
153
BATTERY
Type 12V, 9Ah, maintenance free.
TYRES
Front:
Rear:
100/80 - 16
120/80 - 16
50P (tubeless)
60P (tubeless)
* Indicative Value
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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).
A
Any alteration to the vehicle identification data is pursued by the
Law.
TYRES
F. 3
Type: Tubeless (wiithout inner tube)
B
F. 2
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.
120/80 - 16” - 60P
100/80 - 16” - 50P
F. 4
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.
2.0
(29.0)
2.0
(29.0)
2.1
(30.5)
2.2
(31.9)
2.3
(33.4)
2.3
(33.4)
Tyre inflation pressure must be adjusted while the tyre is at ambient
temperature.
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MAINTENANCE TABLE
Nr.
: coupon
: check
: clean
: adjust
: replace
NOTE - Maintenance operations should be performed more frequently if the vehicle is used in rainy weather, in dusty places or on rough
terrain.
Due to their simplicity, checks with no asterisk CAN also be carried out by technicians not authorised by MALAGUTI, but under
their direct responsibility.
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LUBRICANT TABLE
NOTE - Use only recommended products.
LUBRICANTS
ENGINE OIL (4 STROKE)
CLASS 10W 40
ENGINE TRANSMISSION OIL
CLASS 10W 40
AIR FILTER LUBRICANT
AIR FILTER OIL
RADIATOR FLUID
TOP FLUID
BRAKE CIRCUIT FLUID
BRAKE FLUID DOT 4
FORK ROD OIL
FORK OIL
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FUEL TANK
• The fuel tank cap (A) is accessible by raising the seat, using
the ignition key and turning it clockwise.
Use unleaded fuel.
A
F. 5
COOLANT TANK
• Open the case with the ignition key.
• Remove the plastic protection piece (B).
B
F. 6
• Check the fluid level in the inspection window (C) found
under the shield.
C
If it needs to be topped up, use the product
specified in the lubricants chart.
Do not remove the cap when the motor is hot.
F. 7
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ENGINE OIL
CHECK LEVEL
every 2,000 km
• The engine must be cold and the vehicle
on level ground.
• The level is shown on the cap/ dipstick
(A).
Top with the oil specified in the
lubricant chart.
A
F. 8
CHANGE
• After the first 1,000 Km
• Every 4,000 KM
Warm up the engine for a few minutes and then shut it off.
• Place an appropriate drain pan under the engine (with the vehicle on flat
ground).
• Pull out the cap/ dipstick (A).
• Unscrew the drain plug (S) and let all the used oil drain out.
• Remove the filter/plug (F).
• Wash the screen (1) with solvent or if it is damaged, replace it.
• Check the wear conditions of the O-Ring (3) and replace if necessary.
• Reassembly: O-Ring (3)- Spring (2)- Screen (1) and tighten the filter/plug.
• Screw on and tighten the drain plug (S).
• Top up the engine with 800 cc of Q8 CLASS 10W40 oil and replace the cap/
dipstick.
A
2
1
F
S
Start the engine; leave it running for a few minutes, and check that there
are no leaks.
F. 9
Dispose of used oil in accordance with current laws in force.
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F. 10
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TRANSMISSION OIL
A
CHECK LEVEL/ TOP UP
CHANGE
•
•
•
•
•
•
•
•
•
•
•
•
•
Cold engine
Vehicle on level ground.
Place a drip pan under the engine.
Unscrew the oil filler screw (A).
If necessary, top up with oil specified in the lubricant
chart until the oil starts to overflow.
• Screw on the screw (A).
Cold engine
Vehicle on level ground
Place a drip pan under the engine.
Unscrew the oil filler screw (A).
Unscrew the drain screw (B)
Drain out all the used oil.
Clean the threads of the drain screw and screw back on.
Refill the crankcase with oil specified in the lubricant
chart until the oil starts to overflow.
• Screw back on the screw (A).
B
F. 11
BRAKE FLUID
CHECK
• After the first 1,000 Km
• Every 12,000 Km
S
S
every 30 days
• Visually check by way of the warning signal (S) located on the front and back
brake reservoir, with the vehicle on level ground and perfectly straight.
• The fluid level must be 3mm from the lower limit of the warning signal.
Do not mix different oil types when topping off.
F. 12
CHANGE
Every 12,000 Km or 24 months
If there is any debris or water in the brake fluid, it is essential that it be completely changed and the brake system must be bled. Excessive elasticity in the
brake lever is usually an indication that air is in the system.
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BLEED BRAKE SYSTEM
A
V2
FRONT CALIPER
C
NOTE - Position the vehicle in a stabile manner and
perfectly on level ground.
• Remove the (right side) oil pump reservoir cover (A),
unscrewing the relative screws (V"), in order to be
able to top off the fluid.
• Fill the right brake fluid reservoir (B) to the highest
level.
• Remove the rubber hood (C) of the bleeder screw
(V) and insert a rubber tube to recover the brake
fluid.
• Pump the right brake lever (D), prime it and bring
the system in pressure.
• Keeping the brake lever pumped, loosen the bleeder
screws (V), to allow air to escape. Then, tighten
the bleeder screw (V)
V
B
D
V
F. 13
F. 14
12 ± 16%
A
• Repeat the operation, until only liquid comes out of
the rubber tube.
V2
C
B
• Top up the brake fluid level in the reservoir (B).
V
REAR CALIPER
• To bleed the rear caliper, follow the same operation
above, but pump the left brake lever (S).
