Malaguti Centro 125 Service Manual
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Malaguti Centro 125 Service Manual

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  • Page 2 125 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.
  • Page 3 125 i.e. - 160 i.e. 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;...
  • Page 4 125 i.e. - 160 i.e. 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.
  • Page 5 125 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. •...
  • Page 6 125 i.e. - 160 i.e. • 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. •...

  • Page 7: Table Of Contents

    125 i.e. - 160 i.e. 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 1 2 3 4 TECHNICAL DATA ACCESS- SEAT- HELMET CASE 1 2 3 4 1 2 3 4 IDENTIFICATION INFORMATION: FRAME N°/ ENGINE N°...
  • Page 8 Fuel tank (total) l ................. 8,2* (3,0*) Rear: Swinging engine with double hydraulic shock absorber. Stroke: 74 mm. ENGINE: 2 valve - 4 stroke single cylinder: BATTERY Type ....................MALAGUTI 01 Type 12V, 9Ah, maintenance free. MALAGUTI 02 n° Cylinders ...................... 1 TYRES Bore x stroke mm ................

  • Page 9: Identification Information: Frame N°/ Engine N° - Tires 8 1 2 3

    125 i.e. - 160 i.e. 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 10 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. 11/07...
  • Page 11 125 i.e. - 160 i.e. 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...
  • Page 12 125 i.e. - 160 i.e. FUEL TANK • The fuel tank cap (A) is accessible by raising the seat, using the ignition key and turning it clockwise. Use unleaded fuel. F. 5 COOLANT TANK • Open the case with the ignition key. •...
  • Page 13 125 i.e. - 160 i.e. 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.

  • Page 14: Transmission Oil

    125 i.e. - 160 i.e. TRANSMISSION OIL • After the first 1,000 Km CHECK LEVEL/ TOP UP CHANGE • Every 12,000 Km • Cold engine • Cold engine • Vehicle on level ground. • Vehicle on level ground • Place a drip pan under the engine. •...
  • Page 15 125 i.e. - 160 i.e. BLEED BRAKE SYSTEM FRONT CALIPER 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.

  • Page 16: Check Front/Back Brake Pads And Disks

    125 i.e. - 160 i.e. 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.

  • Page 17: Fork 16 1 2 3

    125 i.e. - 160 i.e. FORK CHANGE FORK OIL • Place an appropriate drip pan under the slider and remove the screws CHECK OIL LEVEL IN THE (V). FORK LEG • Drain out as much oil as possible. • Proceed to dismantle the fork legs, as previously described. •...

  • Page 18: Location Of The Main Electrical And Electronic Elements 17 1 2 3

    125 i.e. - 160 i.e. LOCATION OF THE MAIN ELECTRICAL AND ELECTRONIC ELEMENTS F. 24 11/07...
  • Page 19 125 i.e. - 160 i.e. F. 25 11/07...

  • Page 20: Dashboard

    125 i.e. - 160 i.e. ELECTRIC/SERVICE MALFUNCTION WARNING DASHBOARD LIGHT Speedometer When the starter key is turned in the switch in the Odometer position, without starting the engine, the warning light (as well as the warning light Turn signal warning light (green) will remain on for a few seconds to verify the High beams warning light (blue) functioning, and it will normally shut off after this.

  • Page 21: Left Control - Right Control

    125 i.e. - 160 i.e. KEY SWITCH HANDLEBAR CONTROLS Ignition inhibited (extractable key) LEFT CONTROLS RIGHT CONTROLS Horn button A) light switch: Preset starting position (non extractable key) right= off Turn signals switch. center= tail and dashboard lights Turn signals shutoff switch left= high/low beams Steering lock insert (Ignition inhibited: extractable key).

  • Page 22: Lights

    125 i.e. - 160 i.e. LIGHTS HEADLIGHT 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.
  • Page 23 125 i.e. - 160 i.e. LIGHT BULB REPLACEMENT TAIL LIGHTS • Remove the number plate light (see the next • Tail light (B) paragraph). Light bulb 12V - 5W (W5W). • Remove the taillight cover by unscrewing the two • brake light (S) screws (V).
  • Page 24 125 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. FUSE REPLACEMENT Open the case and take out the fuse and replace it with one having equal capacity.
  • Page 25 125 i.e. - 160 i.e. BATTERY (12V-9AH) NEVER invert the cable connections. Do not use the battery without the battery inserted and connected to wires of the main The battery housing is located in the central tunnel. harness. This could cause breakdowns and BATTERY ASSEMBLY (PRE-DELIVERY OPERATION) short circuits in the electrical system and •...

  • Page 26: Spark Plug 25 1 2 3

    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;...
  • Page 27 125 i.e. - 160 i.e. PROCEDURES FOR DISMANTLING AND • Unscrew the window holder stud bolt (B). REMOVING COMPONENTS REASSEMBLY NOTE REAR VIEW MIRRORS F. 45 • Uncover and loosen the nut (D). " Unscrew the window holder arm, by turning it anti-clockwise.

