Malaguti MALBO Line Service Manual Download Page 2

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03/10

CONTENTS

DESCRIPTION

PAGE

INTRODUCTION

NOTES FOR EASY CONSULTATION

SPECIFICATIONS

MAIN COMPONENTS

IDENTIFICATION DATA: CHASSIS N° / ENGINE N°

ANTI-TAMPERING PLATE

TIRES

PRESSURE

FUEL TANK

FRONT LUGGAGE COMPARTMENT

REAR-VIEW MIRROR

HELMET COMPARTMENT

LUGGAGE HOOK

INSTRUMENT BOARD

HANDLEBAR CONTROLS

RIGHT HAND CONTROL (FIG. 17)

LEFT HAND CONTROL (FIG. 18)

CHECKS BEFORE USE

MAINTENANCE TABLE

TRANSMISSION OIL

ENGINE OIL

LUBRICANT TABLE

SPARK PLUG

THROTTLE FREE PLAY ADJUSTMENT

CHECKING THE PADS AND DISC OF THE FRONT BRAKE (CONDITION AND WEAR)

CHECKING THE REAR BRAKE

HEADLIGHT

FRONT TURN INDICATOR

TAIL LAMP (WITH STOP LIGHT)

FUSES

BATTERY (12V - 5Ar)

BATTERY RECHARGING

FAIRING

DISMANTLING THE FRONT HANDLEBAR COVER

REPLACING THE HEAD LIGHT BULB

DISMANTLING THE REAR HANDLEBAR COVER

DISMANTLING THE FRONT SHIELD

DISMANTLING THE SIDE COVERS

DISMANTLING THE TAIL LIGHT ASSY

DISMANTLING THE REAR HANDLE

DISMANTLING THE HELMET COMPARTMENT

DISMANTLING THE FAIRING

BATTERY BOX

DISMANTLING THE FOOT BOARD

DISMANTLING THE LOWER SHIELD AND INNER SHIELD

REPLACING THE PARK LIGHT AND TURN INDICATORS BULBS

DISMANTLING THE FRONT MUDGUARD

FRONT WHEEL

DISMANTLING THE FRONT WHEEL

DISMANTLING THE FRONT BRAKE CALLIPER

DISMANTLING THE BRAKE DISC

FRONT RIM CHECK (WHEEL REMOVED)

CHECKING THE FRONT WHEEL SPINDLE

Summary of Contents for MALBO Line

Page 1: ......

Page 2: ... BRAKE 11 HEADLIGHT 11 FRONT TURN INDICATOR 11 TAIL LAMP WITH STOP LIGHT 12 FUSES 12 BATTERY 12V 5Ar 13 BATTERY RECHARGING 13 FAIRING 14 DISMANTLING THE FRONT HANDLEBAR COVER 15 REPLACING THE HEAD LIGHT BULB 15 DISMANTLING THE REAR HANDLEBAR COVER 16 DISMANTLING THE FRONT SHIELD 16 DISMANTLING THE SIDE COVERS 17 DISMANTLING THE TAIL LIGHT ASSY 17 DISMANTLING THE REAR HANDLE 18 DISMANTLING THE HELM...

Page 3: ...R CONVEYORS 42 DISMANTLING THE VALVE COVER 43 DISMANTLING THE SECONDARY AIR VALVE 43 DISMANTLING THE ROTOR 44 DISMANTLING THE STATOR AND PICK UP 45 DISMANTLING THE CHAIN TENSIONER 45 DISMANTLING THE HEAD 46 DISMANTLING THE ROCKER ARMS 47 DISMANTLING VALVES AND VALVE STEM SEALS 47 DISMANTLING THE CYLINDER 48 DISMANTLING THE PISTON 49 DISMANTLING THE OIL SUMP 49 DISMANTLING THE OIL PUMP 50 DISMANTLI...

Page 4: ...LING THE FLOAT NEEDLE AND JET 64 REMOVE THE IDLE SCREW AND IDLING ADJUSTING SCREW 65 CYCLE TIGHTENING TORQUES 66 ENGINE TIGHTENING TORQUE 67 TIGHTENING TORQUE GENERIC TABLE 68 FRAME DIMENSION CHECKS 68 ELECTRICAL PART LOCATION 69 SWITCH CHECKS 71 CHECK FUEL LEVEL GAUGE 71 CHECK FUEL LEVEL SENSOR 72 IGNITION 72 HT COIL 72 SPARK PLUG CAP 72 STATOR POWER 70W 72 WIRING DIAGRAM 73 DESCRIPTION PAGE ...

