Malaguti CNK 50 DRAKON Workshop Manual Download

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FRAME AND RUNNING GEAR

DRAKON 50 NKD

03/06

SPECIFICATIONS

05189057

LUBRICANT TABLE

LUBRICANTS

TYPE OF LUBRICANT

ENGINE OIL

Q8 CLASS 10W 40

MIX OIL

Q8 CITY BIKE ULTRA

Q8 DAILY SUPER

LUBRICANT FOR CHAINS

Q8 CHAIN LUBE

OIL FOR AIR FILTERS

Q8 AIR FILTER OIL

RADIATOR FLUID

Q8 TOP FLUID

BRAKE FLUID

Q8 BRAKE FLUID DOT 4

DIMENSIONAL CHECK OF FRAME

If the scooter has been involved in an accident and you suspect even slight distortion of the frame it is essential to
perform the dimensional checking procedure before any further “repair or set-up” work.

Control dimension (A) must be 1001 mm with a tolerance of ± 2 mm.

Control dimension (B) must be 432,5 mm with a tolerance of ± 2 mm.

Do not attempt to bend the frame to restore the original “A” measurement.

Summary of Contents for CNK 50 DRAKON

Page 1: ...FRAME AND RUNNING GEAR WORKSHOP MANUAL CNK 50 DRAKON ...

Page 2: ......

Page 3: ...s or kilometres selection 16 Starting 17 Choosing functions 17 Speed 17 MAIN MENU FUNCTIONS 17 SUB MENU FUNCTIONS 19 HANDLEBAR CONTROLS 20 CLUTCH LEVER 20 FRONT BRAKE LEVER 20 2 STROKE ENGINE OIL 21 REAR CARRIER 21 ADJUSTING THE DRIVING POSITION 21 5 PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE AND LUBRICATION 22 SPARK PLUG 24 Removing the spark plug 24 Inspection 24 Installing the s...

Page 4: ...EAR SHOCK ABSORBER 53 REAR WHEEL 53 SPROCKET 54 REAR DISC 54 REAR BRAKE CALIPER 55 Check the disc and pads of the rear brake for wear 55 FOOTREST ASSEMBLY REAR BRAKE 56 FOOTREST ASSEMBLY GEAR CHANGE PEDAL 56 FILTER BOX 57 SWING ARM 58 REAR FRAME 59 SPEEDOMETER SENSOR 60 FRONT BRAKE CALIPER 61 Checking front brake wear 61 FRONT WHEEL 62 FRONT BRAKE DISC 62 FRONT DAMPER 63 Left 63 Right 63 Checking ...

Page 5: ...o make any changes and modifications hereto it deems necessary without prior notice MANUAL UPDATES The updates will be sent by us in a reasonable time Every CD Rom you receive will supersede the one already in your possession The table of contents will be duly updated in the event that new pages are inserted which render the consultation of the manual difficult IMPORTANT The Workshop Manuals are t...

Page 6: ...r safety recommendations They are therefore to be considered as memory tags In case of any doubt as to their meaning consult the page in which they are fully described ABBREVIATIONS UNITS OF MEASUREMENT All the dimensions in this Manual are shown in mm NOTE The letter V in the illustrations refers to fixing or adjusting screws The number following this letter refers to the number of the same type ...

Page 7: ...to proceed as shown in the figure Except in the case of occasional services prepare a work sheet for the customer on which to take a note of all the work performed and write memos relating to any future checks that may be required RECOMMENDATIONS Before carrying out any work on the vehicle wait for all the parts to cool down completely For operations requiring two mechanics make sure that the vari...

Page 8: ...an the vehicle components Never suck from or blow into the fuel pipe When welding make sure that there are no flammable liquids in the vicinity Always remove the fuel tank even if completely empty and disconnect the negative cable from the battery Never leave the engine running in closed or poorly ventilated areas Before any servicing make sure that the vehicle is perfectly stable The front wheel ...

Page 9: ...sconnect the battery negative cable RISK OF FIRE Indicates operations that may constitute a fire hazard EXPLOSION HAZARD Indicates operations that may constitute a risk of explosion TOXIC FUMES Indicates the risk of intoxication or inflammation of the respiratory tract NO Operations to be absolutely avoided SYMMETRICAL OPERATIONS Operations to repeat on both sides of the unit or component in quest...

