Malaguti Blog 126 Service Manual Download Page 12

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03/09

125 - 160 cc

Blog

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

Summary of Contents for Blog 126

Page 1: ......

Page 2: ...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...

Page 3: ...r 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 Cs To...

Page 4: ...echanical technician MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technician IGNI...

Page 5: ...nts 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 place...

Page 6: ...shop 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 lea...

Page 7: ...123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123...

Page 8: ...ication system wet sump 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...

Page 9: ...and engine crankcase B Any alteration to the vehicle identification data is pursued by the Law When ordering spare parts also quote the vehicle identification data ANTI TAMPERING PLATE An anti tamperi...

Page 10: ...PE APPROVAL 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 indic...

Page 11: ...e 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 MALAGU...

Page 12: ...ICANT 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 CIRCU...

Page 13: ...mely inflammable avoid approaching the fuel filler also during filling with lit cigarettes or naked flames for instance matches Danger of fire COOLANT TANK To gain access to the tank containing the co...

Page 14: ...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 R...

Page 15: ...r is in the system CHANGE After the first 1 000 Km Every 12 000 Km 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...

Page 16: ...ake 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 syste...

Page 17: ...ds 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 REPLAC...

Page 18: ...3 driver and case 4 driver and passenger 5 driver passenger and case CHANGE FORK OIL Place an appropriate drip pan under the slider and remove the screws V Drain out as much oil as possible Proceed to...

Page 19: ...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 t...

Page 20: ...xhaust 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 If the engine does not start release the star ter switch...

Page 21: ...IGHT Quartz halogen lamps A High Low beam lights 55W H7 B Tail lights 5W W7y5 TURN SIGNALS FRONT C Bulbs 10W RY10W TAIL LIGHTS D Tail lights 5W R5W E Stop lights 21 25W P21 5W TURN SIGNALS REAR F 10W...

Page 22: ...y cover LIGHT BEAM ADJUSTMENTS To check adjust the beam proceed as follows Put the vehicle in running conditions at 10 metres from a wall Turn the low beams on and keep the vehicle vertical without st...

Page 23: ...placing F 30 FUSES The electrical wiring includes 9 fuses protecting the main components against faults 8 are located in the glove compartment Do not replace fuses with others that have a higher capac...

Page 24: ...y 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...

Page 25: ...y 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 insula tor provide useful info...

Page 26: ...SSEMBLY NOTE WINDSCREEN SUPPORTS V2 Supports A F 37 F 38 V2 A A F 39 D REAR VIEW MIRRORS RIGHT SIDE MIRROR Uncover and loosen the nut D Unscrew the window holder arm by turning it clockwise LEFT SIDE...

Page 27: ...W2 V2 Release the upper handlebar cover paying attention not to damage the anchoring teeth A Undo the odometer cable ring nut from the instrument panel coupling F 40 F 41 F 42 V2 W2 A UPPER HANDLEBAR...

Page 28: ...28 03 09 125 160 cc Blog Blog Blog Blog Blog V2 F 44 F 47 F 46 DASHBOARD V4 V2 a V4 V4 V2 V2a Disconnect the connector A F 45 A...

Page 29: ...nt brake union 3 Front brake stop switch 4 Rear brake stop switch 5 Rear brake pump 6 Hydraulic rear brake pump union 7 Right switch connector 8 Left switch connector LOWER HANDLEBAR COVER V2 V Releas...

Page 30: ...per cover When reassembling make sure the shield lower teeth are properly engaged into the slots ACCESS 1 Steering adjusting nut 2 Radiator cap 3 Connector electric fan 4 Connector diagnosis socket 5...

Page 31: ...og Blog Blog Blog FRONT SHIELD V2 V2 1 10 W 1 10 W A V2 F 53 F 54 F 55 W Unplug the connector B and remove the front shield completely F 56 B Remove the shield with moderation being careful to not dam...

Page 32: ...2 03 09 125 160 cc Blog Blog Blog Blog Blog F 58 shield parts 1 Turn signals 2 Tail lights 3 High Low beam lights F 57 2 1 2 1 3 2 1 ACCESS motorbike parts 1 Radiator 2 Electric fan 3 Fork stem screw...

Page 33: ...remove the bulb B TAIL LIGHTS Extract the bulb holder C and remove the bulb D HIGH LOW BEAM LIGHTS Release the bulb holder from the clips E Replace the bulb paying attention not to touch the bulb glas...