Page 5: ...tes heat even after the engine has just been turned off We therefore recommend you to careful ly read the following instructions Always allow the engine and muffler to cool down be fore any maintenance operation in order to avoid hot surfaces Make sure you do not park nor stop your vehicle on grass paper deadleaves or other easily inflammable materials The passenger should get on and off the vehic...

Page 6: ... case Spark plug Type NGK CR7HSA A7RTC LDA7TC Transmission Primary automatic speed variator by V belt Final by gears Automatic centrifugal dry clutch Fuel system Automatic starter Fuel unleaded petrol Indicative Value Ignition Electronic Brakes Front brake disk type Ø 155 mm transmission and hydraulic calipers Rear brake drum Ø 110 mm mechanical transmission Chassis High resistance tubular steel f...

Page 7: ...icle s chassis in the positions shown in the photos A Fig 04 Engine identification data are visible on the left engine crankcase B Fig 05 Altering identification data will be punished ac cording to the law When ordering spare parts also quote the vehicle identification data ANTI TAMPERING PLATE An anti tampering plate C Fig 06 bearing all vehicle identification data required by Directive 97 24 CE ...

Page 8: ... W I marks are provided all around the tire side walls These correspond to tire wear indicators which are situ ated in the tire s tread if there is no difference between the thickness of these indicators and the tread depth it self the tire must be replaced Minimum tread depth front and rear is 2 mm Fig 08 PRESSURE The pressure of tires must be adjusted while the tire is at ambient temperature Pre...

Page 9: ...l is extremely inflammable avoid ap proaching the fuel filler also during filling with lit cigarettes or naked flames for instance matches Danger of fire Indicative value in litres FRONT LUGGAGE COMPARTMENT This is located at the centre of the lower fairing A Fig 11 It can be used for storage small and light ob jects It is advisable not to leave any documents or valuables inside these compartments...

Page 10: ...valuables inside the hel met compartment LUGGAGE HOOK The vehicle is fitted with two luggage hooks G Fig 15 on which you can hang small objects or bags One of the hooks is located at the centre of the lower fairing the oth er is in centre position under the seat They must be used only for holding light and stable loads Never use these hooks for loads that alter your riding position or put the vehi...

Page 11: ...BEFORE USE 4 1 2 3 Fig 17 1 5 4 2 3 Fig 18 Part Check Fuel Enough fuel Transmission oil Engine oil Level within limits specified Check for leaks Tires Check pressure wear damage Nuts screws bolts Check tightness Steering Free movement from one end to the other Front Rear brakes Working properly and not worn if necessary adjust or replace Throttle Operation should be smooth if necessary lubricate o...

Page 12: ...tighten the oil filling screw Recommended oil Q8 T35 80W Renew after the first 500 1 000 km 312 624 mi and every 10 000 km 6 240 mi or 24 months 1 Park the vehicle on a level surface on its centre stand 2 Put a container under the drain cap 3 Remove the oil filler screw A Fig 19 4 Unscrew the oil drainage screw B Fig 19 and drain out the entire oil content 5 Clean the drainage screw and refit it 6...

Page 13: ...he read ings If you need to check the level when the engine is warm remember that the level line will be lower It is best to wait at least 10 minutes from stopping the engine in order to have a correct reading Topping up Before topping up check the oil level and in no case allow the level to rise above the MAX notch Never allow the level to rise above the MAX mark Excessive internal pressure can i...

Page 14: ...he engine cool down at least 10 15 minutes since the sediments and the colour of the insulator can provide useful information about the heat rating of the spark plug carburetion lubrication and general conditions of the engine A light brown colour of the insulator around the central electrode indicates good working order 4 After disassembling the spark plug suitably clean the electrodes and the in...

