Malaguti CENTRO SO 4T Service Manual Download

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Summary of Contents for CENTRO SO 4T

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Page 2: ...in order to make sure the topics the technical and safety concepts are clearly understood and the manual can be used as a sure reference text All checks maintenance repairs or replacements of spare parts in our motor bikes are to be performed by skilled and expert technical personnel with specific experience in state of the art technology and full knowledge of the quickest and most rational proced...

Page 3: ...cs dealt with in the page NOTE The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations Cs Torque wrench setting D Nut Dx Right F Picture G Gasket P Page R Washer Sx Left T Table V Screw TECHNICAL DICTIONARY V DC Direct current battery supply V AC Alternating current flywheel supply A Ampere Unit of measureme...

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

Page 5: ...ds repairing Prepare the components that are likely to be replaced and all the original spare parts you may need Use only the original spare parts Mark the components that may be mis placed during re assembly operations Only use quality tools and equipment Only use equipment conforming to EU Directives for lifting the vehicle During operations always keep tools and equipment at hand possibly layin...

Page 6: ...use low flash point solvents to clean the vehicle components When welding make sure that there are no flammable liquids in the vicinity Never suck from or blow into the fuel pipe Never leave the engine running in closed or poorly ventilated areas Do not use fuses with a higher rated capacity than indicated this may cause severe damages to the electrical system and burn a fire as a conse quence of ...

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Page 8: ...NGK CR8E NGK CR8EB TRANSMISSION Primary drive automatic transmission by V belt speed change gear Final by gears Automatic centrifugal dry clutch FUEL SYSTEM Carburettor KEIHIN CVK Automatic starter Fuel unleaded petrol IGNITION Electronic BRAKES Front brake disk type Ø 225 mm transmission and hydraulic calipers Rear brake drum Ø 139 mm mechanical transmission CHASSIS Made of steel pipes with a hig...

Page 9: ...se B Any alteration to the vehicle identification data is pursued by the Law F 3 When ordering spare parts also quote the vehicle identification data ANTI TAMPERING PLATE An anti tampering plate bearing all vehicle identification data required by Directive 97 24 CE is fitted inside the helmet compartment If you have the helmet compartment replaced make sure the plate is fitted too This label must ...

Page 10: ...n lead to higher fuel consumption irregular wear of the tire impaired vehicle performance and riding conditions F 5 Check the tire conditions before every journey if they are broken cracked or cut have them replaced as soon as possible T W I marks are provided all around the tire side walls These correspond to tire wear indicators which are situated in the tire s tread if there is no difference be...

Page 11: ... if the vehicle is used in rainy weather in dusty places or on rough terrain Due to their simplicity checks with no asterisk CAN also be carried out by technicians not authorised by MALAGUTI but under their direct responsibility Nr coupon check clean adjust replace MAINTENANCE TABLE ...

Page 12: ...TE Use only recommended products LUBRICANTS ENGINE OIL 4 STROKE FORMULA EXCEL SAE 5W40 ENGINE TRANSMISSION OIL T35 80W AIR FILTER LUBRICANT AIR FILTER OIL RADIATOR FLUID TOP FLUID BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4 FORK ROD OIL FORK OIL ...

Page 13: ... O Ring B e the filter C Screw on and tighten the drain plug F Top up the engine of oil specified and replace the cap dipstick A Start the engine leave it running for a few minutes and check that there are no leaks Turn the engine off and check the oil level Dispose of used oil in accordance with current laws in force CHANGE Warm up the engine for a few minutes and then shut it off After the first...

Page 14: ...brake lever is usually an indication that air is in the system CHANGE After the first 1 000 Km Every 12 000 Km Cold engine Vehicle on level ground Place a drip pan under the engine Unscrew the oil dipstick A Unscrew the drain screw B Drain out all the used oil Clean the threads of the drain screw and screw back on Refill the crankcase with oil specified Screw the oil dipstick A back CHECK Visually...

Page 15: ...ime it and bring the system in pressure Keeping the brake lever pumped loosen the bleeder screws V to allow air to escape Then tighten the bleeder screw V F 12 F 13 V 12 16 CHECK FRONT BRAKE PADS AND DISK Check the condition of front brake pads and disc every 2 000 Km Carry out a visual check on the thickness of the brake pads The minimum thickness of the brake pad friction material must not be le...

