Malaguti PHANTOM F 12 MAX 125 Workshop Manual Download Page 69

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09.03

CHAPTER

PAGE

ISSUE

CHASSIS

ENGLISH

DISASSEMBLY

- CHASSIS

SECTION 3

F.126

125 cc

F.127

F.128

200 cc

125 cc

Unscrew the nut (A - F.126).

Remove the pin (B - F.127).
Pull the engine out from the rear side.

ENGINE REMOVAL

200 cc VERSION

•

(Remove seat, passenger’s seat, helmet hold-
er, air filter box, muffler, rear wing, rear calipers
and rear wheel)

CAUTION!!!
Before disassembly, hold the centre
chassis section to prevent the vehicle

falling over.

Disengage the transmission cooling sleeve (A -
F.128).

Summary of Contents for PHANTOM F 12 MAX 125

Page 1: ...PHANTOM F 12 MAX A WORKSHOP MANUAL CHASSIS ...

Page 2: ......

Page 3: ...ont brake disc 3 29 Front fairing 3 30 Headlights 3 31 Front indicators 3 32 Headlight guard 3 33 Horn 3 34 Coolant container 3 34 Seat 3 34 Passenger s seat 3 35 Seat lock 3 35 TABLE OF CONTENTS S P DISASSEMBLY 3 23 Battery 3 36 Helmet compartment 3 36 Handle cover 3 38 Rear handle 3 38 Seat lock 3 38 Tail lamps 3 39 Rear indicators 3 39 Number plate light 3 40 Nameplate holder 3 40 Side casings ...

Page 4: ...y the engine manufacturers We therefore decline all responsibility for any error omission or misrepresentation MALAGUTI reserves the right to make any changes and modifications hereto it deems necessary without prior notice For further information and details please contact the Malaguti S p A Service Division MANUAL UPDATES Updated pages of this publication will be delivered by us in a reasonable ...

Page 5: ...ssue appearing in the appropriate box Modified pages may contain new illustrations in this case the added illustration or illustrations will bear the number of the illustration on the former page followed by a letter ADDITIONAL PAGES Any additional pages shall bear the last number of the section to which they belong followed by the letter A and the date of issue ILLUSTRATIONS This manual describes...

Page 6: ...fety recommendations They are therefore to be considered as veritable memory tags In case of any doubt as to their meaning consult the page in which they are fully described ABBREVIATIONS Note the letter V in the illustrations refers to retaining or adjusting screws The number following this letter refers to the number of the same type of screw in the unit or component described and illustrated Le...

Page 7: ...work sheet specifying the operations performed with notes as to any future checks eventually required RECOMMENDATIONS Before carrying out any operation on the vehicle wait for all parts to cool down For operations requiring two mechanics make sure that the various steps to be performed by each of them are clearly defined and coordinated beforehand Make sure that each component has been properly fi...

Page 8: ... low flash point solvents 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 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 motorbike is perf...

Page 9: ...rations which may constitute a fire hazard D RISK OF EXPLOSION Indicates operations which may constitute a risk of explosion E TOXIC FUMES Indicates a possibility of intoxication inflammation or corrosion F MECHANICALMAINTENANCE Operations to be performed only by an expert mechanic G ELECTRICALMAINTENANCE Operations be performed only by an expert electrical electronic technician H NO Operations to...

Page 10: ...1 1 11 5 1 Starting system Lubricating system Ignition system Type of oil Engine oil Total amount 1 4 L 1000 cc Transmission oil Total amount 0 14 L 150 cc Brake fluid Fuel Type Fuel tank capacity Reserve amount Carburettor Type 5XL WVF7 KEI HIN CVK30 Manufacturer TEIKEI Walbro Chassis Frame Spark plug Type NGK CR8EB NGK CR8EB CHAMPION RG6YC Manufacturer Electrode gap Cooling system Type Recommend...

Page 11: ...quipment Battery capacity Horn Lights Low beam High beam Front parking light Front rear right left turn indicators Instrument board lights Stop light Rear parking light Number plate 125 cc 200 cc automatic speed variator by V belt one speed gear type dry centrifugal and automatic tubeless 2 3 bar 2 3 bar 2 3 bar 2 3 bar hydraulic disk type Ø220 mm hydraulic right hand hydraulic disk type Ø220 mm h...