Page 15: ...e idle stroke of the lever is approximately 10 mm To adjust the rear brake turn the adjuster under the en gine as illustrated in Fig 28 HEADLIGHT To increase visibility at night quartz halogen type head lights are fitted Low beam high beam A Fig 29 Bulb 12V 25 25W Parking light bulb B Fig 29 Bulb 12V 5W NOTE We advise you to check if the replaced bulb works properly before refitting the headlight ...

Page 16: ...ocated close to the battery F Fig 31 REPLACING THE FUSE To replace the fuse just open the battery compartment ex tract the blown fuse and replace it with one of the same ca pacity Inside the fuse box you will find a spare fuse S Fig 31 Check that the fuse you are using has the same amperage of the fuse you are replacing Do not replace the fuse with one having a higher capacity as it could seriousl...

Page 17: ...cted to its ca bles This may cause failures and short circuit of the electrical system and its components If the battery remains flat it will be seriously damaged We advise you to use protective gloves and goggles while removing the battery from its compartment for example to recharge the bat tery BATTERY RECHARGING To perform this operation it is recommended to take the battery out of its compart...

Page 18: ... fairing l h 3 Front shield 16 Central fairing 4 Shield lower 17 Side cover r h 5 Inner shield upper 18 Side cover l h 6 Inner shield lower 19 Central fairing 8 VIN number cover 20 Helmet compartment 9 Foot board panel 21 Seat 10 Battery box 22 Rear handle 11 Battery cover 23 Plug 12 Mat set 13 Side cover mounting ...

Page 19: ...NDLEBAR COVER Remove the RIGHT and LEFT mirrors 1 Remove the front handlebar cover 2 Disconnect the connector 3 REPLACING THE HEAD LIGHT BULB Disconnect the connector 1 and replace the light bulb 2 1 Fig 02 2 Fig 03 3 Fig 04 1 2 Fig 05 ...

Page 20: ...03 10 16 DISMANTLING THE REAR HANDLEBAR COVER Remove the rear handlebar cover 1 Remove the speedometer cable 2 DISMANTLING THE FRONT SHIELD Remove the front shield 3 2 1 Fig 06 3 Fig 07 ...

Page 21: ...03 10 17 DISMANTLING THE SIDE COVERS Remove the central fairing 1 Remove the right and left side covers 2 DISMANTLING THE TAIL LIGHT ASSY Unscrew the tail glass screws 1 Fig 08 2 Fig 09 Fig 10 ...

Page 22: ...ting pushing your thumbs on the illustrated points NOTE Be careful not to push too hard on the point 1 the glass could break Tail light bulb 2 Turn indicator light bulbs 3 DISMANTLING THE REAR HANDLE Remove the plug 1 1 Fig 11 2 3 3 Fig 12 1 Fig 13 ...

Page 23: ... DISMANTLING THE HELMET COMPARTMENT Open the seat Unscrew the illustrated screws and nuts Remove the helmet compartment 1 DISMANTLING THE FAIRING Remove the mat set 1 Remove the side cover mounting 2 2 Fig 14 1 Fig 15 1 Fig 16 2 Fig 17 ...

Page 24: ...he fairing release the seat opening cable 4 Remove the fairing 5 BATTERY BOX Remove the battery cover 1 Remove the battery 2 Remove the 10 Ampere fuse box holder 3 Remove the CDI unit 4 Remove the starter relay 5 4 3 Fig 18 5 Fig 19 1 Fig 20 2 4 5 3 Fig 21 ...

Page 25: ...HE LOWER SHIELD AND INNER SHIELD Remove the ignition barrel cover 1 Remove the bag handle hook 2 Remove the screws and remove the inner shield 3 and lower shield 4 NOTE Before removing the lower shield 4 remove the front wheel and front mudguard as indicated in the specific chapters 1 Fig 22 1 Fig 23 2 3 4 Fig 24 ...

Page 26: ... Turn indicator light bulb 2 DISMANTLING THE FRONT MUDGUARD Release the two front mudguard halves wheel side and shield side Remove the wheel as indicated in the specific chapter Release the two mudguard halves wheel and shield sides from the bracket 1 1 2 Fig 25 Fig 26 1 Fig 27 ...

Page 27: ...03 10 23 Remove the rear part 2 and front part 3 2 3 Fig 28 ...