  • Page 28: Front Handlebar Covers 27 1 2 3

    125 i.e. - 160 i.e. FRONT HANDLEBAR COVER • V4. • V. 1 ± 10% 1 ± 10% F. 49 F. 50 • To clear the front handlebar • Free and partially extract cover, push the area the handlebar unit, indicated in the figure (on carefully, as to not damage both sides), paying...

  • Page 29: Access 28 1 2 3

    125 i.e. - 160 i.e. • Disconnect the • Extract the taillights lamp holder (A) lamp holder (B). • Remove the front handlebar cover. F. 53 F. 54 ACCESS (AFTER REMOVING THE FRONT HANDLEBAR COVER) 1) Clock connector 2) Clock (fastened with screws - V2) 3) Front brake "stop"...

  • Page 30: Front Shield

    125 i.e. - 160 i.e. FRONT SHIELD • V2. • W. 1 ± 10% 1 ± 10% F. 56 F. 57 • Unscrew the screws (V5) to separate the grille 1 ± 10% from the shield. • Remove the shield with moderation, being careful to not damage the hooking elements.
  • Page 31 125 i.e. - 160 i.e. ACCESS SEAT (AFTER REMOVING THE SHIELD) • D2. A) Electric fan B) Radiator 3 ± 20% C) Radiator cap D) Diagnosis socket E) Electric fan connector F) Antitheft preset connector G) Key switch connector F. 61 F.

  • Page 32: Seat Locking Device

    125 i.e. - 160 i.e. • Partially lift the helmet • V5. 5 ± 20% compartment, as it is constrained by the seat locking device cable (A). F. 64 F. 65 SEAT BLOCKING DEVICE • Remove the locking/opening • V2. unit, complete with the transmission cable.

  • Page 33: Access

    125 i.e. - 160 i.e. ACCESS (after removing the helmet compartment) • Fuel tank • Fuel level gauge (A) • Fuel level gauge connector (B) • Fuel Pump ( C) • Pump connector (D). F. 68 1) Temperature gauge (coolant) 2) Inlet air temperature sensor connector 3) T.P.S.
  • Page 34 125 i.e. - 160 i.e. FUEL LEVEL SENSOR • 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...

  • Page 35: Fuel Tank

    125 i.e. - 160 i.e. FUEL TANK Do not smoke or use open flames, while operating on the fuel tank. • During the operation, screw the tank cap, on the union (E), to avoid that any foreign matter falls inside. •...

  • Page 36: Access

    125 i.e. - 160 i.e. BATTERY ACCESS COVER • Battery (B). COMPARTMENT • Spark plugs pipette (C). • V3. NOTE - For information • Door (A). concerning the battery, consult page 24. F. 73 F. 74 SIDE STRUTS • W. •...
  • Page 37 125 i.e. - 160 i.e. • Open the strut with When remounting, insert moderation, starting from the strut in the front drive the rear part and take it off (A). by pushing on the front part, being careful to not damage the hooking points (C-F.

  • Page 38: Rear Fairing

    125 i.e. - 160 i.e. REAR FAIRING (including the foot rest panel) • V3. • Unscrew the screw (V), holding the self locking nut (D). 5 ± 10% F. 81 F. 82 • Unscrew the screws (V), remove Clean and grease the the pillion staff and recuperate the fulcrum pin (P).

  • Page 39: Rear Handle

    125 i.e. - 160 i.e. REAR HANDLE • Cap (A). • V. F. 85 F. 86 • V2. • Remove the rear handle including the opening/ • Bushing (B). locking seat device. 43 ± 15% F. 87 F. 88 11/07...
  • Page 40 125 i.e. - 160 i.e. NUMBER PLATE LIGHT REAR LIGHT UNIT SUPPORT • V2. • V. • Rear light frame assembly (B). • Number plate light • Rear light glass assembly support (A). (C). F. 90 F. 89 • Carefully take out the rear •...

  • Page 41: Full Rear Fairing

    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. F. 93 5 ± 10% F. 94 • Take the fairing out of the frame, as illustrated in figure F.

  • Page 42: Access (Right Side)

    125 i.e. - 160 i.e. ACCESS The reassembly stage of any interventions on the wiring involves repositioning these as (RIGHT SIDE) illustrated, and fastening them with new clamps that must be placed in the original 1) Three-phase stator connectors points. connettore regolatore 2) F lasher relay 3) Electric fan relay...

  • Page 43: (Left Side)

    125 i.e. - 160 i.e. (LEFT SIDE) 1) Ignition coil 2) Valve (manage minimum) "IDLE" 3) Electronic control unit 4) Voltage regulator 5) Rollover sensor 6) Horn 7) Fuel hose fastening clamp F. 97 11/07...
  • Page 44 125 i.e. - 160 i.e. ELECTRONIC CONTROL UNIT • 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.

