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FOREWORD
• This 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 Newton/metre 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
THIS MANUAL EXPLOSION MAINTENANCE NO!
Information on Indicates operations Operations to be Operations to be
this 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/ COOLANT
may be obtained by
tract electronic technician
referring to said catalogue FUEL

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”.

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

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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.

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CONTENTS
123
123
DESCRIPTION P. 123
123
123
DESCRIPTION P.
TECHNICAL DATA 8
123
123 SEAT 36
123
123
IDENTIFICATION INFORMATION: FRAME N°/ ENGINE N° 9 CENTRAL SECTION UNDER THE SEAT 36
123
123
ANTI-TAMPERING PLATE 9 123 HELMET CASE 38
TIRES 10 123
123 ACCESS (after removing the helmet compartment) 40
MAINTENANCE CHART 11 123
123 FUEL LEVEL SENSOR 41
LUBRICANT CHART 12 123
123 FUEL PUMP SENSOR 41
123
123
FUEL TANK 13 FOOTBAR 42
123
COOLANT RESERVOIR 13 123
123 REAR FAIRING 45
MOTOR OIL 14 123
123 REAR HANDLE 45
TRANSMISSION OIL 15 123
123 TAIL LIGHTS 46
123
BRAKE FLUID 15 123
123
FULL REAR FAIRING- FAIRING BREAKDOWN 47
BLEEDING THE BRAKE SYSTEM 16 123
123
SEAT LOCK UNIT 48
CHECK FRONT/BACK BRAKE PADS AND DISKS 17 123
123 FUEL TANK 51
REPLACE PADS 17 123
123 ELECTRIC FAN AND RADIATOR 52
FORK 18 123
123 DISASSEMBLING RADIATOR UNIT - COOLING SYSTEM DRAINAGE 53
SHOCK ABSORBER ADJUSTMENTS 18 123
123 FRONT WHEEL 54
DASHBOARD - DIGITAL CLOCK 19
123
123 FRONT BRAKE DISC 54
123
123
KEY SWITCH 20 FRONT BRAKE CALIPER 55
123
HANDLEBAR CONTROLS - LEFT CONTROL - RIGHT CONTROL 20 123
123 FRONT MUD GUARD 55
123
ENGINE STARTER 20 123
123
HANDELBAR CONTROL - BRAKE PUMP 56
LIGHTS 21 123
123
KEYSWITCH 56
LIGHT BULB REPLACEMENT - LIGHT BEAM ADJUSTMENT 22 123
123
HANDLEBAR 57
FUSES 23 123
123 FORK 57
123
BATTERY 24 123
123
FORK LEG 57
SPARK PLUG 25 123
123
COMPLETE FORK 58
DISMANTLING AND REMOVAL PROCEDURES FOR COMPONENTS 26 123 MUFFLER 58
REASSEMBLY NOTES 26
123
123 MANIFOLD EXHAUST 59
123
123
WINDSCREEN SUPPORTS 26 REASSEMBLY OF EXHAUST SYSTEM 59
123
WINDSCREEN 26 123
123 SHOCK ABSORBERS 60
REAR-VIEW MIRROR 26 123
123 REAR MUDGUARD - REAR BRAKE CALIPER 61
123
UPPER HANDLEBAR COVERS 27 123
123
REAR WHEEL 62
DASHBOARD 28 123
123
REAR BRAKE DISK 63
LOWER HANDLEBAR COVERS 29 123
123 STARTER 63
123
UPPER SHIELD 30 123
123
FILTER BOX UNIT 64
FRONT SHIELD 31 123
123
AIR FILTER 66
ACCESS (motorbike parts - shield parts) 32 123 SIDE STAND - CENTRAL STAND 67
CHANGE LIGHT BULB 33
123
123 ENGINE 67
123
123
FRONT FAIRING 34 FRAME SIZE CHECK 68
123
SIDE STRUTS 35 123
123 POSITION OF INJECTION SYSTEM PARTS 69
LEGSHIELD 35 123
123 CABLE POSITIONING, "PIPE SYSTEM" AND ANCHORING TIES 72

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SPECIFICATIONS Capacity cm3 ................................................................................................. 125

153

Compression Ratio ................................................................................... 10,6 : 1

11,3 : 1

Cooling ........................................................................................................ liquid