Page 28: ...Fig 29 Nr Item Nr Item 1 Front rim 7 Brake disc 2 Front tyre Tubeless 8 Bolt M8x24 3 Spacer 9 Spacer front brake 4 Bearing 6002 ø15x32x9 10 Nut M12 5 Bearing 6003 ø17x35x10 11 Front wheel spindle 6 Oil seal 12 Speedo drive ...

Page 29: ...eedometer cable 2 Unscrew the nut 1 DISMANTLING THE FRONT BRAKE CALLIPER Unscrew the front brake calliper screws 3 Lift the vehicle using the lift and remove the wheel DISMANTLING THE BRAKE DISC Unscrew the 3 illustrated screws and remove the brake disc 1 Cs N m 53 2 1 Fig 30 3 Cs N m 26 3 Fig 31 V3 Cs N m 23 Fig 32 ...

Page 30: ...ace with a new rim Oscillation limit 2 0 mm CHECKING THE FRONT WHEEL SPINDLE Check front shaft oscillation with a centesimal gauge and replace it if it exceeds the service limit Measurement instrument Micrometer Linearity limit 0 25 mm DISMANTLING THE BRAKE PAD SET Do not pull the brake lever before installing the pad set Remove the screw 4 Rotate the calliper away from the cover Remove the callip...

Page 31: ... set 6 facing them in the indicated direc tions flat side 7 facing towards the cover When reassembling the pad set fully push the piston into its housing After reassembling pull the brake lever several times to position the pad set in contact with the brake disk 5 6 7 Fig 36 ...

Page 32: ...g 3 Nut 19 Spring 4 Bolt 20 Piston tube 5 Screw 21 Seeger 6 Lock nut 22 Return spring 7 Lock washer 23 Fork tube 8 Adjustable cone 24 Dust seal 9 Steering ball cages N 26 ø 5 32 25 Seeger 10 Upper washer 26 Oil seal 11 Lower washer 27 R h fork leg assy 12 Steering ball cages lower N 29 ø 5 32 28 Copper washer 13 Steering cone 29 Screw 14 Bottom yoke 15 Screw 16 L h fork leg assy ...

Page 33: ...er Remove the front shield Slide the handlebar off the fork tube Unscrew the steering lock nut 3 Slide off the lock washer 4 Unscrew the adjustable cone 5 Slide out the fork being careful of ball cages REPLACING CAPS AND STEERING CONES Using a wrench remove the steering caps Using a chisel slide off the steering cone 6 Fig 38 1 2 4 3 5 Fig 39 6 Fig 40 ...

Page 34: ...he steering shaft Install and tighten the adjustable cone 11 Loosen and re tighten the adjustable cone Position the lock washer 12 Install and tighten the steering lock nut 13 OIL LEVEL CHECK Insert a stick or gauge and check that oil is 110 5 mm from the upper edge of the rod move the rod to end stop If necessary top up with oil Q8 FORK OIL 8 7 Fig 41 13 Cs N m 30 11 13 9 12 10 Fig 42 Quantity pe...

Page 35: ...ws Disconnect the connector Remove the key switch 1 REAR WHEEL AND SHOCK ABSORBER 1 Fig 44 Fig 45 Nr Item Nr Item 1 Rear rim 8 Nut M6 2 Rear tire 9 Washer 3 Brake shoes 10 Wheel nut 4 Spring 11 Shock absorber 5 Cam 12 Bolt M10x71 6 Brake lever 13 Nut 7 Bolt M6 x 28 14 Bolt M8x24 ...

Page 36: ...E BRAKE SHOES Remove the rear wheel Unscrew the screw V Remove the brake shoes 1 being careful not to dam age the springs M DISMANTLING THE SHOCK ABSORBER Remove the rear fairing Remove the air filter Unscrew the screws V2 Remove the rear shock absorber D Cs N m 120 Fig 46 D 1 Fig 47 V M V2 Cs N m 29 Fig 48 V2 ...

Page 37: ...AL DIAMETER exceeds wear limits Wear limit 120 7 mm CHECKING BRAKE SHOES Make sure brake shoes are not worn or damaged and re place the complete brake shoe set if necessary CHECKING THE SHOCK ABSORBER Make sure the shock absorber does not leak and that it is not damaged Replace if necessary Fig 49 Fig 50 Fig 51 ...