Page 10: ...ke liquid cooled Cylinder arrangement Forward inclinedsingle cylinder Displacement 49 cm3 Bore x stroke 40 3 x 39 mm Compression ratio 12 1 0 5 Starting system Electric Lubrication system Separate TYPE OF OIL Engined oil Oil for 2 stroke engines JASO FC or ISO LEGD Tank capacity 10 l Reserve 0 3 l Transmission oil SAE 10W40 Engine capacity 0 82 l FUEL Type Regular unleaded petrol 95 RON Tank capac...

Page 11: ...Type Tubeless Front 100 80 17 52S Rear 130 70 17 62S BRAKES Disk brake with hydraulic transmission Front Right hand operation Rear Right foot pedal control SUSPENSION Front Hydraulicfork stemsØ36mm Max stroke 88 2 mm Rear Swing arm with shock absorber Max stroke 28 2 mm ELECTRICAL EQUIPMENT Ignition system C D I Charging system rated power FLYWHEEL MAGNET 95W Battery Maintenance free Battery capac...

Page 12: ...UID Q8 TOP FLUID BRAKE FLUID Q8 BRAKE FLUID DOT 4 DIMENSIONAL CHECK OF FRAME If the scooter has been involved in an accident and you suspect even slight distortion of the frame it is essential to perform the dimensional checking procedure before any further repair or set up work Control dimension A must be 1001 mm with a tolerance of 2 mm Control dimension B must be 432 5 mm with a tolerance of 2 ...

Page 13: ...dal 4 Air filter 5 Battery 6 Passenger holder RIGHT VIEW 6 Passenger holder 7 Tail light 8 Number plate light number plate holder SWITZERLAND only 9 Passenger footrests 10 Rear brake pedal 11 Radiator 12 Fuel tank cap 13 Fuse 14 Owner s tool bag 1 2 6 5 4 3 14 13 6 7 8 9 12 11 10 05189002 05189003 DESCRIP ...

Page 14: ...NTS 15 Manual starter lever 16 MODE switch 17 Clutch lever 18 Rear view mirror 19 Left handlebar switches 20 Starter button 21 Throttle grip 22 Front brake lever 23 Front brake pump 24 Multifunction digital instrument panel 25 Main switch 05189004 17 16 15 25 24 18 19 23 22 21 20 ...

Page 15: ...eft push the key in and turn it counter clockwise Disengaging turn the key clockwise 05189005 INDICATOR LIGHTS 1 Turn signal indicator light This light flashes when the turn indicator is pushed to the left or right 2 Low beam indicator light This indicator comes on when the low beam headlight is operated 3 Fuel level warning light This light comes on when the fuel level is low Fill the fuel tank 4...

Page 16: ...ion about your vehi cle SETTING Power up the instrument board by connecting the battery to the vehicle s cables Put the key in the ignition switch and turn it to The names of stored flywheels appear successively on the display before selecting your type check the type of flywheel installedon your vehicle on the anti tampering label under the seat seepage 33 When the code of your model appears on t...

Page 17: ...out their characteristics a description is provided here below indicating the functions in the order in which they appear on the display Menu functions can be seen from every sub menu MAIN MENU FUNCTIONS A TOD FUNCTION This indicates the total distance travelled this value is never reset and remains even after the vehicle is turned off the total distance travelled will be stored for 10 years runni...

Page 18: ... disappears then press the MODE button again to actually change the time setting The increase will be slow for the first ten units and then become faster To return to the normal display do not press MODE for at least 3 If power is discon nected this function will be automatically reset The setting operation must be thus repeated This operation must be performed with the vehicle at a standstill F L...

Page 19: ...cally activated irrespective of the function selected and the last dash of the bar graph will flash If you change function the battery logo will remain displayed until the correct power supply is resumed When the warning light comes on charge the battery as soon as possible RPM ENGINE SPEED This function shows engine speed in graphic format The numeric value can be displayed with the RPM function ...

Page 20: ...n to select functions of the digital in strument board 5 Low beam high beam light switch This switch operates the low beam high beam lights 6 START button This button starts the engine This button is active only when the main switch is ON and the clutch lever is operated 05189021 05189022 5 2 4 1 3 6 A B FRONT BRAKE LEVER The front brake lever is on the right hand side of the han dlebar To apply t...