Page 34: ...og Blog V4 W2 Remove the front wheel and mud guard FRONT FAIRING Remove the front fairing with care V V1 V3 V2 ACCESS 1 Electronic control unit 2 Horn F 61 F 62 F 63 F 60 V V1 W2 V4 V4 2 1 V2 V3 V4 2...

Page 35: ...5 160 cc Blog Blog Blog Blog Blog SIDE STRUTS V4 V3 V LEGSHIELD After removing the front shield V2 b F 67 F 67 a V2 B A V2b V3 V 1 10 V4 1 10 V2 5 10 V2 Bag hook A Key swith lid B V2 a V2a F 66 F 65 V...

Page 36: ...09 125 160 cc Blog Blog Blog Blog Blog SEAT V4 V Release the leg fender with care paying attention not to damage the sides A V4 3 20 V 1 10 CENTRAL SECTION UNDER THE SEAT V3 F 68 F 69 F 70 V V4 A F 7...

Page 37: ...ACCESS Rollover sensor A When reassembling the removed components make sure that the tilt sensor is horizontal An inclination of approximately 45 would prevent the engine from starting V3 Battery cove...

Page 38: ...g Blog Blog Blog V3 Cap T V3 5 20 F 76 F 77 T V3 V2 F 75 A V4 F 74 After undoing the screws V2 open up the fairing as shown in the figure V4 V1 HELMET CASE V2 V1 P V2 Remove the seat fastening plate P...

Page 39: ...et compartment Remove the seat lock unit A Disconnect the connector B Remove the helmet compartment In case you need to release the cable C follow the instructions below F 80 V2 3 20 F 78 F 79 V2 A B...

Page 40: ...ter removing the helmet compartment A Fuel level gauge B Fuel Pump C Pump connector D Fuel tank 1 Injector connector 2 Temperature gauge coolant 3 Throttle body 4 Coolant drainage hose 5 T P S connect...

Page 41: ...cated below V4 Remove the sensor D V4 2 10 F 84 D E F FUEL PUMP Disconnect the connector G Disconnect the gas hose H pressing on the fitting with one finger R Keep a rag close by to swab up any leakin...

Page 42: ...ear fairing by coupling teeth In order to release the footbar from the rear fairing move the rear fairing backwards with care and lift it simultaneously in order to release the coupling teeth B F 87 F...

Page 43: ...43 03 09 125 160 cc Blog Blog Blog Blog Blog F 90 ACCESS 1 Ignition coil 2 Horn 3 Voltage regulator 4 Rollover sensor 5 Regulator connector System connector 6 Electronic control unit 6 2 3 4 1 5...

Page 44: ...t the connector G see 1 F 107 cut the clamp H remove the sheaths I and disconnect the inside connector ROLLOVER SENSOR Connector F Free the sensor D from its housing HORN Faston D Screw V1 IGNITION CO...

Page 45: ...45 03 09 125 160 cc Blog Blog Blog Blog Blog REAR FAIRING REAR HANDLE V By means of a screwdriver release and remove the upper cover A V3 Rear handle B F 93 F 94 F 95 V3 A B V3 43 15 F 92 V...

Page 46: ...he complete tail light In order to replace the bulbs it is not necessary to remove the complete tail light unit FULL REAR FAIRING After removing the seat the helmet compartment the rear handhold and t...

Page 47: ...125 160 cc Blog Blog Blog Blog Blog F 99 F 100 F 101 Ve Vi A B A B V5 Ve Vi FAIRING BREAKDOWN V2 Release the electric cables from the hose rings A V5 Split the two fairing halves from the coupling te...

Page 48: ...60 cc Blog Blog Blog Blog Blog SEAT LOCK UNIT V3 Lid A Lift and remove the key switch block lock clip F 102 F 103 Release the cable F 104 Remove the cable holder bracket F 105 Remove the key switch bl...

Page 49: ...ted and fastening them with new clamps that must be placed in the original points NOTE Access to the various mechanical componen ts can be deduced from the illustrations ACCESS 1 Three phase stator co...

Page 50: ...Thermal unit 15 Fuel hose fastening clamp 14 O2 sensor connector NOTE To reach the indica ted components disassemble only the helmet compartment F 109 11 13 12 F 108 9 10 F 110 14 F 111 15 11 Exhaust...