Page 38: ...ehicle so that it does not fall when the main stand is removed Remove the split pin 1 Remove the spring 2 Slide out the pin 3 and remove the main stand REMOVING THE ENGINE FROM THE CHASSIS Remove the helmet compartment 1 1 Fig 52 3 2 Fig 53 1 Fig 54 ...

Page 39: ... and left side covers 2 Disconnect the carburettor starter connector A and stator connector B Release the throttle cable 3 the fuel hose 4 and de pression hose 5 Unscrew the filter box clamp 6 2 Fig 55 Fig 56 A B 5 4 6 3 Fig 57 ...

Page 40: ... Disconnect the positive and negative starter motor ca bles 7 Remove the rear brake cable adjustment nut 8 Remove the filter case 9 Unscrew the rear shock absorber screw 10 7 Fig 58 8 Fig 59 9 Fig 60 10 Fig 61 ...

Page 41: ...nd see specific chapter Unscrew the nut 12 slide off the engine pin and re move the engine from the frame Unscrew the screws 13 Unscrew the exhaust manifold screws 14 and remove the exhaust 11 Fig 62 12 Fig 63 13 Cs N m 24 13 13 Fig 64 14 Cs N m 10 14 14 Fig 65 ...

Page 42: ...03 10 38 Unscrew the nut 15 and remove the rear wheel 15 Fig 66 ...

Page 43: ...le the dismantled parts If the pressure readings are below those indicated check the rpm used for the test if it is low check the starter system If the number of rpm is perfect or slightly above make sure the correct seal has been chosen for the cyl inder base and check the seals of the thermal part elastic bands valves etc IF YOU HAVE A HARD TIME INSERTING THE PRESSURE GAUGE FITTING DISCONNECT TH...

Page 44: ...nd drain oil Note the filtering net 3 must be cleaned and the gasket replaced at each oil change DISMANTLING THE CLUTCH COVER Unscrew the 8 cover fixing screws Remove the clutch cover Remove the gasket Remove the 2 bushes Replace the gasket each time the cover is disman tled 2 Cs N m 20 Fig 01 Fig 02 V8 Cs N m 10 Fig 03 ...

Page 45: ...the primary fixed half pulley 5 Remove the V belt Remove the clutch assy 6 and bush 7 Remove the washer 8 Dismantle the starter pinion unit assy 9 DISMANTLING THE REAR CLUTCH ASSY Lock the clutch housing using the specific tool Unscrew the nut 1 Dismantle the clutch housing and the rear clutch assy 1 Cs N m 50 Fig 04 Fig 05 1 Cs N m 50 Fig 06 ...

Page 46: ...arter motor O Ring conditions DISMANTLING THE ETC INTAKE MANIFOLD Unscrew the 2 intake manifold fixing nuts Remove the intake manifold Remove the two O Rings If necessary replace the O Rings DISMANTLING THE AIR CONVEYORS Remove the 4 fixing screws 1 Remove the conveyor 2 Unscrew the fixing screw 3 1 Cs N m 10 Fig 07 1 Cs N m 10 Fig 08 Fig 09 ...

Page 47: ...ew the 4 fixing screws 1 Unscrew the 2 secondary air hose screws 2 Remove the valve cover with its gasket The gasket must be replaced at each dismantling DISMANTLING THE SECONDARY AIR VALVE Remove the secondary air filter Unscrew the 2 screws 1 Unscrew the screw 2 Remove the air valve cover 3 Remove the air valve 4 Fig 10 1 2 Cs N m 10 Fig 11 Fig 12 ...

Page 48: ...he specific tool Unscrew the nut D Warning using an unsuitable tool may deterio rate the magneto flywheel coils Screw in the flywheel extractor E on the rotor 2 and screw in the central screw until the rotor detaches V4 Cs N m 10 D Cs N m 50 FLYWHEEL EXTRACTOR Code 64023700 Fig 13 V4 Fig 14 D Fig 15 E ...

Page 49: ... screws 2 Remove the stator and pick up DISMANTLING THE CHAIN TENSIONER Unscrew the screw O Ring and chain tensioner spring 1 Unscrew the 2 chain tensioner screws 2 Remove the chain tensioner and pull it by the lock tab A Remove the gasket 1 Cs N m 6 2 Cs N m 8 Fig 16 1 Cs N m 8 2 Cs N m 10 Fig 17 Fig 18 ...

