FOREWORD. Some basic technical information has been intentionally omitted as it is considered to be common knowledge.

Transcription

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2 FOREWORD The present manual specifically addresses to specialised technical personnel (MLGUTI authorised service centres and single motor mechanics) and contains all the service interventions indicated by the Manufacturer until the publishing of this document. Some basic technical information has been intentionally omitted as it is considered to be common knowledge. dditional information is available in the SPRE PRTS CTLOGUES of each model. It is important to read all the general information before going through the manual to the specific topics and the maintenance operations to be carried out on the motor-bike 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. ll 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 procedures, technical characteristics, setting values, tightening torques and information as to which may only be properly and exhaustively provided by the manufacturer. It is important to adhere strictly to the following instructions. ny operation carried out carelessly or not carried out at all may lead to personal injury, damage to the motorcycle or simply to complaints. MLGUTI S.p.. reserves the right to make any changes and modifications hereto it deems necessary without prior notice. For further information and details, please contact MLGUTI S.p.. Servicing or Engineering Division. MLGUTI S.p.. Via Emilia 498, San Lazzaro di Savena (O) - ITLY Tel Fax info@malaguti.com - http: // /07

3 NOTES FOR ESY CONSULTTION REVITIONS TECHNICL DICTIONRY Cs D Dx F G P R Sx T V Torque wrench setting Nut Right Picture Gasket Page Washer Left Table Screw V = (DC) Direct current (battery supply) V ~ (C) lternating current (flywheel supply) : mpere Unit of measurement of the electrical current W : Watt Unit of measurement of the electrical power (product of Volts and mperes; x V = W) Ω : OHM Unit of measurement of the electrical resistance < Lower > Higher bar N * m Lower or equal Higher or equal Unit of measurement of pressure Unit of measurement of the tightening torque EDITING SYMOLS: Symbols have been provided for quick and easy reference, identifying situations requiring utmost attention or providing practical suggestions or simple information. These symbols may appear next to a text (in which case they refer solely to the text itself), next to a figure (in which case they refer to the topic illustrated in the figure and to the relative text), or at the top of the page (in which case they refer to all the topics 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. 2 07/07

4 SYMOL LIST DISSSEMLY OPERTIONS CUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity. SFETY GLOVES These operations require the use of safety gloves IDLING ENGINE Switch on the engine, at idling speed, to perfom these interventions. SSEMLY OPERTIONS WRNING! Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment, vehicle or equipment IMPORTNT This topic requires special attention ENGINE OFF Indicates operations to be performed with engine off SYMMETRICL OPERTIONS Operations that must be carried out also on the other side of the unit or component. FIRE HZRD. Indicates operations which may constitute a fire hazard GENERL SERVICE PERSONNEL Skilled electronic or mechanical technician. POWER OFF Indicates that negative pole is to be disconnected from the battery before performing the operation PRESENT MNUL Information on the present manual RISK OF EXPLOSION Indicates operations which may constitute a risk of explosion MECHNICL MINTENNCE Operations to be performed only by an expert mechanic NO! Operations to be absolutely avoided M ENGINE SERVICE MNUL Indicates information which may be obtained by referring to said catalogue TOXIC FUMES Indicates a possibility of intoxication or inflammation of the upper respiratory tract ELECTRICL MINTENNCE Operations be performed only by an expert electrical/ electronic technician EMPTY THE CIRCUIT OIL FUEL R SPRE PRTS CTLOGUE Indicates information which may be obtained by referring to said catalogue WRNING! Danger of crashing arms IGNITION KEY ON (ON position) REPLCE WITH NEW, ORIGINL SPRE PRTS 3 07/07