S
F. 15
F. 16
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CHECK FRONT/BACK BRAKE PADS AND DISKS
• Check the condition of front and back brake pads and discs
every 2,000 Km.
• Carry out a visual check on the thickness of the brake pads as
shown in the illustration. The minimum thickness of the brake
pad friction material must not be less than 2mm.
• Replace the pads if they are close to the allowed limit, or if they
are damaged.
F. 17
F. 18
REPLACING PADS
NOTE - The procedures for replacing front and back brake pads
can be deduced from the illustration shown below.
F. 19
FRONT BRAKE
REAR BRAKE
F. 20
F. 21
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FORK
CHANGE FORK OIL
CHECK OIL LEVEL IN THE
FORK LEG
• Place an appropriate drip pan under the slider and remove the screws
(V).
• Drain out as much oil as possible.
• Proceed to dismantle the fork legs, as previously described.
• Turn the fork legs upside-down, to let the remaining oil drain out.
• Remove the fork leg.
If a "limit switch" of the fork is
found, or if they produce
abnormal sounds, the oil level
inside the pins must be
checked. Removal of the legs
can be seen in F. 22.
Hydraulic oil is corrosive and may cause personal injury.
Do not improperly dispose of used oil in the environment.
• Remount the drain screw (V).
NOTE - When remounting, replace the copper washer located under the
screw (V).
• Insert a ruler or gauge and
check that the oil is at least
75mm from the upper edge
of the leg.
• If necessary, top up with oil:
FORK OIL
V
17 ± 15%
• Carefully pour the "new" oil in the fork.
Quantity per fork 90 cc.
• Check the oil level, as previously described.
• Reassemble the fork components and the fork on the motorcycle.
SHOCK ABSORBER
ADJUSTMENTS
5) adjustment positions are included:
1) driver only (to 75 kg)
2) driver only (over 75 kg)
3) driver and case
4) driver and passenger
5) driver, passenger, and case.
V
A
F. 22
Perform adjustments using the special key equipped on the ring nut (A), located on the upper part of the shock absorbers;
turning it anti- clockwise will increase the strength of the spring (increase in load)
Adjust both shock absorbers using these instructions.
Uneven adjustment can compromise the stability of the vehicle.
F. 23
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LOCATION OF THE MAIN ELECTRICAL AND ELECTRONIC ELEMENTS
F. 24
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F. 25
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DASHBOARD
1)
Speedometer
2)
Odometer
3)
Turn signal warning light (green)
4)
High beams warning light (blue)
5)
Electric/SERVICE Malfunction warning light
(orange)
6)
coolant temperature too high warning light
(red)
7)
Fuel gauge indicator
8)
Coolant temperature indicator (red zone:
temperature too high)
9)
Digital clock
9
1
8
2
7
3
6
5
4
F. 26
DIGITAL CLOCK
• Date and month readout
Press the top button once (after a few seconds the clock will automatically reappear).
• Seconds readout
Press the top button twice; to restore the initial configuration, press the button again.
To set the clock and calendar, use the two buttons on the right hand side of the dial, starting with the time display.
• Setting the month
Press the lower button twice; and then with the top button select the exact number.
• Setting the date
Press the lower button three times; and then using the top button select the exact number.
• Setting the time
Press the lower button four times, and then using the top button select the exact number.
• Setting the minutes
Press the lower button four times, and then using the top button select the exact number.
Press the lower button once again to return to the time display. Confirm modifications by pressing the top button.
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ELECTRIC/SERVICE MALFUNCTION WARNING
LIGHT
When the starter key is turned in the switch in the
position, without starting the engine, the
warning light
(as well as the warning light
)
will remain on for a few seconds to verify the
functioning, and it will normally shut off after this.
If it stays on longer (fully and/or flickering) it means:
• Electrical Malfunction (blinking light): indicates a
malfunction in the electrical system.
• SERVICE (15 short blinking lights): indicates the
need to perform programmed maintenance (see the
Maintenance Chart on page 9).
In both cases, reset the signal after performing the
necessary operations.
The warning light interval of the SERVICE
sign
of the may have different
meanings as shown in the Maintenance
Chart, depending on the vehicles conditions
of use.
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KEY SWITCH
Ignition inhibited (extractable key)
Preset starting position (non extractable key)
Steering lock insert (Ignition inhibited: extractable
key).
HANDLEBAR CONTROLS
LEFT CONTROLS
1)
Horn button
2)
Turn signals switch.
3)
Turn signals shutoff switch
4)
Turn on lights:
In case both of the equipped keys are lost the entire
locking kit must be replaced.
RIGHT CONTROLS
A) light switch:
right= off
center= tail and dashboard lights
left= high/low beams
B) Electric starter button
high beam
low beam
STARTING THE ENGINE
Before pushing the starter button to start the motor,
first pull the front or rear brake lever and keep it
pulled.
Do not start the engine in a closed ambient,
because the exhaust is highly toxic.
To not damage the injection system, never
operate the "START" button if the fuel tank
is empty, or turn the key switch to "ON".
4
A
B
If the engine does not start, release the starter
switch, wait a moment, and then press it
again. In order not to drain the battery, do
not operate the starter for more than 10
seconds on each try. Do not rev the engine to
its limit when it is cold.
3
Start the engine with the headlights off.
2
1
F. 27
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LIGHTS
HEADLIGHT
A
The headlights are quartz lamps (halogen).
• High/Low beam lights (A). Halogen Bulb 12V - 60/55W (H4).