Page 50: ...Loosen the 2 screws 1 Gradually loosen the four head nuts 2 in crossed order Remove the 4 nuts washers and 2 screws Remove the valve rocker arm bracket 3 Remove the timing chain 4 Slide out the cam shaft 5 Remove the head the head gasket 6 and 2 pins 7 Remove the timing chain sliding shoe 8 located in the cylinder on the exhaust side Fig 19 Fig 20 Fig 21 Fig 22 ...

Page 51: ...ker arms DISMANTLING VALVES AND VALVE STEM SEALS Compress the valve spring using the specific tool Remove the 2 valve stem halves 1 Decompress the spring and remove the tool Remove Upper valve cup 2 Springs 3 Lower washer 4 Valve 5 Remove the second valve following the same proce dure Fig 23 Fig 24 Fig 25 ...

Page 52: ...ed thoroughly grease the rocker arm shafts cams and contact points between the rocker arm and valve to avoid jamming when the engine is started use Molykote type grease Valve stem seals must be lubricated DISMANTLING THE CYLINDER Remove the cylinder 1 Remove the base cylinder gasket 2 and 2 pins 3 Remove the timing chain sliding shoe 5 screw 4 Slide out the timing chain sliding shoe Fig 26 Fig 27 ...

Page 53: ...emove the piston pin Remove the piston 2 DISMANTLING THE OIL SUMP Unscrew the 4 screws 1 85 mm Unscrew the 4 screws 2 100mm No tool is required to remove the oil sump Remove the oil sump 3 Remove the 2 pins 4 and the gasket 5 Fig 30 1 2 Cs N m 10 Fig 31 Fig 32 ...

Page 54: ...pinion nut 1 Remove the oil pump pinion 2 Unscrew the 3 oil pump screws 3 Remove the oil pump When the oil pump is removed always replace the 2 O Rings 3 Before reassembling the oil pump submerge it in a container with specific engine oil 3 Cs N m 10 Fig 33 Fig 34 Fig 35 ...

Page 55: ...nkcase 4 Remove the 2 pins Remove the gasket DISMANTLING THE CRANK SHAFT Remove the crank shaft 1 Remove the timing chain marking the rotation direction 2 CHECK CONNECTING ROD ASSEMBLY Check connecting rod axial play using a thickness gauge Maximum admitted connecting rod axial play must not exceed 0 55 mm 3 Cs N m 10 Fig 36 Fig 37 Fig 38 ...

Page 56: ...heel side B DISMANTLING THE TRANSMISSION COVER Drain oil through the drain cap 1 Fill and check oil level through the cap 2 Unscrew the 2 screws 3 30 mm Unscrew the screw 4 35 mm Unscrew the 3 screws 5 40 mm Remove the transmission cover Remove the 2 pins and the gasket Fig 39 2 Cs N m 12 3 4 5 Cs N m 12 Fig 40 Fig 41 Fig 42 ...

Page 57: ... assy 3 Remove the wheel axle 4 Remove the primary drive shaft 5 ASSEMBLY CRANKCASE ASSEMBLY The oil seals must be replaced each time the crankcase is dismantled Replace crankcase oil seals Mount the engine shaft and timing chain in the left crank case Fig 43 Fig 44 Fig 45 ...

Page 58: ...crew 3 Mount the oil pump pin 4 and 2 O Rings 5 Assemble the oil pump Tighten the 3 screws Assemble the oil pump pinion 6 Assemble the gasket and 2 pins ASSEMBLE THE OIL SUMP Position the oil seal 1 using a suitable tool The oil seals must be replaced each time the crankcase is dismantled Fig 46 Fig 47 Fig 48 Fig 49 ...

Page 59: ...ICK UP Position the stator as indicated Tighten the 2 screws 1 Tighten the 2 screws 2 Check correct woodruff key 3 position as indi cated in the figure before mounting Position the rotor on the crank shaft Lock the rotor with the specific tool Position and tighten the rotor nut to the indicated tight ening torque Page 44 Fig 14 3 4 Cs N m 10 Fig 50 1 Cs N m 6 2 Cs N m 8 Fig 51 Fig 52 ...