5 GENERL WORK PROCEDURES The recommendations given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment damage and idle times, and should therefore be strictly adhered to. lways listen with attention to the customer s opinion and complaints about the motor-bike operation, asking specific questions in order to have a complete understanding of all the symptoms and identify with good approximation the real causes of the trouble. The present manual provides the technical information and the basic indications on the intervention procedures but these have to be integrated with the personal expertise. We suggest planning the service interventions in order to avoid any waste of time or downtime. Try to reduce as much as possible the operations necessary to reach the components that needs 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 laying them out according to the sequence in which they are to be used. bsolutely avoid putting them on the vehicle itself, out-of-sight or in poorly accessible places. lways keep the work area neat and clean. When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progressive pulls using a criss-cross pattern. The torque settings specified in the manual refer to the final torque, which must be attained progressively by steps. Preferably use open-end box wrenches by pulling and not pushing. The roller adjustable wrenches must be used only in case of emergency, that is to say when the right size wrench is not available. In fact, when force is applied, the mobile vice tends to open and this may cause damage to the bolts and also result in a scarcely reliable tightening torque. lways use the wrenches as indicated in Figure. F /07

6 efore carrying out any operation, 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 co-ordinated beforehand. Make sure that each component has been properly mounted before proceeding with assembling the next one. lways replace gaskets, O-rings, circlips and split pins at every refitting. Only use screwdrivers with sizes suitable to the screws to be loosened or tightened. 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 short circuit. Never use open flames for any reason. Never leave open containers or containers not suitable for holding fuel in passageways, close to heat sources, etc. Never use petrol to clean the vehicle or the floor of the workshop. lways 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. Make sure that the vehicle is stable and not to have to take on awkward working positions. Never reuse old gaskets or circlips. Never use a screwdriver as a lever or chisel. Never use pincers to loosen or tighten screws or nuts because, in addition to not providing a sufficient clamping force, they may also damage the screw head or nut hexagon. Never tap the wrench with a hammer or other similar tool to loosen or tighten screws and nuts. Never attempt to increase the lever arm by fitting a tube into the wrench. 5 07/07 F. 2

7 efore any servicing, make sure that the vehicle is perfectly stable. The front wheel should preferably be anchored to fixture (), which is integral with the lift platform. F. 3 It is absolutely forbidden to walk on the lifting device. 6 07/07

8 CONTENTS DESCRIPTION P. SPECIFICTIONS 8 IDENTIFICTION DT: FRME N / ENGINE N 9 TYRES 9 MINTENNCE TLE 10 LURICNT TLE 11 RER MIRRORS 12 FIRING 12 FRONT HNDLER COVER 12 DSHORD HOLDER 12 DSHORD 12 CCESSES (after removing the front handlebar cover) 13 FRONT SHIELD 13 HEDLIGHTS 15 DIRECTION INDICTORS 15 CCESSES (after removing the shield) 16 LOWER SIDE PNELS 17 FLOORORDS 17 TTERY SET COVER 17 TTERY 17 FUSE DESCRIPTION 18 FUSE REPLCEMENT 18 SET COVER STORGE COMPRTMENT 18 CCESSES 19 LEG SHIELD 19 SET 20 SET LOCKING DEVICE 20 HELMET COMPRTMENT 21 CCESSES (after removing the helmet compartment) 21 FUEL LEVEL PROE 22 COVER 22 CCESSES (after removing the cover) 22 RER FIRING 23 NUMER PLTE HOLDER 24 DESCRIPTION P. CENTRL TUNNEL 24 OIL TNK 25 FUEL TNK 25 GS PEDL CLE SPLITTER 27 RER MUDGURD 28 FRONT MUDGURD 28 HNDLER COMMNDS 29 RKE PUMPS 29 HNDLER 29 KEY SWITCH 30 HORN 30 ODOMETER SENSOR 30 FRONT WHEEL 31 FRONT RKE 32 CHECKING LINING WER ND RKE DISC 32 REPLCING THE LININGS 32 RKE CLIPER 32 FORK 33 WHEEL SHFT 33 OIL LEVEL CHECK 33 OIL REPLCEMENT (wheel shafts) 34 FORK SSY 34 RER WHEEL 35 RER DRUM RKE 35 CHECKING 36 RKE LEVER DJUSTMENT 36 EXHUST SYSTEM 37 RDITOR 37 IR FILTER (Maintenance) (Removing) 38 ENGINE 39 FRME DIMENSION CHECK 41 CLE POSITIONING, PIPE SYSTEM ND 42 LOCTION OF NCHORING STRPS 7 07/07

