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

Phantom f 12 max series
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CHASSIS
PHANTOM F 12 MAX
WORKSHOP MANUAL

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  • Page 1 CHASSIS PHANTOM F 12 MAX WORKSHOP MANUAL...

  • Page 3: Table Of Contents

    - CHASSIS CHASSIS INTRODUCTION CHAPTER TABLE OF CONTENTS DISASSEMBLY INTRODUCTION Battery Notes for easy consultation Helmet compartment Abbreviations Handle cover General work procedures Rear handle Editing symbols Seat lock GETTING TO KNOW YOUR VEHICLE Tail lamps Specifications Rear indicators Unpacking Number plate light Appearance check Nameplate holder...

  • Page 4: Introduction

    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.

  • Page 5: Notes For Easy Consultation 1

    - CHASSIS CHASSIS INTRODUCTION CHAPTER PAGE LAYOUT Chapter Section title Page N° Date of issue (RH PAGE) 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.

  • Page 6: Abbreviations

    - CHASSIS CHASSIS INTRODUCTION CHAPTER 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).
  • Page 7 - CHASSIS CHASSIS INTRODUCTION CHAPTER 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 se- quence in which they are to be used.
  • Page 8 - CHASSIS CHASSIS INTRODUCTION CHAPTER 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.

  • Page 9: Editing Symbols

    - CHASSIS CHASSIS INTRODUCTION CHAPTER EDITING SYMBOLS CAUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity. 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. FIRE HAZARD Indicates operations which may constitute a fire hazard.

  • Page 10: Getting To Know Your Vehicle

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER SPECIFICATIONS 125 cc Mode: 200 cc Dimensions: 1980 mm Max. length 760 mm Max. width Max. height 1210 mm 1280 mm Wheel base 1400 mm 1410 mm Weight: kerb weight 139 kg 143 kg 170 kg maximum load...
  • Page 11 - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 125 cc 200 cc Transmission: Type automatic speed variator, by V-belt, one speed Primary reduction system gear type Clutch dry, centrifugal and automatic Tires: tubeless Type Front 130/70-13 57P 130/70-13 57S Rear 130/60-18 63P 140/60-13 63S...

  • Page 12: Unpacking

    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) MARCHIO DI FABBRICA: MALAGUTI S.P.A. 1 - --------------------- CATEGORIA DEL VEICOLO: (*) 2 - ---------------------...

  • Page 13: Main Components

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER MAIN COMPONENTS (Left hand side) Digital instrument board Switch with key Front ticket holder Front disc brake calipers Carburettor Rear turn indicators Tail light Nameplate holder Air filter Seat lock Left hand rear view mirror Passenger’s handle Adjustable shock absorbers F.5i...

  • Page 14: Controls 2

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 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 F.7i Left hand controls...

  • Page 15: Stands 2

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 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.
  • Page 16 - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER TIRE PRESSURE CHECK Tire pressure must be checked when the tires are cold. (psi) (33,4) (33,4) (33,4) (33,4) F.12i FUEL TANK Open the hatch (A - F. 13i) with the starter key, unscrew the cap (B - F.

  • Page 17: Coolant 2

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 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.
  • Page 18 - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 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 oper- ating temperature; turn off the engine and wait 5-10 min- utes to enable the oil to flow into the sump.

  • Page 19: Transmission Oil 2

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 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.

  • Page 20: Brake Fluid 2

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 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 per- fectly upright.

  • Page 21: Shock Absorber Adjustment 2

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 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.

  • Page 22: Checking The Shape Of The Chassis 2

    - CHASSIS CHASSIS GETTING TO KNOW YOUR VEHICLE CHAPTER 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 ±...

  • Page 23: Disassembly 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE FRONT HANDLEBAR COVER Undo the centre screw (V1 - F.1) which is ac- cessed by removing the cover (A - F.1b). F. 1 F. 1/b Undo the side screws (V4 - F.2). F. 2 Pull the handlebar cover up (A - F.