• Tail lights (B). Bulb 12V - 5W (W5W).
• With a Philips screwdriver, adjust the headlight adjustment
screws ( R), keeping in mind that turning clockwise lowers
the light beam and vice versa.
• Adjust the beam so that the lower line of the beam is about 95
cm off the ground when projected on a wall.
B
R
LIGHT BEAM ADJUSTMENTS
F. 29
F. 28
• Place the vehicle in gear, 10 m from a wall.
• Turn on the low beam and keep the vehicle vertical without the kickstand and without people sitting on it.
CHANGE LIGHT BULB
• For information on access to the headlight bulb consult page 28).
TURN SIGNALS
Front
D
• Orange bulb ( C) 12V - 10W (RY 10W).
LIGHT BULB REPLACEMENT
• For information on access to the turn signal light bulbs see
page 46) .
REAR
D
C
• Light bulb (D) 12V - 10W (RY 10W).
LIGHT BULB REPLACEMENT
• For information on access to the rear turn signal light bulbs
see page 39).
C
F. 30
F. 31
21
11/07
125 i.e. - 160 i.e.
TAIL LIGHTS
• Tail light (B)
Light bulb 12V - 5W (W5W).
• brake light (S)
Light bulb 12V - 10W (R10W).
• Turn signal (E) 12V-10W light
bulb
W
S
S
W
E
E
LIGHT BULB REPLACEMENT
• Remove the number plate light (see the next
paragraph).
• Remove the taillight cover by unscrewing the two
screws (V).
• Remove the parabola by unscrewing the two screws
(W).
B
Stop light (S) and turn signal light (E)
• Remove the coloured hood that is held by two hooks.
• Replace the light bulb.
• Reposition the coloured hood and remount the cover.
When performing the operations described
above, be very careful to not damage the near
by parts (transmission, cables, gaskets, etc.).
F. 32
NUMBER PLATE LIGHT
LIGHT BULB REPLACEMENT
Light bulb 12V - 5W (W5W)
• Remove the number plate light (F), unscrew the screws
(V).
• Remove the rubber lamp holder from the plastic cover.
• Replace the light bulb.
• Reposition the lamp holder and remount the cover.
C
F. 34
V
Tail lights (B)
• Take out the lamp holder from inside the headlight.
• Replace the light bulb.
• Reposition the rubber lamp holder (pressure) and
remount the cover.
B
To check that a light bulb (C ) is
properly functioning, position the
light switch, which is located on
the right control panel, in the
center position and turn the key
to the starting position.
V
F. 33
F
V
When performing the operations described
above, be very careful not to damage the near
by parts (transmission, cables, gaskets, etc.).
F. 35
22
11/07
125 i.e. - 160 i.e.
FUSES
The electric wiring includes eight fuses that are located in
the front case and protect the main components from any
malfunctions.
S
P
FUSE REPLACEMENT
Open the case and take out the fuse and replace it with
one having equal capacity. Spare fuses are located
inside the compartment (S).
Do not replace fuses with others that have a
higher capacity, as it could seriously damage the
electrical system and cause the vehicle to catch
fire if there is a short circuit.
It is important to identify the cause of blown
fuses.
F. 36
NOTE - Use the appropriate grippers (P) when replacing
a fuse.
23
11/07
S
125 i.e. - 160 i.e.
BATTERY (12V-9AH)
The battery housing is located in the central tunnel.
BATTERY ASSEMBLY (PRE-DELIVERY OPERATION)
• Take the battery that has been previously charged
• Apply the adhesive strip (A) supplied in the kit, by removing the
protective film located on the end of the adhesive area, shown
by the arrows (P).
• Remove the 30 A general protection fuse (F).
• Unscrew the three screws (V3) and remove the central panel
under the seat.
• Remove the battery fastening cover by removing the screws
(V2).
• Insert the battery, ensuring it fits in its housing.
• Connect the battery to the cables
- positive pole (+) RED/BLUE wires
- negative pole (-) BLACK wires
• Properly tighten the battery clamps.
• Properly position the battery clamps.
• Replace the previously removed 30 A general protection fuse in
F. 37
its place.
• Check that the battery and cables are properly positioned; then
remount the battery fastening cover.
• Remount the central panel under the seat.
CHARGE BATTERY
• To carry out this operation, it is advisable to remove the battery
from its housing, unless the special electrical outlet is used.
• Disconnect cables.
• It is a good rule to recharge using amperage that is equal to
1/10 of the power of the battery charger.
• Remount the battery, paying attention to connect the positive
cable (red/blue) to the + pole and the negative cable to the pole.
• Properly tighten the battery clamps.
• It is important that the battery always remains fully charged;
therefore, during the winter months or when the vehicle remains
unused, it should be recharged at least once a month.
NEVER invert the cable connections.
Do not use the battery without the battery
inserted and connected to wires of the main
harness. This could cause breakdowns and
short circuits in the electrical system and
components.
It is advisable to use gloves and protective
eyewear, when the battery must be removed from
its housing; for example, when it needs to be
recharged.
A
V3
F
F. 39
P
V2
B
F. 38
Danger of explosion! Do not use open
flames (lighters, matchsticks, etc.).
F. 40
The battery contains highly toxic sulphuric
acid. Avoid contact with the eyes, skin, and
clothes. Keep the battery out of reach from
children.
If for charging/ maintenance of the
battery the special electrical outlet
connection is used (B), open the battery
case to permit proper ventilation.
F. 41
24
11/07
125 i.e. - 160 i.e.
