Malaguti Password 250 Workshop Manual Download

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110

09/05

PASSWORD 250

FRAME AND RUNNING GEAR

DISASSEMBLY

135 ± 15%

45 ± 15%

REAR WHEEL

• (Remove silencer).

• (Remove right-hand rear shock-absorber).

• (Remove mudguard).

• (Remove rear brake calliper).

• Undo nut (D) with washer and screws (V2).

• Remove spacer (B) from the wheel spindle.

When refitting the wheel spacer (B) must be
positioned with the largest diameter side
towards the wheel bearing, as shown in the
photo.

• Remove swingarm (C).

There is a spacer behind the swingarm sim-
ilar to the spacer IN FRONT of the arm; the
spacer must be refitted with the smallest di-
ameter side facing the arm. See also follow-
ing pages.

Summary of Contents for Password 250

Page 1: ...FRAME AND RUNNING GEAR WORKSHOP MANUAL ...

Page 2: ...nction 24 MILES OR KILOMETRES SELECTION 24 HANDLEBAR CONTROLS 25 Right hand control 26 Left hand control 26 KEYSWITCH 27 HANDLEBAR LOCK 27 Locking 27 Unlocking 27 STANDS 28 Centre stand 28 Side stand 28 OWNER STOOLKIT 29 DIMENSIONAL CHECK OF FRAME 30 3 INSTRUCTIONS FOR USE STARTINGTHE ENGINE 31 4 MAINTENANCE INTRODUCTION 32 Warnings 32 MAINTENANCE TABLE 32 TRANSMISSION OIL 33 Level check 33 ENGINE...

Page 3: ...witch 82 CENTRE STAND 83 FUEL PUMP 84 RADIATOR 85 ACCESSIBILITY 89 FAN UNIT 89 RADIATOR assembly 90 KEYSWITCH 91 SEAT 92 HELMET COMPARTMENT 92 SEAT LOCK 93 ACCESSIBILITY 94 FUEL LEVEL SENSOR 95 PILLION GRAB HANDLE 96 TAILLIGHT 97 ACCESSIBILITY 97 TAILLIGHT assembly 98 NUMBER PLATE LIGHT 99 REAR FAIRING 100 ACCESSIBILITY 102 FUEL TANK 103 SILENCER 105 REAR SHOCK ABSORBERS 107 REAR MUDGUARD 108 REAR...

Page 4: ... rear fairing 137 Under the helmet compartment 137 BRAKE SYSTEM 138 Front brake master cylinder 139 Rear brake master cylinder 139 Rear calliper 141 Front calliper 141 COOLANT SYSTEM 142 Under the helmet compartment 143 Under the footboard 143 Under the footboard 145 Engine left side 145 FUEL SYSTEM 146 Under the helmet compartment 147 Under the rear fairing 147 Under the footboard 147 THROTTLETRA...

Page 5: ...ves the right to 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 Worksho...

Page 6: ...t basic technical concepts or 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 ...

Page 7: ...ke care 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 ...

Page 8: ...ts to clean 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 fro...

Page 9: ...ed disconnect 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 ...

Page 10: ...wet sump SPARK PLUG type NGK DR8EA TRANSMISSION Primary automatic speed variator with V belt Final gearbox Automatic centrifugal clutch FUEL SYSTEM Carburettor KEIHIN 4MSA Automatic starter Fuel unleaded petrol IGNITION Electronic with digital control CDI BRAKES Front brake Ø 270 mm disc hydraulic calliper with double Ø 25 mm piston Rear brake Ø 240 mm disc hydraulic calliper with Ø 30 mm piston F...

Page 11: ...7 Fuel tank cap 8 Pillion grab handles 9 Rear turn indicators 10 Parking and stop lights 11 Number plate light 12 Number plate holder 13 Air filter 14 Centre stand 15 Side stand 16 Left hand pillion bracket 17 Bag hook 18 Glove compartment 19 Left hand mirror IDENTIFICATION OF MAIN COMPONENTS right hand side 20 Front turn indicator 21 Front parking light 22 Headlights 23 Radiator 24 Coolant tank 2...

Page 12: ...ain access to the vehicle identification number VIN A lift the right hand rubber floor mat and remove the cover Engine identification data are located on the left hand engine crankcase B Alteration of identification data is a criminal offence When ordering spare parts it is essential to quote the vehicle identification data ...

Page 13: ...rip if they are damaged cracks or cut have them replaced as soon as possible There are T W I marks all around the tyre sidewalls 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 the tread depth the tyre must be changed NOTE Minimum tread depth front and rear is 2 mm INFLATION PRESSURE Tyre inflatio...

Page 14: ... the scoot er body immediately since fuel may damage surface finishes The quantity of fuel and the use of the reserve fuel ca pacity are displayed by the relative function of the on board computer and the amber warning light on the right hand side of the instrument panel Use UNLEADED PETROL Guideline value Petrol is extremely inflammable avoid approaching the fuel filler also when refuelling with ...

Page 15: ...never remove coolant tank cap B when the engine is hot Do not top up with water except in emergen cy situations in which case drain the tank completely and fill with the prescribed cool ant as soon as possible REAR VIEW MIRRORS The left and right rear view mirrors must be fitted to the specific locations on the handlebars and firmly secured in place Adjust the visual angle of the mirrors while sit...

Page 16: ... lights off note that using the socket reduces battery recharging and can reduce the battery charge level in certain circumstances Do not use the socket for appliances with an excessive power draw max power draw 30W The socket can also be used to recharge the battery by connecting it to a battery charger for sealed batteries when the engine is switched off Remember to refit the socket cap after us...

