32
11/06
A
PASSWORD 250 i.e.
FRAME AND RUNNING GEAR
4
M A I N T E N A N C E
MAINTENANCE TABLE
Spark plug
(electrode condition and gap)
Engine oil and mesh strainer cleaning
Gearbox oil
Valves
(clearance)
Idling speed
V-belt
Clutch ground
Primary speed variator rollers
Variator pulley bushing
(greasing)
Tightness of brake lines
Air filter
State of the battery and charge level
Wear: Brake pads – Brake discs
Level and density of coolant (
change every 2 years
) – Correct fitting and tightness of hoses
Brake fluid circuit
Wheel bearings
Frame linkages
Steering operation and play
(lubricate if necessary)
Operation and oil-tightness of fork and shock absorbers
Tightness of nuts and bolts
Tightness of side and centre stands – Pivot lubrication
Operation of side stand switch - Lubrication
Tyre pressure – Tread wear
Final check:
Condition of tyres - Pressure – Lights - Indicators - Switch
functions - Road test
CHECKS AND REPLACEMENT OPERATIONS
= first service
30000
km
every 2000 km
27000
km
24000
km
21000
km
18000
km
15000
km
12000 km
or 24 months
9000 km
or 18 months
6000 km
or 12 months
3000 km
or 6 months
FIRST
1000 km
*****
*****
*****
*****
= change
= adjustment
= cleaning
= inspection
1
2
4
5
6
every 24 months or 12000 km
3
INTRODUCTION
WARNINGS
For the safety of your customers and others and to ensure correct operation of the vehicle, it is
essential to carry out the routine maintenance operations within the scheduled times indicated in the
relative table in this manual.
Failure to perform routine maintenance operations can impair operation of the vehicle, with all the
relevant consequences, including INVALIDATION OF THE WARRANTY.
For information on the warranty, refer to the “Warranty and Log Book”.
Before starting any work on the vehicle, stop the engine, remove the ignition key and wait for the
engine, the exhaust and the cooling systems to cool down completely to avoid the risk of burns.
When performing maintenance work, wear protective goggles and gloves and make sure that all
heated parts of the vehicle have cooled down to avoid the risk of burns.
THE FIRST SERVICE must be carried out at 1000 km: for subsequent services see the MAINTENANCE TABLE.
MAINTENANCE
The maintenance schedule is based on average riding conditions. Machines subject to severe use or ridden in unusu-
ally wet or dusty conditions or off the road require more frequent servicing.
NOTE
Certain simple checks, i.e. those marked with an asterisk, MAY be performed under the direct respon-
sibility of technicians not specifically authorised by MALAGUTI.