SPARK PLUG
REPLACEMENT
every 12,000 km
Remove the spark plug when the engine is cold.
Type of spark plug to be used: NGK DPR7EA9
• For maintenance, disassemble the central panel under the seat (P), remove the fastening screws
(V3) and lift the internal profile (with the help of a screwdriver) that is held on two lugs in the foot rest
board, carefully extract the hood (C ), with small clockwise and anti clockwise movements; then
unscrew the spark plug.
• Examine the condition of the sparkplug. Deposits and colorations of the insulator provide useful
information on the thermal grade, on the carburetion, on the lubrication and on the general condition
of the engine. If there is a light brownish color on the insulator around the central electrodes, it means
that it functions properly.
• After removing the sparkplug, proceed to clean thoroughly the electrodes and insulators, using a
metallic brush. Adjust the electrode gap, using a laminar feeler gauge: the gap must be 0,6 ÷ 0,7 mm
P
F. 42
Spark plugs with a thermal grade that is different than that deduced by the advised symbols
may seriously damage the engine.
Replace all spark plug with cracks on the insulator or corroded electrodes.
C
• Remove any residue, using jets of compressed air.
• Grease the sparkplug threads with motor oil and manually rescrew it.
• Tightening the spark plugs:
17,5
F. 43
25
11/07
V3
125 i.e. - 160 i.e.
• Unscrew the window holder stud
bolt (B).
PROCEDURES FOR DISMANTLING AND
REMOVING COMPONENTS
REASSEMBLY NOTE
B
D
REAR VIEW
MIRRORS
A
F. 45
• Uncover and loosen the nut (D).
C
" Unscrew the window holder arm, by
turning it anti-clockwise.
NOTE - The left stud bolt is noted
by the groove (C).
" Remove the protection (A).
F. 46
F. 44
V2
• Remove the upper cover, sliding
it towards the rear part.
UPPER
COVER
• V2.
F. 47
F. 48
26
11/07
125 i.e. - 160 i.e.
V4
FRONT HANDLEBAR COVER
• V4.
• V.
V
V4
1 ± 10%
1 ± 10%
V
F. 49
F. 50
• To clear the front handlebar
cover, push the area
indicated in the figure (on
both sides), paying
attention to not damage the
hooking points.
• Free and partially extract
the handlebar unit,
carefully, as to not damage
the paint of the under
shield or rip the electrical
headlight wires.
F. 51
F. 52
27
11/07
V4
125 i.e. - 160 i.e.
A
• Disconnect the
lamp holder (A)
• Extract the taillights
lamp holder (B).
• Remove the front
handlebar cover.
F. 53
B
F. 54
6
11
1
V2
2
V2
8
11
7
ACCESS
(AFTER REMOVING THE FRONT HANDLEBAR
COVER)
1) Clock connector
2) Clock (fastened with screws - V2)
3) Front brake "stop" switch
4) Rear brake "stop" switch
5) Dashboard connectors
6) Hydraulic front brake pump union
7) Hydraulic rear brake pump union
8) Fastening ring nut transmission odometer
9) Right switch connector
3
10
9
10) Left switch connector
11) Dashboard lighting lamps
F. 55
28
11/07
5
4
125 i.e. - 160 i.e.
FRONT SHIELD
V2
• V2.
• W.
V2
W
1 ± 10%
1 ± 10%
F. 56
W
F. 57
• Unscrew the screws (V5) to separate the grille
from the shield.
V5
• Remove the shield with
moderation, being careful to
not damage the hooking
elements.
V5
F. 58
F. 59
29
11/07
1 ± 10%
125 i.e. - 160 i.e.
ACCESS
(AFTER REMOVING
THE SHIELD)
A) Electric fan
B) Radiator
G
E
SEAT
C
• D2.
D2
F
D2
3 ± 20%
C) Radiator cap
D) Diagnosis socket
E) Electric fan connector
D
F) Antitheft preset
connector
G) Key switch connector
B
F. 61
A
F. 60
A
HELMET COMPARTMENT
• Cap (A).
D
B
• Droplet catcher cup (B), after having removed the clamp (C)
of the breather pipe (D).
C
F. 62
F. 63
30
11/07
125 i.e. - 160 i.e.
V5
• V5.
• Partially lift the helmet
compartment, as it is
constrained by the seat
locking device cable (A).
5 ± 20%
F. 64
A
F. 65
V5
V2
SEAT BLOCKING DEVICE
• Remove the locking/opening
unit, complete with the
transmission cable.
• V2.
V2
3 ± 20%
F. 66
F. 67
31
11/07
125 i.e. - 160 i.e.
ACCESS
A
(after removing the helmet compartment)
•
•
•
•
•
B
Fuel tank
Fuel level gauge (A)
Fuel level gauge connector (B)
Fuel Pump ( C)
Pump connector (D).
C
D
2
3
F. 68
4
1) Temperature gauge (coolant)
2) Inlet air temperature sensor connector
3) T.P.S. connector
4) Injector connector
5) O2 sensor connector
5
1
F. 69
32
11/07
125 i.e. - 160 i.e.
FUEL LEVEL
SENSOR
E
A
• During operations, screw the
tank cap on the union (E), to
avoid that any foreign matter
falls inside.
• Disconnect the connector (H).
• V4.
• Open the clamp (B).
NOTE - When reassembling,
insert the floater (l) so
that the base (A)
remains as it was
originally. It is advisable
to mark the correct
position before removal.
Check the condition of
the gaskets (L) and
replace them if
necessary.