Page 17: ...is fitted with a lock that can be opened with the ignition key turn the key clockwise The glove compartment contains the electrical system fuses B and relative spare fuses C are contained in a pocket in the door see the relative section in the manual Do not place heavy objects or temperature sensitive items lighters matches inflamma ble liquids perishable goods etc in the compartments Do not leave...

Page 18: ...te that the Engine Stop button is set to OFF 5 Green low beam indicator light 6 Blue high beam indicator light 7 Green left hand turn indicator light 8 Green right hand turn indicator light 9 Fuel level indicator The warning light illuminates to indicate that the reserve fuel level has been reached 10 These lights are not used The engine is not equipped with an oil tem perature probe so the oil wa...

Page 19: ...signal disappears the following appear 1 Secondary Menu or Submenu 2 Main Menu 3 Bar graph To select a function press the MODE button on the right hand control Operation of the MODE button is illustrated in the following diagrams by means of an arrow symbol accompanied by the time for which the button must be held down If the time is not specified momentary pressure on the button 1 sec is sufficie...

Page 20: ...unctions are always accessible irrespective of the Main Menu that has been opened The choice of the speedometer unit of measurement km or miles can only be made from the relative selection menu when the battery is hooked up to the scooter When selecting the unit of measurement adhere strictly to the rules in force in your country SECONDARY MENU OR SUBMENU A TOD FUNCTION total km or miles Indicates...

Page 21: ...ess the MODE button for 3 seconds until only the minutes and seconds are shown on the display Change the flashing number by pressing the MODE button briefly and repeatedly Holding down the button for a longer interval serves to switch to the next digit to change Not pressing the MODE button for 3 seconds serves to quit time setting mode E AIR TEMPERATURE FUNCTION Shows ambient temperature in degre...

Page 22: ...fuel in the tank The quantity of fuel in the tank is displayed in graphic form by means of an 8 segment bar graph on the right hand side of the display When the second segment switches off this means the scooter is running on the reserve supply the corresponding amber warning light will illuminate B BATTERY LEVEL INDICATOR FUNCTION Vbatt Shows the battery charge level Charge level is displayed in ...

Page 23: ...h the engine off this indication appears in flashing mode C OIL CHANGE ALARM Prompts the rider to execute a scheduled service The symbol appears with the message OIL CHA This indication will flash for 1 minute when the ignition key is turned on if the limit for a scheduled service see MAINTENANCE TABLE has been reached It is the responsibility of local Authorised MALAGUTI Service Centres to reset ...

Page 24: ...tes by removing and refitting the main fuse The selection menu will appear on the display Turn ON the ignition key Select the desired unit of measurement by pressing the MODE button when the unit required is displayed The data in the memory except TOD will be reset This choice must be made every time the digital instrument panel remains without power for several minutes IMPORTANT Using a unit of m...

Page 25: ...he various digital instrument panel functions A Emergency switch engine stop Position Engine start Position Engine stop B Lights switch rh position off centralposition parkinglightsandinstrumentpanel lh position low beam high beam C Electric starter button LEFT HAND CONTROL 1 High beam flasher lever passing 2 Rear brake lever 3 Counterweight 4 Horn button 5 Turn indicator switch 6 Lights selector ...

Page 26: ...compartment lock a Ignition disabled key can be removed b Ready to start position key cannot be re moved c Handlebar lock on ignition disabled key can be removed d Helmet compartment lock NOTE The scooter is supplied with two keys HANDLEBAR LOCK LOCKING Turn the handlebars all the way to the left insert the key press and turn it counter clockwise UNLOCKING Turn the key clockwise ...

Page 27: ...DE STAND The side stand is located on the left hand side of the scooter B and it is monitored by a microswitch that prevents the engine from starting unless the stand is properly closed Do not remove or tamper with this safety device We advise you to check the retaining system of both stands regularly The system is com posed of tension springs Irrespective of whether using the side stand or centre...

Page 28: ... D E A OWNER S TOOLKIT The scooter is equipped with a tool bag stowed under the seat The bag contains the following tools A Spark plug wrench B Handle for tool inserts C Double insert PH2 Allen wrench size 4 to be used with handle B D Pliers E C spanner for shock absorber adjustment ...

Page 29: ...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 1206 mm with a tolerance of 2 mm Do not attempt to bend the frame to restore the original A measurement ...

Page 30: ...is set to OFF The OFF position of the emergency stop switch is signalled by a warning light on the digital instrument panel To start the engine before pressing the ignition button activate the start enable permissive switch by pulling the front or rear brake lever and keeping it pulled The fuel system is designed to manage engine starting on the basis of engine conditions cold warm and ambient tem...

Page 31: ...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 incl...

Page 32: ... oil Recommended oil Q8 T35 80W Capacity 0 25l 7 Fit the filler cap Oil change after the first 1 000 km and every 12 000 km thereafter 1 Perform the operations described in points 1 2 3 4 5 2 Fill the crankcase with new oil of the recommended type Recommended oil Q8 T35 80W Capacity 0 25l 3 Fit the filler cap Perform this operation with the engine off and when it is cold NOTE Regularly check for o...

Page 33: ...e scooter on flat ground and put it on its centre stand 2 Stop the engine and wait a few minutes for the oil level to stabilise 3 Unscrew the cap dipstick A dry the dipstick with a clean cloth and re insert it without screwing down the cap 4 Remove the cap dipstick and make sure the level is between the MAX and MIN marks if necessary top up with Q8 CLASS 10W 40 oil Maximum oil quantity 1 4 l Max o...

Page 34: ...changed Engine oil change and mesh strainer cleaning after the first 1000 km and every 3000 km or 6 months thereafter 1 Warm the engine up for a few minutes 2 Stop the engine Place an oil container under the en gine and remove the dipstick 3 Remove drain plug A and dipstick and allow the oil to flow into the container 4 Clean strainer B with solvent 5 Check O ring C and renew if damaged 6 Refit th...