Page 21: ... the instrument board on when the tank is running out of lubricant When the reserve light comes on fill the tank at the first opportunity REAR CARRIER Do not exceed the load limit 2 kg T 05189025 ADJUSTING THE DRIVING POSITION By moving the bottom fastening element of shock absor ber M double hole in the bottom fixing bracket you can adjust the height of the vehicle s seat This operation must be p...

Page 22: ...just Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Check every 2000 km if worn to the limit 1242 74 mi Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Check every 2000 km if worn to the limit 1242 74 mi Brake hoses Check for cracks or damage Replace Every 4 years Wheels Check for run out and damage and check tightne...

Page 23: ...ions or off the road require more frequent servicing 2 6 1 8 1 4 1 2 0 2 X X X X X X 1 2 X X X X 2 2 X X X X X X X 3 2 X X X X X 4 2 X X X X X X 5 2 X X X X X 6 2 X X X X X X N POSITION CHECKS OR MAINTENANCE JOB ODOMETER READING X 1000 KM 621 37 MI ANNUAL CHECK Carburettor Check choke operation Adjust engine idling speed Mix oil pump Check operation Purge air if necessary Transmission oil Check oi...

Page 24: ...rent colour the engine could be defective Do not attempt to diagnose such problems yourself Instead have a MALAGUTI Dealer check the vehicle Remove the spark plug and thoroughly clean its elec trodes and insulator using a metal brush Adjust the gap between the electrodes with a thickness gauge the gap should be 0 6 0 7 mm Using spark plugs with heat rating other than the recommended value as marke...

Page 25: ...e screw back into hole F install the oil filler cap R and tighten it The use of SAE 10W 40 oil is recommended Refit crankcase C and secure in place by tightening the four screws V Do not mix any chemical additives with the oil Transmission oil also lubricates the clutch and chemical additives may cause slippage Dispose of oil in accordance to the laws in force DO NOT DISPOSE OF WASTE OIL IN THE EN...

Page 26: ...cessary to correct the proportion of coolant and water in order to avoid freezing or possible damage 05189030 05189031 T Mx Mn AIR FILTER DISASSEMBLY Remove the seat S by slackening screw V Remove the general protection fuse Remove battery B by removing the elastic band and disconnecting the terminals Remove partition P to access screw R Remove filter F by slackening the two fixing screws R The ai...

Page 27: ...m it up for several minutes at about 1000 2000 rpm while occasionally revving it to 4000 to 5000 RPM The engine is warm when it quickly responds to the throttle To adjust the engine idling speed turn the throttle stop screw G Turn the screw clockwise to increase idling speed or counter clockwise to decrease it Standard engine idling speed 1800 2000 rpm ADJUSTING THE THROTTLE CABLE The engine idlin...

Page 28: ...ce and safe ty characteristics of the vehicle Do not car ry along loosely packed items which can dislodge during a ride Check the tire condi tion and air pressure before each ride NEVER OVERLOAD YOUR VEHICLE Make sure the total weight of the cargo rider pas senger and accessories cowling bags etc if approved for this model does not exceed the specified maximum load for the vehicle 160 Kg The user ...

Page 29: ...POSITION The upper end of the brake pedal must be positioned 15 mm under the upper part of the footboard 05189040 G 05189041 15 mm CHECKING THE FRONT AND REAR BRAKE PADS It is good practice to check the front rear pads and discs every 2 000 km The minimum thickness of the brake pad lining is 2 mm visually check the thickness of the brake pads If the pads have worn to their minimum permissible thic...

Page 30: ... the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 Refill with the same make of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brak ing performance When adding fluid be careful that water does not enter the container Water will significantly lower the boiling point of the fluid and may result in vapour ...

Page 31: ...fork adjustment must be identical on both sides to obtain this condi tion refer to scale G located on the fork An excessively taut chain will put the engine and drive components under excessive strain maintain chain tightness within the specified limits Whilst carrying out these adjustments hold the vehicle firmly in place otherwise it will fall over 05189048 G B V C ADJUSTING THE BEAM To adjust t...

