Malaguti PHANTHOM F12R Sevice Manual
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Malaguti PHANTHOM F12R Sevice Manual

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Summary of Contents for Malaguti PHANTHOM F12R

  • Page 2 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.
  • Page 3 NOTES FOR EASY CONSULTATION ABBREVIATIONS TECHNICAL DICTIONARY Torque wrench setting = (DC) Direct current (battery supply) ~ (AC) Alternating current (flywheel supply) Right : Ampere Unit of measurement of the electrical current Picture : Watt Unit of measurement of the electrical power (product of Volts and Amperes; A x V = W) Ω...
  • Page 4 SYMBOL LIST CAUTION! IDLING ENGINE Recommendations and SAFETY GLOVES DISASSEMBLY Switch on the engine, at precautions regarding rider These operations require OPERATIONS idling speed, to perfom safety and motor vehicle the use of safety gloves these interventions. integrity. WARNING! Situations entailing the risk of personal ENGINE OFF IMPORTANT...

  • Page 5: Description

    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.
  • Page 6 • 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. •...
  • Page 7 Before any servicing, make sure that the vehicle is perfectly stable. The front wheel should preferably be anchored to fixture (A), which is integral with the lift platform. F. 3 It is absolutely forbidden to walk on the lifting device. 07/07...

  • Page 8: Table Of Contents

    CONTENTS 1 2 3 4 1 2 3 4 1 2 3 4 DESCRIPTION DESCRIPTION 1 2 3 4 1 2 3 4 1 2 3 4 SPECIFICATIONS CENTRAL TUNNEL 1 2 3 4 1 2 3 4 IDENTIFICATION DATA: FRAME N° / ENGINE N° 1 2 3 4 OIL TANK 1 2 3 4...

  • Page 9: Specifications

    Capacity cm3 ....................49 SPECIFICATIONS Cooling ......................air Starting system..........electric starter and/or kick starter SPARK PLUG Type ....................NGK BR7 ES TRANSMISSION Automatic speed variator with expandable pulleys, V- belt, automatic dry centrifuge clutch, reduction gear. FUEL SYSTEM Carburettor make / type: GURTNER PY 12 automatic starter.

  • Page 10: Identification Data: Frame N° / Engine N

    IDENTIFICATION DATA: FRAME N° / ENGINE N° • The vehicle’s identification number (VIN) (A) is located on the rear side of the chassis, under the helmet compartment. • Engine identification data are located on the left-hand engine crankcase (B). Any alteration to the vehicle identification data is pursued by the Law.

  • Page 11: Maintenance Table

    NOTE - Maintenance operations should be performed more frequently if the vehicle is used in rainy weather, in dusty places or on rough : check terrain. : clean : adjust Due to their simplicity, checks with no asterisk CAN also be carried out by technicians not authorised by MALAGUTI, but under : replace their direct responsibility. 07/07...

  • Page 12: Lubricant Table

    LUBRICANT TABLE NOTE - Use only recommended products. LUBRICANTS ENGINE TRANSMISSION OIL T35 - 80W OIL FOR MIXING CITY BIKE ULTRA (synthetic) DAILY SUPER (semi-synthetic) AIR FILTER LUBRICANT AIR FILTER OIL BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4 FORK ROD OIL FORK OIL OIL TANK Litres...

  • Page 13: Rear Mirrors

    FAIRING REAR MIRRORS • Uncover and loosen the nut (D). FRONT HANDLEBAR COVER • Unscrew the arm holding the mirror. • V3 - 1 ± 10% F. 9 F. 10 DASHBOARD HOLDER • V3 - 1 ± 10% • Remove the front handlebar, DASHBOARD including the dashboard.

  • Page 14: Front Shield

    ACCESSES (after removing the front handlebar cover) 1) Dashboard connector 2) Front brake “stop” switch 3) Rear brake “stop” switch 4) Right switch connector 5) Left switch connector 6) Front brake pump oil connection 7) Rear brake transmission 8) Dashboard protection condenser FRONT SHIELD F.
  • Page 15 • Gently separate the shield and disconnect the connector (A). • V6 - 2 ± 10% F. 17 • Remove the shield, including the headlights and the direction indicators. F. 16 F. 18 07/07...