Page 35: ...NT The coolant expansion tank is located under the rubber mat on the right hand side The coolant level can be checked with reference to the MIN and MAX marks which are visible through the chassis number inspection window Check the coolant level in the tank when the engine is cool in order to avoid burns The coolant level is correct when it is between the MIN and MAX marks on the reservoir If it is...

Page 36: ...to cool down and check that cooling surface of the radiator located between the headlights is not obstructed remove any debris that coolant is not leaking from the circuit see coolant level top up that the fan fuse has not blown change the fuse if necessary LUBRICANT TABLE The lifetime of the scooter depends on various factors including the execution of correct lubrication LUBRICANTS TYPE OF LUBRI...

Page 37: ... waiting at least 10 15 minutes for the engine to cool Any deposits on the plug and the colour of the insulator can provide useful information concern ing the heat rating the fuel air mixture and the general condition of the engine If the engine and spark plug are in good working order the insulator should dis play light brown discolouration around the central elec trode After removing the spark p...

Page 38: ...ck absorbers to the same position Unbalanced adjustment will affect the stability of the scooter When travelling with pillion set the shock absorber spring to position 4 Wear gloves when adjusting the shock absorbers risk of abrasion injury ADJUSTING IDLING SPEED Engine idling speed should be adjusted whenever you notice that the engine is idling unevenly To check idle speed start the engine and r...

Page 39: ...t is good practice to check the front rear pads and discs every 2 000 km Minimum thickness of the brake pads is 2 mm Inspect brake pad thickness as illustrated in points A and B If the thickness of the pads is close to the minimum limit or if they are damaged have them replaced immediately Worn brake discs and pads must be replaced as soon as possible ...

Page 40: ...it ADJUSTING THE BEAM To check adjust the vertical beam angle proceed as follows position the scooter in running conditions at 10 metres from a wall switch on the low beam headlights and keep the scooter upright without a stand and without rider e g lean it against a side wall remove the two adjusting screw caps inside the glove compartment use a cross head screwdriver to turn the headlight adjust...

Page 41: ...ring by undoing the 4 screws V Low beam high beam bulbs A Remove the wiring connector rubber cap and spring change the bulb refit the spring rubber cap and wiring connector refit the upper fairing Parking light B Remove the rubber bulbholder change the bulb refit the rubber bulbholder by pressing and refit the upper fairing FRONT TURN INDICATOR Front turn indicator A 12V 16W bulb W16W ...

Page 42: ...older by turning it clockwise Secure the handlebar casing The rate at which the turn indicator warning light on the instrument panel flashes will increase to signal that one of the four indicators is not working When performing the operations described above take care not to damage parts in the vicinity transmissions wiring seals etc TAILLIGHT with brake light Parking light A 12V 5W bulb W5W Brake...

Page 43: ... A Remove the bulbholder from the inside of the taillight replace the bulb refit the rubber bulbholder by pressing and the cover Brake light B and turn indicator C Remove the coloured cap secured by means of 2 clips from the taillight replace the bulb refit the coloured cap and cover When performing the operations described above take care not to damage parts in the vicinity transmissions wiring s...

Page 44: ...trol to its central position and turn the key to starting position REPLACING THE NUMBER PLATE LIGHT BULB To replace the number plate light bulb remove the number plate light cover B by undoing screw V remove the rubber bulbholder from the plastic cover replace the bulb refit the bulbholder and the cover When performing the operations described above take care not to damage parts in the vicinity tr...

Page 45: ...se F 5 A Fuel pump G 7 5 A Fan H 30 A Battery charge protection To change a fuse simply open the lower fairing cover and remove the blown fuse replacing it with an identi cally rated fuse Several spare fuses A are provided on the inside of the cover Check that the fuse you intend to fit is identi cally rated to the one you are replacing Do not replace fuses with others of higher rating This action...

Page 46: ... films from the ends of the adhesive area as shown by the arrow in the drawing A remove the two sponge vibration dampers from the orig inal battery you have just removed and apply them to the new battery Procure new vibration dampers if nec essary remove the 30A main fuse remove the rubber mats B undo the 4 screws V remove the centre partition un der the seat C remove the elastic band D and the pl...

Page 47: ... action may cause faults and short circuits on the electrical system and its components NEVER invert battery cable connection polarity If the battery is allowed to discharge completely and allowed to remain in this condition it will deteriorate rapidly NOTE Use protective gloves and goggles when removing the battery e g for recharging RECHARGING THE BATTERY It is good practice to remove the batter...

Page 48: ...rying to start the engine if the engine fails to start remove the spark plug and dry it carefully then refit the spark plug and try to start the engine again 5 Clogged or dirty air filter 6 Starter motor runs too slowly the battery is discharged or partially discharged 7 Starter motor runs but engine fails to start check condition of the spark plug clean or change if necessary STORAGE To keep the ...

Page 49: ...solvents which can cause rapid oxidation of metal parts Do not use excessively high pressure water jets when cleaning the vehicle as this may damage mechanical and electrical components especially at the front of the scooter handlebars upper fairing instrument panel lights etc Avoid high pressure washing e g pressure washers etc To clean the windshield correctly use a soft clean cloth or a sponge ...

Page 50: ...eleased from all liability for damage to the vehicle or to the user due to installation of non original accessories Likewise MALAGUTI Spa is released from all liability for damage to the vehicle or harm to the user due to improper installation of accessories including genuine original accessories In this case all responsibility is borne by the person organisation that performed said installation I...