Starting system ............................................................................ electric starter
lubrication system ................................................................................ wet sump
SPARK PLUG
Type ............................................................................................ NGK DPR7EA9
TRANSMISSION
Primary drive: automatic transmission by V-belt speed change gear
Final: by gears.
Automatic centrifugal dry clutch.
F. 1 FUEL SYSTEM
Electronic fuel injection with electric fuel pump.
DIMENSIONS Fuel: unleaded petrol.
Wheel base (A) m ....................................................................................... 1,470 IGNITION
Max. length (B) m ........................................................................................ 2,090
Digital
Max. width (C) m ......................................................................................... 0,750
Max. height (D) m ........................................................................................ 1,330 BRAKES
Kerb weight kg ............................................................................................... 155 Front brake: disk type Ø 225 mm double piston hydraulic caliper Ø 25 mm
Max. load with rider, passenger and luggage kg .............................................. 180 Rear brake: disk type Ø 220 mm piston hydraulic caliper Ø 34 mm

CAPACITY CHASSIS
Engine oil cm3 ........................................................................................... 1000* High-tensile steel tubes
Transmission oil cm3 ................................................................................... 150* SUSPENSIONS
Fuel tank (total) l ................................................................................. 8,0* (3,0*) Front: hydraulically fork Ø 35 mm; Stroke: 87,5 mm.
Rear: Swinging engine with double hydraulic shock absorber. Stroke: 74 mm.
ENGINE: 2 valve - 4 stroke single cylinder:
Type ............................................................................................. MALAGUTI 03 BATTERY
Type 12V, 7Ah, no maintenance.
MALAGUTI 04
n° Cylinders ...................................................................................................... 1 TIRES
Bore x stroke mm ......................................................................... Ø 52,4 x 57,8 Front: 110/90 - 13 56P M/C (tubeless)
Rear: 130/70 - 13 63P M/C (tubeless)
Ø 58,0 x 57,8 * Indicative Value
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IDENTIFICATION DATA: FRAME N° / ENGINE N° ANTI-TAMPERING PLATE

• The vehicle’s identification number (VIN) (A) is located on the rear side of the chas- • An anti-tampering plate, bearing all vehicle identification data required by Directive
sis, under the helmet compartment. 97/24/CE. Is fitted inside the helmet compartment. If you have the helmet compartment
• Engine identification data are located on the left-hand engine crankcase (B). replaced, make sure the plate is fitted too.

Any alteration to the vehicle identification data is pursued by the Law. Do not remove or alter this plate.

• When ordering spare parts, also quote the vehicle identification data.

A F. 4

F. 2

F. 3

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TYRES
Type: Tubeless (without inner tube)

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.

F. 5

• 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.

Minimum tread depth (front and rear) is 2 mm (F. 6).

F. 6

PRESSURE
Tyre inflation pressure must be adjusted while the tyre is at ambient
temperature. 1.9 1.9 1.9
Pressure differing from that indicated can lead to higher fuel (27.6) (27.6) (27.6)
consumption, irregular wear of the tire, impaired vehicle performance
and riding conditions. 2.0 2.1 2.1
(29.0) (30.5) (30.5)

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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 OIL (4 STROKE) CLASS 10W 40

ENGINE TRANSMISSION OIL CLASS 10W 40

AIR FILTER LUBRICANT AIR FILTER OIL

RADIATOR FLUID TOP FLUID

BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4

FORK ROD OIL FORK OIL

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FUEL TANK
• Insert the ignition key in the switch block and it into the lock on the left hand side of the seat (B).
• Open seat by turning ignition key clockwise.
• The quantity of fuel, as well as a low fuel level, are displayed by the corresponding indicator on the right hand side of
the instrument board.

Petrol is extremely inflammable; avoid approaching the fuel filler - also during filling - with lit cigarettes or
naked flames (for instance matches). Danger of fire!

B
FUEL TANK Liters
F. 7
TOTAL TANK CAPACITY 8,0
RESERVE 3,0

Use UNLEADED PETROL.

COOLANT TANK A
• To gain access to the tank containing the coolant, loosen the two screws (A) next to the handlebar
and remove the front fairing.
• Check the level of coolant with respect to the “MIN” and “MAX” notches, next to the tank, by
checking through the sight glass located under front fairing on the right hand side.

If it needs to be topped up, use the product

specified in the lubricants chart.

Do not remove the cap when the engine is hot.

F. 8
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ENGINE OIL

CHECK LEVEL every 2,000 km

• The engine must be cold and the vehicle A

on level ground.
• The level is shown on the cap/ dipstick
(A).

Top with the oil specified in the

lubricant chart.

Check the level with the plug

tightened.

F. 9

• After the first 1,000 Km

CHANGE • Every 4,000 KM

Warm up the engine for a few minutes and then shut it off.

