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 FOREWORD
• The present manual specifically addresses to specialised technical personnel (MALAGUTI 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.

• Additional information is available in the SPARE PARTS CATALOGUES 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.

• 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 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. Any operation carried out carelessly or not carried out at all may lead to personal injury, damage to the motorcycle
or simply to complaints.

MALAGUTI S.p.A. reserves the right to make any changes and modifications hereto it deems necessary without prior notice.
For further information and details, please contact MALAGUTI S.p.A. Servicing or Engineering Division.

MALAGUTI S.p.A.
Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY
Tel. 051.62.24.811 - Fax 051.69.47.782
e-mail: [email protected] - http: // www.malaguti.com

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 NOTES FOR EASY CONSULTATION

ABBREVIATIONS TECHNICAL DICTIONARY

Cs Torque wrench setting V = (DC) Direct current (battery supply)

D Nut V ~ (AC) Alternating current (flywheel supply)
Dx Right A : Ampere Unit of measurement of the electrical current
F Picture W : Watt Unit of measurement of the electrical power (product of Volts and Amperes; A x V = W)
G Gasket Ω : OHM Unit of measurement of the electrical resistance
P Page < Lower
R Washer ≤ Lower or equal
Sx Left
> Higher
T Table
≥ Higher or equal
V Screw
bar Unit of measurement of pressure

N*m Unit of measurement of the tightening torque

EDITING SYMBOLS:
• 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.

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 SYMBOL LIST

CAUTION!
SAFETY GLOVES IDLING ENGINE
Recommendations and
DISASSEMBLY Switch on the engine, at
precautions regarding rider These operations require
OPERATIONS idling speed, to perfom
safety and motor vehicle the use of safety gloves
integrity. these interventions.

WARNING! Situations
entailing the risk of personal ENGINE OFF
injury to maintenance or repair IMPORTANT
ASSEMBLY Indicates operations to
mechanics, other workshop This topic requires special
OPERATIONS be performed with
personnel or third parties, or attention engine off
damage to environment,
vehicle or equipment

SYMMETRICAL
OPERATIONS GENERAL SERVICE POWER OFF
FIRE HAZARD.
Operations that must be PERSONNEL Indicates that negative
Indicates operations which
carried out also on the other pole is to be disconnected
may constitute a fire Skilled electronic or
side of the unit or from the battery before
hazard mechanical technician.
component. performing the operation

RISK OF MECHANICAL
PRESENT MANUAL EXPLOSION MAINTENANCE NO!
Information on the Indicates operations Operations to be Operations to be
present manual which may constitute a performed only by an absolutely avoided
risk of explosion expert mechanic

“ENGINE” SERVICE TOXIC FUMES EMPTY THE CIRCUIT

ELECTRICAL
MANUAL Indicates a possibility of MAINTENANCE
OIL
M Indicates information which
intoxication or inflammation Operations be performed
of the upper respiratory only by an expert electrical/
may be obtained by FUEL
tract electronic technician
referring to said catalogue

SPARE PARTS
CATALOGUE WARNING! REPLACE WITH NEW,
IGNITION KEY ON
R Indicates information which Danger of crashing (ON position) ORIGINAL SPARE
may be obtained by arms PARTS
referring to said catalogue

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 GENERAL 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.

• Always 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. Absolutely avoid putting them on the
vehicle itself, out-of-sight or in poorly accessible places.

• Always 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. Always use the wrenches as indicated in Figure.

F. 1

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 • Before 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.

• Always 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. Always 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.

F. 2
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 Before any servicing, make sure that the vehicle is perfectly stable.
The front wheel should preferably be anchored to fixture (A), which is integral with the lift platform.

F. 3

It is absolutely forbidden to walk on the lifting device.