Page 32: ...l A is located under the seat It bears all the vehicle identification data envisaged by the 97 24 CE Directive If you intend to replace the compartment under the seat make sure it is provided with the anti tampering label When ordering spare parts also quote the vehicle identi fication data This label identifies the type of flywheel in stalled on the engine V this piece of infor mation will be nee...

Page 33: ... the top ones are longer than the lower ones V2b if switched over during the successive mounting they push through the headlight guard V2b Undo the height adjustment screw V of the beam Once the headlight guard has been mount ed it is necessary to adjust the beam See Adjusting the beam V V2a DISASSEM 05189013_1 05189019_1 ...

Page 34: ...ISASSEMBLY Disconnect the connector A from the headlights and remove the headlight guard B ACCESSIBILITY Removing the footboard provides access to the following components connector of the digital instrument panel A horn B A B A B 05189014_1 05189025_1 ...

Page 35: ...e burnt out bulb anticlockwise through 90 and remove it from the headlight Remove the bulb and replace it LIGHT BULBS USED A bulb for high beam 12V 35W B bulb for low beam headlight 12V 35W C bulb for parking lights 12V 3W HEADLIGHT Remove the headlight guard Pull back the retaining lips of the anti vibration pro tection from the A of the headlight B so as to un hook them Remove the headlight B fr...

Page 36: ...UMENT PANEL Remove the headlight guard Pull away the rubber protection A and disconnect the connector B from the digital instrument panel C Undo the screws V2 holding a spanner under the nuts D2 then remove the digital instrument panel C A D2 C B V2 C D2 05189028_1 05189029_1 ...

Page 37: ...S wrench for tamperproof screws to un screw screws V2 Malaguti spare part 086 066 00 then pull out the key switch E from the digital instru ment panel C HORN Remove the headlight guard Disconnect connectors A Undo screw V and remove horn B C V2 E A V B 05189030_1 05189034_1 05189025_2 ...

Page 38: ...EAT Undo the special screw V Disengage the saddle A pulling towards the rear of the scooter and remove it ACCESSIBILITY Removing the seat provides access to the following com ponents main fuse 10 A A battery B air filter C V A A B C 05189302_1 05189039_1 05189041_1 ...

Page 39: ...e seat Disconnect the clamps A and remove the battery B Note that the RED leads must be connected to the battery POS ITIVE terminal the BLACK lead must be connected to the battery NEG ATIVE terminal the battery terminals must be towards the REAR of the scooter A B A 05189041_1 ...

Page 40: ...s V2a besides being shorter than the screws V4 are screwed into brass inserts set in the tank of the scooter therefore take care not to ruin the thread of these inserts when reassem bling The screws too V2b have bushes but they are longer than the previous ones Disconnect the connectors A from the front turn in dicators on BOTH sides of the scooter V2a V4 V2b A 05189043_1 05189050_1 05189051_1 ...

Page 41: ...the scooter Disconnect the two vent tubes A and undo the screws V Watch out for the bush under the screw V Raise the tank B slightly making sure not to dam age the electrical cables of the fuel level sensor Disconnect the depression tube C and the fuel tube D from the valve E The depression tube C is the one with the SMALLER diameter and should be connected to LOWER fitting of the valve E vice ver...

Page 42: ...tor F and remove the tank B The connector F can be reached from UN DER the tube section of the frame B F G E To replace the valve E it is necessary to loosen the clamp G and pull the valve E out entirely The fuel gauge sensor is incor porated into the fuel valve 05189068_1 05189063_1 ...

Page 43: ...prolonged period plug the hole to prevent the accumulation of petrol vapour in the workshop Undo the screws V3 and after opening the cap undo the screw V Pay attention to the arrangement of the screws V3 Watch out for the reduction ring located under the cap V3 V V3 LEFT AND RIGHT REAR FAIRING Remove seat Undo screws V2 Undo screw V then remove rear fairing A pulling towards rear of scooter V V2 A...

Page 44: ...flashing for turn indicators A starter motor relay B Removing the left rear fairing provides access to the fol lowing components voltage regulator C A B C V4 V4 A GRAB HANDLE Remove seat Remove the right and left rear fairings Undo screws V4 and remove the grab handle Pay attention to the four bushes located under the screws 05189086_1 05189087_1 05189099_1 ...

