Malaguti F10 Service Manual Download Page 35 | Manualshive

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03/08

34

ENGINE

• Remove the rear fairing (p. 19) and the lower side

panels (p. 16).

• Dismantle the muffler (p. 29)
• Dismantle the tyre (p. 31)
• Disconnect the ignition motor wires (A)
• Disconnect the stator connector (B)
• Pull off the spark plug lead (C).
• Disconnect the electric starter connector (D)
• Disconnect the engine oil outlet pipe (E) and use a

screw to close it.

• Use the spring (F) to release the air filter from the

carburetor.

• Remove the air filter unit (p. 33).

F.70

F.71

F.72

F.73

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Summary of Contents for F10

Page 1: ......

Page 2: ...r 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 of spare parts in our motor bikes are to be performed by skilled and expert technical personnel with specific experience in state of the art technology and full knowledge of the quickest and most rational...

Page 3: ...opics 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 Torque wrench setting D Nut Dx Right F Picture G Gasket P Page R Washer Sx Left T Table V Screw TECHNICAL DICTIONARY V DC Direct current battery supply V AC Alternating current flywheel supply A Ampere Unit of measur...

Page 4: ...ECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technician IGNITION KEY ON ON position PRESENT MANUAL Information on the present manual ENGINE SERVICE MANUAL Indicates information which may be obtained by referring to said catalogue SPARE PARTS CATALOGUE Indicates information which ma...

Page 5: ...ch the components that needs repairing Prepare the components that are likely to be replaced Use only the original spare parts Mark the components that may be mis placed during re assembly operations 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...

Page 6: ...ys 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 leave the engine running in closed or poorly ventilated areas Do not use fuses with a higher rated capacity than indicated this may cause severe damages to the electrical system and burn a fire as a conse quence ...

Page 7: ...y servicing make sure that the vehicle is perfectly stable The front wheel should preferably be anchored to fixture A which is integral with the lift platform It is absolutely forbidden to walk on the lifting device F 3 ...

Page 8: ... SHIELD 18 SEAT 18 INSPECTION LID 18 REAR LIGHT 19 REAR FAIRING 19 ACCESSES 20 HELMET COMPARTMENT 21 SEAT LOCKING DEVICE 21 PEDANA POGGIAPIEDI 21 ACCESSES 22 FUEL LEVEL PROBE 22 OIL TANK 23 FUEL TANK 23 RIGHT AND LEFT SWITCH UNIT 24 KEY SWITCH 25 HORN 25 REPLACING THE LININGS 26 BRAKE CALIPER 26 FORK 27 OIL REPLACEMENT 28 FORK ASSY 28 SUSPENSION 29 CENTRAL KICK STAND 30 FOOT REST RODS 30 REAR WHEE...

Page 9: ...ES NGK BR7 ES TRANSMISSION Automatic speed variator with expandable pulleys V belt automatic dry centrifuge clutch reduction gear FUEL SYSTEM Carburettor make type GURTNER PY 12 automatic starter Fuel unleaded petrol IGNITION Electronic BRAKES Front brake disk type Ø 155 mm with transmission and hydraulic calipers Rear brake drum type Ø 110 mm with mechanical transmission CHASSIS Steel tube single...

Page 10: ...s that are higher than or identical to those indicated It is however necessary for speed indexes to be identical for both tyres Use only tyres with the relevant type approval Minimum tread depth is 2 mm 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 indicators and...

Page 11: ...uld be performed more 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 MALAGUTI but under their direct responsibility ...

Page 12: ...03 08 11 LUBRICANT TABLE NOTE Use only recommended products To fill remove the inspection cover unscrewing the screw V and cap A pulling outwards Pour in oil 1 4 0 4 F 8 ...

Page 13: ...connector Disconnect the odometer transmission by pressing the two tabs and simultaneously rotating the connector to remove it from its housing Remove the fastom A and all the light bulb sockets B from the fuel indicator and odometer instruments INSTRUMENTS The odometer and fuel indicator are pressure inserted to remove them press as shown being careful to hold the front part of the instrument wit...

Page 14: ...top switch 4 Rear brake stop switch 5 Right switch connector 6 Left switch connector 7 Front brake pump oil connection 8 Rear brake transmission 9 Dashboard protection condenser FRONT SHIELD Remove the foot rest mat V4 V2 Lighting hit upwards to release the shield V4 Cs N m 2 10 V2 Cs N m 2 10 F 14 F 15 F 13 ...