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 CONTENTS
1234 1234
DESCRIPTION P. 1234
1234
1234 DESCRIPTION P.
SPECIFICATIONS 8
1234
1234 CENTRAL TUNNEL 24
1234
1234
IDENTIFICATION DATA: FRAME N° / ENGINE N° 9 1234 OIL TANK 25
1234
1234
TYRES 9 FUEL TANK 25
1234
1234
MAINTENANCE TABLE 10 1234 GAS PEDAL CABLE SPLITTER 27
1234
1234
LUBRICANT TABLE 11 REAR MUDGUARD 28
1234
1234
REAR MIRRORS 12 1234
1234
FRONT MUDGUARD 28
FAIRING 12 1234 HANDLEBAR COMMANDS 29
1234
FRONT HANDLEBAR COVER 12 1234
1234 BRAKE PUMPS 29
1234
1234
DASHBOARD HOLDER 12 HANDLEBAR 29
1234
1234
DASHBOARD 12 1234 KEY SWITCH 30
1234
1234
ACCESSES (after removing the front handlebar cover) 13 HORN 30
1234
FRONT SHIELD 13 1234
1234 ODOMETER SENSOR 30
1234
1234
HEADLIGHTS 15 1234 FRONT WHEEL 31
DIRECTION INDICATORS 15 1234
1234 FRONT BRAKE 32
1234
ACCESSES (after removing the shield) 16 1234
1234 CHECKING LINING WEAR AND BRAKE DISC 32
1234
LOWER SIDE PANELS 17 1234
1234
REPLACING THE LININGS 32
1234
FLOORBOARDS 17 1234
1234
BRAKE CALIPER 32
BATTERY SEAT COVER 17 1234 FORK 33
1234
1234
BATTERY 17 1234
1234
WHEEL SHAFT 33
FUSE DESCRIPTION 18 1234
1234
OIL LEVEL CHECK 33
1234
FUSE REPLACEMENT 18 1234
1234
OIL REPLACEMENT (wheel shafts) 34
SEAT COVER STORAGE COMPARTMENT 18 1234
1234
FORK ASSY 34
1234
ACCESSES 19 1234
1234
REAR WHEEL 35
LEG SHIELD 19 1234
1234
REAR DRUM BRAKE 35
SEAT 20 1234
1234 CHECKING 36
SEAT LOCKING DEVICE 20
1234
1234 BRAKE LEVER ADJUSTMENT 36
1234
1234
HELMET COMPARTMENT 21 1234 EXHAUST SYSTEM 37
ACCESSES (after removing the helmet compartment) 21
1234
1234 RADIATOR 37
1234
1234
FUEL LEVEL PROBE 22 1234 AIR FILTER (Maintenance) (Removing) 38
1234
1234
COVER 22 ENGINE 39
1234
ACCESSES (after removing the cover) 22 1234
1234 FRAME DIMENSION CHECK 41
1234
1234
REAR FAIRING 23 CABLE POSITIONING, “PIPE SYSTEM” AND 42
1234
NUMBER PLATE HOLDER 24 1234
1234 LOCATION OF ANCHORING STRAPS

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 SPECIFICATIONS Capacity cm3 .................................................................................................. 49
Cooling ............................................................................................................ air
Starting system. ............................................. electric starter and/or kick starter

SPARK PLUG
Type ............................................................................................... NGK BR7 ES

TRANSMISSION
Automatic 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 Electronic.

BRAKES
DIMENSIONS
Front brake: disk type, Ø 190 mm with transmission and hydraulic calipers
Wheel base (A) m ....................................................................................... 1,300 Rear brake: drum type, Ø 110 mm with mechanical transmission.
Max. length (B) m ........................................................................................ 1,830
Max. width (C) m ......................................................................................... 0,705 CHASSIS
Max. height (D) m ........................................................................................ 1,160
Kerb weight kg ............................................................................................... 105 Steel tube single beam, split at the footrest.
Max. load with rider, passenger and luggage kg .............................................. 175
SUSPENSIONS
CAPACITY Front: hydraulically controlled fork with two Ø 30 mm rods. Stroke: 88 mm.
Engine oil cm3 ........................................................................................... 1400* Rear: hydraulic shock absorber. Stroke: 60 mm.
Transmission oil cm3 ................................................................................... 100*
Fuel tank (total) ........................................................................................... l 9.5* BATTERY
Type 12V, 5Ah.
TWO-STROKE ENGINE
Type ...................................................................................................... CMA02C TYRES
Cylinders ........................................................................................................... 1 Front: 130/60 - 13 53 J
Bore x stroke mm ............................................................................. Ø 40 x 39,2 Rear: 130/60 - 13 53 J
* Indicative Value

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 IDENTIFICATION DATA: FRAME N° / ENGINE N°
• The vehicle’s identification number (VIN) (A) is located on the rear side of the
chassis, under the helmet compartment.
• Engine identification data are located on the left-hand engine crankcase (B).