Page 51: ... V2 V2 V4 V4 REMOVAL INSTRUMENT PANEL WINDSHIELD Remove the two covers A taking care not to snap off the tabs holding them in place Undo screws V4 and remove the windshield Recover the rubber grommets under the screws UPPER HANDLEBAR COVER Undo screws V2 Undo screws V4 ...

Page 52: ...andlebar cover A upwards complete with the instrument panel Take care not to damage instrument panel connector cable B INSTRUMENT PANEL Remove windshield Remove upper handlebar cover Detach the connector B Undo screws V4 and screw V then detach instru ment panel from upper handlebar cover ...

Page 53: ...t panel provides access to the following components Instrument panel connector A Connector for LH handlebar control B Connector for RH handlebar control C RH control STOP switch D LH control STOP switch E Rear brake master cylinder union F Front brake master cylinder union G Turn indicators connector H Ambient temperature sensor connector L ...

Page 54: ...or A Remove sensor B from lower handlebar cover C The sensor must be mounted EXTERNAL LY to the lower handlebar cover as shown in the figure LEFT HAND CONTROL Remove windshield Remove upper handlebar cover Undo screw V and remove counterweight Undo screws V2 and remove LH control Use compressed air to reduce friction when removing and refitting the twist grip ...

Page 55: ...ove windshield Remove upper handlebar cover Disconnect throttle opening A and closing B cables Undo screw V and remove counterweight Undo screws V2 and remove throttle control Use compressed air to reduce friction when removing and refitting the twist grip FRONT FAIRING Undo screws V2 Undo screws V2 ...

Page 56: ...nd lift the lower part slightly and disconnect connector B now remove the fairing When refitting take care not to pinch the headlight cable ACCESSIBILITY Removing the front fairing provides access to the follow ing components Radiator and relative cap A Fan connector B Coolant hoses with clamps C ...

Page 57: ... DISASSEMBLY 6 58 09 05 V6 V6 V4 B V6 V6 V4 HEADLIGHTS Remove front fairing Undo screws V6 and remove headlights To change the bulbs refer to Replacing headlight bulbs page 42 GRILLE Remove front fairing Undo screws V4 and remove grille B ...

Page 58: ... MUDGUARD Undo screw V and remove nut D responsible for securing hydraulic hose clamp A Unscrew screws V4 on the underside of the mud guard Remove the mudguard sliding it through the forks and taking care to protect from scratching Pay attention to the four bushes B located under the screws ...

Page 59: ... does not fall Disconnect the electronic transmission connector See Systems section When refitting use a feeler gauge to check that the sensor disc gap is 1 2 mm Remove the sensor complete with the transmission FRONT BRAKE CALLIPER Undo screws V2 and free the complete calliper When refitting insert the longest screw in the top fitting ...

Page 60: ...he hydraulic circuit and drain the fluid into a container so that it may be disposed of in compliance with statutory environmental and waste disposal legislation When removing the calliper take care to protect the hydraulic line disc and brake pads from damage After working on the brake system make sure that the brake fluid line is not twisted that the discs and pads are not contaminated with oil ...

Page 61: ... scooter from fall ing Remove speedometer sensor Remove front brake calliper Loosen screw V Unscrew and remove wheel spindle A paying atten tion to spacer B 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 to refit the spacer and grease spindle A ...

Page 62: ...ME AND RUNNING GEAR DISASSEMBLY 6 V6 11 10 V6 V6 V6 FRONT BRAKE DISC Remove speedometer sensor Remove front brake calliper Remove front wheel Undo screws V6 When reassembling use new screws and apply a high strength threadlocker ...

Page 63: ...A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 64 09 05 V4 V4 V4 A LEFT AND RIGHT HALF SHIELD Remove front fairing Remove rubber mats A Undo screws V4 ...

Page 64: ...65 09 05 A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 V4 V4 V1 Undo screws V4 Undo screw V1 Pay attention screw V1 is internal and con cealed by the fairing Remove the half shield ...

Page 65: ...ASSEMBLY 6 66 09 05 A B C E D ACCESSIBILITY Removing the right hand half shield provides access to the following components Fuse connections A Horn B Keyswitch connector C Connector D provision for anti theft system Odometer sensor connector E ...

Page 66: ...g the left half shield provides access to the fol lowing components Coolant hoses F HORN Remove right hand half shield Undo screw V and disconnect the cables For subsequent reassembly connect BLUE wire A to the horn INTERNAL terminal and ORANGE wire B to the EXTERNAL termi nal ...

Page 67: ...AME AND RUNNING GEAR DISASSEMBLY 6 68 09 05 V2 A B RIGHT AND LEFT LATERAL SUB PANELS Remove rubber mats Undo screws V2 Grasp lateral sub panel A and disengage it from foot board attachment point B by turning it outwards ...

Page 68: ...provides access to the following components Seat lock transmission A NOTE If you need to open the helmet compartment WITHOUT the key remove rubber protection B and then pull the two control cable sheaths Removing the left hand sub panel provides access to the following components Side stand and relative switch C A ...

Page 69: ...A B V2 C C D C D D E Removing both sub panels provides access to the follow ing components CDI control unit D Voltage regulator E CDI CONTROL UNIT Free connector A by pulling purple tab B then dis connect the connector Undo screws V2 and remove CDI control unit C ...

Page 70: ...71 09 05 A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 A V2 B VOLTAGE REGULATOR Disconnect connector A by pressing the tab Undo screws V2 and remove regulator B ...

Page 71: ...A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 72 09 05 V4 V4 A V4 BATTERY COMPARTMENT TUNNEL COVER Undo screws V4 Gently pull tunnel cover A towards the front of the scooter to remove it ...