  • Page 16: Headlights

    HEADLIGHTS • V2 • V2a • V - (regulation screws for the beam of light) • Gutter (A) • Shell (D) • Faston (C) DIRECTION INDICATORS • Shell (D) • V1 F. 20 F. 19 F. 21 07/07...
  • Page 17 ACCESSES (after removing the shield) NOTE - Cut the strap (A - F. 12) and remove the sheath (B) to access connectors (F.12/a). 1) Odometer transmission connector 2) Key switch connector 3) Connector for anti-theft device 4) Headlights connector 5) Fuse box connections 6) Steering wheel allowance regulation ring nut 7) Horn 8) Fork...

  • Page 18: Lower Side Panels

    LOWER SIDE PANELS FLOORBOARDS (after removing the lower side panels) • V2 - • V - • V3 - (F. 24) • V2 - 2 ± 10% 5 ± 20% F. 23 F. 24 BATTERY • V1 BATTERY SEAT • Stop battery (B) COVER •...

  • Page 19: Fuse Description

    When reassembling BATTERY the battery, do not forget to insert the • Connect the cables as illu- strated in the figure; connect vent pipe. Make sure the positive cable first. it exits the battery seat without bending or strangling. Do not invert cable connection.

  • Page 20: Accesses 19 1 2 3

    LEG SHIELD ACCESSES • V - (F. 31) • Socket for battery recharging • V1 - (B) (max. 5 Ah). 5 ± 20% • Remove the cover (A - F. 31) of the key switch. 5 ± 20% F. 32 F.

  • Page 21: Seat

    • Remove the cables • Gently separate the from the battery, leg shield and from the front part. disconnect the connector (D) of the recharge socket. F. 35 F. 36 SEAT LOCKING SEAT DEVICE • D2 - • V2 - 3 ±...

  • Page 22: Helmet Compartment 21 1 2 3

    HELMET COMPARTMENT • V - • V4 - • Cover (A). • Gasket (B). • Cover (C). • Gasket (D). 5 ± 20% F. 39 F. 40 ACCESSES (after removing the helmet compartment) • Fuel level probe (A) • Engine oil probe (B) •...

  • Page 23: Fuel Level Probe Cover

    COVER FUEL LEVEL PROBE • V - • V4 - (F. 41) 2 ± 10% NOTE - During reassembly, insert the float (1) so that the probe con- nector is turned as shown in F. 42. F. 43 F. 42 ACCESSES (after removing the cover) •...
  • Page 24 REAR FAIRING • V2 - • V2 - • Rear light frame (A). 5 ± 20% NOTE - In these conditions, the lamp can be replaced. To replace the lamp of the indicators, loosen the screws (V). F. 46 F. 47 •...

  • Page 25: Number Plate Holder 24 1 2 3

    • Free the anchoring notches • V - (A) of the fairing. Gently remove the fairing itself, being careful with the cabling of the rear lights. 5 ± 20% F. 50 F. 51 • Disconnect the connector (B) and definitely remove the fairing, including the number plate holder.

  • Page 26: Oil Tank

    OIL TANK NOTE - In order to reach the oil tank and the fuel tank, it is necessary to remove the rear fairing. • Use pincers to release the strap (A) and discon- nect the pipe (B). • Insert a screw, which shall function as tap, in the tank exit connection.
  • Page 27 NOTE - Should you need to replace the pipe (B) of the mixer oil, (pointed out in yellow) position and anchor it according to the illustrations below. If not properly fixed, the pipe may interfere with the exhaust gas pipe. F.

  • Page 28: Gas Pedal Cable Splitter

    GAS PEDAL CABLE SPLITTER • V - NOTE - Selective transmissions (cables C): one is connected to the carburetor and • Disconnect the clamp cables (A). the other to the oil pump. F. 61 NOTE - The ignition coil (B) is positioned under the left footbord. F.

  • Page 29: Rear Mudguard

    • V2 - and relative bushs. REAR MUDGUARD • V2 - 3 ± 20% 5 ± 20% During re-assembly insert the removed parts, both outside and inside the fender. F. 62 F. 63 FRONT MUDGUARD • V2 - 3 ± 20% F.