Page 12: ...Engine registration data A F 1i are on the left engine crankcase VEHICLE REGISTRATION NUMBER To access the vehicle registration number open the centre hatch using the ignition keys and remove the cover B F 2i VIN LABEL The vehicle s VIN label is applied to the front of the vehicle on the right hand side under the upper fairing C F 3i ANTI TAMPERING LABEL Anti tampering label only for version 125 c...

Page 13: ...ont ticket holder 4 Front disc brake calipers 5 Carburettor 6 Rear turn indicators 7 Tail light 8 Nameplate holder 9 Air filter 10 Seat lock 11 Left hand rear view mirror 12 Passenger s handle 13 Adjustable shock absorbers MAIN COMPONENTS Right hand side 14 Right hand mirror 15a High beam headlight 15b Low beam headlight 16 Front turn indicators 17 Helmet holder 18 Fork 19 Fuel tank cap 20 Muffler...

Page 14: ... lever 37 Counterweight 38 Light switch 39 Turn indicator switch 40 Horn button START SWITCH KEYS The main switch controls the ignition circuit and steering lock all electrical contacts are disconnected contacts are connected The engine can start the steering lock is on KEYS The vehicle is supplied with two keys featuring a code number which have the following functions Providing the ignition cont...

Page 15: ...a regular basis DISPLAY 1 Coolant temperature indicator The red notch A and the activation of the red warning light B mean that the liquid is too hot owing to a fault in the cooling circuit or to a shortage of coolant Bring the vehicle to an immediate stop 2 Fuel level indicator The warning light C comes on to indicate that the reserve amount has been reached 3 Green low beam indicator light 4 Blu...

Page 16: ...3 4 33 4 2 3 2 3 33 4 33 4 X Y X Y F 13i F 12i B A TIRE PRESSURE CHECK Tire pressure must be checked when the tires are cold FUEL TANK Open the hatch A F 13i with the starter key unscrew the cap B F 13i and fill the tank Immediately wipe off spilled fuel Use unleaded petrol Fuel tank capacity Total 9 5 L Reserve amount 3 L ...

Page 17: ...ine and wait a few minutes for the oil level to stabilise before checking Unscrew the dipstick from the engine crankcase A F 15i Clean the dipstick and put it back into its seat but do not screw it in place By means of this operation you will check the oil level The level must be between the MIN and MAX marks on the dipstick F 15i If the level is low add oil Put the dipstick back into its seat and...

Page 18: ... checking refit the cap and dipstick and screw firmly in place REPLACEMENT Warm up the engine for a few minutes stop the engine and put an oil pan under the casing in correspondence with the cap A F 18i Remove the drainage cap and the dipstick and let the oil flow out Clean the filtering net with compressed air check the state of the cap s O ring and if damaged replace it Remove the cartridge filt...

Page 19: ... and the drainage cap to drain out the oil B F 20i let the oil flow into a suita ble container pay attention to avoid scorching Close the drainage cap and add new oil You can now close the filling cap TRANSMISSION OIL 200 cc CHECK Park the scooter on flat ground and place it on its cen tre stand Unscrew the dipstick A F 21i clean it and screw it back into place Take it out again and make sure the ...

Page 20: ... removing the covers A B after loosening the fixing screws REPLACEMENT If the fluid features traces of dirt debris or water it must be replaced A soft and spongy feeling in the brake lever can indicate the presence of air in the circuit Contact an authorised service centre at once ADJUSTMENT OF ENGINE IDLING SPEED Engine idling speed must be adjusted every time it seems irregular To perform a corr...

Page 21: ...y fitted to the ring nut A F 25i turn it clockwise to increase the spring preload FUSES The electrical equipment includes four fuses protecting the main components against faults These are located in the glove compartment Fig 26i An illustration of the protected component is placed next to each fuse To replace a fuse remove the screw A to open the left hand hatch using the pliers supplied P F 26i ...

Page 22: ... THE SHAPE OF THE CHASSIS If your scooter has had an accident and you believe that the chassis is deformed it is essential to perform a check on its shape before providing any further repair and setting up work The checking value A F 27i must be 1220 mm with a tolerance of 2 mm Never deform the chassis to obtain the original A measure ...

Page 23: ...V1 V4 A B A REMOVING THE FRONT HANDLEBAR COVER Undo the centre screw V1 F 1 which is ac cessed by removing the cover A F 1b Undo the side screws V4 F 2 Pull the handlebar cover up A F 3 along with the instrument board Pay attention in order not to damage the instrument board connector cable B F 3 ...