Page 72: ...es access to the fol lowing components Starter motor relay A Flasher unit B Starter motor disconnection relay C WHITE Fuel pump relay D BLACK Ignition coil E Battery compartment F Spark plug G NOTE If you need to disconnect ignition coil E re member that the ORANGE wire must be con nected to the coil BLACK connector while the BLACK wire must be connected to the GREEN terminal ...

Page 73: ...battery leads are routed through opening A in the rear of the cover cover B can be removed ONLY if all battery leads are disconnected the RED leads must be connected to the battery POS ITIVE pole the BLACK lead must be connected to the battery NEGATIVE pole the battery poles must be towards the REAR of the scooter ...

Page 74: ...D RUNNING GEAR DISASSEMBLY 6 V2b Vc V2a SUB FAIRING Remove half shields Remove front mudguard Undo screws V2a Undo screws V2b Undo screw Vc Screws V2a and Vc are equipped with bushes that must be recovered when the screws are removed ...

Page 75: ...FAIRING Remove upper fairing Remove front half fairings Remove sub fairing Remove keyswitch cover A rotating it counter clock wise through of a turn Open the luggage compartment and undo fusebox screws V2 When reassembling note that the LIGHT BLUE 15A fuse must be uppermost ...

Page 76: ...77 09 05 A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 V V V2 Undo bag hook screws V2 Undo screw V Undo screw V ...

Page 77: ... fairing to wards the front of the scooter also disengage screw inserts C Make sure the luggage compartment is CLOSED now rotate lower fairing D slightly towards the rear of the scooter and remove by lifting upwards There is a 12V socket in the luggage com partment the Faston connectors must be disconnected from the socket before the lower fairing can be removed ...

Page 78: ...RUNNING GEAR DISASSEMBLY 6 A V4 V4 FOOTBOARD Remove the battery compartment tunnel cover Remove the battery Remove the sub panels Remove right left half fairings Remove lower fairing Undo screws V4 Rotate footboard A upwards and remove ...

Page 79: ...D 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 D B A C ACCESSIBILITY Removing the footboard provides access to the following components Coolant expansion tank A Fuel pump B Side stand switch connector C Fuel pump connector D ...

Page 80: ...sub fairing Remove lower fairing Remove footboard DANGER OF BURNS Before proceeding make sure that the cool ant temperature is lower than 50 C Undo the radiator cap Place a 2 l recipient under expansion tank A Open clamp B and slide down the hose now slide out hose C wait for all the coolant to drain out from both the hose and the tank Undo screws V3 and remove tank A ...

Page 81: ...50 FRAME AND RUNNING GEAR DISASSEMBLY 6 V 20 15 V A V2 A V2 5 20 SIDE STAND Detach springs A and undo screw V SIDE STAND SWITCH Undo screws V2 Disconnect connector A under the footboard on the right hand side of the scooter ...

Page 82: ...RUNNING GEAR DISASSEMBLY 6 A C D B CENTRE STAND Prop up the centre of the scooter to prevent it from falling Detach two springs A Remove snap ring B washer C then remove pin D When reassembling ALWAYS insert washer C UNDER the snap ring ...

Page 83: ...d Remove sub fairing Remove lower fairing Remove footboard Obtain two Ø 5 mm plugs DANGER During this procedure do not use heat and keep sparks and naked flames well clear of the scooter Loosen clamps A and remove hoses B from pump C Immediately plug hoses B with the plugs Disconnect connector D Withdraw pump C towards the rear of the scooter ...

Page 84: ... cool ant temperature is lower than 50 C Remove radiator cap A Place a 5 l recipient under the scooter Remove screw V and wait for ALL the coolant to flow out When refitting screw V renew the copper washer NOTE When reassembling follow the procedure outlined at the end of the heading Empty the tank of coolant Open clamp B and free the fan cable At the time of reassembly remember to se cure the cab...

Page 85: ... AND RUNNING GEAR DISASSEMBLY 6 V4 V2 V2 C Undo screws V4 Undo screws V2 Remove clamps C NOTE For the subsequent assembly phase the clamps must be positioned immediately be hind the point at which the metal pipe diame ter increases ...

Page 86: ...S to remove the clamps Detach rubber hoses D from metal pipes NOTE To facilitate this operation prise the hose by inserting a screwdriver under it while simul taneously pulling it Remove radiator cap E and lift the edges F of radi ator support partition G to disengage the radiator at tachment points ...

Page 87: ...es M are marked with a coloured dot to distinguish their re spective functions the one with the GREEN dot serves to con nect disconnect the radiator fan YELLOW wires the one with the BROWN dot serves to dis connect the carburettor choke when cool ant temperature exceeds 50 C as soon as the keyswitch is set to ON and the EN GINE STOP button is set to the start po sition WHITE BROWN wire BLACK wire ...

Page 88: ...ro vides access to the following components Keyswitch connector A Odometer pickup connector B Headlights connector C Anti theft system connector D provision Fan connector E Radiator thermal switch Faston connectors F FAN UNIT Undo screws V3 NOTE For reassembly position the fan as shown in the figure and position clamp A under the screw as indicated ...

Page 89: ...NG GEAR DISASSEMBLY 6 V A 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 loosen screw V and allow ALLTHE AIR to escape now tighten screw V ...

Page 90: ...run it at IDLE speed for a few minutes then switch off and unscrew the bleed screw again to vent any residual air Now retighten the bleed screw KEYSWITCH Remove sub fairing Remove front half fairings Remove lower fairing Detach connector A and disconnect transmission B now undo screws V2 NOTE Use aTORKS wrench for tamperproof screws to unscrew screws V2 ...