• Place an appropriate drain pan under the engine (with the vehicle on flat
ground).
• Pull out the cap/ dipstick (A).
• Unscrew the drain plug (S) and let all the used oil drain out.
• Remove the filter/plug (F).
• Wash the screen (1) with solvent or if it is damaged, replace it.
• Check the wear conditions of the O-Ring (3) and replace if necessary.
• Reassembly: O-Ring (3)- Spring (2)- Screen (1) and tighten the filter/plug.
• Screw on and tighten the drain plug (S).
2
• Top up the engine with 800 cc of Q8 CLASS 10W40 oil and replace the cap/
dipstick. 1

Start the engine; leave it running for a few minutes, and check that there
are no leaks. 3

Dispose of used oil in accordance with current laws in force. F. 10

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TRANSMISSION OIL
• After the first 1,000 Km
CHECK LEVEL/ TOP UP CHANGE
• Every 12,000 Km
• Cold engine • Cold engine
• Vehicle on level ground. A • Vehicle on level ground
• Place a drip pan under the engine. • Place a drip pan under the engine.
• Unscrew the oil filler screw (A). • Unscrew the oil filler screw (A).
• If necessary, top up with oil specified in the lubricant • Unscrew the drain screw (B)
chart until the oil starts to overflow. • Drain out all the used oil.
• Screw on the screw (A). • Clean the threads of the drain screw and screw back on.
B • Refill the crankcase with oil specified in the lubricant
chart until the oil starts to overflow.
F. 11 • Screw back on the screw (A).

S S

BRAKE FLUID
CHECK every 30 days
• Visually check by way of the warning signal (S) located on the front and back
brake reservoir, with the vehicle on level ground and perfectly straight.
• The fluid level must be 3mm from the lower limit of the warning signal.

Do not mix different oil types when topping off.

CHANGE Every 12,000 Km or 24 months

F. 12

If there is any debris or water in the brake fluid, it is essential that it be completely changed and the brake system must be bled. Excessive elasticity in the
brake lever is usually an indication that air is in the system.

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BLEED BRAKE SYSTEM A V2 C

FRONT CALIPER

NOTE - Position the vehicle in a stabile manner and

perfectly on level ground.

• Remove the (right side) oil pump reservoir cover B

(A), unscrewing the relative screws (V"), in order to
be able to top off the fluid. D
• Fill the right brake fluid reservoir (B) to the highest
level.
• Remove the rubber hood (C) of the bleeder screw
(V) and insert a rubber tube to recover the brake F. 13 V
fluid.
• Pump the right brake lever (D), prime it and bring
the system in pressure.
• Keeping the brake lever pumped, loosen the blee-
V 12 ± 16%
der screws (V), to allow air to escape. Then, tighten F. 14
the bleeder screw (V).
• Repeat the operation, until only liquid comes out of
the rubber tube.
• Top up the brake fluid level in the reservoir (B). C

A V2 V
B

REAR CALIPER
• To bleed the rear caliper, follow the same operation
above, but pump the left brake lever (S).

F. 15 F. 16

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CHECK FRONT/BACK BRAKE PADS AND DISKS

• Check the condition of front and back brake pads and discs
every 2,000 Km.

• Carry out a visual check on the thickness of the brake pads as

shown in the illustration. The minimum thickness of the brake
pad friction material must not be less than 2mm.
• Replace the pads if they are close to the allowed limit, or if they
are damaged.

F. 17 F. 18

REPLACING PADS
The procedures for replacing front and back brake pads To remove back brake pads, see Rear brake caliper
can be deduced from the illustration shown below. removal (page 61).
(M/N table bill of materials).
F. 19
FRONT BRAKE REAR BRAKE

F. 20 F. 21

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FORK • Remount the drain screw (V).

CHANGE FORK OIL NOTE - When remounting, replace the copper washer
• Place an appropriate drip pan under the slider and remove the screws (V). located under the screw (V).
• Drain out as much oil as possible.
• Proceed to dismantle the fork legs, as described p. 57.
• Turn the fork legs upside-down, to let the remaining oil drain out. V 17 ± 15%
Hydraulic oil is corrosive and may cause personal injury.
• Carefully pour the "new" oil in the fork.
Do not improperly dispose of used oil in the environment.
Quantity per fork: 98 cc.

• Reassemble the fork components and the fork on the

motorcycle.

SHOCK ABSORBER ADJUSTMENTS V

5 adjustment positions are included:
1) driver only (to 75 kg) F. 22

2) driver only (over 75 kg) A

3) driver and case
4) driver and passenger
5) driver, passenger, and case.

Perform adjustments using the special key equipped on the ring nut (A), located on the upper part of the shock absorbers; turning
it anti- clockwise will increase the strength of the spring (increase in load)

Adjust both shock absorbers using these instructions.