Page 24: ...screws V4 F 4 and detach the in strument board from the front handlebar cover COMPONENTS ACCESSED BY REMOVING THE FRONT HANDLEBAR COVER By removing the front handlebar cover you gain access to the following components Instrument board cables A Connector for the handlebar controls right left B STOP switch right hand control C STOP switch left hand control D Coupling for the rear brake pump E Coupli...

Page 25: ...rew V F 7 and remove the counter weight Undo the screws V2 F 7 and remove the left control Caution To reduce friction during knob removal and refitting use com pressed air Detach the fast ons of the stop switch wiring A F 7 Undo the hydraulic transmission screw B F 7 paying attention to oil leaks Loosen the screws V2a F 7 and remove the rear brake pump Caution When refitting remember to replace th...

Page 26: ...ttention to oil leaks Loosen the screws V2a F 8 and remove the front brake pump Caution When refitting remember to replace the copper gaskets and to bleed using the relevant equipment REMOVING THE RIGHT CONTROL 200 cc VERSION Remove front handlebar cover Disconnect the throttle cable A F 9 Undo the screw V F 9 and remove the counter weight Undo the screws V2 F 9 and remove the throttle control Cau...

Page 27: ...VING THE SPEEDOMETER SENSOR Undo the screw V F 11 paying attention not to lose the spacer Caution When refitting use a thick ness gage to make sure that the gap between the sensor and disc is 1 2 mm on the contrary provide a shim near the spacer REMOVING THE FRONT CALIPERS Undo the screws V2 F 12 undo the hydraulic transmission screw V F 12 and detach the hy draulic transmission from the pliers Ca...

Page 28: ... so that it may be disposed of in accordance to the laws in force concerning waste disposal Caution Whenremovingthecalipers pay special attention to prevent dam age to the oil duct disc and brake pads Caution Minimum thickness of the pads is 2 mm F 13 After working on the braking system make sure that the brake fluid pipe is not twisted that the discs and pads are not soiled with oil or grease and...

Page 29: ...n place with an Allen wrench Remove the wheel pin whilst paying attention to the spacers the long one A F 15 two short ones B F 15 Remove the wheel assembly Caution Do not operate the brake lever after removing the wheel since the pads would come into contact with each other Caution When refitting make sure to refit the spacers and grease the wheel pin C F 15 REMOVING THE FRONT DISC Remove speedom...

Page 30: ...F 17 V10 V10 F 19 a V REMOVING THE FRONT UPPER FAIRING Remove front wheel and front wing Remove the centre foot rest fitted to the lower fair ing paying attention not to damage the tabs Caution This operation is symmetri cal Undo the screws V10 F 18 Undo the screw V F 19 a under the strut ...

Page 31: ...e down with its painted side facing upwards REMOVING THE HEADLIGHTS Caution There is no need to remove the upper fairing it can be placed on the front wing covered beforehand with scratch proof material To remove the low beam headlight undo the screws V4 F 21 To gain access to the light bulb remove the lamp socket A F 21 by turning it 15 anti clockwise Toremovethehighbeamheadlight undothescrews V4...

Page 32: ... refitting the adjust ment knob install all parts in the right sequence To adjust the beam act on the knob A as fol lows tighten to raise the beam loosen to lower the beam REMOVING THE FRONT INDICATORS Caution There is no need to remove the upper fairing it can be placed on the front wing covered beforehand with scratch proof material Undo the screws V2 F 25 To gain access to the light bulb remove...

Page 33: ...e placed on the front wing covered beforehand with scratch proof material Loosen the screws V4 F 26 and remove the guard COMPONENTS THAT CAN BEACCESSED BY REMOVING THE UPPER FAIRING By removing the upper fairing you can gain access to the following components Horn A Fuse carrier B Coolant container C Fork D Radiator E Switch with key F The fan s thermal switch G Ring nuts of the steering system H ...

Page 34: ...n the front wing covered beforehand with scratch proof material Undo the screw V F 28 and disconnect the ca bles Caution Refit components in the right sequence COOLANT CONTAINER Remove upper fairing Undo the screws V2 F 29 Loosen the clamp A F 29 and remove the pipe Loosen the clamp B F 29 and remove the pipe REMOVING THE SEAT Release the seat with a wrench A F 30 and tip it over ...