A
B
I
B
H
R
F
C
V4
L
D
G
F. 71
F
F. 70
Reposition the clamp (B).
V4
V4
2 ± 10%
Do not smoke or use open flames, during
operations on the fuel tank.
FUEL PUMP
G
• Disconnect the connector (D).
• Disconnect the gas hose (F), pressing on
the fitting with one finger (R). Keep a rag
close by to swab up any leaking fuel.
• Unscrew the ring nut (G).
• Take out the pump (C).
C
F. 72
33
11/07
125 i.e. - 160 i.e.
FUEL TANK
O
V4
E
Do not smoke or use open
flames, while operating on the
fuel tank.
T
V4
H
N
O
D
• During the operation, screw the tank
cap, on the union (E), to avoid that
any foreign matter falls inside.
• Disconnect the connector (D).
• Disconnect the gas hose (F),
pressing on the fitting with one finger
( R). Keep a rag close by to swab up
any leaking fuel.
• Open the clamp (T).
• Disconnect the connector (H).
• Unscrew the screws (v4), being
careful not to lose the anti-vibration
pads (M), bushings (N) and clamps
(O).
F
M
N
M
V4
V4
Remove the tank and place it far
from heat sources and sparks
and/or open flames.
F. 72/a
34
11/07
5 ± 10%
125 i.e. - 160 i.e.
ACCESS
BATTERY
COVER
COMPARTMENT
A
• Battery (B).
• Spark plugs pipette (C).
• V3.
NOTE - For information
concerning the
battery, consult
page 24.
• Door (A).
V3
F. 73
F. 74
SIDE STRUTS
B
C
• W.
• V2.
• Washer (R).
W
R
V2
F. 76
F. 75
35
11/07
125 i.e. - 160 i.e.
• Open the strut with
moderation, starting from
the rear part and take it off
by pushing on the front
part, being careful to not
damage the hooking points
(C-F. 80); be careful not to
lose the prestoles (P).
When remounting, insert
the strut in the front drive
(A).
A
F. 77
P
F. 78
C
ACCESS
1) Electronic control unit
2) Ignition coil
3) Rollover sensor
4) Voltage regulator
F. 79
1
2
F. 80
3
36
11/07
4
125 i.e. - 160 i.e.
REAR FAIRING
(including the foot rest panel)
• V3.
• Unscrew the screw (V), holding
the self locking nut (D).
V3
V
5 ± 10%
V3
D
F. 81
F. 82
V
V
G
• Unscrew the screws (V), remove
the pillion staff and recuperate the
underlying spring (M).
Clean and grease the
fulcrum pin (P).
P
D
F. 83
F. 84
M
37
11/07
125 i.e. - 160 i.e.
REAR HANDLE
• Cap (A).
• V.
V
A
F. 85
F. 86
V2
B
• V2.
• Bushing (B).
V
V2
• Remove the rear handle
including the opening/
locking seat device.
V
43 ± 15%
F. 87
F. 88
38
11/07
125 i.e. - 160 i.e.
NUMBER PLATE LIGHT
SUPPORT
REAR LIGHT UNIT
B
• V2.
• V.
V2
• Rear light frame assembly
(B).
V2
• Number plate light
support (A).
C
• Rear light glass assembly
(C).
A
V
F. 90
F. 89
V 2A
• Carefully take out the rear
light unit.
• V2A.
• Disconnect the wires.
F. 91
F. 92
39
11/07
125 i.e. - 160 i.e.
FULL REAR
FAIRING
• V2.
• Lift slightly the rear fairing,
complete with the footrest
panel and number plate
holder guards.
V2
V2
F. 93
V2
5 ± 10%
F. 94
• Take the fairing out of the frame, as
illustrated in figure
F. 95
40
11/07
125 i.e. - 160 i.e.
ACCESS
The reassembly stage of any interventions on
the wiring involves repositioning these as
illustrated, and fastening them with new
clamps that must be placed in the original
points.
(RIGHT SIDE)
1) Three-phase stator connectors
connettore regolatore
2) Flasher relay
3) Electric fan relay
4) Injection system relay
5) Starter relay
6) Pick-up connector
7) Ground assembly
8) Regulator connector
system connector
NOTE - Access to the various
mechanical components
can be deduced from
the illustrations.
7
5
4
3
2
6
1
8
F. 96
41
11/07
125 i.e. - 160 i.e.
(LEFT SIDE)
1) Ignition coil
2) Valve (manage minimum)
"IDLE"
3) Electronic control unit
2
4) Voltage regulator
5) Rollover sensor
7
6) Horn
7) Fuel hose fastening clamp
6
1
F. 97
3
4
1
5
42
11/07
125 i.e. - 160 i.e.
ELECTRONIC
CONTROL UNIT
V2
B
• Disconnect the connector
(A).
• V2.
VOLTAGE
REGULATOR
• Disconnect the connector
(M) and the connector (N)..
• V2a.
IGNITION COIL
• Disconnect the connector
(B).
• Unscrew the screws (V2)
and remove the coil
complete with the support
staff.
V2
A
V2/a
C
D
ROLLOVER SENSOR
• Disconnect the connector
(C).
• Free the sensor (D) from its
housing.
When reassembling, be
careful to reposition the
sensor in a horizontal
position as it was
originally.
F. 98
N
M
43
11/07
125 i.e. - 160 i.e.
REAR FAIRING BREAKDOWN FROM THE FOOT
REST PANEL
REAR FAIRING BREAKDOWN FROM THE NUMBER
PLATE HOLDER GUARD.