9 SPECIFICTIONS Capacity cm Cooling... air Starting system.... electric starter and/or kick starter SPRK PLUG Type... NGK R7 ES TRNSMISSION utomatic speed variator with expandable pulleys, V- belt, automatic dry centrifuge clutch, reduction gear. FUEL SYSTEM Carburettor make / type: GURTNER PY 12 automatic starter. Fuel: unleaded petrol. IGNITION F. 4 DIMENSIONS Wheel base () m... 1,300 Max. length () m... 1,830 Max. width (C) m...0,705 Max. height (D) m... 1,160 Kerb weight kg Max. load with rider, passenger and luggage kg CPCITY Engine oil cm * Transmission oil cm * Fuel tank (total)... l 9.5* TWO-STROKE ENGINE Type... CM02C Cylinders... 1 ore x stroke mm... Ø 40 x 39,2 Electronic. RKES Front brake: disk type, Ø 190 mm with transmission and hydraulic calipers Rear brake: drum type, Ø 110 mm with mechanical transmission. CHSSIS Steel tube single beam, split at the footrest. SUSPENSIONS Front: hydraulically controlled fork with two Ø 30 mm rods. Stroke: 88 mm. Rear: hydraulic shock absorber. Stroke: 60 mm. TTERY Type 12V, 5h. TYRES Front: 130/ J Rear: 130/ J * Indicative Value 8 07/07

10 IDENTIFICTION DT: FRME N / ENGINE N The vehicle s identification number (VIN) () is located on the rear side of the chassis, under the helmet compartment. Engine identification data are located on the left-hand engine crankcase (). ny alteration to the vehicle identification data is pursued by the Law. TYRES Type: Tubeless F. 5 F. 6 F / J 130/ J Minimum tread depth is 2 mm. There are T.W.I. marks all around the tyre sides. 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 replaced. It is possible to use tyres with load and speed indexes that are higher than or identical to those indicated. It is however necessary for speed indexes to be identical for both tyres. Use only tyres with the relevant type approval. Tyre inflation pressure must be adjusted while the tyre is at ambient temperature. 9 07/07

11 MINTENNCE TLE Nr. : coupon : check : clean : adjust : replace NOTE - Maintenance operations should be performed more frequently if the vehicle is used in rainy weather, in dusty places or on rough terrain. Due to their simplicity, checks with no asterisk CN also be carried out by technicians not authorised by MLGUTI, but under their direct responsibility /07

12 LURICNT TLE NOTE - Use only recommended products. LURICNTS ENGINE TRNSMISSION OIL OIL FOR MIXING IR FILTER LURICNT T35-80W CITY IKE ULTR (synthetic) DILY SUPER (semi-synthetic) IR FILTER OIL RKE CIRCUIT FLUID RKE FLUID DOT 4 FORK ROD OIL FORK OIL OIL TNK TOTL TNK CPCITY RESERVE Litres To fill up the oil tank, remove the cover () by pulling its side flap. F /07

13 RER MIRRORS Uncover and loosen the nut (D). Unscrew the arm holding the mirror. FIRING FRONT HNDLER COVER V3 - V3 D V3 1 ± 10% V3 F. 9 F. 10 DSHORD HOLDER V3 - V3 1 ± 10% V3 Remove the front handlebar, including the dashboard. Disconnect the dashboard connector. DSHORD V4 - V4 F. 11 F /07