  • Page 24: Instrument Board 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 in- strument board from the front handlebar cover.

  • Page 25: Handlebar Upper Fairing 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE HANDLEBAR UPPER FAIRING • (Remove front handlebar cover) Undo the screws (V5 - F.6). F. 6 REMOVING THE LEFT CONTROL • (Remove front handlebar cover) Undo the screw (V - F.7) and remove the counter- weight.

  • Page 26: Right Control 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE RIGHT CONTROL 125 cc 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 counter- weight.

  • Page 27: Front Wing 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 symmetri- cal.
  • Page 28 - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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...

  • Page 29: Front Wheel 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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.
  • Page 30 - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE FRONT UPPER FAIRING • (Remove front wheel and front wing) Remove the centre foot rest fitted to the lower fair- ing (paying attention not to damage the tabs). Caution!!! This operation is symmetri- cal.

  • Page 31: Headlights 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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.

  • Page 32: Front Indicators 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER To access the parking light bulbs, remove the lamp sockets (A - F.23). F.23 To remove the entire headlight assembly, undo the screws (V2 - F.24) and unscrew the light adjust- ment knob (A - F.24). Caution!!! When refitting the adjust- ment knob, install all parts in the right sequence.

  • Page 33: Headlight Guard 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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.
  • Page 34 - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 ca- bles. Caution!!! Refit components in the right sequence.

  • Page 35: Passenger's Seat 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER Unscrew the nuts (D2 - F.31), remove the seat and position it with the stuffing facing upwards. F.31 REMOVING THE PASSENGER’S SEAT Undo the screws (V2 - F.32) and remove the pas- senger’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...

  • Page 36: Battery 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER Release the cable from the lock by unhooking the spring (A - F.34). F.34 REMOVING THE BATTERY (Remove passenger’s seat) • Detach the cables (A-B - F.35) from their termi- nals. Carefully lift the battery and before actually pulling it out of its compartment, release it from the ex- haust pipe (C - F.35).
  • Page 37 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Undo the screws (V2 - F.37). Raise the helmet holder and pull out battery ca- bles (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.

  • Page 38: Handle Cover 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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. F.39 REMOVING THE REAR HANDLE (Remove seat, passenger’s seat, helmet hold- •...

  • Page 39: Tail Lamps 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 con- nector (B - F.42). F.42 Undo the screws (V3 - F.43) and release the snap locks.

  • Page 40: Number Plate Light 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 re- fitting removed parts. F.45 REMOVING THE NUMBER PLATE HOLDER Remove the number plate by undoing the four...

  • Page 41: Rear Cowling 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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) F.48 REMOVING THE REAR COWLING •...

  • Page 42: Rear Reflector

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE REAR REFLECTOR Undo the screws (V2 - F.51) and remove the re- flector by pulling it outwards. F.51 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.

  • Page 43: Starter Relays

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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) •...

  • Page 44: Regulator

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE FLASHLIGHT 125 cc 125 cc VERSION ONLY (Remove side casings and rear cowling) • Disconnect the connector (A - F.56) and release the flashlight from the chassis. F.56 REMOVING THE REGULATOR 125 cc 125 cc VERSION (Remove side casings and rear cowling) •...

  • Page 45: Control Unit

    F.57 - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE CONTROL UNIT 125 cc 125 cc VERSION (Remove side casings and rear cowling) • Remove the clamps and detach the connector (A - F.59). F.59 Take the control unit out of its rubber protection (G 125 cc - F.60).

  • Page 46: Fuel Probe

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER Undo the screws (V2 - F.62). 200 cc Caution!!! The flashlight is built into the control unit. F.62 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.

  • Page 47: Strut

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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). F.65 F.65/b Undo the screw (V - F.66). F.66 Undo the screw (V - F.67).

  • Page 48: Footboard

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE FOOTBOARD 125 cc 125 cc VERSION (Remove side casings, rear cowling and strut) • Undo the screws (V3 - F.68) on both sides. F.68 Undo the screws (V2 - F.69) to release the foot- 125 cc board from the secondary air valve.