Any alteration to the vehicle identification data is pursued by the

Law.

TYRES
Type: Tubeless

F. 5 F. 6

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.

130/60 13”53J 130/60 13”53J

F. 7

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.

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 MAINTENANCE TABLE

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

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 LUBRICANT TABLE
NOTE - Use only recommended products.

LUBRICANTS

ENGINE TRANSMISSION OIL T35 - 80W

OIL FOR MIXING CITY BIKE ULTRA (synthetic)

DAILY SUPER (semi-synthetic)

AIR FILTER LUBRICANT AIR FILTER OIL

BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4

FORK ROD OIL FORK OIL

OIL TANK Litres

TOTAL TANK CAPACITY • To fill up the oil tank, remove the cover (A) by pulling
its side flap.
RESERVE

F. 8

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 REAR MIRRORS FAIRING V3
• Uncover and loosen the nut
(D).
FRONT HANDLEBAR
• Unscrew the arm holding COVER
the mirror.
• V3 -

D V3 1 ± 10%

V3
F. 9 F. 10

DASHBOARD HOLDER
• V3 -

V3 1 ± 10% V3
• Remove the front handlebar, DASHBOARD
including the dashboard.
• V4 -
• Disconnect the dashboard
connector.

V4
F. 11 F. 12

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 ACCESSES 4 5 1
(after removing the front handlebar cover)
1) 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

6 8 7
FRONT SHIELD F. 13
• Position adequate support beneath the scooter.

NOTE - Remove:
- Front mudguard (p. 28)
- Front wheel (p. 31).

• V-
• V3 - V V3

V 5 ± 20%

V3 2 ± 10%

F. 14 F. 15

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 • Gently separate the shield and disconnect the connector (A).

• V6 -

V6
V6 2 ± 10%
F. 17

• Remove the shield, including the

headlights and the direction indicators.

F. 16

F. 18

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 HEADLIGHTS
D V 2a A B D B
• V2
• V2a
• V - (regulation screws for the
beam of light)
• Gutter (A)
• Shell (D)
• Faston (C)

C
DIRECTION
INDICATORS
• Shell (D)
• V1 F. 20

F. 19
V2

V1

F. 21

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 ACCESSES
(after removing the shield)

NOTE - Cut the strap (A - F. 12) and remove the sheath

B A
(B) 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

2
After removing the cables, reposition and
anchor the cables with new straps, as
described in the figure. 3

4 7 8
F. 22

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 LOWER SIDE PANELS FLOORBOARDS
(after removing the V V2
• V2 - lower side panels)
• V-
• V3 - (F. 24)
• V2 -

V2
V3 2 ± 10% V2
V3

V2 5 ± 20%
F. 23 F. 24 V2

A BATTERY

• V1
BATTERY SEAT • Stop battery (B) C
COVER • Remove battery
B
•V • Disconnect the vent
• Cover (A) pipe (C)
• Disconnect the cables;
firstly the cable V1
V connected to
mass
-
F. 25 F. 26

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 When reassembling
BATTERY
the battery, do not
• Connect the cables as illu- forget to insert the
strated in the figure; connect vent pipe. Make sure
the positive cable + first. it exits the battery
seat without bending
or strangling.
Do not invert cable
connection.

F. 27 F. 28

FUSE DESCRIPTION
A) 10 A - General protection/ A
Recharge
B) 5 A - Stop protection/
Direction indicators/
Horn SEAT COVER
C) 7,5 A - Lights protection/ B STORAGE COMPARTMENT
Starter • V-
• Cover (A).
FUSE REPLACEMENT
Always replace a fuse with C
another of same capacity.
Higher capacity may result
in serious damage to the
electric system, including F. 30
the risk of fire. A V

F. 29

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 ACCESSES LEG SHIELD
A
• Socket for battery recharging • V - (F. 31)
• V1 - V1
(B) (max. 5 Ah).