Uneven adjustment can compromise the stability of the vehicle. F. 23

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DASHBOARD ELECTRIC/SERVICE MALFUNCTION WARNING

1) Speedometer LIGHT
1 9 When the starter key is turned in the switch in the
2) Odometer position, without starting the engine, the war-
3) Turn signal warning light (green) ning light (as well as the warning light ) will
2 8 remain on for a few seconds to verify the functioning,
4) High beams warning light (blue) and it will normally shut off after this.
5) Electric/SERVICE Malfunction warning If it stays on longer (fully and/or flickering) it means:
light (orange)
3 • Electrical Malfunction (blinking light): indicates a
6) coolant temperature too high warning light
malfunction in the electrical system.
(red) 7 • SERVICE (15 short blinking lights): indicates the
7) Fuel gauge indicator need to perform programmed maintenance (see the
4 Maintenance Chart on page 11).
8) Coolant temperature indicator (red zone:
temperature too high)
In both cases, reset the signal after performing
9) Digital clock 6 5 the necessary operations.
F. 24
DIGITAL CLOCK The warning light interval of the SERVICE
• Date and month readout sign of the may have different meanin-
Press the top button once (after a few seconds the clock will automatically reappear). gs as shown in the Maintenance Chart, de-
• Seconds readout pending on the vehicles conditions of use.
Press the top button twice; to restore the initial configuration, press the button again.

To set the clock and calendar, use the two buttons on the right hand side of the dial, starting with the time display.
• Setting the month
Press the lower button twice; and then with the top button select the exact number.

• Setting the date

Press the lower button three times; and then using the top button select the exact number.

• Setting the time

Press the lower button four times, and then using the top button select the exact number.

• Setting the minutes

Press the lower button four times, and then using the top button select the exact number.
Press the lower button once again to return to the time display. Confirm modifications by pressing the top button.

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KEY SWITCH HANDLEBAR CONTROLS

Ignition inhibited (extractable key) LEFT CONTROLS RIGHT CONTROLS
1) Horn button A) light switch:
Preset starting position (non extractable key) right= off
2) Turn signals switch.
center= tail and dashboard lights
Steering lock insert (Ignition inhibited: extracta- 3) Turn signals shutoff switch left= high/low beams
ble key). 4) Turn on lights:
B) Electric starter button
In case both of the equipped keys are lost the entire high beam
locking kit must be replaced.
low beam

STARTING THE ENGINE

Before pushing the starter button to start the motor,
first pull the front or rear brake lever and keep it
pulled.

Do not start the engine in a closed ambient,

4 A
because the exhaust is highly toxic.
To not damage the injection system, never B
3
operate the "START" button if the fuel tank
is empty, or turn the key switch to "ON".

If the engine does not start, release the star-

ter switch, wait a moment, and then press it
again. In order not to drain the battery, do not 2
operate the starter for more than 10 seconds
on each try. Do not rev the engine to its limit 1
when it is cold.

Start the engine with the headlights off.

F. 25

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LIGHTS (12 V)
D E
HEADLIGHT
(Quartz halogen lamps) F
A) High/Low beam lights:
55W (H7).
B) Tail lights:
5W (W7y5).

C
TURN SIGNALS D
FRONT
C) Bulbs: 10W (RY10W).
C
TAIL LIGHTS
D) Tail lights:
5W (R5W). F
E) Stop lights: B
21/25W (P21/5W).
A

TURN SIGNALS
REAR B
F) 10W (W10W). A
G
NUMBER PLATE LIGHT
G) 5W (W5W).

F. 26

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LIGHT BULB REPLACEMENT

F
HEADLIGHT
• In order to access the headlight bulbs, refer to the topics at page (33).

TURN SIGNALS
FRONT: See page (33). V V
REAR: Undo the screws (V) and remove the rear reflectors. Turn the bulb anti-clockwise and replace it by a new
identical one. V2

TAIL LIGHTS
F. 27
• Undo the screws (V”) and remove he tail light cover. This operation will allow releasing the whole light unit (body +
cover).

NUMBER PLATE LIGHT

• Undo the screw (W) and remove the tail light cover (F).
• Remove the rubber bulb holder from the plastic cover and
replace the bulb.
F
NOTE - Before reassembling any component removed to
replace one or more bulbs, check the light opera-
W
tion.

F. 28

LIGHT BEAM ADJUSTMENTS

To check/adjust the beam, proceed as follows:
• Put the vehicle in running conditions at 10 metres from a wall.
• Turn the low beams on and keep the vehicle vertical, without stand or driver.
• Using an adjustable spanner, turn the projector screw (R), bearing in mind that turning anti-
clockwise raises the beam and vice versa. R
F. 29

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FUSES
The electrical wiring includes 9 fuses, protecting the main components against faults.
8 are located in the glove compartment.

F. 30

• A 5A fuse (I) below the helmet compartment is installed to protect the recharge plug.

F. 30/a

REPLACING THE FUSES

• Extract the blown fuse and replace it with one of the same capacity. Inside the compartment, you will find some spare fuses (S).
• Check that the fuse you are using has the same amperage of the fuse you are replacing.

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.