Page 91: ... surface with the upholstery upwards HELMET COMPARTMENT Remove seat Undo screws V2 and V4 With the helmet compartment fitted the car burettor can be adjusted through opening A Remove fuel tank cap B remove gasket C discon necting it from the drip hose then refit the cap Screw the fuel tank cap back on immediate ly after removing the gasket The helmet compartment is still attached to the scooter vi...

Page 92: ...ble C from metal clamp D NOTE Make a mental note of the path followed by transmission cable C thereby making sure you refit in the correct position at the time of reassembly Unscrew screws V2 ensuring you recover the rela tive nuts NOTE You can now remove the helmet compart ment from the scooter NOTE If the seat lock jams or if you lose the key refer to the section on accessibility after re moving...

Page 93: ...tank A Fuel level sensor B Fuel suction filter C Carburettor valve cover D Automatic choke connector E Engine temperature thermistor F Throttle control cables G Idle speed adjusting screw H Cooling system air bleed screw L Intake valve cover M Timing chain tensioner N NOTE Note that the idle speed adjusting screw is ALSO accessible through the opening in the helmet compartment ...

Page 94: ...dure do not use heat and keep sparks and naked flames well clear of the scooter If the tank remains without the fuel level sensor fitted for a prolonged peri od plug the hole to prevent the accumula tion of petrol vapour in the workshop A V4 Remove sensor C When removing the sensor take care when the float is being extracted through the hole in the tank When reassembling MAKE SURE the float is fac...

Page 95: ... V2 V A V2 43 15 PILLION GRAB HANDLE Remove seat Remove helmet compartment Remove seat lock Undo screws V2 and V and remove handle A When refitting the grab handle pay atten tion to seat lock cable A which must fol low the route indicated with respect to the grab handle ...

Page 96: ...aillight bulb page 44 To remove the complete unit first free the electrical cables from cable tie A now de tach connector B located under the pillion grab handle see Pillion grab handle ACCESSIBILITY Removing the taillight provides access to the following components Number plate light connectors A ...

Page 97: ... B C A TAILLIGHT Insert the electrical cable through opening A Fit the taillight unit paying attention to attachment point B in the scooter number plate holder rear fairing the attachment point must interlock with tab on the tail light Now reconnect connector C ...

Page 98: ...T See Replacing the number plate light bulb page 45 Remove taillight Open clamp A and free the electrical cable At the time of reassembly the electrical ca ble must be restrained in the clamp again Disconnect connectors B When reassembling pay attention to the wire colour coding A ...

Page 99: ...Remove seat Remove helmet compartment Remove seat lock Remove taillight Remove pillion grab handle Remove battery compartment tunnel Undo screws V2 Undo screws V4 NOTE To remove screws V4 use a screwdriver with a 90 angled blade Slide out the fairing towards the rear of the scooter ...

Page 100: ...101 09 05 A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 V4 V4 V2 The figure shows the rear fairing with an indication of ALL the screws to be removed ...

Page 101: ...2 09 05 A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 A B C ACCESSIBILITY Removing the rear fairing provides access to the follow ing components Fuel filter A Flywheel connectors B Ground terminal C ...

Page 102: ...mes well clear of the scooter If the tank remains without the fuel level sensor fitted for a prolonged peri od plug the hole to prevent the accumula tion of petrol vapour in the workshop Make sure the tank is empty Before emptying the tank wait for the en gine to cool down Use a manual pump Open clamps A At the time of reassembly the rear clamps must restrain the electrical cables while the front ...

Page 103: ...SSEMBLY 6 V4 V4 V4 C D Undo screws V4 There is a bushing C under each screw V4 The tank support must rest on a rubber SilentBlock D ensure the rubber mount does not fall Fit the electrical cable ties under the two rear screws when refitting the fuel tank ...

Page 104: ... the components have cooled down and always wear suita ble protective gloves Undo exhaust manifold nuts D2 Undo screws V2 Unscrew screw V while supporting the silencer and then remove the silencer from the scooter complete with protection and exhaust manifold Follow the proposed disassembly procedure manifold nuts lower screws upper screw in order to facilitate the operation ...

Page 105: ...ure for disassembling the components of the exhaust unit is illustrated in the figure When refitting the silencer always renew gasket A and check the condition of gas ket B Note that before separating the silencer from the exhaust pipe you must FIRST remove the wire heat shield C ...

Page 106: ...GEAR DISASSEMBLY 6 REAR SHOCK ABSORBERS Before removing the rear shock absorbers support the centre of the frame to prevent the scooter from falling First undo lower screw Va then upper screw Vb Remove shock absorber A Va 24 15 Vb A Va Vb 45 15 ...

Page 107: ...108 09 05 A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 V V2 V 3 5 20 V REAR MUDGUARD Undo screws V2 Undo screw V Undo screw V then remove mudguard towards rear of scooter ...

Page 108: ...ed or the thickness less than 3 5 mm it must be renewed Minimum thickness of the pads is 2 mm REPLACING THE REAR CALLIPER Empty the brake fluid circuit draining the fluid into a sui table container for disposal in compliance with statutory environmental legislation When removing the calliper beware of the risk of damaging the brake fluid line the disc and the brake pads After working on the brakin...

Page 109: ...nut D with washer and screws V2 Remove spacer B from the wheel spindle When refitting the wheel spacer B must be positioned with the largest diameter side towards the wheel bearing as shown in the photo Remove swingarm C There is a spacer behind the swingarm sim ilar to the spacer IN FRONT of the arm the spacer must be refitted with the smallest di ameter side facing the arm See also follow ing pa...

Page 110: ...oved snap ring E Remove rear wheel F Spacer H is located on shaft G behind the wheel Before reassembling grease shaft G abundantly especially on the splines The layout of the following components is shown in the figure A nut B spacer H spacer L washer M spacer The arm must be positioned between the two spacers B and M the wheel must be positioned between spa cers M and H ...