14 CCESSES (after removing the front handlebar cover) ) Dashboard connector 2) Front brake stop switch 3) Rear brake stop switch 4) Right switch connector 5) Left switch connector 6) Front brake pump oil connection 7) Rear brake transmission 8) Dashboard protection condenser 2 3 FRONT SHIELD Position adequate support beneath the scooter. F NOTE - Remove: - Front mudguard (p. 28) - Front wheel (p. 31). V - V3 - V V3 V 5 ± 20% V3 2 ± 10% F. 14 F /07

15 Gently separate the shield and disconnect the connector (). V6 - V6 2 ± 10% V6 F. 17 Remove the shield, including the headlights and the direction indicators. F. 16 F /07

16 V2 HEDLIGHTS D V2a D V2a V - (regulation screws for the beam of light) Gutter () Shell (D) Faston (C) DIRECTION INDICTORS C Shell (D) V1 F. 20 F. 19 V2 V1 V F /07

17 CCESSES (after removing the shield) NOTE - Cut the strap ( - F. 12) and remove the sheath () to access connectors (F.12/a). 6 1) Odometer transmission connector 2) Key switch connector 3) Connector for anti-theft device 4) Headlights connector 5) Fuse box connections 6) Steering wheel allowance regulation ring nut 7) Horn 8) Fork 5 F. 12 fter removing the cables, reposition and anchor the cables with new straps, as described in the figure F /07

18 LOWER SIDE PNELS V2 - FLOORORDS (after removing the lower side panels) V V2 V3 - (F. 24) V - V2 - V2 V3 2 ± 10% V2 V3 F. 23 V2 5 ± 20% F. 24 V2 TTERY TTERY SET COVER V Cover () V V1 Stop battery () Remove battery Disconnect the vent pipe (C) Disconnect the cables; firstly the cable connected to mass - C V1 F. 25 F /07

19 TTERY Connect the cables as illustrated in the figure; connect the positive cable first. + Do not invert cable connection. When reassembling the battery, do not forget to insert the vent pipe. Make sure it exits the battery seat without bending or strangling. F. 27 F. 28 FUSE DESCRIPTION ) 10 - General protection/ Recharge ) 5 - Stop protection/ Direction indicators/ Horn C) 7,5 - Lights protection/ Starter FUSE REPLCEMENT SET COVER STORGE COMPRTMENT V - Cover (). lways replace a fuse with another of same capacity. Higher capacity may result in serious damage to the electric system, including the risk of fire. C F. 30 V F /07

20 CCESSES Socket for battery recharging () (max. 5 h). LEG SHIELD V - (F. 31) V1 - V1 V1 5 ± 20% Remove the cover ( - F. 31) of the key switch. V 5 ± 20% V F. 32 F. 31 Remove the Fastons () on the back of the fuse box. Write down the positions of the Fastons before disconnecting them. Open the two wire clamps (C). C F. 33 F /07

21 Remove the cables from the battery, from the front part. Gently separate the leg shield and disconnect the connector (D) of the recharge socket. D F. 35 F. 36 D2 - SET V2 - SET LOCKING DEVICE D2 3 ± 20% D2 V2 3 ± 20% D2 (F. 40) R2 (F. 40) V2 D2 - F. 37 F /07

22 HELMET COMPRTMENT V- V4 - Cover (). Gasket (). Cover (C). Gasket (D). V V4 C R2 V V4 5 ± 20% V4 D2 D F. 39 F. 40 CCESSES (after removing the helmet compartment) G F E D Fuel level probe () Engine oil probe () Low fuel warning light (C) Engine oil probe connector (D) Low fuel warning light sensor connector (E) Fuel level probe connector (F) Rear light connector (G) C V4 F /07

23 V4 - (F. 41) FUEL LEVEL PROE COVER V - V V4 2 ± 10% NOTE - During reassembly, insert the float (1) so that the probe connector is turned as shown in F F. 43 F. 42 CCESSES (after removing the cover) CDI unit () Tension regulator () Flasher relays (C) Start relay (D) Mass rope (E) E D C F. 44 F /07

