Malaguti 500 cc 4T, Service Manual, Page: 3 / 78

2 10/07
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 engine 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.
• Mark the components that may be mis-placed during re-assembly operations.
• Only use quality tools and equipment.
• During operations, always keep tools and equipment at hand, possibly laying them out according to the sequence in which they are to be used.
• 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”.
• 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.
Never use open flames for any reason.
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 reuse old gaskets or circlips.
• Never use a screwdriver as a lever or chisel.
• Never use pincers to loosen or tighten screws or nuts.
• 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.