  • Page 45: Rear Fairing Breakdown

    125 i.e. - 160 i.e. REAR FAIRING BREAKDOWN FROM THE NUMBER REAR FAIRING BREAKDOWN FROM THE FOOT REST PANEL PLATE HOLDER GUARD. • V3. • V3. F. 99 F. 100 11/07...

  • Page 46: Legshield

    125 i.e. - 160 i.e. LEGSHIELD • V2. • Extract the cover (B) of the • Bag holder hook (A). key switch. • V4 5 ± 10% • Unscrew the fixing screws (V") of the fuse holder. F. 101 • V. •...

  • Page 47: Access

    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 D) Expansion reservoir turn signals. They are accessible through the side grille of E) Handlebar fixing nuts the leg shield F) Steering wheel play...
  • Page 48 125 i.e. - 160 i.e. KEY SWITCH HORN • Disconnect the "faston" (A). • Disconnect the connector from the wiring. • V - • Unscrew the tamperproof screws (V). 10 ± 15% 7 ± 10% F. 107 F. 108 FRONT WHEEL •...

  • Page 49: Sequence Of Front Wheel Reassembly

    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) 53 ± 10% FRONT BRAKE CALIPER • Place an appropriate drain pan under the brake calliper. •...
  • Page 50 125 i.e. - 160 i.e. FRONT MUDGUARD • V • V1 • Clamp (A) • Clamp (C) • V3 3 ± 10% F. 113 F. 114 • V2 • Spacer (B) FRONT SHIELD • Remove the mudguard (P). Do not forget to remount •...
  • Page 51 125 i.e. - 160 i.e. BACK HANDLEBAR COVER • Unscrew the screws (V4), to free the handlebar commands. 2 ± 15% • Central screw (V) • Disconnect the dashboard connector (A). • Unscrew the ring nut (B) of the odometer cable. •...
  • Page 52 125 i.e. - 160 i.e. HANDLEBAR • 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) •...
  • Page 53 125 i.e. - 160 i.e. • Disconnect the electric • Unscrew the radiator and electric vent • Remove the housing and electric fan. fan connector (A). housing fixing screws (V4) • Unscrew the screws (V3). • Separate the electric fan unit from its housing.

  • Page 54: Expansion Tank

    125 i.e. - 160 i.e. • V2. EXPANSION TANK 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; F.
  • Page 55 125 i.e. - 160 i.e. FORK FORK LEG NOTE - When removing the fork leg, as well • Loosen (V) as the full fork, the following should be removed beforehand: • Raise the fork leg a few - Front wheel (page 47) millimetres (A).
  • Page 56 125 i.e. - 160 i.e. • Loosen the clamp fixing MUFFLER screws (V) of the muffler/ Before operating on exhaust pipe. the muffler and the • Remove the muffler. exhaust pipe, ensure that the components are cool. • V3. 24 ± 10% F.
  • Page 57 125 i.e. - 160 i.e. EXHAUST REMOUNTING THE MANIFOLD EXHAUST SYSTEM 45 ± 10% • D2. • Screw the O2 sensor (D) on the • Remove the exhaust exhaust connector (1). 30 ± 10% manifold and related • Position the collector (1) in gaskets.

  • Page 58: Rear Mudguard

    125 i.e. - 160 i.e. REAR MUDGUARD Right side Left side • V2. • V. 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. 3,5 ±...
  • Page 59 125 i.e. - 160 i.e. 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). •...

  • Page 60: Air Filter

    125 i.e. - 160 i.e. • Unscrew the fixing screws (V1) of the filter box- • Remove the whole rear mudguard. air intake system. • Unscrew the fixing screws (V) of the flexible air • To remove the intake tube. intake air sensor •...

  • Page 61: Air Filter Maintenance - Starter

    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. •...
  • Page 62 125 i.e. - 160 i.e. REAR BRAKE CALIPER • 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.
  • Page 63 125 i.e. - 160 i.e. REAR WHEEL • Remove beforehand: - Muffler (page 55) - Rear mudguard (page 57) - Rear brake calliper (page 61) • Position the motorcycle on the stand and place a suitable support under the engine. •...

  • Page 64: Rear Brake Caliper

    125 i.e. - 160 i.e. REAR BRAKE REAR CALIPER WHEEL • When removing the back • Before remounting the rear wheel, check the state of wheel, grease the shaft in use of the brake disc. In case points A-B. of scoring or thickness below the minimum limit of 3.5 mm, remove it by unscrewing the screws (V4) and replace it.

  • Page 65: Frame Size Check

    125 i.e. - 160 i.e. • Unscrew the nut (D) and slide off the pin (A). 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.
  • Page 66 125 i.e. - 160 i.e. CABLE POSITIONING, "PIPE SYSTEM" AND ANCHORING TIES. F. 164 F. 165 11/07...
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