24 RER FIRING V2 - V2 - Rear light frame (). V2 5 ± 20% NOTE - In these conditions, the lamp can be replaced. To replace the lamp of the indicators, loosen the screws (V). V2 V V2 F. 46 F. 47 (Gently) separate the side flanks. Remove the side flanks by sliding them towards the rear part of the scooter. F. 48 F /07

25 V - V 5 ± 20% V Free the anchoring notches () of the fairing. Gently remove the fairing itself, being careful with the cabling of the rear lights. F. 50 F. 51 Disconnect the connector () and definitely remove the fairing, including the number plate holder. F. 52 NUMER PLTE HOLDER V2 - V2 CENTRL TUNNEL V4 - Release the tunnel () from the hooks and let it slide in the direction indicated by the arrow. V4 V4 F. 53 F /07

26 OIL TNK NOTE - In order to reach the oil tank and the fuel tank, it is necessary to remove the rear fairing. Use pincers to release the strap () and disconnect the pipe (). Insert a screw, which shall function as tap, in the tank exit connection. Disconnect the connector (C). V3 - C D V3 2 ± 20% V3 F. 55 FUEL TNK fter removing the oil tank: Disconnect the connector (D - F. 55). Disconnect the connector (E). Disconnect the fuel supply pipe. V4 - E V4 V4 5 ± 20% F /07

27 NOTE - Should you need to replace the pipe () of the mixer oil, (pointed out in yellow) position and anchor it according to the illustrations below. If not properly fixed, the pipe may interfere with the exhaust gas pipe. F. 57 F. 58 F /07

28 GS PEDL CLE SPLITTER V - Disconnect the clamp cables (). NOTE - Selective transmissions (cables C): one is connected to the carburetor and the other to the oil pump. V C C F. 61 F. 60 NOTE - The ignition coil () is positioned under the left footbord /07

29 RER MUDGURD V2 - V2 - and relative bushs. V2 5 ± 20% V2 3 ± 20% During re-assembly insert the removed parts, both outside and inside the fender. F. 62 V2 V2 F. 63 FRONT MUDGURD V2 - V2 V2 3 ± 20% F /07

30 HNDLER COMMNDS V2 - Disconnect the connectors (). Disconnect the accelerator transmission (T). V1 V2/b V2 1,6 ± 20% T FRONT RKE PUMP V2/a - U-bolt (). Screw/connection (V). Disconnect the Fastons (C). V V2 V2 V 20 ± 20% V2/a 28 ± 20% C HNDLER Remove: - Front handlebar cover (p. 12) - Front shield (p. 13). V2/a V2/b - V1 - Loosen nut (D) and slide the handlebar off, being careful not to damage cables or pipes. D V2/b 10 ± 10% V D 50 ± 20% F /07 F. 65/a

31 KEY SWITCH Separate the front shield (p. 13). Disconnect the connector. V3 - (foolproof screws). V3 10 ± 15% V3 F. 66 HORN Disconnect the Fastons (). V - V 7 ± 10% V ODOMETER SENSOR V1 (F. 74). Connector (C). V1 10 ± 20% C F. 67 F /07

32 FRONT WHEEL Make sure the scooter is perfectly stable and insert a suitable support beneath the lower side panels. Remove the front mudguard (p. 28). Unscrew the nut (D), preventing it from falling by using a wrench for the wheel pin. D Slide the wheel pin off (P). Do not activate the brake lever while the wheel is off. D 45 ± 15% P F. 69 F. 70 When reassembling the wheel pin, insert the spacers ( - ). F. 71 F /07