  • Page 49: Lower Fairing

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE FOOTBOARD 200 cc 200 cc VERSION (Remove side casings, rear cowling and strut) • Undo the screws (V3 - F.71) on both sides. F.71 Open the tank’s hatch (A - F.72), unscrew the cap 200 cc (T - F.72) and remove the gasket (B - F.72).
  • Page 50 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Undo the screw (V - F.74) under the footrest. Caution!!! This operation is sym- metrcal. F.74 Undo the screws (V2 - F.75) of the luggage hook. F.75 Remove the cover (A - F.76) of the switch with key by turning it 1/4 of a turn clockwise.
  • Page 51 - CHASSIS CHASSIS DISASSEMBLY CHAPTER COMPONENTS THAT ARE ACCESSED BY REMOVING THE STRUT, FOOTBOARD AND THE LOWER FAIR- By removing the strut, footboard and lower fairing, you can gain access to the following components: • 15 A recharge fuse (A) •...

  • Page 52: Fuel Filter

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 nar- row bends of the pipes.

  • Page 53: Radiator

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE RADIATOR 125 cc 125 cc VERSION (Remove upper fairing) • CAUTION!!! Empty the radiator by putting a suita- ble container under it. Now open the pipe clamp (A - F.81) and detach the pipe from its coupling.
  • Page 54 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Remove the two pipes, by unscrewing the clamps 125 cc (A/B - F.84). F.84 Disengage and remove the radiator support plate 125 cc by loosening the screws (V2 - F.85). Remove the radiator by pulling it downwards. F.85 09.03 PAGE...
  • Page 55 - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE RADIATOR 200 cc 200 cc VERSION (Remove upper fairing) • CAUTION!!! Empty the radiator by putting a suita- ble container under it. Now open the pipe clamp (A - F.86) and detach the pipe from its coupling.

  • Page 56: Radiator Fan

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER Remove the two pipes, by unscrewing the clamps 200cc (A/B - F.89). F.89 Disengage and remove the radiator support plate 200cc by loosening the screws (V2 - F.90). Remove the radiator by pulling it downwards. F.90 RADIATOR FAN (Remove radiator)

  • Page 57: Rear Shock Absorbers

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE FRONT SHOCK ABSORBERS 125 cc 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 to- wards the rear side.

  • Page 58: Air Filter Box 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE AIR FILTER BOX 125 cc 125 cc VERSION (Remove helmet holder) • Open the clamp (A - F.95) and disconnect the steam recycling pipe (B - F.95). F.95 Unscrew the clamp (A - F.96) and disconnect the 125 cc suction pipe.
  • Page 59 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Undo the screw (V - F.98) and remove the filter box 125 cc assembly, complete with its coupling. F.98 REMOVING THE AIR FILTER BOX 200 cc 200 cc VERSION (Remove helmet holder) • Open the clamp (A - F.99) and disconnect the steam recycling pipe (B - F.99).

  • Page 60: Muffler

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER Undo the screws (V2 - F.101) and remove the filter 200 cc box. F.101 REMOVING THE MUFFLER 125 cc 125 cc VERSION CAUTION!!! Before removing, make sure the muf- fler has cooled down. Undo the screws (V2 - F.102) securing the exhaust manifold in place.
  • Page 61 - CHASSIS CHASSIS DISASSEMBLY CHAPTER The parts composing the exhaust assembly must 125 cc be disassembled as illustrated in F.104. Caution!!! When refitting the muffler, remember to replace part G. F.104 REMOVING THE MUFFLER 200 cc 200 cc VERSION CAUTION!!! Before removing, make sure the muf- fler has cooled down.

  • Page 62: Rear Wing

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER The parts composing the exhaust assembly must 200 cc be disassembled as illustrated in F.107. Caution!!! When refitting the muffler, remember to replace part G. F.107 REMOVING THE REAR WING 125 cc 125 cc VERSION (Remove muffler compartment) •...