Page 35: ... facing upwards REMOVING THE PASSENGER S SEAT Undo the screws V2 F 32 and remove the pas senger s seat by pulling it out from the front side Caution The level of electrolyte in the battery can be checked through the sight glass under the passenger s seat thus avoiding removal REMOVING THE SEAT LOCK Remove passenger s seat Remove the nut covers A F 33 and undo the screws V2 F 33 ...

Page 36: ...efully lift the battery and before actually pulling it out of its compartment release it from the ex haust pipe C F 35 Caution Refit the battery making sure that the exhaust pipe is connect ed that it is coming out of the battery compartment and that is not bent clogged or twisted REMOVING THE HELMET HOLDER Remove battery seat and passenger s seat Undo the screws V2 F 36 Caution With the helmet ho...

Page 37: ...tery ca bles A B F 37 exhaust pipe C F 37 and seat lock cable Caution When refitting take care to put the exhaust pipe battery cables and seat lock cable back into their openings COMPONENTS THAT CAN BEACCESSED BY REMOVING THE HELMET HOLDER By removing the helmet holder you can gain access to the following components Fuel probe A Carburettor B Control unit connector C ...

Page 38: ...e after disengaging its hooks REMOVING THE REAR HANDLE Remove seat passenger s seat helmet hold er and handle cover Undo the screws V3 F 40 Undo the screws V2 F 40 Remove the rear handle Caution The handle features four threaded holes for fastening the lug gage container or rack REMOVING THE SEAT LOCK Remove seat passenger s seat and helmet holder Remove the spring A F 41 and pull out the cable B ...

Page 39: ...se the snap locks To access the bulb of the stop light remove the centre lamp socket by turning it 45 clockwise To access the 5 bulbs of the parking lights re move the relative lamp sockets Caution Test operation before re fitting removed parts REMOVING THE REAR INDICATORS Undo the screw V F 44 Remove the glass cover and detach the lamp sock et cables Undo the fixing screw V1 F 44 Remove the cover...

Page 40: ...the cables Caution Test operation before re fitting removed parts REMOVING THE NUMBER PLATE HOLDER Remove the number plate by undoing the four screws or rivets Undo the screws V3 F 46 Caution Do not use glue two sided adhesive tape etc to refit the number plate REMOVING THE SIDE CASINGS Undo the screw V F 47 Remove the side casing by pulling out from the front so that it detaches from its snap loc...

Page 41: ...lator A Control unit B Weights C REMOVING THE REAR COWLING Remove seat passenger s seat helmet hol der handle cover rear handle and side casin gs Detach the cable of the tail lamp Undo the screws V4 F 49 on the right and left Undo the screw V F 50 by releasing the shock absorber plaque Caution This operation is symmetri cal Raise and release the rear cowling from its hooks by pulling its front sid...

Page 42: ...EFLECTOR Undo the screws V2 F 51 and remove the re flector by pulling it outwards REMOVING THE TAIL SECTION Remove seat passenger s seat helmet hol der handle cover and rear handle Undo the screws V2 F 52 on both sides Undo the screws V2 F 53 release the snap locks on the top side of the tail and remove the tail sec tion ...

Page 43: ...By removing the rear cowling you can gain access to the following components Starter relay 1 A Starter relay 2 B Flashlight C 125 cc only Fuel pump D REMOVING STARTER RELAYS 1 2 Remove side casings and rear cowling 1st relay A F 55 release from the chassis by pulling upwards then detach the connector C F 55 2 nd relay B F 55 take out of the relay holder P F 55 ...

Page 44: ...e flashlight from the chassis REMOVING THE REGULATOR 125 cc VERSION Remove side casings and rear cowling Detach the connector A F 57 Undo the screws V2 F 57 Caution When refitting fasten the weights M F 57 firmly in place REMOVING THE REGULATOR 200 cc VERSION Remove side casings and rear cowling Detach the connector A F 58 Undo the screws V2 F 58 Caution When refitting fasten the weights M F 58 fi...

Page 45: ...IT 125 cc VERSION Remove side casings and rear cowling Remove the clamps and detach the connector A F 59 Take the control unit out of its rubber protection G F 60 REMOVING THE CONTROL UNIT 200 cc VERSION Remove side casings and rear cowling Remove the rubber protection A F 61 release the connector B F 61 and cut the clamps hold ing the wires in place ...