33 FRONT RKE CHECKING LINING WER ND RKE DISC every 2,000 km (approx. 1,205 miles) Check the wear of the linings by looking from the front part of the fork. In case of doubt regarding their validity, remove them and replace them. Check also the state of the brake disc. In case of excessive wear or anomaly, replace it. Minimum thickness of linings should be 2 mm. Minimum thickness of disc should be 3,5 mm. F. 73 REPLCING THE LININGS Remove the cover (). Remove the seeger (). Remove the pin (C) and the spring (D). Operate in the opposite direction to remount the components. V2 V1 RKE CLIPER V2 - R - R V2 30 ± 20% R 20 ± 20% F /07

34 FORK OIL LEVEL CHECK WHEEL SHFT Remove: - Front mudguard (p. 28) - Front wheel (p. 31) - rake caliper (for left shaft) (p. 32) - Odometer sensor (for left shaft) (p. 30). V lock the wheel shaft in a clamp, in vertical position. Remove: - Cover () - Seeger ring () - Propeller nut (C), complete with O-Ring (D) - Spring (E) (let oil drip off it) ring the shaft (F) to its end-of-travel position. Loosen (V) Lift the shaft a few millimeters (). F. 75 Remove the spring ring (). Slide the shaft downwards (). V 30 ± 20% F. 76 Insert a measuring pin or a caliber and make sure the oil is at a depth of 110 mm (approx. 3,93 inches) from the upper rim of the shaft. If necessary, fill up with oil: FORK OIL ~ 90 cc per shaft 33 07/07 F. 77

35 OIL REPLCEMENT (wheel shafts) With the shaft blocked in a clamp, in vertical position, place a container beneath the screw (V). V- Let the oil flow for a few minutes. Remove the wheel shaft as described above. Turn the shaft upside down and let any residual oil drip out. Do not disperse oil in the environment. Make sure it is eliminated according to local norms regarding special garbage disposal. Tighten the screw (V) with its relative gasket. Carefully pour new oil in the shaft: ~ 90 cc (right - left) Check oil level as described above. Reassemble the parts. V 24 ± 10% V FORK SSY To remove the complete fork, remove: Shield (p. 13). Front mudguard (p. 28). Front wheel (p. 31). rake caliper (p. 32). Odometer sensor (p. 30). Handlebar (p. 29). To release the fork: Upper lock-nut () Lower lock-nut (). F. 79 NOTE - While removing the fork group, be careful not to let the balls (S) out. Clean the cap seats (C). Check them for wear and replace them if necessary. Grease and reassemble the fork unit. Upper balls 22 (Ø 3/16 ) Lower balls 19 (Ø 1/4 ) F. 78 F /07

36 RER WHEEL NOTE - To remove the rear wheel, you must remove the exhaust system (p. 37). Position the scooter on the stand and insert a suitable support beneath the engine. Remove the cover (). D - Carefully remove the wheel, making sure the vehicle is stable. D 100 ± 20% D F. 81 F. 82 RER DRUM RKE Remove the rear wheel. Unscrew and remove the adjustung nut (D). C E D1 Grasp (with both hands) the two sectors of the rear brake shoes (), open them out vigorously, in order to separate them from cam/pin (E). The high strength of the springs () may cause the crushing of your fingers. E F. 83 D Loosen the nut (D1- F. 83) and remove the lever (C - F. 83), paying attention to the torsion spring with which is connected. Extract the cam/pin (E). F. 84 Clean and grease only the central part of the cam/pin. During re-assembly, the cam/pin should be inserted in its seat and free from any frictions. Do not use any tools to insert the cam/pin. Control the correct hooking of the springs () /07

37 NOTE - Rear brake transmission is secured in the lower part of the motorcycle, by the screw (V). CHECKING Friction material Control the conditions of the brake shoes, verify the minimum thickness of the friction material, which should t be thinner then mm 2, otherwise, replace the shoes. V Drum Clean carefully the inner part of the drum, verifying that there are no clearly visible scores or damages. Otherwise proceed with the replacement of the rear rim. F. 86 F. 85 RKE LEVER DJUSTMENT Pull the lever verifying that the brake begins working, after an idle stroke of the lever of about 10 mm. If necessary, carry out adjustment by acting on the adjustment nut (D). Rotate the wheel manually, operating for different times the brake lever verifying the idle stroke, the braking efficacy and the free rotation of the wheel, after having released the lever itself. F. 87 fter the adjustment, verify that the adjustment nut thread is not completely employed up to the end of the thread itself (that would mean that the brake shoes are completely worn out). D F /07