  • Page 63: Transmission Cooling Sleeve

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE TRANSMISSION COOLING 125 cc SLEEVE 125 cc VERSION (Remove strut) • Undo the screws (V3 - F.110). Cut the clamp (A - F.110) and pull out the sleeve. F.110 REMOVING THE TRANSMISSION COOLING 200 cc SLEEVE 200 cc VERSION...
  • Page 64 - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE REAR CALIPERS 200 cc 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.

  • Page 65: Rear Wheel 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE REAR WHEEL 125 cc VERSION (Remove muffler, rear wing and rear calipers) • CAUTION!!! Before disassembly, hold the centre 125 cc 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.

  • Page 66: Rear Disc

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 lock- F.117 ENGINE REMOVAL 125 cc 125 cc VERSION (Remove seat, passenger’s seat, helmet hold- •...
  • Page 67 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Remove the pipe for delivery to the radiator (A - 125 cc F.120), by unscrewing the clamp (B - F.120). F.120 Remove the return pipe of the radiator (A - F.121) 125 cc by unscrewing the clamp (B - F.121). F.121 Detach the flywheel connectors (A - F.122) and 125 cc...
  • Page 68 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Detach the fast-on (A - F.123) and the pipe of the 125 cc fuel pump (B - F.123). F.123 Disengage the carburettor from the engine by un- 125 cc doing the screws (V2 - F.124) and secure the car- burettor to the chassis.
  • Page 69 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Unscrew the nut (A - F.126). 125 cc F.126 Remove the pin (B - F.127). 125 cc Pull the engine out from the rear side. F.127 ENGINE REMOVAL 200 cc 200 cc VERSION (Remove seat, passenger’s seat, helmet hold- •...
  • Page 70 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Remove the connector (A - F.129) from the flywheel 200 cc cover. F.129 Disengage the rear shock absorber by unscrewing 200 cc 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.
  • Page 71 - CHASSIS CHASSIS DISASSEMBLY CHAPTER Remove the pipe (A - F.132) . 200 cc Disengage the carburettor from the engine by un- doing the screws (V3 - F.132) and secure the car- burettor to the chassis. F.132 Remove the radiator return pipe (A - F.133), by 200 cc unscrewing the clamp (B - F.133).

  • Page 72: Centre Stand 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER Remove the pin (B - F.135) and pull the engine out 200 cc from the rear side of the vehicle. F.135 REMOVING THE CENTRE STAND 125 cc 125 cc VERSION CAUTION!!! Before disassembly, hold the vehicle in place to prevent it falling over.

  • Page 73: Side Stand

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE CENTRE STAND 200 cc 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.

  • Page 74: Engine Fixing Plate

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER Disconnect the cables (A - F.141) and cut the ca- ble clamps. F.141 REMOVING THE ENGINE FIXING PLATE 125 cc 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...

  • Page 75: Switch With Key 3

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER REMOVING THE ENGINE FIXING PLATE 200 cc 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).

  • Page 76: Handlebar

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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. F.147 REMOVING THE FORK (Remove handlebar, upper fairing, front wheel, •...

  • Page 77: Assembly

    - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 stan- chion 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.
  • Page 78 - CHASSIS CHASSIS DISASSEMBLY CHAPTER 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 possi- ble flow out. Disassemble the stanchions-wheel holders and tip them over to drain out any residual oil.

  • Page 79: Chassis Torque Wrench Settings

    - CHASSIS CHASSIS ASSEMBLY CHAPTER CHASSIS TORQUE WRENCH SETTINGS 125 cc 200 cc TORQUE WRENCH SETTINGS Kg*m Kg*m Front wheel pin Front brake calipers Handlebar clamp Steering lock 14.0 14.0 Muffler-arm coupling Rear arm Engine pin Engine fixing pin Rear brake calipers Rear wheel 10.0 10.0...
  • Page 80 - CHASSIS CHASSIS ASSEMBLY CHAPTER 05.03 PAGE ISSUE SECTION 4...

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