B
V1 5 ± 20%

• Remove the cover

(A - F. 31) of the key
switch.

V 5 ± 20%
V
F. 32

F. 31

• Remove the Fastons (B) on

the back of the fuse box. B
C
Write down the • Open the two wire
positions of the clamps (C).
Fastons before
disconnecting them.

F. 33
F. 34

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 • Remove the cables • Gently separate the
from the battery, leg shield and
from the front part. disconnect the
connector (D) of the D
recharge socket.

F. 35 F. 36

SEAT SEAT LOCKING

DEVICE
• D2 - • V2 -

D2
D2 3 ± 20%
V2 3 ± 20%

• D2 (F. 40)
• R2 (F. 40) V2

• D2 -

F. 37 F. 38

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 HELMET COMPARTMENT
V A
• V-
• V4 - R2
• Cover (A).
• Gasket (B). V4
• Cover (C). C
• Gasket (D).

V V4
V4 5 ± 20% B
D2

D
F. 39 F. 40

B E
G F
D
ACCESSES
(after removing the helmet compartment)
• Fuel level probe (A)
• Engine oil probe (B)
• Low fuel warning light (C)
• Engine oil probe connector (D)
• Low fuel warning light sensor connector (E)
• Fuel level probe connector (F)
B C
• Rear light connector (G)

A V4
F. 41

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 FUEL LEVEL COVER
PROBE • V- V

• V4 - (F. 41)

V4 2 ± 10%

NOTE - During reassembly, insert the

float (1) so that the probe con-
nector is turned as shown in
F. 42. 1 F. 43

F. 42

ACCESSES A E
(after removing the cover)
• CDI unit (A)
• Tension regulator (B)
• Flasher relays (C)
• Start relay (D)
• Mass rope (E)

F. 44 F. 45

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 REAR FAIRING • V2 -
• V2 -
• Rear light frame (A). A V2 5 ± 20%

NOTE - In these conditions, V2

the lamp can be
replaced. To replace V
the lamp of the
indicators, loosen
the screws (V). V2

F. 46 F. 47

• Remove the side

• (Gently) separate the side flanks by sliding
flanks. them towards the
rear part of the
scooter.

F. 48 F. 49

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 • Free the anchoring notches
• V- V (A) of the fairing. Gently
remove the fairing itself,
being careful with the
V 5 ± 20% cabling of the rear lights.

F. 50 F. 51
A

• Disconnect the connector

(B) and definitely remove
the fairing, including the
number plate holder.

B NUMBER PLATE HOLDER

• V2 -
F. 52
V2

CENTRAL TUNNEL
• V4 -
• Release the tunnel (A) from
the hooks and let it slide in V4 V4
the direction indicated by
the arrow.

F. 53
F. 54
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 OIL TANK
D
NOTE - In order to reach the oil tank and the fuel
tank, it is necessary to remove the rear
fairing.
C
• Use pincers to release the strap (A) and discon-
nect the pipe (B).
• Insert a screw, which shall function as tap, in
the tank exit connection.
• Disconnect the connector (C).
• V3 - A

V3 V3
2 ± 20%
B

F. 55

FUEL TANK
After removing the oil tank:
• Disconnect the connector (D - F. 55). V4
• Disconnect the connector (E).
• Disconnect the fuel supply pipe.
• V4 - E

V4 5 ± 20%

F. 56

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 NOTE - Should you need to replace the pipe (B) 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. 59

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 GAS PEDAL CABLE SPLITTER

• V- NOTE - Selective transmissions (cables C): one is connected to the carburetor and
• Disconnect the clamp cables (A). the other to the oil pump.

B C

F. 61

NOTE - The ignition coil (B) is positioned under the left footbord.
F. 60

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 REAR MUDGUARD • V2 - and relative bushs.
• V2 -

V2
V2 5 ± 20%
3 ± 20%

During re-assembly
insert the removed
parts, both outside
and inside the fender.