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BATTERY (12V - 9Ah)

A
The battery housing is located in the central tunnel.
BATTERY ASSEMBLY (PRE-DELIVERY OPERATION)
• Take the battery that has been previously charged
• Apply the adhesive strip (A) supplied in the kit, by removing
the protective film located on the end of the adhesive area,
shown by the arrows (P).
• Remove the 30 A general protection fuse.
P
• Unscrew the three screws (V3) and remove the central panel S V3
under the seat (S).
F. 31 F. 32
• Remove the battery fastening cover by removing the 3
screws (W).
• Insert the battery, ensuring it fits in its housing. NEVER invert the cable connections. W B
• Connect the battery to the cables Do not use the battery without the battery
- positive pole (+) RED/BLUE wires inserted and connected to wires of the main
- negative pole (-) BLACK wires harness.This could cause breakdowns and
• Properly tighten the battery clamps. short circuits in the electrical system and
• Properly position the battery clamps. components.
• Replace the previously removed 30 A general protection fuse
in its place. It is advisable to use gloves and protective
• Check that the battery and cables are properly positioned; eyewear, when the battery must be removed
then remount the battery fastening cover. from its housing; for example, when it needs to
• Remount the central panel under the seat. be recharged.

Make sure that the tilt sensor (B) is perfectly F. 33

CHARGE BATTERY horizontal.
• To carry out this operation, it is advisable to remove the
battery from its housing, unless the special electrical outlet is
Danger of explosion! Do not use open flames
used.
(lighters, matchsticks, etc.).
• Disconnect cables.
• It is a good rule to recharge using amperage that is equal to
The battery contains highly toxic sulphuric acid.
1/10 of the power of the battery.
Avoid contact with the eyes, skin, and clothes.
• Remount the battery, paying attention to connect the positive
Keep the battery out of reach from children.
cable (red/blue) to the + pole and the negative cable to the -
pole.
If for charging/maintenance of the battery the
• Properly tighten the battery clamps.
special electrical outlet connection is used,
• It is important that the battery always remains fully charged;
open the battery case to permit proper
therefore, during the winter months or when the vehicle re-
ventilation.
mains unused, it should be recharged at least once a month. F. 34

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125 - 160 cc

SPARK PLUG
C
REPLACEMENT every 12,000 km

Remove the spark plug when the engine is cold.

Type of spark plug to be used: NGK DPR7EA9

• For maintenance, disassemble the central panel under the seat (P), remove the
fastening screws (V3) and lift the internal profile (with the help of a screwdriver) P V3
that is held on two lugs in the foot rest board, carefully extract the hood (C ),
with small clockwise and anti clockwise movements; then unscrew the spark
F. 35
plug.
• Examine the condition of the sparkplug. Deposits and colorations of the insula-
tor provide useful information on the thermal grade, on the carburetion, on the F. 36
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 properly.
• After removing the sparkplug, proceed to clean thoroughly the electrodes and insulators, using a
metallic brush. Adjust the electrode gap, using a laminar feeler gauge: the gap must be 0,6 ÷ 0,7 mm

Spark plugs with a thermal grade that is different than that deduced by the advised
symbols may seriously damage the engine.
Replace all spark plug with cracks on the insulator or corroded electrodes.

• Remove any residue, using jets of compressed air.

• Grease the sparkplug threads with motor oil and manually rescrew it.

• Tightening the spark plugs:

17,5

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PROCEDURES FOR DISMANTLING AND WINDSCREEN

REMOVING COMPONENTS SUPPORTS
V2
REASSEMBLY NOTE • V2.
• Supports (A).

WINDSCREEN A
• V4.
F. 38
• Windscreen.
V4

F. 37

REAR VIEW MIRRORS

RIGHT SIDE MIRROR D
• Uncover and loosen the nut (D).
• Unscrew the window holder arm, by turning it clockwise.

LEFT SIDE MIRROR

• After undoing the nut (D), unscrew the mirror holder, anti-clockwise.

F. 39
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UPPER
HANDLEBAR
COVERS
• V2.
V2
• W2.

W2
F. 41
F. 40

• Release the upper • Disconnect the

handlebar cover, connectors (C - D).
paying attention not
to damage the
anchoring teeth (A). C
• Undo the odometer
cable ring nut from
the instrument panel
coupling.

A
D

F. 42 F. 43

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• Disconnect the
DASHBOARD V4 connector (A). A
• V4.

F. 45

V4

F. 44

• V2. • V2/a.
V 2a
V2

F. 46 F. 47

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ACCESS 1
(after removing the upper handlebar cover) 2 6
1) Front brake pump
2) Hydraulic front brake union
7
3) Front brake "stop" switch
4) Rear brake "stop" switch 3 5
5) Rear brake pump
6) Hydraulic rear brake pump union 4
7) Right switch connector
8) Left switch connector

F. 48

8 7 LOWER HANDLEBAR COVER

G • V2.
• V.
• Release the gas transmission (G).
• Remove the lower handlebar cover (C) pushing it backwards.