Page 111: ...must NEVER be less than 3 5 mm otherwise RENEWTHE DISC Undo screws V5 When reassembling use new screws and apply a high strength threadlocker NUMBER PLATE HOLDER REAR FAIRING Remove seat Remove helmet compartment Remove battery compartment tunnel cover Remove rear fairing Remove taillight Disconnect cables C Undo screws V4 There is a metal bushing under each screw NOTE At the time of reassembly re...

Page 112: ...SSEMBLY 6 B C A FILTER BOX Remove seat Remove helmet compartment Open the clamp and disconnect oil vapour recovery hose A Open the clamp and disconnect hose B for A I S valve Air Induction System Loosen clamp C securing the filter box to the carbu rettor ...

Page 113: ...114 09 05 A PASSWORD 250 FRAME AND RUNNING GEAR DISASSEMBLY 6 V D V Undo screw V Undo screw V working through opening D ...

Page 114: ...ING GEAR DISASSEMBLY 6 V7 V7 V7 E F Remove filter box E from the scooter prising gently in carburettor connection point F Undo screws V7 to open the filter box The sequence for disassembling the filter box compo nents is shown in the figure ...

Page 115: ...EAR DISASSEMBLY 6 A V2 B C D E V2 PILLION FOOTREST Undo screws V2 and remove plastic cover A Remove ring B and withdraw pivot pin C Remove footrest D To remove rubber covers E undo screws V2 NOTE Note that each screw V2 is threaded into a bushing ...

Page 116: ...ly op eration prop up the centre of the frame to prevent the scooter falling Disconnect flywheel connectors A Undo screw V and detach the ground cables from the frame Disconnect throttle cables B from the carburettor Detach tank to carburettor hose C detach coolant return hose D disconnect choke connector E and Faston connector F from the engine temperature ther mistor Before disconnecting hose D ...

Page 117: ... RUNNING GEAR DISASSEMBLY 6 H L G F P Unscrew clamp F Detach hose G from water pump P Before disconnecting hose G empty the cooling system see Removing the radia tor Disconnect cap from spark plug H Disconnect wires L from starter motor ...

Page 118: ...DISASSEMBLY 6 N M M 45 20 Insert a jack under the engine and raise it until it is in contact with the engine now unscrew nut M and re move engine mounting bolt N Lower the engine by acting on the jack and then re move it from the rear of the scooter ...

Page 119: ...d 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 torque After assembling the brake master cylinders front rear f...

Page 120: ...Cut all cable and hose ties Disconnect connectors A Disconnect cables from brake light switches B Disconnect throttle cables C Undo screws V4 Undo screw V1 Loosen nut D then extract the handlebars upwards and disengage the lower handlebar cover l from the handlebars When removing the handlebars pay atten tion to the electrical connectors and all the other parts affected by the operation ...

Page 121: ...cooter falling Sever all the electrical cable ties to proceed with the operation position the brake calliper and the brake line to BEHIND the scooter frame Undo and remove ring nut A Undo and remove underlying ring nut B Remove the forks assembly in a downward direction Support the forks to prevent them falling Pay attention because balls C may fall from their rac es Clean away any grease includin...

Page 122: ...the hydraulic unit proceed as follows unscrew 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 stanchion 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 B renew the O ring if necessary The stanchion contains...

Page 123: ...level in the stanchions as follows Undo upper plug A Carefully remove spring B and allow the oil in which it was immersed to drip off Bring the stanchion to its bottom travel limit while keep ing it in a perfectly vertical position With the aid of a rule or a gauge rod check the oil level The correct level is 138 mm from the upper edge of the stanchion Top up with Q8 FORK OIL if necessary ...

Page 124: ...own to drain out the resid ual oil Hydraulic fluid is corrosive and can cause serious personal injury Spent oil must be disposed of in compliance with local legislation Refit drain screw V NOTE Before refitting renew the copper washer under screw V Carefully pour new oil into the stanchion Quantity per stanchion 120 cc Check the oil level as described above Reassemble the stanchion components and ...

Page 125: ...rake fluid Dispose of used brake fluid in compliance with statutory legislation Do not operate the brake lever after removing the callipers This action may cause the plungers to come out of their pistons resulting in spillage of brake fluid Note that brake fluid is highly corrosive and can cause serious personal injury CHANGING THE FRONT CALLIPER After removing the front brake calliper undo screw ...

Page 126: ... to dam 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 fit new wiper seals and oil seals Refit the plungers oilseals C andwiperseals B lubricatingwithbrakefluid After terminating the inspection cleaning and replacement procedures refit all the parts in reverse sequence with ...

Page 127: ...ve gaskets After having removed the calliper from its seat place a recipient under it to collect the brake fluid Dispose of used brake fluid in compliance with statutory legislation REAR CALLIPER DISASSEMBLY Remove retaining ring A of brake pad pin B Remove pad pin B Remove spring C and the two pads D NOTE Note that the minimum thickness of the pads is 2 mm Spring C and pads D are marked with an a...

Page 128: ...gasket G do not fall Remove wiper seal H and oil seal L in both calliper halves taking care not to damage the relative grooves Check that the plungers and their seats are undam aged Always fit new wiper seals and new oil seals Refit the plungers the O rings the retaining rings and the wiper seals lubricating the parts with brake fluid NOTE After working on the braking system make sure that the bra...

Page 129: ...recovery 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 callipers 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 e...

Page 130: ...N AND HELMET COMPARTMENT LOCK NOTE The introductory figure for all systems contains a series of numbers the numbers correspond to illustra tions and a description of the parts in question Alongside the descriptive text accompanying certain parts a reference is given to the page in the Manual in which the part in question is mentioned SYSTEMS ...