Page 46: ... cc V2 F 62 F 64 V4 Undo the screws V2 F 62 Caution The flashlight is built into the control unit REMOVING THE FUEL PROBE Remove seat passenger s seat and helmet holder Detach the connector A F 63 and cut the clamps that hold the wires in place Undo the screws V4 F 64 and remove the probe ...

Page 47: ...UT Place the scooter on its centre stand Remove the rubber mat on the footboard A F 65 Undo the screws V2 F 65 b Undo the screw V F 66 Undo the screw V F 67 Carefully pull the strut towards the front Caution When refitting remember that the V F 66 67 screws are longer than the V2 F 65 b screws These operations are symmetrical ...

Page 48: ... 125 cc VERSION Remove side casings rear cowling and strut Undo the screws V3 F 68 on both sides Undo the screws V2 F 69 to release the foot board from the secondary air valve Open the tank s hatch A F 70 unscrew the cap T F 70 and remove the gasket B F 70 Pull the footboard upwards Caution After removing the foot board screw the tank s cap back on ...

Page 49: ...k s hatch A F 72 unscrew the cap T F 72 and remove the gasket B F 72 Pull the footboard upwards Caution After removing the foot board screw the tank s cap back on REMOVING THE LOWER FAIRING Remove side casings rear cowling strut foot board and upper fairing Detach cables A F 73 from fuses Caution When reassembling fasten the fast ons as follows 15 A fuse BLUE RED LIGHT BLUE 7 5 A fuse YELLOW BLUE ...

Page 50: ... F 75 V2 A F 74 V Undo the screw V F 74 under the footrest Caution This operation is sym metrcal Undo the screws V2 F 75 of the luggage hook Remove the cover A F 76 of the switch with key by turning it 1 4 of a turn clockwise Remove the lower fairing by pulling it carefully downwards ...

Page 51: ... 3 F 77 A B C E D COMPONENTS THAT AREACCESSED BY REMOVING THE STRUT FOOTBOARDAND THE LOWER FAIR ING By removing the strut footboard and lower fairing you can gain access to the following components 15 A recharge fuse A Side stand switch B Radiator fan C Tank D Petrol filter E ...

Page 52: ... 79 the fuel outlet pipe B F 79 and the vacuum pipe C F 79 Undo the screws V2 F 79 Caution When refitting connect the pipes in their correct position REMOVING THE FUEL TANK Remove side casings rear cowling strut foot board and lower fairing CAUTION Make sure the tank is empty Before emptying the tank wait for the engine to cool down Use a manual pump Release the petrol filter and disconnect the pr...

Page 53: ...per fairing CAUTION Empty the radiator by putting a suita ble container under it Now open the pipe clamp A F 81 and detach the pipe from its coupling The radiator is installed on a Silentblock to re move this proceed as follows Disconnect the fan connector A F 82 Disconnect the cables of the thermostatic fan A F 83 and of the thermal switch when these are warm B F 83 ...

Page 54: ...SH DISASSEMBLY A CHASSIS SECTION 3 F 84 A B F 85 125 cc 125 cc V2 Remove the two pipes by unscrewing the clamps A B F 84 Disengage and remove the radiator support plate by loosening the screws V2 F 85 Remove the radiator by pulling it downwards ...

Page 55: ... upper fairing CAUTION Empty the radiator by putting a suita ble container under it Now open the pipe clamp A F 86 and detach the pipe from its coupling The radiator is installed on a Silentblock to re move this proceed as follows Disconnect the fan connector A F 87 Disconnect the cables of the thermostatic fan A F 88 Caution Do not remove the drain age cap B F 88 ...

Page 56: ...3 V2 200cc A Remove the two pipes by unscrewing the clamps A B F 89 Disengage and remove the radiator support plate by loosening the screws V2 F 90 Remove the radiator by pulling it downwards RADIATOR FAN Remove radiator Detach the connector A F 90 Undo the screws V3 F 91 Remove fan by pulling it sideways ...

Page 57: ...mmetri cal REMOVING THE REAR SHOCK ABSORBERS 200 cc VERSION Remove filter box and muffler CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over To remove the right shock absorber unscrew the top bolt A F 93 and the bottom nut B F 93 and remove the shock absorber by pulling it to wards the rear side Undo the nut B and pull the shock absorber out wards withou...