Page 45: ... mudguard A Watch out for the four bushes B located under the mudguard the two rear bushes are higher than the two front ones B SUB PANEL Undo screws V2a Undo screw Vb Undo the screw Vc keeping the nut under it then pull out the sub panel A V2a Vc V2a Vb A A V4 05189101_1 05189101 05189104_1 05189105_1 ...

Page 46: ... ACCESSIBILITY Removing the sub panel provides access to the following components the pinion A neutral gear switch B the tension rod of the gear change pedal C B A C LEFT AND RIGHT SIDE PANEL Undo the screw V and remove the side panel A V A 05189108_1 05189115_1 ...

Page 47: ...he four bushes located under the screws V4 AIR FILTER Remove seat Remove fuel tank cover Remove fuel tank Remove intake box guard Remove battery Undo screws Va and Vb The screw Va is LONGER than the screw Vb and during assembly it is inserted in the FRONT part of the filter Va Vb B A Remove the filter B pulling it out towards the front of the scooter 05189121_1 05189124_1 05189126_1 ...

Page 48: ...ER COVER Remove seat Remove the right and left rear fairings Remove grab handle Remove intake box guard Remove battery Undo screws V2 Undo screws V4 and the screw V V4 V2 Lower the number plate holder A then open the rub ber protection B A B V 05189246_1 05189130_1 05189248_1 ...

Page 49: ...the next reassembly the GREEN and BLACK cables are connected to the right turn indicator while the PURPLE and BLACK cables are connected to the LEFT indicator Undo the screws V2 and the nut D to remove the reinforcement strut E from the number plate holder A NOTE Undoing the screws V2 the taillight F also comes away F D C A D V2 E 05189249_1 05189136_1 ...

Page 50: ...othed washer located under the screw Lower the silencer of the exhaust pipe slightly then dis engage the shock absorber cover H from the rear frame L using leverage downwards and towards the inside of the scooter This operation is to disengage the housings M from the inside of the bushes N V2 V G N N H V2 M 05189139_1 05189142_1 05189141_1 ...

Page 51: ...51 A FRAME AND RUNNING GEAR DRAKON 50 NKD 7 DISASSEMBLY 03 06 REAR TAILLIGHT BULB Undo screws V2 Undo the screws V3 then the nuts D2 then re place the bulb D2 V3 V3 V2 05189136_1 05189137_1 ...

Page 52: ...AR MUDGUARD Undo screws V4 and remove the mudguard A Pay attention to the four bushes located under the screws V A A V4 V4 DRIVE CHAIN Remove the split pin A then the links B and C finally pull out the chain To tension the chain see Gearing chain tension regula tion C B A 05189133_1 05189143_1 05189147_1 051891006 ...

Page 53: ...undo lower screw Va then upper screw Vb Remove shock absorber A NOTE It is possible to insert the screw Vb in two different places in order to set the height of the scooter Va 45 15 Vb 45 15 REAR WHEEL Remove the gearing chain Before disassembly support the frame at the centre to prevent the scooter from fall ing Undo the nut D Pull out the spindle V then remove the wheel NOTE The caliper A also f...

Page 54: ...hen reassembling use new screws and apply a high strength thread locker SPROCKET Remove rear wheel Unfold the wings of the flange A then undo the screws V3 When reassembling once the screws have been tight ened fold down the wings of the flange again A NOTE In the event that the scooter does not have a flange request one from the Malaguti Spare Parts Service V5 A V3 V5 11 10 05189019_1 05189148_1 ...

Page 55: ...ic trans mission and the caliper from its seat place a recipient under it to collect the brake flu id Dispose of used brake fluid in compli ance with statutory legislation V 20 10 2 mm V CHECK THE DISC AND PADS OF THE REAR BRAKE FOR WEAR Take the opportunity to check also wear of the brake disc If the disc is badly damaged or the thickness less than 3 5 mm it must be renewed Minimum thickness of t...

Page 56: ...ake master cylinder Undo screws V2 and the screw V then remove the unit A Undo the screw V to remove the footrest B and the brake pedal C V2 A V V C FOOTREST ASSEMBLY GEAR CHANGE PEDAL Remove the sub panel Disengage the spring A from the pedal B pull it out and invert the tension rod C B C A B 05189151_1 05189154_1 05189158_1 ...