• V3.
• V3.
V3
V3
F. 99
F. 100
44
11/07
125 i.e. - 160 i.e.
V2
LEGSHIELD
A
B
• V2.
• Bag holder hook (A).
• Extract the cover (B) of the
key switch.
• V4
V2
V2
5 ± 10%
V
• Unscrew the fixing screws
(V") of the fuse holder.
F. 101
• V.
V4
C
• Open (carefully) the leg
shield, on the right side.
• Remove the fuse holder box
(C).
• Disconnect the connector
(D).
• Remove the leg shield unit.
F. 102
D
F. 103
45
11/07
V
5 ± 10%
V4
2 ± 10%
125 i.e. - 160 i.e.
ACCESS
(after the legshield is removed)
A) Front turn signals
C) Horn
NOTE - It is not necessary to move the leg shield to replace the front
turn signals. They are accessible through the side grille of
the leg shield
D) Expansion reservoir
E
E) Handlebar fixing nuts
F) Steering wheel play
regulator ferrules
B) Key switch
D
B
A
F. 104
F
A
F. 105
F. 106
46
11/07
C
125 i.e. - 160 i.e.
KEY SWITCH
• Disconnect the "faston" (A).
• V-
• Disconnect the connector from the wiring.
• Unscrew the tamperproof screws (V).
V2
A
HORN
V
10 ± 15%
7 ± 10%
V
V2
F. 107
F. 108
FRONT WHEEL
• Unscrew the nut (D), holding the wheel pin
with a wrench.
• Remove the wheel
pin (P).
• Take off the wheel.
FRONT BRAKE DISC
• When removing the front wheel, check the
condition of the brake disc. In case of deep
scoring or if the thickness is below the minimum limit of 3.5 mm, remove it by unscrewing the screws and replace it.
V4
Do not use the
brake lever, with
the wheel removed.
D
11 ± 10%
Apply Loctite threadlocker (Strong
type) on the screw threading.
F. 109
F. 110
V4
47
P
11/07
125 i.e. - 160 i.e.
SEQUENCE OF FRONT WHEEL REASSEMBLY
• Spacer (A)
• Odometer transmission (B)
• Washer (R )
• Wheel pin (P)
• Spacer (C)
• Wheel pin (D)
P
R
D
B
53 ± 10%
A
FRONT BRAKE CALIPER
• Place an appropriate drain pan under the brake calliper.
• Unscrew the hydraulic fitting (A).
C
Empty the hydraulic circuit completely, pouring the fluid in a special container for
proper disposal in accordance with specific waste disposal laws.
D
F. 111
• V2.
• Remove the calliper.
V2
Hydraulic oil is corrosive and may cause personal injury.
A
Remove the calliper, taking care that fluid line does not get damaged and
the disc and pads do not get dirty. At the end of removal and replacement
operations, check that there are no losses, dry up any traces of fluid and
bleed the system as indicated in page 14.
G
A
During reassembly, change the gaskets (G).
V2
30 ± 20%
A
20 ± 20%
F. 112
48
11/07
V2
125 i.e. - 160 i.e.
FRONT
MUDGUARD
V3
•V
• Clamp (A)
• V3
• V1
• Clamp (C)
C
V
A
V3
V1
3 ± 10%
B
F. 113
F. 114
P
• V2
• Spacer (B)
• Remove the mudguard (P).
V
V2
FRONT SHIELD
Do not forget to remount
the spacers (B) and
clamps (A-C).
• Lower screws (W-F 115)
• Top screws (V)
• Take out the shield (with
care)
W
W
V
F. 115
5 ± 10%
F. 116
49
11/07
125 i.e. - 160 i.e.
BACK HANDLEBAR COVER
E
• Unscrew the screws (V4), to free the handlebar commands.
V4
•
•
•
•
B
2 ± 15%
Central screw (V)
Disconnect the dashboard connector (A).
Unscrew the ring nut (B) of the odometer cable.
Remove (with care) the rear handlebar cover including the
dashboard.
V4
C
F
V4
D
HANDLEBAR CONTROLS
• V4
• Disconnect the throttle transmission (C).
• Disconnect the connectors (D-E)
A
F
V
F. 117
V2/a
V
V2/a
BRAKE PUMP
•
•
•
•
V2/a
Brackets (B).
Disconnect the "faston" (F).
Remove the brake pump and place it in a vertical position on a
dry cloth.
B
Brake fluid is corrosive.
V
F. 118
50
11/07
B
125 i.e. - 160 i.e.
HANDLEBAR
P
N
D
• Remove beforehand:
- Front handlebar (page 27)
- Front shield (page 49).
- Brake pump (page 50).
- Right switch and left switch (M).
- Counterweights (P).
- Handlebars (N)
- Cut the cable and tube holding ties.
- Remove the throttle cable (A)
• Loosen the nuts and slide the pin off (H), taking care not to
damage the cables and tubes.
• Slide off the grips.
L
M
M
A
H
D
F. 119
D
50 ± 20%
ELECTRIC FAN AND RADIATOR
A
B
Before any operations on the cooling system, check that
the fluid is below 50°C.
•
•
•
•
Remove the front shield (page 49).
Cut the cable and tube holding ties.
Unscrew the radiator cap (A).
Position the engine in a container suitable for collecting the
used coolant.
• Loosen the clamps (F) and slide the tube off (T) of the water
pump.
• Disconnect the tube (B).
F
F. 120
F. 121
51
11/07
T
N
P
125 i.e. - 160 i.e.