  • Page 30: Handlebar Commands

    HANDLEBAR COMMANDS 1,6 ± 20% • V2 - • Disconnect the connectors (A). • Disconnect the accelerator transmission (T). FRONT BRAKE PUMP • V2/a - • U-bolt (B). • Screw/connection (V). • Disconnect the Fastons (C). 28 ± 20% 20 ± 20% HANDLEBAR •...

  • Page 31: Key Switch

    KEY SWITCH • Separate the front shield (p. 13). • Disconnect the connector. • V3 - (foolproof screws). 10 ± 15% F. 66 ODOMETER HORN SENSOR • Disconnect the Fastons • V1 (F. 74). (A). • Connector (C). • V - 7 ±...

  • Page 32: Front Wheel

    FRONT WHEEL Make sure the scooter is perfectly stable and insert a suitable support beneath the lower side panels. • Remove the front mudguard (p. 28). • Slide the wheel pin off (P). • Unscrew the nut (D), preventing it from falling by Do not activate the using a wrench for the brake lever while the...

  • Page 33: Front Brake

    FRONT BRAKE CHECKING LINING WEAR AND BRAKE DISC every 2,000 km (approx. 1,205 miles) • Check the wear of the linings by looking from the front part of the fork. In case of doubt regarding their “validity”, remove them and replace them. •...

  • Page 34: Fork

    FORK OIL LEVEL CHECK • Block the wheel shaft in a clamp, in vertical WHEEL SHAFT position. • Remove: • Remove: - Front mudguard (p. 28) - Cover (A) - Front wheel (p. 31) - Seeger ring (B) - Brake caliper (for left shaft) - Propeller nut (C), complete with O-Ring (D) (p.

  • Page 35: Oil Replacement (Wheel Shafts)

    OIL REPLACEMENT FORK ASSY (wheel shafts) To remove the complete fork, • With the shaft blocked in a clamp, in vertical remove: position, place a container beneath the screw (V). • Shield (p. 13). • V - • Front mudguard (p. 28). •...

  • Page 36: Rear Wheel

    REAR • D - • Carefully remove the wheel, WHEEL making sure the vehicle is NOTE - To remove the rear stable. wheel, you must remove the exhaust system (p. 37). • Position the scooter on the 100 ± 20% stand and insert a suitable support beneath the engine.

  • Page 37: Checking

    NOTE - Rear brake CHECKING transmission is secured Friction material in the lower part of the • Control the conditions of the brake shoes, verify motorcycle, by the the minimum thickness of the friction material, screw (V). which should’t be thinner then mm 2, otherwise, replace the shoes.

  • Page 38: Exhaust System

    EXHAUST SYSTEM SUSPENSION The operations described • D - • V - below should be carried out only when the exhaust system has cooled down. 40 ± 20% • V2 - (see “removing the rear mudguard”, p. 28). 24 ± 20% F.

  • Page 39: Air Filter (Maintenance) (Removing)

    • V3 - AIR FILTER • Remove: (Maintenance) - Cover (A) • The air filter can be - Filtering element (B). reached by removing the • Immerge the filtering element lower side panels (p. 17). in a solution: solvent for •...

  • Page 40: Engine

    ENGINE • Remove the rear fairing (p. 23) and the lower side panels (p. 17). • Disconnect the connector (A) of the start engine. • Disconnect the mass pipe (B) of the start engine. • Disconnect the flywheel connector (C) and the three “faston”...
  • Page 41 • V - • Disconnect the first • V2 - accelerator cable, from the • Lateral air conveyor, paying carburetor. attention to the hook • Disconnect the second element positioned in the accelerator cable (A) from lower part of the conveyor the cam (B) which operates itself.

  • Page 42: Frame Dimension Check

    • Unscrew the locking nut (D) and slide the pin out (A). 62 ± 15% Before removing the engine shaft, you must lift the scooter from its rear part. For this operation it is advisable to have another operator help you. Removing the engine from the frame is a dangerous operation, and should be carried out with maximum care and attention in order to...

  • Page 43: Cable Positioning, "Pipe System" And

    CABLE POSITIONING, “PIPE SYSTEM” AND LOCATION OF ANCHORING STRAPS F. 106 F. 107 F. 108 07/07...
  • Page 44 F. 109 07/07...
  • Page 45 F. 110 07/07...

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