Page 60: ...ion Position the piston ring 3 with reference A facing up Position the upper piston ring 4 with reference A fac ing up ASSEMBLING THE PISTON Assemble the piston so that the IN reference is on the intake side Piston pin circlips must be replaced each time the piston is dismantled Piston pin circlip opening 1 must face either up or down but never to the side Fig 53 Fig 54 Fig 55 ...

Page 61: ... cylinder Pass the timing chain through the cylinder slot Manually compress piston rings and individually mount them in the cylinder Mount the timing chain sliding shoe fitting it in the cylin der housing A on the exhaust side ASSEMBLING THE HEAD Position the 2 pins 1 and the cylinder head gasket 2 on the cylinder Pass the timing chain through the head slot Any intervention that requires head dism...

Page 62: ... the refer ence 3 Position the timing chain on the cam shaft pinion 5 Make sure the cam shaft references 3 are parallel to the head level 4 Position the valve rocker arm bracket HEAD CYLINDER TIGHTENING This operation is performed in several steps Slightly grease the stud bolts Position the 4 washers Snugly fit the 4 nuts 6 and 2 screws 7 Tighten the 4 nuts in crossed order Tighten the 2 screws 7 ...

Page 63: ...d 13 Make sure the cam shaft references 14 are parallel to the head level 15 If references are not aligned repeat the timing procedure VALVE TIMING ADJUSTMENT Manually rotate the crank shaft in the operating direction to correctly align the rocker arm with the cam A Loosen the rocker arm adjusting screw locknut 1 With a thickness gauge adjust timing on each valve us ing the rocker arm adjusting sc...

Page 64: ...he roller bearing 6 ASSEMBLING THE STARTING SYSTEM Position the spring 1 hook the longer side on the cover pin A Position the roller bearing 2 Position the kick starter shaft 3 in the previously greased housing Hook the other side of the spring B to the kick starter shaft Load the spring until the kick starter shaft is positioned on the cover lock C Turn the cover position the seeger and washer on...

Page 65: ...p 11 and 3 dowels 12 Remove the 6 centrifugal rollers 13 Centrifugal rollers must be replaced if abnormally worn Assembly Proceed in reverse dismantling order without greasing the centrifugal rollers DISMANTLING THE CLUTCH ASSY Unscrew the 8 cover screws Remove the clutch cover Remove the gasket Remove the 2 pins Replace the gasket each time the cover is disman tled Lock the clutch housing using t...

Page 66: ...UTCH ASSY After ensuring that the 2 oils seals 1 Fig 73 and mo bile pulley O Rings 2 are in good conditions grease the 3 guide pins 6 and install parts in reverse disman tling order Tighten the nut 1 Fig 72 DISMANTLING THE CARBURETTOR DISMANTLING THE STARTER Remove the starter cover 1 Remove the screw 2 and starter plate 3 Remove the starter 4 marking its direction Fig 72 1 Cs N m 50 Fig 73 Fig 74...

Page 67: ... Remove the 2 valve cover screws 1 Remove the valve cover 2 Remove the spring Remove the needle valve and diaphragm Remove the needle lock 1 and relevant spring 2 ro tating it a turn Remove the needle and relevant washer 3 The needle position is adjusted by the manufac turer and cannot be modified Fig 75 Fig 76 Fig 77 ...

Page 68: ...AND JET Remove the 3 float chamber screws 1 Remove the float chamber 1 and relevant O Ring Remove the float 2 relevant float pin 3 and needle 4 Remove the idle jet 5 Ø 30 Remove the max jet 6 Ø 78 Remove the atomizer 7 Fig 78 Fig 79 Fig 80 ...

Page 69: ... it to be replaced in the same regulation position when reassembled Turn the screw 2 clockwise counting the number of turns until stop This operation allows it to be replaced in the same regulation position when reassembled Clean the carburettor and parts with specific solvents Spray all carburettor body ducts and its jets with com pressed air Do not use metallic tools which could ruin ducts or so...

Page 70: ...03 10 66 CYCLE TIGHTENING TORQUES Fig 85 Fig 87 Fig 89 Fig 91 Fig 86 Fig 88 Fig 90 Fig 92 ...