Page 51: ...the fitting with one finger D Keep a rag close by to swab up any leaking fuel Start the engine and let it run until the pipe C is completely empty Disconnect the connector B Cut the clamp I Disconnec...

Page 52: ...y opera tions on the cooling system check that the fluid is below 50 C Remove the front shield page 31 Cut the cable and tube holding ties Unscrew the radiator cap A Disconnect the connector B electri...

Page 53: ...s an abnormal rise in temperature is found manually bleed it by following these steps F 117 F 116 T Partially lift and rotate the helmet case sideways page 38 Wait until the fluid has cooled down unsc...

Page 54: ...f the thickness is below the minimum limit of 3 5 mm remove it by unscrewing the screws V5 and repla ce it V5 11 10 Extract the wheel pin P paying attention not to damage the spacers B B1 the odometer...

Page 55: ...V2 Remove the calliper Hydraulic oil is corrosive and may cause personal injury Remove the calliper taking care that fluid line does not get damaged and the disc and pads do not get dirty At the end o...

Page 56: ...sconnect the throttle transmission A Disconnect the faston F F 125 V2 a Brackets B Remove the brake pump and place it in a vertical position on a dry cloth Brake fluid is corrosive F F KEY SWITCH Disc...

Page 57: ...de off the grips D 50 20 FORK NOTE When removing the fork leg as well as the full fork the following should be removed beforehand Front wheel page 54 Front mudguard page 55 Front brake calliper page 5...

Page 58: ...eat of the caps C Check the usage conditions and if necessary replace them Grease and remount the fork unit Top bearings 3 16 n 22 Lower bearings 1 4 n 19 C C B A S S F 132 MUFFLER Before operating on...

Page 59: ...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...

Page 60: ...5 160 cc Blog Blog Blog Blog Blog F 136 Vs 45 15 Vi 24 15 Support the scooter on the central part of the chassis Lower screws Vi SHOCK ABSORBERS Nuts D Top screws Vs Remove the shock absorbers F 137 V...

Page 61: ...ring the fluid in a special container for disposal in accordance with specific waste disposal laws Unscrew the screws V2 and remove the caliper taking care not to damage the rim previously removed fro...

Page 62: ...screw the wheel nut D Unscrew the fixing screws V2 of the slider arm B Extract the external spacer A Remove the slider arm B Slide off the wheel pin the internal spacer C Check the wear conditions of...

Page 63: ...se of scoring or thick ness below the minimum limit of 3 5 mm remove it by unscrewing the screws V4 and replace it V4 11 10 REAR WHEEL Before remounting the rear wheel grease the shaft in points A B A...

Page 64: ...sleeve Remove the clamps B Disconnect the vapour recovery tube C Cut the ties E Disconnect the connector F Inlet air temperature sensor Loosen the clamps G F 147 F 148 C E F A G E The ties that have b...

Page 65: ...A unscrew the screws V2A Unscrew the fixing screws V1 of the filter box rear mudguard Unscrew the fixing screws V of the flexible air intake tube Unscrew the screws V2 V V1 V2 5 10 F 150 V2a A F 149...

Page 66: ...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 dam...

Page 67: ...e is a task that should be performed with care and the utmost attention Raise the rear part of the motorcycle before sliding off the engine pin A It is advisable to have a second operator available to...

Page 68: ...deformation even slight of the frame following an acci dent 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...

Page 69: ...log Blog Blog Blog POSITION OF INJECTION SYSTEM PARTS F 159 Battery H T coil Tilt sensor Inlet air temperature sensor Side stand switch Starter motor ground cable O2 sensor Lambda sensor Idle control...

Page 70: ...cc Blog Blog Blog Blog Blog F 160 Wiring ground cables Injection system relay red Fuel pump ECU engine control unit Injection warnig light orange Diagnosis plug RPM connector Pick up Regulator Water t...

Page 71: ...71 03 09 125 160 cc Blog Blog Blog Blog Blog F 161 Fuel injector Stator three phase connector regulator TPS sensor Regulator connector system Radiator fan Fan relay yellow...

Page 72: ...72 03 09 125 160 cc Blog Blog Blog Blog Blog CABLE POSITIONING PIPE SYSTEM AND ANCHORING TIES F 162...

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