Page 16: ... necessary top up with oil FORK OIL CHANGE FORK OIL Place an appropriate drip pan under the slider and remove the screws V Drain out as much oil as possible Proceed to dismantle the fork legs as previously described Turn the fork legs upside down to let the remaining oil drain out Hydraulic oil is corrosive and may cause personal injury Do not improperly dispose of used oil in the environment Remo...

Page 17: ...tting minutes press the bottom button 5 times and select the correct number with the top button Press the bottom button again to return to time display mode If you have changed your settings save them by pressing the top button INSTRUMENT BOARD 1 Analogue instruments Speedometer Current speed in kmh or mph 2 Odometer Total distance travelled in kmh 3 Green turn indicator light 4 Blue high beam ind...

Page 18: ...el tank is empty or turn the key switch to ON If the engine does not start release the starter switch wait a moment and then press it again In order not to drain the battery do not operate the starter for more than 10 seconds on each try Do not rev the engine to its limit when it is cold Start the engine with the headlights off HANDLEBAR CONTROLS A B 3 2 1 5 3 1 2 4 RIGHT HAND CONTROL 1 Counterwei...

Page 19: ...m and keep the vehicle vertical without the kickstand and without people sitting on it With a Philips screwdriver adjust the headlight adjustment screws R keeping in mind that turning clockwise lowers the light beam and vice versa Adjust the beam so that the lower line of the beam is about 95 cm off the ground when projected on a wall F 24 C C TURN SIGNALS FRONT Bulb C 12V 10W RY 10W Light bulb re...

Page 20: ...5W Brake lights S Lightbulb12V 10W R10W Turn signals E 12V 10W Undo the two central screws securing the parabolic spring F 28 Light bulb replacement Unscrew the screws V2 F 26 V2 V2 To access the bulbs remove the frame A and the pane of glass B F 27 A B F 25 E E S S P P ...

Page 21: ... When performing the operations described above be very careful not to damage the near by parts transmission cables gaskets etc F 31 F V F 30 C Tail light Take out the lamp holder from inside the headlight Replace the light bulb Reposition the rubber lamp holder pressure and remount the cover Stop light and turn signal light Remove the coloured hood that is held by two hooks Replace the light bulb...

Page 22: ... fuse and replace it with one having equal capacity Spare fuses are located inside the compartment S Do not replace fuses with others that have a higher capacity as it could seriously damage the electrical system and cause the vehicle to catch fire if there is a short circuit It is important to identify the cause of blown fuses NOTE Use the appropriate grippers P when replacing a fuse F 32 P S S A...

Page 23: ...ED RED BLUE cables negative pole to the BLACK cables Wrench down the battery terminals Refit the 10A general protection fuse previously removed Check that the battery and the wiring harness are correctly installed Refit the cover of battery case and the front guard NEVERinvertthecableconnections Donotusethebatterywithoutthebatteryinsertedand connected to wires of the main harness This could cause ...

Page 24: ...out this operation it is advisable to remove the battery from its housing unless the special electrical outlet A is used Disconnect cables It is a good rule to recharge using amperage that is equal to 1 10 of the power of the battery charger Remount the battery paying attention to connect the positive cable red blue to the pole and the negative cable to the pole Properly tighten the battery clamps...

Page 25: ...with small clockwise and anti clockwise movements then unscrew the spark plug Examine the condition of the sparkplug Deposits and colorations of the insulator provide useful information on the thermal grade on the carburetion on the lubrication and on the general condition of the engine If there is a light brownish color on the insulator around the central electrodes it means that it functions pro...

Page 26: ... the upper cover sliding it towards the rear part F 42 F 44 F 43 D V2 REAR VIEW MIRROR Left Uncover and loosen the nut D Unscrew the window holder arm by turning it anti clockwise Remove the protection A UPPER COVER V2 F 45 REAR VIEW MIRROR Right optional First remove the protection cap B B A ...

Page 27: ...R V V4 Free and partially extract the handlebar unit carefully as to not damage the paint of the under shield or rip the electrical headlight wires To clear the front handlebar cover push the area indicated in the figure on both sides paying attention to not damage the hooking points ...