Page 58: ... SECTION 3 F 97 V2 F 96 A A B F 95 125 cc 125 cc 125 cc REMOVING THE AIR FILTER BOX 125 cc VERSION Remove helmet holder Open the clamp A F 95 and disconnect the steam recycling pipe B F 95 Unscrew the clamp A F 96 and disconnect the suction pipe Undo the screws V2 F 97 ...

Page 59: ... 100 200 cc 200 cc A B A Undo the screw V F 98 and remove the filter box assembly complete with its coupling REMOVING THE AIR FILTER BOX 200 cc VERSION Remove helmet holder Open the clamp A F 99 and disconnect the steam recycling pipe B F 99 Unscrew the clamp A F 100 and disconnect the suction pipe ...

Page 60: ... 125 cc 125 cc 200 cc V2 Undo the screws V2 F 101 and remove the filter box REMOVING THE MUFFLER 125 cc VERSION CAUTION Before removing make sure the muf fler has cooled down Undo the screws V2 F 102 securing the exhaust manifold in place Undo the screws V3 F 103 and remove the muf fler with its guard ...

Page 61: ...exhaust assembly must be disassembled as illustrated in F 104 Caution When refitting the muffler remember to replace part G REMOVING THE MUFFLER 200 cc VERSION CAUTION Before removing make sure the muf fler has cooled down Undo the screws V2 F 105 securing the exhaust manifold in place Undo the screws V3 F 106 and remove the muf fler with its guard ...

Page 62: ...ing the muffler remember to replace part G REMOVING THE REAR WING 125 cc VERSION Remove muffler compartment Undo the screws V2 F 108 Undo the screws V2 F 97 page 57 the screw V F 98 page 58 and push the filter box aside to enable removal of the wing REMOVING THE REAR WING 200 cc VERSION Remove muffler compartment Undo the screws V2 F 109 Undo the screws V2 F 101 page 59 and push the filter box asi...

Page 63: ... 110 Cut the clamp A F 110 and pull out the sleeve REMOVING THE TRANSMISSION COOLING SLEEVE 200 cc VERSION Remove strut Undo the screws V3 F 111 Cut the clamp A F 111 and pull out the sleeve REMOVING THE REAR CALIPERS 125 cc VERSION Removemuffler Undo the screws V2 F 112 Loosen the hydraulic transmission screw V F 112 and detach the pipe from the calipers Caution When refitting replace the gasket ...

Page 64: ...them ground If they are particularly damaged or are thinner than 2 mm replace them Caution Minimum thickness of the pads is 2 mm F 114 REPLACING THE REAR CALIPERS Empty the hydraulic circuit and drain fluid into a special container so that it may be disposed of in accordance to the laws in force concerning waste disposal Caution Whenremovingthecalipers pay special attention to prevent dam age to t...

Page 65: ...screw in the bottom section F 115 Undo the nut A F 115 and remove the wheel Caution When refitting insert all parts in the right order and grease them REMOVING THE REAR WHEEL 200 cc VERSION Remove muffler rear wing and rear calipers CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over Disassemble the arm as follows Undo the bottom screw of the right shock ...

Page 66: ... replace the screws and apply a high strength thread lock er ENGINE REMOVAL 125 cc VERSION Remove seat passenger s seat helmet hold er air filter box muffler rear wing rear calipers and rear wheel CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over Disengage the rear left shock absorber by undoing the screw V F 118 Disengage the transmission cooling sleev...

Page 67: ...A F 121 F 122 125 cc 125 cc F 120 B A 125 cc Remove the pipe for delivery to the radiator A F 120 by unscrewing the clamp B F 120 Remove the return pipe of the radiator A F 121 by unscrewing the clamp B F 121 Detach the flywheel connectors A F 122 and cut all the cable fixing clamps ...

Page 68: ...5 125 cc A B 125 cc V2 125 cc V Detach the fast on A F 123 and the pipe of the fuel pump B F 123 Disengage the carburettor from the engine by un doing the screws V2 F 124 and secure the car burettor to the chassis Undo the screw V F 125 and remove the sup port of the hydraulic transmission pipe ...

Page 69: ...26 Remove the pin B F 127 Pull the engine out from the rear side ENGINE REMOVAL 200 cc VERSION Remove seat passenger s seat helmet hold er air filter box muffler rear wing rear calipers and rear wheel CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over Disengage the transmission cooling sleeve A F 128 ...