• Disconnect the electric
fan connector (A).
• Unscrew the radiator and electric vent
housing fixing screws (V4)
• Remove the housing and electric fan.
• Unscrew the screws (V3).
• Separate the electric fan unit from its
housing.
V4
A
B
V3
V4
F. 123
F. 122
• Free the radiator from
the hoses (M).
• Separate the radiator
from its housing (S).
F. 124
The cooling system is "self-bleeding".
But if, after the radiator is reassembled,
filled with fluid and tested with the engine
idling for a few minutes, an abnormal
rise in temperature is found, manually
bleed it by following these steps:
M
S
F. 125
T
• Partially lift and rotate the helmet case
sideways (page 30).
• Wait until the fluid has cooled down,
unscrew the cap (B) and completely fill the
radiator.
• Slide off the tube (T) (after freeing it from
the clamps); Liquid should come out from
F. 125/a
the union, in abundance.
• Insert the tube (T) and the cap (B)
• Before replacing the helmet case, start the engine and check that there is no abnormal rise in
temperature.
52
11/07
125 i.e. - 160 i.e.
• V2.
EXPANSION
TANK
B
Before any operations
on the cooling system,
check that the fluid is
below 50°C.
• Place an appropriate drain
pain under the expansion
tank.
• Disconnect the tube (A) and
empty the expansion tank;
remove the filling cap (B) to
make it easier to empty.
A
F. 126
V2
F. 127
V2
R
B
• V2.
• Remove the expansion
tank.
V2
V2
When remounting,
insert the washers (R).
3 ± 15%
R
V2
A
F. 128
F. 129
53
11/07
125 i.e. - 160 i.e.
FORK LEG
FORK
NOTE - When removing the fork leg, as well
as the full fork, the following should be
removed beforehand:
- Front wheel (page 47)
- Front mudguard (page 49)
- Front brake calliper (page 48)
- Odometer transmission (page 48)
• Loosen (V)
• Raise the fork leg a few
millimetres (A).
• Take out the elastic ring (B)
• Slide out the fork leg (A)
downwards.
For the full fork, also remove the:
- Front shield (page 29)
- Handlebar (page 20)
V
V
B
A
A
30 ± 20%
F. 130
B
• To check the oil level and to change oil,
see page 16).
S
C
FULL FORK
A
• Upper ring nut (A)
• Lower ring nut (A)
S
B
C
NOTE - When extracting the fork unit, take care with the bearings (S) spilling out.
• Remove grease the seat of the caps (C). Check the usage conditions and if necessary
replace them.
Grease and remount the fork unit.
Top bearings (Ø 3/16") n° 22
Lower bearings (Ø 1/4") n° 19
B
12 ± 10%
A
140 ± 15%
F. 131
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F. 132
125 i.e. - 160 i.e.
• Loosen the clamp fixing
screws (V) of the muffler/
exhaust pipe.
• Remove the muffler.
MUFFLER
Before operating on
the muffler and the
exhaust pipe, ensure
that the components
are cool.
V
• V3.
24 ± 10%
V
V3
F. 132
F. 133
• Free the O2 sensor cables
from the various ties (B).
O2 SENSOR
• Disconnect the O2 sensor
connector (A).
B
A
F. 134
F. 135
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EXHAUST
MANIFOLD
REMOUNTING THE
EXHAUST SYSTEM
• D2.
• Remove the exhaust
manifold and related
gaskets.
D
D2
D
• Screw the O2 sensor (D) on the
exhaust connector (1).
• Position the collector (1) in
correspondence with the engine,
inserting the gasket (2) that should
be replaced if they are deteriorated.
• Screw and tighten the nuts (D2).
• Insert the gasket (3).
• Insert the muffler (4) on the manifold
exhaust.
• Screw and tighten the screws (V3),
after having inserted the washers
(R ).
• Tighten the clamps (F).
D2
2
45 ± 10%
D
D2
30 ± 10%
1
R
V3
4
3
F
F. 138
F. 139
V3
VS
R
SHOCK
ABSORBERS
V3
REMOUNTING THE
SHOCK ABSORBERS
Support the central
part of the frame.
• First, insert the top screws (Vs) with
the washers (R) and nuts (D).
• Insert the lower screws (Vi) and
relevant washers ( R).
• Lower screws (Vi)
• Top screws (Vs)
• Extract the shock
absorbers.
Vi
Vi
F. 140
Vs
45 ± 15%
Vi
24 ± 15%
R
VS
D
Vi
R
F. 141
F. 142
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42 ± 15%
125 i.e. - 160 i.e.
REAR
MUDGUARD
Left side
• V.
Right side
• V2.
V
V2
F. 143
F. 144
When remounting the rear mudguard, do not forget to insert the bushing (A) and the
washers (B-C).
Check the inserted prestole (D) is properly.
V
3,5 ± 20%
V2
V2
A
3,5 ± 20%
D
B
C
V
F. 145
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INTAKE SYSTEM
•
•
•
•
•
•
•
Unhook the clamp (A).
Disconnect the tube (C ) "IDLE" valve- filter box sleeve.
Remove the clamps (B-F. 147).
Disconnect the vapour recovery tube (C1-F. 147).
Cut the ties (E).
Disconnect the connector (F) (Inlet air temperature sensor)
Loosen the clamps (G).
A
B
C
C1
F. 146
F. 147
F
E
G
The ties that have been cut in order to remove various components must be replaced
with identical ones, and placed in the original position.