Page 28: ...27 07 08 50 cc 4 T A B F 51 F 50 FRONT COVER V4 W F 52 F 53 V4 1 10 W 1 10 W V4 Disconnect the lamp holder A Extract the taillights lamp holder B Remove the front handlebar cover ...

Page 29: ...preset connector B Key switch connector C Battery case cover pag 22 D2 3 20 SEAT D2 D2 A C B F 57 F 56 V4 V A V V4 5 20 V V4 HELMET COMPARTMENT Remove the fuel tank plug and fit an adequate protection onto the filler A in order to prevent any outside particle to get into the tank ...

Page 30: ... 4 T F 58 F 59 F 60 D2 3 20 Partially lift the helmet compartment as it is constrained by the seat locking device cable Remove the locking opening unit complete with the transmission cable D2 SEAT BLOCKING DEVICE D2 ...

Page 31: ...oving the helmet compartment A Fuel tank B Fuel level gauge C Fuel gauge connector 1 Throttle cable 2 Electric starter carburator 3 Carburator valve cover 4 Vacuum pipe and fuel valve 5 Oil fumes expansion pipe B C A 1 2 3 4 5 F 61 F 62 ...

Page 32: ... tank During the operation screw the tank cap to avoid that any foreign matter falls inside V4 FUEL TANK V4 A B G V4 V4 5 10 Remove the tank and place it far from heat sources and sparks and or open flames F 66 a V4 Remove the cover 1 Undo the clamp B and remove the vacuum valve C B C F F 66 1 NOTE When reassembling insert the floater C so that the base remains as it was originally It is advisable...

Page 33: ...a screwdriver that is secured to the footbar by means of two coupling teeth CENTRAL BAR 2 Voltage regulator 3 CDI unit 4 Start relay ACCESS Spark plugs pipette 1 F 67 1 V3 F 69 2 3 4 F 68 Ground end fixing screws can be reached M F 68 through the hole F F 70 F ...

Page 34: ...3 07 08 50 cc 4 T W SIDE STRUTS V3 V2 Remove the side pins and the front coupling element A PASSANGER LEVERS Undo the upper screw V holding the self locking nut underneath F 71 F 72 F 73 F 74 V3 V2 W V A ...

Page 35: ...ear fairing with care paying attention not to lose the four fasteners A Clean and grease the fulcrum pin P Unscrew the screws V remove the pillion staff and recuperate the underlying spring M D V F 75 P G M FOOTBAR V4 W4 V4 5 10 F 77 F 76 A A A V4 W4 ...

Page 36: ...AIRING REAR HANDLE V After removing the closing cap V2 A F 78 F 79 F 81 F 80 V V2 A V2 B B C V2 V2 V Remove the rear handle including the opening locking seat device A REAR LIGHT UNIT V2 Rear light frame assembly B Rear light glass assembly C Number plate light support A NUMBER PLATE LIGHT SUPPORT V ...

Page 37: ...36 07 08 50 cc 4 T V2A V2A F 83 F 82 V4 5 10 F 84 V4 V4 Carefully take out the rear light unit Disconnect the wires FULL REAR FAIRING V4 ...

Page 38: ...e rear fairing with care Put the fairing in a safe place away from accidental crashes and heat sources ACCESS RIGHT SIDE 1 Electric starter resistance connector LEFT SIDE 2 Fuel sensor connector inside the sheaths F 86 F 85 F 88 F 87 V 2 1 ...

Page 39: ...38 07 08 50 cc 4 T V3 F 89 F 90 V3 V3 A Pay attention not to damage to the coupling system A FRONT PART REAR PART V3 REAR FAIRING BREAKDOWN V3 ...

Page 40: ...4 2 10 F 91 V2 F 92 F 93 F 94 A V C B W2 V V4 V V4 LEGSHIELD V2 Bag holder hook A Open carefully the leg shield on the left side Remove the fuse holder box Disconnect the connector C of the charge plug Extract the cover B of the key switch V4 ...

Page 41: ...ter removing the leg fender pay attention not to lose the fasteners A ACCESS after the legshield is removed 1 Front turn signals 2 Key switch 3 Horn 4 Handlebar fixing nuts 5 Steering wheel regulator ferrules 6 Fuse box F 95 F 97 F 96 3 A 4 5 6 1 2 1 ...