Page 57: ... V2 and the screw V then remove the unit D To remove the footrest E and the gear pedal F use Table A of the Spare Parts Catalogue FILTER BOX Remove seat Remove intake box guard Remove rear mudguard Removing the box can be understood from Table I of the Spare Parts Catalogue 05189159_1 ...

Page 58: ...prevent the scooter from fall ing Remove the chain Remove rear wheel Remove rear mudguard Remove the footrest assembly brake pedal Disengage the rear shock absorber downwards Remove the screw V and remove the clamp A Undo the nut D A V V A Pull out the screw V then pull out the fork A D D 60 10 05189163_1 05189157_1 05189159_1 ...

Page 59: ...ove fuel tank Remove grab handle Remove battery Remove the right and left rear fairings Remove intake box guard Remove the right and left number plate holder Remove the cover from the intake box Remove silencer Remove the chain Remove rear wheel Remove rear mudguard Remove the fork Undo screws V4 and remove the rear frame A NOTE Recover the nuts located under the screws A V4 V4 V4 20 15 05189166_1...

Page 60: ...KON 50 NKD 7 DISASSEMBLY SPEEDOMETER SENSOR Undo screw V ensuring the spacer does not fall When refitting use a feeler gauge to check that the sensor disc gap is 1 2 mm Remove the sensor complete with the transmission V 10 15 V 05189175_1 ...

Page 61: ... the caliper see the specific chapter 05189306 2 m m FRONT BRAKE CALIPER Undo the screw of the hydraulic transmission V and remove the hydraulic transmission and its gaskets When reassembling replace the gaskets of the hydraulic transmission V2 V2 V2 30 20 V 20 10 Undo screws V2 and free the complete caliper After having removed the hydraulic trans mission and the caliper from its seat place a rec...

Page 62: ...spacer B V A A FRONT BRAKE DISC Remove speedometer sensor Remove front brake caliper Remove front wheel Undo screws V7 Wear tolerance limit mm 3 5 When reassembling use new screws and apply a high strength thread locker V7 11 10 V7 Remove wheel assembly Do not operate the brake lever after remov ing the wheel since the pads would come into contact with each other When refitting the wheel be sure t...

Page 63: ...screw plug C and then turn the shock absorber upside down and drain the oil contents into a 1 litre container undo screw V and remove damper D from slider E NOTE When reassembling renew copper washer under screw V remove wiper seal F retaining ring G and oil seal H There is an O ring C1 located on cap C renew the O ring if necessary The damper contains oil Do not turn it up side down or tilt it ex...

Page 64: ...s undo upper plug A carefully remove spring B and allow the oil in which it was immersed to drip off bring the damper to its bottom travel limit while keep ing it in a perfectly vertical position B A With the aid of a rule or a gauge rod check the oil level The correct level is 150 mm from the upper edge of the damper Top up with Q8 FORK OIL if necessary Quantity of oil for damper 310 cc 150 mm 05...

Page 65: ...ard Remove the digital instrument panel Undo screws V2 and remove support A Undo screws V4a remove U clamps B and han dlebar C Unscrew the nut D and the screws V2b then pull out the upper bar E V2b V2b E D C V4a B A V2 V4a G B D E V2b F Unscrew the ring nut F pull out the dust guard G then pull out the entire fork downwards V4a 21 15 V2b 21 15 D 30 15 05189180_1 05189252_1 05189312 ...

Page 66: ...t the cool ant temperature is lower than 50 C Undo screws V2a Undo screws V2b and remove grille A Recover the bushes located under the screws V2b Under the screw V2a on the right side there is a cable gland while the screw V2a on the left side holds the oil tank when reas sembling make sure to replace screws cor rectly V2a A V2a V2a V2b 05189186_1 05189187_1 05189196_1 ...

Page 67: ...he procedure ou tlined at the end of the heading Loosen the clamps C and D and pull out the rub ber tubes Undo screws V3 and remove the radiator E D V C B V3 RADIATOR After having refitted the radiator and filled the cooling system by pouring coolant into filler point A bleed air from the system as follows start the engine and idle for a few minutes then stop it check the radiator liq uid level ag...