V 3 ± 10%
V2 C V2

F. 49

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UPPER • Tapping slightly with

SHIELD the hand palm,
release the upper
• V2. cover.
V2

V 1 ± 10%

F. 50

7
When reassembling, make sure
the shield lower teeth are properly F. 51
engaged into the slots. 6 1

A
ACCESS
1) Steering adjusting nut. 2
2) Radiator cap
3) Connector electric fan
5
4) Connector diagnosis socket
5) Front headlight connector
6) Expansion reservoir plug 3
7) Handlebar screw 4

F. 52

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FRONT
SHIELD
• W.
• V2.

V2
V2 1 ± 10% W 1 ± 10%

F. 53 F. 54

• Remove the shield with • Unplug the

moderation, being careful A connector (B) and
to not damage the remove the front
hooking elements (A). shield completely.
B

F. 55 F. 56

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ACCESS
(motorbike parts)
1) Radiator
2) Electric fan
3) Fork stem screw

1 2

2 3

F. 57

(shield parts)
1) Turn signals
1 2) Tail lights
3) High/Low beam lights
2 3

F. 58

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CHANGE LIGHT BULB

TURN SIGNALS
• Turn the bulb holder (A) anti-clockwise and remove the bulb (B).

TAIL LIGHTS B
• Extract the bulb holder (C) and remove the bulb (D).

HIGH/LOW BEAM LIGHTS

• Release the bulb holder from the clips (E).
• Replace the bulb, paying attention not to touch the bulb glass with bare fingers.

NOTE - We recommend to test the new bulbs before reassembling the removed
components.

D
A
C

F. 59
E

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FRONT
FAIRING
• Remove the front fairing with • V2.
care. V1
• V.
• V1.
• V3.

V2 V2
2 ± 10%
V
V3 1 ± 10% V3 V
F. 60
V1 3 ± 10%
W2

F. 61
• V4. ACCESS
• W2. V4 V4
• Remove the front wheel 1) Electronic 2
and mud guard. control unit
2) Horn

V4 2 ± 10%

W2 3 ± 10%

1
F. 62 F. 63

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SIDE
STRUTS

• V4. • V3.
• V.

V3
V4 1 ± 10% V 1 ± 10%
V4

V3 V

F. 64 F. 65

LEGSHIELD
(After removing the front shield)
• V2/a. • V2. • V2/b.
• Bag hook (A)
• Key swith lid (B).

V2 5 ± 10% B

V2b
V2 A

V 2a

F. 66 F. 67 F. 67/a

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• V. • Release the leg-fender

with care, paying
attention not to damage
V the sides (A).
1 ± 10%

A
V

F. 68 F. 69

SEAT CENTRAL
• V4. SECTION
UNDER THE
SEAT
V4 3 ± 20% • V3.

V4

V3
F. 71

F. 70
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ACCESS
• Rollover sensor (A).

When reassembling the removed components, make sure that the tilt sensor is
horizontal.
An inclination of approximately 45° would prevent the engine from starting.

C
A
V3
F. 72
• V3.
• Battery cover (C).
• Battery compartment (B).

F. 73

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HELMET CASE

• After undoing • Remove the cover (A).

the screws
(V2), open up
the fairing, as
shown in the
V1
figure.
A
• V4.
• V1.

V4
V2

F. 74 F. 75

P
• V2. • V3.
• Remove the seat • Cap (T).
fastening plate (P).

T
V3

V2
V2 5 ± 20% V3 5 ± 20%

F. 76 F. 77

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• V2. • Lift the helmet

compartment.
• Remove the seat
lock unit (A). A
• Disconnect the
connector (B).
V2 • Remove the
helmet
compartment.

V2 3 ± 20%

F. 78 F. 79

• In case you need • Move the clip (D)

to release the
C sideways to
D
cable (C) follow release the cable
the instructions (C).
below:

D
F. 80 F. 81

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ACCESS
(after removing the helmet compartment)
A) Fuel level gauge
B) Fuel Pump
C) Pump connector
D) Fuel tank
5

1) Injector connector
3
2) Temperature gauge (coolant)
3) Throttle body
4) Coolant drainage hose
1
5) T.P.S. connector
6) Thermal expansion valve
A D

2
B C

F. 82

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FUEL LEVEL V4
SENSOR
V4 D
Do not smoke or use open flames,
D
during operations on the fuel tank. B
R A
• During operations, screw the tank cap
(A), to avoid that any foreign matter G
falls inside.
• Remove the sheaths (B) and disconnect E
the connector located below. H
• V4.
• Remove the sensor (D).
F

F. 84

When reassembling, insert the

floater (E) so that the base (D) I
remains as it was originally. It is
advisable to mark the correct
position before removal. Check the
F. 83 H
condition of the gaskets (F) and
replace them if necessary.