Page 42: ...cc 4 T F 98 V2 V A F 99 F 100 F 101 V A V2 10 15 V 7 10 V1 B KEY SWITCH Disconnect the connector from the wiring Unscrew the tamperproof screws V2 HORN Disconnect the faston A V FRONT MUDGUARD V Clamp A V1 Clamp B ...

Page 43: ... if the thick ness is below the minimum limit of 3 5 mm remove it by unscrewing the screws V5 and replace it V5 11 10 V Spacer A V3 Remove the wheel pin P Take off the wheel Pay attention not to lose the spacer A Do not use the brake lever with the wheel removed Remove the front mudguard F 102 F 103 F 104 F 105 P A D V5 V3 3 10 Apply Loctite threadlocker Strong type on the screw threading V3 A V ...

Page 44: ...e hydraulic circuit completely pouring the fluid in a special container for proper disposal in accordance with specific waste disposal laws V2 Remove the calliper Hydraulic oil is corrosive and may cause personal injury Remove the calliper taking care that fluid line does not get damaged and the disc and pads do not get dirty At the end of removal and replacement operations check that there are no...

Page 45: ...e HANDLEBAR Front handlebar Rear handlebar M Disconnect the accelerator transmission A Disconnect the dashboard connectors Disconnect the Stop faston Undo the odometer cable ring nut Remove with care the rear handlebar cover including the dashboard F 109 A G 50 20 M FRONT SHIELD Release the leg fender P 39 Remove the front mudguard P 41 Remove the front wheel P 42 V2 Take out the shield with care ...

Page 46: ...l fork the following should be removed beforehand Front wheel page 42 Front mudguard page 41 Front brake calliper page 43 left wheel stem For the full fork also remove the Front shield page 44 Handlebar page 44 To check the oil level and to change oil see page 15 FULL FORK Upper ring nut A Lower ring nut A NOTE When extracting the fork unit take care with the bearings S spilling out Remove grease ...

Page 47: ...W 8 15 F 117 F 118 D B R V2 Nut D Remove the rear wheel D 100 20 F 116 G V2 C W V2 30 20 MUFFLER Before operating on the muffler and the exhaust pipe ensure that the components are cool V2 REAR WHEEL Remove beforehand the muffler Undo the adjuster R Remove the split pin C and the nut cover B ...

Page 48: ...l solvent solution for filters for a few minutes Squeeze the filter wearing rubber gloves until all traces of the solvent are eliminated Apply oil for air filters on the entire surface of the filter eliminating any extra oil the result should be a uniformly impregnated filter without excess oil dripping off If the filter element is damaged replace it with a new original one When remounting the air...

Page 49: ... 40 15 Vi 40 15 SHOCK ABSORBER F 123 F 124 DS Vi DS Vi Di Vs ENGINE Remove beforehand Rear fairing page 35 Lower fixing screws shock absorber Air filter unit page 47 not compulsory Muffler page 55 It is essential that all the tube and cable ties are cut from the engine and all relevant connectors are disconnected After remounting the previously removed components all cables pipeli nes and ties sho...

Page 50: ... by undoing the clamp E Release the camping spring F Release the rear brake cable G from the cable ring supports H Disconnect the cables B C of the starter motor Disconnect the oil fume expansion pipe I Disconnect the vacuum pipe L Release the accelerator cable M I L M C B A G E H H F 127 D F ...

Page 51: ...nd remove the connector protection sheaths A Disconnect the electric starter connector A F 129 F 130 F 131 F 132 Disconnect the rear brake cable B Disconnect the spark plug C Unscreew the nut D Remember to fit the washer C 45 15 D A D B ...

Page 52: ...the rear part of the motorcycle before sliding off the engine pin It is advisa ble to have a second operator available to help carry out this operation Removing the engine from the frame is a task that should be performed with care and the utmost attention in order to avoid crushing of the hands lower limbs and safeguard the integrity of the engine The removal of parts and components that allow th...

Page 53: ...52 07 08 50 cc 4 T F 135 F 136 F 137 F 138 CABLE POSITIONING PIPE SYSTEM AND ANCHORING TIES ...

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Malaguti CENTRO SO 4T, Service Manual

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