F. 62
V2
V2

F. 63

FRONT MUDGUARD
V2
• V2 -

V2 3 ± 20%

F. 64

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 HANDLEBAR COMMANDS
V1 V2/b V2 1,6 ± 20%
• V2 -
• Disconnect the connectors (A).
• Disconnect the accelerator transmission (T).

FRONT BRAKE PUMP

• V2/a - V2 V A A V2
• U-bolt (B).
• Screw/connection (V).
• Disconnect the Fastons (C).

V 20 ± 20%
V2/a 28 ± 20%

HANDLEBAR
V2/a
• Remove:
- Front handlebar cover (p. 12)
- Front shield (p. 13).
• V2/b - 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. 65 F. 65/a
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 KEY SWITCH
• Separate the front shield (p. 13).
• Disconnect the connector.
• V3 - (foolproof screws).

V3 10 ± 15%

V3

F. 66

ODOMETER
HORN
SENSOR
• Disconnect the Fastons C
• V1 (F. 74).
(A).
• Connector (C).
• V-
A
V
V 7 ± 10% V1 10 ± 20%

F. 67

F. 68
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 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).
• Slide the wheel pin off (P).
• Unscrew the nut (D),
preventing it from falling by D
Do not activate the
using a wrench for the
brake lever while the
wheel pin.
wheel is off.

D 45 ± 15%
P

F. 69 F. 70

• When reassembling the wheel pin, insert

the spacers (A - B).
A

F. 71 F. 72

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 FRONT BRAKE
CHECKING LINING WEAR AND BRAKE 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

REPLACING THE LININGS

• Remove the cover (A).
• Remove the seeger (B). V2
• Remove the pin (C) and the spring (D).
• Operate in the opposite direction to remount the components.
V1

BRAKE CALIPER
• V2 -
• R-
R

V2 30 ± 20%
R 20 ± 20%

F. 74
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 FORK OIL LEVEL CHECK

WHEEL SHAFT • Block the wheel shaft in a clamp, in vertical

position.
• Remove: • Remove:
- Front mudguard (p. 28) - Cover (A)
- Front wheel (p. 31) - Seeger ring (B)
- Brake caliper (for left shaft)
V
- Propeller nut (C), complete with O-Ring (D)
(p. 32)
B - Spring (E) (let oil drip off it)
- Odometer sensor (for left shaft) (p. 30). A • Bring the shaft (F) to its end-of-travel position.
• Loosen (V)
F. 75
• Lift the shaft a few millimeters (A).
• Remove the spring ring (B).
• Slide the shaft downwards (A).

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

F. 77

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 OIL REPLACEMENT
FORK ASSY
(wheel shafts) A
To remove the complete fork,
• With the shaft blocked in a clamp, in vertical
remove: B
position, place a container beneath the screw (V).
• Shield (p. 13).
•V- • Front mudguard (p. 28).
• Let the oil flow for a few minutes. • Front wheel (p. 31).
• Remove the wheel shaft as described above. • Brake caliper (p. 32).
• Turn the shaft upside down and let any residual oil • Odometer sensor (p. 30).
drip out. • Handlebar (p. 29).
Do not disperse oil in the environment. Make sure F. 79
it is eliminated according to local norms regarding To release the fork:
special garbage disposal.
• Upper lock-nut (A)
• Lower lock-nut (B).
• Tighten the screw (V) with its relative gasket.
• Carefully pour new oil in the shaft:
NOTE - While removing the fork group, be careful not to
let the balls (S) out.
~ 90 cc (right - left)
• Clean the cap seats (C). Check them for wear and replace
• Check oil level as described above. them if necessary.
• Reassemble the parts.
Grease and reassemble the fork unit.
V
V 24 ± 10% Upper balls 22 (Ø 3/16”)
Lower balls 19 (Ø 1/4”)
F. 78 F. 80