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• Unscrew the fixing screws (V1) of the filter boxrear mudguard.
• Unscrew the fixing screws (V) of the flexible air
intake tube.
V1
• Unscrew the screws (V2).
• Remove the whole
air intake system.
• To remove the
intake air sensor
(A) unscrew the
screws (V2A).
V 2A
A
V
V
V1
V2
5 ± 10%
F. 149
V2
F. 148
When remounting
the inlet air sensor,
check the condition
of the O-ring (B);
replace if
necessary.
A
AIR FILTER
B
• Unscrew
the screws
(V5),
remove the
cover and
take out
the filtering
element.
V 2A
F. 150
F. 151
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V5
125 i.e. - 160 i.e.
AIR FILTER MAINTENANCE
• Soak the filtering element (A) in a special solvent solution for filters, for a few minutes.
• Squeeze the filter (wearing rubber gloves) until all traces of the solvent are eliminated.
• Apply oil for air filters on the entire surface of the filter, eliminating any extra oil; the
result should be a uniformly impregnated filter without excess oil dripping off.
• If the filter element is damaged, replace it with a new original one.
B
A
C
When remounting the air filter unit, check that the filter casing seals (B) and the
filter cover, are correctly inserted in the relative housing.
Position the cover and fasten it with screws (V5).
V5
F. 152
STARTER
• Disconnect the "faston" from the connector (A).
• Unscrew the screws (V2).
V2
10 ± 10%
V2
A
F. 153
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REAR BRAKE CALIPER
R
• Place an appropriate drain pan under the brake calliper.
• Unscrew the hydraulic fitting (R).
Empty out the hydraulic circuit, pouring the fluid in a special container for disposal in accordance with specific
waste disposal laws.
• Unscrew the screws (V2) and remove the calliper.
V2
Brake fluid is corrosive and can cause personal injury.
Remove the calliper, taking care that fluid line does not get damaged and the disc and pads do not get
dirty. When the removal and replacement operations are finished, check that there are no losses, dry up
any traces of fluid and bleed the system as indicated in page 14.
G
During reassembly, change the gaskets (G).
R
20 ± 10%
V2
30 ± 20%
F. 155
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F. 154
125 i.e. - 160 i.e.
REAR WHEEL
V
A
• Remove beforehand:
- Muffler (page 55)
- Rear mudguard (page 57)
- Rear brake calliper (page 61)
G
F
V2
H
• Position the motorcycle on the stand and place a
suitable support under the engine.
• Unscrew the lower screws (V) of the right shock
absorber. Rotate and anchor the shock absorber up
high.
E
V2
V2
I
B
B
D
100 ± 20%
D
A
F. 157
F. 156
V2
45 ± 15%
C
•
•
•
•
•
•
•
•
•
Unscrew the wheel nut (D).
Unscrew the fixing screws (V") of the slider arm.
Extract the external spacer (A).
Remove the slider arm (B).
Slide off the wheel pin the internal spacer (C).
Check the wear conditions of the oil seals (E- F) and replace it if necessary.
Check the condition of the silent-block (G).
A appropriate puller must be used for bearing (H) replacement operations, after having removed the Seeger ring (l).
Slide off the wheel with care, ensuring that the vehicle is stable.
F. 158
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C
125 i.e. - 160 i.e.
REAR BRAKE
CALIPER
REAR
WHEEL
• When removing the back
wheel, check the state of
use of the brake disc. In case
of scoring or thickness below
the minimum limit of 3.5 mm,
remove it by unscrewing the
screws (V4) and replace it.
• Before remounting the rear
wheel, grease the shaft in
points A-B.
A
V4
11 ± 10%
Apply Loctite threadlocker (Strong type)
on the screw threading.
B
F. 160
V4
F. 159
ENGINE
It is essential that all the tube and cable ties are cut from the engine and all
relevant connectors are disconnected.
After remounting the previously removed components, all cables, pipelines
and ties should result as they were originally; in concern to this, carefully
consult the following pages.
• Remove beforehand:
-
Rear fairing (page 40)
Rear mudguard (page 57)
Lower fixing screws, shock absorbers (page 56)
Air filter unit (page 59)
Muffler (page 55)
Slider arm (page 62)
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• Unscrew the nut (D) and slide off the pin (A).
D
45 ± 15%
Raise the rear part of the motorcycle before
sliding off the engine pin. It is advisable to have
a second operator available to help carry out this
operation.
Removing the engine from the frame is a task
that should be performed with care and the
utmost attention, in order to avoid crushing of
the hands, lower limbs and safeguard the
integrity of the engine.
D
F. 161
A
F. 162
The removal of parts and components that allow the engine to be
separated from the frame includes a certain number of bands being
cut. These must be replaced and positioned as they were originally.
For this purpose, consult the illustrations on the following pages.
FRAME SIZE CHECK
• In case of suspected deformation (even slight) of the frame following an
accident, perform a size check of the frame.
Check that the distance A = 1168 mm ( ± 2mm tolerance)
• If it results to be outside of the tolerance, replace the frame.
It is absolutely forbidden to deform the frame to restore the
original distance (A).
F. 163
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CABLE POSITIONING, "PIPE SYSTEM" AND
ANCHORING TIES.
F. 164
F. 165
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F. 166
F. 167
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F. 168
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F. 169
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F. 170
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F. 171
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F. 172
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F. 173
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F. 174
F. 175
F. 176
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F. 177
F. 178
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F. 179
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F. 180
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F. 181
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F. 182
F. 183
F. 184
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