FUEL PUMP
I
• Disconnect the connector (G).
• Disconnect the gas hose (H), pressing on the fitting
with one finger (R). Keep a rag close by to swab up any
V4 2 ± 10% leaking fuel. P
• Unscrew the ring nut (I).
• Take out the pump (P).

F. 85

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FOOTBAR • V. V
A 1 ± 10%
• Remove the
lids (A) by V
means of a
screwdriver.
• V3.

V3 5 ± 10%

V3
F. 86 F. 87

In the ending part, the • In order to release the

footbar is linked to the footbar from the rear
rear fairing by coupling fairing, move the rear
teeth. fairing backwards, with
care, and lift it
simultaneously in order to
release the coupling teeth
(B).

B
F. 88 F. 89

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ACCESS
1) Ignition coil 3
2) Horn
3) Voltage regulator 2
4) Rollover sensor
5) Regulator connector 4
System connector
6) Electronic control unit

6
F. 90

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IGNITION COIL
• Connector (A).
V2
• Screw (V).
• H.T. cable (C)
• Remove the coil complete with the support staff.

HORN
H I
• Faston (D). F
• Screw (V1).

V1

VOLTAGE REGULATOR
• V2.
• Disconnect the connector (G) (see 1 - F. 107), cut the clamp
(H), remove the sheaths (I) and disconnect the inside
connector. D V

A
ROLLOVER SENSOR C
• Connector (F).
L
• Free the sensor (D) from its housing.

W2

ELECTRONIC CONTROL UNIT

• Connector (L).
• W2. F. 91

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REAR • By means of a screwdriver,

FAIRING release and remove the
upper cover (A).
REAR HANDLE
• V.

A
V

F. 92 F. 93

• V3. • Rear handle (B).

V3 43 ± 15%

B
V3

F. 94 F. 95

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TAIL LIGHTS
• V2. • Disconnect the faston
connectors and remove the
complete tail light.

• In order to replace the bulbs,

it is not necessary to remove
the complete tail light unit.

V2

F. 96 F. 97

FULL REAR FAIRING

After removing the seat, the helmet
compartment, the rear handhold
and the tail light and after releasing
the footbar, proceed as follows:
• V2.
• Lift, while moving backwards,
the fairing with care.
V2

F. 98

F. 98/a

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FAIRING BREAKDOWN
• V2. B
• Release the electric cables
from the hose rings (A). B
• V5. V2
• Split the two fairing halves A A
from the coupling teeth (B).

V5
F. 99

Ve

• Ve. • Vi.

Vi

F. 100 F. 101

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SEAT LOCK V3
UNIT

• V3. • Lift and remove the key

• Lid (A). switch block lock clip.

A
F. 102 F. 103

• Release the cable. • Remove the cable holder bracket. • Remove the key switch block.

F. 104 F. 105 F. 106

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ACCESS The reassembly stage of any interventions

on the wiring involves repositioning these as
1) Three-phase stator illustrated, and fastening them with new
connectors clamps that must be placed in the original
Regulator connector points.
2) Connector pick-up
3) Intermittence
4) Mass assembly
5) Electric fan relay
6) Injection system relay
8
7) Starter relay
8) Idle control valve

NOTE - Access to the various

mechanical componen-
ts can be deduced from
the illustrations.

2
3
4

5
6 7
F. 107

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9) O2 sensor 11) Exhaust manifold

10) Thermal unit 12) Spark plugs cap
13) Starter motor
ground cable

10

9 11 12 13
F. 108 F. 109

15

14) O2 sensor connector 15) Fuel hose fastening

clamp

NOTE - To reach the indica-

ted components
disassemble only
the helmet 14
compartment.
F. 110 F. 111

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FUEL TANK V4

Do not smoke or use open flames, A

I L
while operating on the fuel tank.

• During the operation, screw the tank cap E

(A), to avoid that any foreign matter falls
inside.
• Disconnect the gas hose (C), pressing on
the fitting with one finger ( D). Keep a rag
close by to swab up any leaking fuel.
• Start the engine and let it run until the pipe
(C) is completely empty.
• Disconnect the connector (B).
• Cut the clamp (I).
• Disconnect the connector (L) inside the
sheaths (E). M
• Unscrew the screws (V4), being careful not B
to lose the anti-vibration pads, bushings
and clamp (M).
• When reassembling, put the clamp back
(M),

V4 5 ± 10%

D C V4

F. 112

Remove the tank and place it far from heat sources and sparks and/or open flames.