Page 68: ...king on the silencer and the ex haust manifold wait until all the component shave cooled down and always wear suita ble protective gloves Detach the two springs A and B Pull out the rubber tube from the metal tube C Undo screw V Disengage the spring D and undo the screw V Pay attention to the toothed washer locat ed under the screw C A B V D V V 8 10 05189192_1 05189193_1 05189142_1 ...

Page 69: ...RUNNING GEAR DRAKON 50 NKD 7 DISASSEMBLY 03 06 Undo the screws V2 then remove the entire silenc er The procedure for disassembling the components of the exhaust unit is illustrated in the figure V2 05189246_1 05189313 ...

Page 70: ...essary to BLEED off the air from the oil pump See at the end of this chapter Remove the grill A as explained in the paragraph Radiator A B V2 C D Using a screwdriver raise the sensor C pull it out of the tank B and disconnect its connector D Pull out the oil suction hose then remove the oil tank Undo the screws V2 and disengage the tank B but without removing it from the scooter Recover the bushes...

Page 71: ... or replacement of a tube dismantling the engine Undo screws V2 and remove cover A Loosen the screw V and wait until air bubbles stop then tighten the screw Start the engine for a few moments accelerating it a little a few times the stop it Loosen the screw V again and make sure that air bubbles no longer come out then tighten it and re place the cover A V A V2 05189204_1 05189210_1 ...

Page 72: ...he neutral gear sensor M disconnect the starter cables N of the scooter and the flywheel ca bles O N O M L I E F H G B A D After removing the cover disconnect the transmission E of the mixer and the oil feed tube F Whenever the oil circuit is disconnected re moving the oil tank disconnection or re placement of a tube dismantling the en gine it is necessary to BLEED off the air from the oil pump Se...

Page 73: ...73 A FRAME AND RUNNING GEAR DRAKON 50 NKD 7 DISASSEMBLY 03 06 Undo screws V3 and remove engine pulling it to wards the right V3 23 10 V3 V3 V3 05189208_1 05189209_1 ...

Page 74: ... A FRAME AND RUNNING GEAR DRAKON 50 NKD 7 DISASSEMBLY CONTROLS ON THE HANDLEBAR To dismantle the controls follow the figure shown below For greater detail refer to Table F of the Spare Parts Catalogue 05189314 ...

Page 75: ...Remove the oil seals H in both caliper halves mak ing sure not to damage their seatings Check that the plungers and their seats are undam aged Always use new oil seals Reassembly the plungers lubricating them with the appropriate grease NOTE After working on the braking system always check that the brake fluid lines are not damaged crushed or twisted the disc and pads are not contaminated with oil...

Page 76: ...m age the wiper seal and oil seal grooves Check the pistons and their cylinders for any signs of scoring Clean the parts thoroughly and flush with exclusively alcohol Always use new oil seals Remount the plungers lubricating them with the appropriate grease After terminating the inspection cleaning and replace ment procedures refit all the parts in reverse sequence with respect to the sequence of ...

Page 77: ...njury and damage to paint ed parts of the scooter Unscrew and remove union A Remove brake fluid line B and gaskets C Disconnect brake light switch S Undo screws V2 and remove U clamp D Remove master cylinder unit E To refit the master cylinder first start the lower screw using a long T handle wrench without tightening it and then start the upper screw then tighten both screws to the prescribed tor...

Page 78: ... The STOP switch is incorporated into the fit ting C Unscrew and remove union C Remove brake fluid line D and gaskets E Pull out the Faston connectors S Undo screws V2 and remove the pump F The screws V2 are screwed onto the foot rest G make sure it does not fall After assembling the brake master cylinders install the tube D interposing two new gas kets E and tighten the union C to the pre scribed...

Page 79: ...e fluid only flows out of the rubber tube Replenish the brake fluid level in the reservoir While bleeding the brakes ensure that no brake fluid comes into contact with the scooter bodywork risk of damage In addi tion while bleeding the brake calipers avoid contamination of brake discs or pads with brake fluid Failure to comply with this pre scription will have a negative effect on the efficiency o...

Page 80: ...ish the brake fluid level in the reservoir While bleeding the brakes ensure that no brake fluid comes into contact with the scooter bodywork risk of damage In addi tion while bleeding the brake calipers avoid contamination of brake discs or pads with brake fluid Failure to comply with this pre scription will have a negative effect on the efficiency of the brake system If the escaping brake fluid c...

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