Page 131: ... 4 5 1 2 3 4 5 6 7 8 9 MAIN ELECTRICAL SYSTEM UNDER THE BATTERY TUNNEL UNDER THE HELMET COMPARTMENT UNDER THE REAR FAIRING UNDER THE HELMET COMPARTMENT UNDER THE INSTRUMENT PANEL BEHIND THE RADIATOR ALONGSIDE THE KEYSWITCH UNDER THE FOOTBOARD CONNECTORS LEFT HAND STANCHION ...

Page 132: ... G F B C B A UNDER THE INSTRUMENT PANEL A instrument panel B front brake switch C rear brake switch D LH switch E temperature sensor F RH switch G RH switch H turn indicators BEHIND THE RADIATOR A fan unit page 89 B fan thermal switch page 88 C choke thermal switch page 88 ...

Page 133: ...SWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 134 09 05 3 B C A 3 4 5 6 ALONGSIDETHE KEYSWITCH A keyswitch B anti theft connector provision C odometer pick up data transmission connector MAIN ELECTRICAL SYSTEM ...

Page 134: ...eedometer sensor UNDER THE BATTERY TUNNEL A starter motor relay B flasher unit C starter motor disconnection relay D fuel pump relay E ignition coil F battery G spark plug cap CONNECTORS UNDER THE FOOTBOARD A CDI control unit page 70 B voltage regulator page 71 C fuel pump page 84 D side stand switch page 82 ...

Page 135: ...A PASSWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 136 09 05 9 8 7 7 A B UNDER THE HELMET COMPARTMENT A carburettor choke B thermistor MAIN ELECTRICAL SYSTEM ...

Page 136: ...SWORD 250 8 C B A 9 C A B UNDER THE REAR FAIRING A 2 way flywheel connector pick up B 3 way flywheel connector battery charge C ground terminals group UNDER THE HELMET COMPARTMENT A fuel level sensor B taillights rear indicators C number plate light ...

Page 137: ...A PASSWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 138 09 05 1 2 3 4 1 2 3 4 BRAKE SYSTEM FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER REAR CALLIPER FRONT CALLIPER ...

Page 138: ... 139 09 05 PASSWORD 250 1 A C B 2 C B A FRONT BRAKE MASTER CYLINDER pages 56 and 120 A washers B brake fluid line C brake fluid line screw REAR BRAKE MASTER CYLINDER pages 55 and 120 A washers B brake fluid line C brake fluid line screw ...

Page 139: ...A PASSWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 140 09 05 3 4 BRAKE SYSTEM ...

Page 140: ...141 09 05 PASSWORD 250 3 A B D C 4 B A C D REAR CALLIPER pages 109 and 128 A calliper B brake fluid line C washers D brake fluid line screw FRONT CALLIPER pages 61 and 126 A calliper B brake fluid line C washers D brake fluid line screw ...

Page 141: ...A PASSWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 142 09 05 1 2 3 4 1 4 2 3 COOLANT SYSTEM UNDER THE HELMET COMPARTMENT UNDER THE FOOTBOARD UNDER THE FOOTBOARD ENGINE LEFT SIDE ...

Page 142: ...AND RUNNING GEAR SYSTEMS 7 143 09 05 PASSWORD 250 1 B A 2 A B UNDER THE HELMET COMPARTMENT A engine radiator hose B air bleed screw page 90 UNDER THE FOOTBOARD A water pump radiator hose B engine radiator hose ...

Page 143: ...A PASSWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 144 09 05 4 3 COOLANT SYSTEM ...

Page 144: ...ING GEAR SYSTEMS 7 145 09 05 PASSWORD 250 3 4 A B A B C UNDER THE FOOTBOARD A expansion tank page 81 B radiator expansion tank hose ENGINE LEFT SIDE A radiator water pump hose B coolant drain screw page 90 C water pump ...

Page 145: ...A PASSWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 146 09 05 1 2 3 1 2 3 FUEL SYSTEM UNDER THE HELMET COMPARTMENT UNDER THE REAR FAIRING UNDER THE FOOTBOARD ...

Page 146: ...ith filter B tank filter hose C fuel level sensor page 95 D drip recovery hose E fuel pump carburettor hose F fuel tank page 103 G fuel filler cap UNDER THE REAR FAIRING A tank filter hose B filter C filter fuel pump hose D fuel pump carburettor hose UNDER THE FOOTBOARD A fuel pump page 84 B fuel pump carburettor hose C filter fuel pump hose ...

Page 147: ...A PASSWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 148 09 05 1 2 3 4 4 2 3 1 THROTTLE TRANSMISSION AND HELMET COMPARTMENT LOCK THROTTLE CONTROL CARBURETTOR HOSE CLAMP SEAT LOCK BLOCK ...

Page 148: ...ME AND RUNNING GEAR SYSTEMS 7 149 09 05 PASSWORD 250 1 2 A B B A C THROTTLE CONTROL A throttle opening cable B throttle closing cable C adjusters CARBURETTOR A throttle opening cable B throttle closing cable ...

Page 149: ...A PASSWORD 250 FRAME AND RUNNING GEAR SYSTEMS 7 150 09 05 4 3 THROTTLE TRANSMISSION AND HELMET COMPARTMENT LOCK ...

Page 150: ...A FRAME AND RUNNING GEAR SYSTEMS 7 151 09 05 PASSWORD 250 3 A B C A C B 4 HOSE CLAMP A control cable B cable gland C clamp SEAT LOCK BLOCK A control cable B seat lock page 93 C clamp ...

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Malaguti Password 250, Workshop Manual

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