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 REAR • D-
WHEEL • Carefully remove the wheel,
making sure the vehicle is
NOTE - To remove the rear stable.
wheel, you must remove the
exhaust system (p. 37).
• Position the scooter on the D 100 ± 20% D
stand and insert a suitable
support beneath the engine.
• Remove the cover (A).
A

F. 81 F. 82

REAR DRUM • Grasp (with both hands) the

BRAKE E two sectors of the rear brake
shoes (A), open them out
• Remove the rear wheel. vigorously, in order to separate
• Unscrew and remove the them from cam/pin (E).
adjustung nut (D).
A
The high strength of
D1
C the springs (B) may
cause the crushing of
your fingers. E

D • Loosen the nut (D1- F. 83)

and remove the lever (C - F.
F. 83 83), paying attention to the
torsion spring with which is A
connected. B
• 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 (B).

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 NOTE - Rear brake CHECKING
transmission is secured
in the lower part of the Friction material
motorcycle, by the • Control the conditions of the brake shoes, verify
screw (V). the minimum thickness of the friction material,
which should’t be thinner then mm 2, otherwise,
replace the shoes.

Drum
V • 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

BRAKE LEVER ADJUSTMENT

• 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

After 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).

F. 88

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 SUSPENSION EXHAUST SYSTEM
The operations described
V2
• D- D
• V- below should be carried
out only when the exhaust
D 40 ± 20%
system has cooled down.

• V2 - (see “removing the rear

mudguard”, p. 28).
V 24 ± 20%

F. 90

F. 89

• V2/a - • Remove the strap (A)

• Gasket (replace it with and disconnect the
a new one). secondary air emission
pipe (B).
• V2/b -
V2/a 8 ± 15%
V2/b 30 ± 20%

V2/b
B
V2/a
F. 91
A
F. 92

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 AIR FILTER • V3 -
(Maintenance) • Remove:
- Cover (A)
• The air filter can be - Filtering element (B).
reached by removing the
lower side panels (p. 17). • Immerge the filtering element
• Release the spring (A) on in a solution: solvent for
the carburetor. 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
F. 93
must be uniformly
impregnated, without dripping.
• In case the filtering element is F. 94
damaged, replace with a new,
original one.

When reassembling the air filter unit, make sure the container contact
surfaces are perfectly adherent, to avoid aspiration of non-filtered air.
(Removing)
• V2 -
• Release the spring (A) on the
carburetor.
• Remove the filter case (C).

V2 10 ± 15%

V2

C
F. 95

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 ENGINE B
• Remove the rear fairing (p. 23) and the lower
side panels (p. 17).
A
• Disconnect the connector (A) of the start
engine.
• Disconnect the mass pipe (B) 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.
F. 96 F. 97
• 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).

E
C

D
F

F. 97/a F. 98 F. 99

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 • V- • Disconnect the first
• V2 - accelerator cable, from the
• Lateral air conveyor, paying carburetor.
attention to the hook • Disconnect the second
element positioned in the accelerator cable (A) from
lower part of the conveyor the cam (B) which operates
itself. on the oil mixer.
• Disconnect the carburetor
starter connector (C) (page
41 F. 103).
V
During the re-
connection of the
V2 cable, verify that the
B C A
side (C) of the cam, is
F. 99/a aligned with the notch F. 100
on the fixed point of
reference.

• Unscrew the lower locking screw (V) of

V
• Remove the muffler the shock absorber.
(p. 37). • Rotate the suspension upwards and
• Release the rear brake anchor it to the scooter frame.
transmission cable by • Remove the stand.
operating on the nut (D).
• Remove the rear wheel p.
35. D

F. 101

F. 102

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 • Unscrew the locking nut (D) and slide the
pin out (A). C

D 62 ± 15%

Before 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 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
D
engine itself. F. 103 F. 104
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.

FRAME DIMENSION CHECK

• In case of presumed deformation, however slight, of the frame after an
accident, check the dimensions of the frame.

Check value A = 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

(A) as in its original configuration.

F. 105
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 CABLE POSITIONING, “PIPE SYSTEM” AND
LOCATION OF ANCHORING STRAPS

F. 106

F. 107 F. 108
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 F. 109
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 F. 110
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