38 D - V - SUSPENSION D 40 ± 20% D EXHUST SYSTEM The operations described below should be carried out only when the exhaust system has cooled down. V2 V 24 ± 20% V2 - (see removing the rear mudguard, p. 28). F. 90 V F. 89 V2/a - Gasket (replace it with a new one). V2/a 8 ± 15% Remove the strap () and disconnect the secondary air emission pipe (). V2/b - V2/b 30 ± 20% V2/a V2/b F. 91 F /07

39 IR FILTER (Maintenance) The air filter can be reached by removing the lower side panels (p. 17). Release the spring () on the carburetor. F. 93 V3 - Remove: - Cover () - Filtering element (). Immerge the filtering element in a solution: solvent for filters, for a few minutes. Squeeze the filter (wearing rubber gloves) until all solvent is eliminated. Spread oil for air filter on the entire surface of the filter, eliminating any excessive material; in fact, the filter must be uniformly impregnated, without dripping. In case the filtering element is damaged, replace with a new, original one. F. 94 (Removing) V2 - Release the spring () on the carburetor. Remove the filter case (C). When reassembling the air filter unit, make sure the container contact surfaces are perfectly adherent, to avoid aspiration of non-filtered air. V2 10 ± 15% V2 C F /07

40 ENGINE Remove the rear fairing (p. 23) and the lower side panels (p. 17). Disconnect the connector () of the start engine. Disconnect the mass pipe () of the start engine. Disconnect the flywheel connector (C) and the three faston connectors (F). Engine oil tank (p. 25). Disconnect the engine oil outlet pipe (C) and use a screw to close it. Pull off the spark plug lead (D). Use the spring (E) to release the air filter from the carburetor. Remove the air filter unit (p. 38). F. 96 F. 97 C E C F D F. 97/a F. 98 F /07

41 V - V2 - Lateral air conveyor, paying attention to the hook element positioned in the lower part of the conveyor itself. F. 99/a V V2 Disconnect the first accelerator cable, from the carburetor. Disconnect the second accelerator cable () from the cam () which operates on the oil mixer. Disconnect the carburetor starter connector (C) (page 41 F. 103). During the reconnection of the cable, verify that the side (C) of the cam, is aligned with the notch on the fixed point of reference. F. 100 C Remove the muffler (p. 37). Release the rear brake transmission cable by operating on the nut (D). Remove the rear wheel p. 35. D Unscrew the lower locking screw (V) of the shock absorber. Rotate the suspension upwards and anchor it to the scooter frame. Remove the stand. V F. 101 F /07

42 Unscrew the locking nut (D) and slide the pin out (). C D 62 ± 15% efore removing the engine shaft, you must lift the scooter from its rear part. For this operation it is advisable to have another operator help you. Removing the engine from the frame is a dangerous operation, and should be carried out with maximum care and attention in order to avoid crushing arms and legs and to protect the engine itself. Removing the pieces and parts which allow the engine to be separated from the frame means that a certain number of straps must be cut. These must be replaced and positioned as in the original configuration. Check the illustrations on the upcoming pages. F. 103 F. 104 D FRME DIMENSION CHECK In case of presumed deformation, however slight, of the frame after an accident, check the dimensions of the frame. Check value = 1026 mm (tolerance ± 2 mm) In case the values found are out of the tolerance range, replace the frame. It is absolutely forbidden to deform the frame in order to reset value () as in its original configuration. F /07

43 CLE POSITIONING, PIPE SYSTEM ND LOCTION OF NCHORING STRPS F. 106 F /07 F. 108

44 F /07

45 F /07