Page 15: ...ove the shield including the headlights and blinkers GRUPPO FARI V3 V Vite regolazione fascio luminoso When reassembling check correct OR positioning C Plexiglas Always replace the gasket before reassembling V2 Faston A DIRECTION INDICATORS V1 Faston B F 16 F 17 F 18 F 19 ...

Page 16: ...y switch connector 3 Connector for anti theft device 4 Headlights connector 5 Handlebar nut and bult 6 7 5 A light protection fuse 7 Horn 8 Twin gas mixer After removing the cables reposition and anchor the cables with new straps as described in the figure F 20 ...

Page 17: ... V2 Cs N m 2 10 V2 Cs N m 2 10 V1 Cs N m 2 10 Release the strut B from the rear hood and foot rest being careful not to break the fastening hooks Release the rear brake cable C ACCESSES after removing the lower side panels 1 A T coil F 21 F 22 F 23 F 24 ...

Page 18: ... damage to the electric system including the risk of fire BATTERY Battery cover A Remove battery Disconnect the vent pipe D Disconnect the cables firstly the cable connected to mass BATTERY Connect the cables as illustrated in the figure connect the positive cable first Do not invert cable connection When reassembling the battery do not forget to insert the vent pipe Make sure it exits the battery...

Page 19: ...Battery p 17 Unscrew the ring nut A V3 Remove the wiring Remove the leg guard B as indicated V3 Cs N m 5 20 SEAT Open the seat A D2 INSPECTION LID V1 Be careful to correctly insert the reference tabs when reassembling D2 Cs N m 3 10 F 29 F 30 F 31 F 32 ...

Page 20: ...n B pink wire must be connected on the same side as the faston D black grounding wire REAR FAIRING NOTE Remove Rear light p 19 Seat p 18 Inspection lid p 18 V2 V Fig 33 Carefully remove the rear hood A slighting spreading the sides V2 Cs N m 2 10 F 34 F 35 F 36 F 33 ...

Page 21: ... 20 ACCESSES after removing the seat and rear hood 1 Fuel level probe 2 Gas level probe connector 3 Electronic panel 4 Ignition relay 5 Flywheel connector 6 Engine oil probe connector 7 Engine oil probe F 37 ...

Page 22: ...p 18 Rear fairing p 19 A V2 D2 SEAT LOCKING DEVICE NOTE Remove Helmet compartment p 21 V2 Be careful of the washers R2 V2 Cs N m 5 20 V2 Cs N m 5 20 PEDANA POGGIAPIEDI NOTE Remove Rear fairing p 19 Leg shield p 18 V2 V2 Cs N m 5 20 F 38 F 40 F 39 ...

Page 23: ...ce 2 Air filter case sleeve 3 Carburettor transmission 4 Mixer pipe 5 Electric carburettor starter connector FUEL LEVEL PROBE V4 Disconnect the connector A NOTE When reassembling insert the float so that the probe connector is facing the direction illustrated in figure F39 V4 Cs N m 2 10 F 41 F 42 ...

Page 24: ...all function as tap in the tank exit connection V2 When reassembling replace the strap with a new one After filling with oil drain the mixer oil See engine manual V2 Cs N m 5 20 FUEL TANK NOTE Remove Helmet compartment p 21 Connector A After emptying the tank free the straps B and remove pipes C and D V2 V2a V2 Cs N m 2 10 V2a Cs N m 5 20 F 43 F 44 ...

Page 25: ...nnect the Fastons F V2a U bolt E Screw connection V HANDLEBAR NOTE Remove Upper handlebar Cover p 12 Lower handlebar cover G unscrewing the V4 screws Right and left switch unit p 24 Front brake pump p 24 Accelerator control and brake transmission Loosen nut D1 Fully remove the handlebar being careful not to damage the wiring and tubes V2 Cs N m 1 6 20 V Cs N m V2a Cs N m 20 20 28 20 D1 Cs N m 50 2...

Page 26: ...5 V Cs N m 7 10 FRONT WHEEL Check perfect motor vehicle stability positioning on the central kick stand Unscrew the nut B holding the pin C with a wrench Unscrew and remove the odometer transmission A using pliers Remove the wheel pin C being careful of odometer return D Do not activate the brake lever while the wheel is off B Cs N m 45 15 F 46 F 47 F 48 F 49 ...