Page 71: ... bolt 23 2 3 89 8 Caliper screw 26 2 6 90 9 Clamp drain valve 7 5 0 75 90 10 Front disc screw 23 2 3 90 11 Rear wheel nut 120 12 91 12 Shock absorber screw 29 2 9 92 13 Rear brake lever nut 11 1 1 93 14 Engine mount pivot 98 9 8 94 15 Engine pivot 80 8 0 94 Item Nm Kgm Figure Cylinder head screw 10 1 0 Cam shaft nut 18 1 8 Rocker arm nut 10 1 0 Crankcase cover screw 10 1 0 Clutch housing nut 50 5 ...

Page 72: ...riginal settings is strictly prohibited Pick up screw 6 0 6 Oil pump gear nut 10 1 0 Oil filter cap 20 2 0 Starter motor screw 10 1 0 Gear motor oil level screw 12 1 2 Gear motor crankcase screw 12 1 2 Oil pump screw 10 1 0 Crankcase screw 10 1 0 Cylinder stud bolt 25 2 5 Cooling fan screw 8 0 8 Intake manifold screw 10 1 0 Spark plug 18 1 8 Item Nm Kgm M5 nut and bolt 4 0 4 M6 nut and bolt 9 0 9 ...

Page 73: ... 69 ELECTRICAL PART LOCATION Legend 1 Ignition switch 2 Regulator 3 Horn 4 Resistance 5 Relay 6 Front stop switch 7 Rear stop switch 8 Right switch connector 9 Left switch connector 5 1 2 3 4 Fig 96 6 9 7 8 ...

Page 74: ...older 10 A 12 CDI unit 13 Starter relay 14 Fuel level gauge 15 Fuel level gauge connector 16 Tail light wiring connector 17 Flywheel connectors 18 HT coil 19 Starter motor wire connector 20 Ground wire 18 17 19 10 12 13 11 20 Fig 97 16 15 14 ...

Page 75: ... F symbol FUEL If the gauge remains on E check Yellow White wire and White Black wire GROUND continuity If necessary replace the dash board NOTA The White Blue wire controls the fuel reserve warning signal Position White Black Red Black Off On Position White Blue Blue White Black High beam Low beam Passing Position Orange Grey Light Blue L R Position Yellow Green Yel low Red Push Position Black Li...

Page 76: ...IGNITION Ignition type Advance variable HT COIL SPARK PLUG CAP STATOR POWER 70W 1 Fig 99 Float position Resistance F position 6 10 Ω E position 90 100 Ω F E Fig 100 Resistance Winding Primary 0 45Ω 10 at 25 C Winding Secondary 3KΩ 20 at 25 C Resistance 5KΩ 20 Component Resistance Pick up Blue yellow wire 153Ω 10 Coil Red Black wire 420Ω 10 Light supply Yellow wire 0 9 Ω Battery charge White wire 1...

Page 77: ... GR AZ N B N B GL R N R ON 0FF GL R GL V N R B N R N N B N B R N N R R 10A R GL R B R GL V R B N B N L G BL GL N N B N R N R N N R N R GL BL GL BL GL B GL GL GL BL B B R B N B N GL N GL N 12V B N VC B BL BL B GL B GL B L G N B N W W 10 10 5 21 W AZ M VR GL V AR AR GL V B N GL AZ O N 0FF 0FF N B L B R A GR Z A N C V B BL B BL AR GR AZ N VC VC BL B BL B N VR GL VR N VR 5 5W GL N VR W VR B E L 3 4 5 ...

Page 78: ...8 Ignition switch 19 Horn 20 Fuel level sensor 21 Flywheel 22 CDI unit 23 Regulator 24 Battery 25 Starter resistance 26 Electric starter 27 Left turn indicator 28 Stop light 29 Right turn indicator 30 Coil 31 Starter motor Code Colour AR Orange AZ Light Blue B White B N White Black B BL White Blue B R White Red BL Blue GL Yellow GL B Yellow White GL BL Yellow Blue GL N Yellow Black GL V Yellow Gre...

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Malaguti MALBO Line, Service Manual

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Summary of Contents for MALBO Line

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