Page 70: ...he connector A F 129 from the flywheel cover Disengage the rear shock absorber by unscrewing the bolt A F 130 The shock absorber can also be disengaged by removing the screws V2 F 130 that secure the support B F 130 to the engine Remove the pipe for delivery to the radiator A F 131 by unscrewing the clamp B F 131 Detach the fast on C F 131 ...

Page 71: ...A V2 A Remove the pipe A F 132 Disengage the carburettor from the engine by un doing the screws V3 F 132 and secure the car burettor to the chassis Remove the radiator return pipe A F 133 by unscrewing the clamp B F 133 Undo the screw V F 133 and remove the sup port of the hydraulic transmission pipe Unscrew the nut A F 134 ...

Page 72: ...137 125 cc A Remove the pin B F 135 and pull the engine out from the rear side of the vehicle REMOVING THE CENTRE STAND 125 cc VERSION CAUTION Before disassembly hold the vehicle in place to prevent it falling over Undo the screw V F 136 Undo the screw V F 137 Remove the double spring A F 137 and hence the stand ...

Page 73: ...r Remove the double spring A F 138 Unscrew the nut B F 138 remove the pin and hence the stand REMOVING THE SIDE STAND Remove the double spring A F 139 Undo the screw V F 139 Furthermore check correct operation of the switch which should prevent engine ignition if the stand is operated Caution Do not tamper with this safety device REMOVING THE SIDE STAND SWITCH Remove seat passenger s seat and helm...

Page 74: ...ps REMOVING THE ENGINE FIXING PLATE 125 cc VERSION Remove seat passenger s seat helmet hold er handle cover rear handle side casings tail section and strut CAUTION Before disassembly hold the vehicle in place to prevent it falling over Remove the spring A F 142 Undo the screw V F 143 Remove the pin A F 143 by unscrewing the nut B F 143 b Remove the pin C F 143 by unscrewing the nut D F 143 b ...

Page 75: ...andle cover rear handle side casings tail section and strut CAUTION Before disassembly hold the vehicle in place to prevent it falling over Remove the spring A F 144 Undo the screw V F 145 Remove the pin A F 145 by unscrewing the nut B F 145 b Remove the pin C F 145 by unscrewing the nut D F 145 b REMOVING THE SWITCH WITH KEY Removehandlebarcover upperfairingandlow er fairing Undo the screws V2 F ...

Page 76: ...lebar upper fairing front wheel front wing and front calipers Unscrew and remove the ring nut A F 148 Unscrew and remove the underlying ring nut B F 148 Remove the fork assembly by pulling it outwards CAUTION Support the fork to prevent it falling Pay attention as the bottom balls A F 149 may come out Clean away any grease including the grease in the seats Check for wear and make the neces sary re...

Page 77: ... to put soft protective material be tween the jaws and the components in order to prevent crushing or scratches If the fork has reached its travel end position or is making too much noise check the oil level inside the stanchions as follows remove the top cap A F 151 and the snap ring B F 151 by pressing the cap C F 151 complete with its O ring D F 151 down with a screwdriver Remove the spring E F...

Page 78: ...w V F 153 and let as much oil as possi ble flow out Disassemble the stanchions wheel holders and tip them over to drain out any residual oil Oil wastes must be disposed of correctly Refit the drainage screw V F 153 Carefully pour new oil into the stanchion 100 cc both for the right and left stanchions Check the oil level as described above Reassemble the stanchions and refit the assem bly on the s...

Page 79: ...3 23 2 3 68 6 8 68 6 8 37 3 7 37 3 7 30 3 0 30 3 0 100 10 0 100 10 0 45 4 5 45 4 5 24 2 4 40 4 0 30 3 0 35 3 5 35 3 5 38 3 8 38 3 8 TORQUE WRENCH SETTINGS Front wheel pin Front brake calipers Handlebar clamp Steering lock Muffler arm coupling Rear arm Engine pin Engine fixing pin Rear brake calipers Rear wheel Top shock absorber Bottom shock absorber Bottom shock absorber coupler Top handlebar cla...

Page 80: ...A 80 05 03 CHAPTER PAGE ISSUE ENGLISH CHASSIS ASSEMBLY A CHASSIS SECTION 4 ...

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