Page 27: ...e them and replace them Check also the state of the brake disc In case of excessive wear or anomaly replace it Minimum thickness of linings should be 2 mm Minimum thickness of disc should be 3 5 mm REPLACING THE LININGS Remove the cover A Remove the seeger B Remove the pin C and the spring D Operate in the opposite direction to remount the components BRAKE CALIPER V2 R V2 Cs N m 30 20 R Cs N m 20 ...

Page 28: ...s from the upper rim of the shaft If necessary fill up with oil FORK OIL 50 cc per shaft OIL LEVEL CHECK Block the wheel shaft in a clamp in vertical position Remove Cover A Seeger ring B Propeller nut C complete with O Ring D Spring E let oil drip off it Bring the shaft F to its end of travel position Before reassembling the shaft unit parts apply grease on the O ring D or replace it with a new o...

Page 29: ...he screw V with its relative gasket Carefully pour new oil in the shaft 50 cc right left Check oil level as described above Reassemble the parts FORK ASSY To remove the complete fork remove Shield p 13 Front wheel p 25 Odometer return Brake caliper p 26 Handlebar p 24 To release the fork Ring nut A Replace the fork A to prevent falling NOTE While removing the fork group be careful not to let the b...

Page 30: ...uld be carried out only when the exhaust system has cooled down V2 Gasket to be replaced with a new one Remove the strap A and disconnect the secondary air supply pipe V2 a V2 Cs N m 8 15 V2a Cs N m 30 20 SUSPENSION D V D Cs N m 40 20 V Cs N m 24 20 F 58 F 59 ...

Page 31: ... Secure the vehicle so that it does not fall when the central kick stand is removed Split pin A Pin B Spring C When reassembling secure the rear transmission wire to the support plate D FOOT REST RODS V2 V2 Cs N m 35 15 F 60 F 61 ...

Page 32: ...AKE Remove the rear wheel Unscrew and remove the adjustung nut D Grasp with both hands the two sectors of the rear brake shoes A open them out vigorously in order to separate them from cam pin E The high strength of the springs B may cause the crushing of your fingers Clean and grease only the central part of the cam pin During re assembly the cam pin should be inserted in its seat and free from a...

Page 33: ...R ADJUSTMENT Pull the lever verifying that the brake begins working after an idle stroke of the lever of about 10 mm If necessary carry out adjustment by acting on the adjustment nut D Rotate the wheel manually operating for different times the brake lever verifying the idle stroke the braking efficacy and the free rotation of the wheel after having released the lever itself After the adjustment v...

Page 34: ...ll solvent is eliminated Spread oil for air filter on the entire surface of the filter eliminating any excessive material in fact the filter must be uniformly impregnated without dripping In case the filtering element is damaged replace with a new original one When reassembling the air filter unit make sure the container contact surfaces are perfectly adherent to avoid aspiration of non filtered a...

Page 35: ...Disconnect the ignition motor wires A Disconnect the stator connector B Pull off the spark plug lead C Disconnect the electric starter connector D Disconnect the engine oil outlet pipe E and use a screw to close it Use the spring F to release the air filter from the carburetor Remove the air filter unit p 33 F 70 F 71 F 72 F 73 ...

Page 36: ...ixer When reassem bling the wire make sure the two notches C one on the cam and one on the guard are aligned To adjust use the ring nut D Release the rear brake transmission cable by operating on the nut D Unscrew the lower locking screw V of the shock absorber Rotate the suspension upwards and anchor it to the scooter frame Remove the stand p 30 Unscrew the locking nut D and slide the pin out A D...

Page 37: ...s which allow the engine to be separated from the frame means that a certain number of straps must be cut These must be replaced and positioned as in the original configuration Check the illustrations on the upcoming pages FRAME DIMENSION CHECK In case of presumed deformation however slight of the frame after an accident check the dimensions of the frame Check value A 819 mm tolerance 2 mm In case...

Page 38: ...03 08 37 CABLE POSITIONING PIPE SYSTEM AND LOCATION OF ANCHORING STRAPS F 79 ...

Page 39: ...03 08 38 F 80 F 81 ...

Page 40: ...03 08 39 F 82 ...

Page 41: ...03 08 40 F 83 ...

Page 42: ...03 08 41 F 84 ...

Page 43: ...03 08 42 F 85 ...

Page 44: ...03 08 43 F 86 ...

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