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ELECTRIC FAN AND RADIATOR

Before any opera- • Position the engine
tions on the cooling A in a container
system, check that suitable for collec-
the fluid is below B ting the used
50°C. coolant. F
• Loosen the clamps
• Remove the front shield (F) and slide the
(page 31). tube off (T) of the
• Cut the cable and tube water pump.
holding ties.
• Unscrew the radiator
cap (A).
• Disconnect the T
connector (B) electric
fan.
F. 113 F. 114

• Release the clamps • Remove the hose

and the hoses (M) (T).
connected to the
• V2.
radiator. T
• Remove the
radiator unit, along
with the frame, the
expansion reservoir
and the electric
fan.

M
V2

F. 115 F. 115/a

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DISASSEMBLING RADIATOR UNIT

• Disassemble the radiator unit, as shown in the figure.

COOLING SYSTEM DRAINAGE

The cooling system is "self-bleeding".
But if, after the radiator is reassembled, filled with fluid and tested with
the engine idling for a few minutes, an abnormal rise in temperature is
found, manually bleed it by following these steps:

F. 116

• Partially lift and rotate the helmet case sideways (page 38).
• Wait until the fluid has cooled down, unscrew the cap and completely fill the radiator.
• Slide off the tube (T) (after freeing it from the clamps); Liquid should come out from the
union, in abundance.
• Insert the tube (T) and the cap radiator.
• Before replacing the helmet case, start the engine and check that there is no abnormal
rise in temperature.

F. 117

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FRONT WHEEL
• Unscrew the nut (D), holding the wheel pin with a wrench (P).

A P
D
F. 118 F. 119

P
R

• Extract the wheel pin (P)

paying attention not to FRONT BRAKE DISC
damage the spacers
• When removing the front wheel, check the condi-
(B - B1), the odometer
tion of the brake disc. In case of deep scoring or if
unit (A) and the washer (R).
the thickness is below the minimum limit of 3.5 mm,
V5 remove it by unscrewing the screws (V5) and repla-
A
• Remove the wheel pin (P). ce it.
• Take off the wheel.
B1
Do not use the brake V5
lever, with the wheel 11 ± 10%
removed.

Apply Loctite threadlocker (Strong type) on

B the screw threading.
D 53 ± 10% D

F. 120

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FRONT BRAKE CALIPER

• Place an appropriate drain pan under the brake calliper.
• Unscrew the hydraulic fitting (A).

Empty the hydraulic circuit completely, pouring the fluid in a special container for
A
proper disposal in accordance with specific waste disposal laws.
• V2. G
• Remove the calliper.
V2
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 V2
operations, check that there are no losses, dry up any traces of fluid and A
bleed the system.

F. 121 V2 30 ± 20% A 20 ± 20%

P
W
FRONT V2 W
MUDGUARD
V2
• V2. • Release the odometer
• W (with inside nuts). cable (A) and extract the
cable ring (B).
• Mud guard (P).
V2 3 ± 10% B

W 3 ± 10%
A

F. 122 F. 123

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HANDLEBAR CONTROLS
ANDBRAKE PUMP
• Disconnect the throttle transmission (A). • Disconnect
the "faston"
(F).

A
F F

F. 124

F. 125

• V2/a
• Brackets (B). V2/a V V2/a KEY SWITCH
• Remove the brake pump
• Disconnect the connector (A).
and place it in a vertical
• Tamperproof screws (V2).
position on a dry cloth. V2
Brake fluid is corrosive.
B V2 10 ± 15%

V B

F. 126 F. 127

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HANDLEBAR P
D
• Remove beforehand: N
- Upper handlebar covers (page 27)
- Front shield (page 31). L
- Brake pump (page 56).
- Right switch and left switch (M). M
- Counterweights (P).
- Handlebars (N)
- Cut the cable and tube holding ties.
- Remove the throttle cable (A)
• Loosen the nuts (D) and slide the pin off (H), taking care not to damage the cables M N P
and tubes.
• Slide off the grips.

D 50 ± 20% A
H
D

F. 128

FORK FORK LEG

NOTE - When removing the fork leg, as well as the full fork, the B
• Loosen the screws (V2)
following should be removed beforehand:
- Front wheel (page 54) • Raise the fork leg a few millimetres (A) and
- Front mudguard (page 55) tighten only the lower screw.
- Front brake calliper (page 55) (only for the left stem). • Unscrew the cap (B) and undo the lower
screw.
For the full fork, also remove the:
• Slide out the fork leg (A) downwards. V2
- Front shield (page 31)
- Handlebar

• To check the oil level and to change oil, see page 18.
V2 30 ± 20%
A
F. 129

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FULL FORK
B
• Upper ring nut (A) B
• Lower ring nut (A) A
NOTE - When extracting the fork unit, take care with the bearings (S) spilling out. A
S
• Remove grease the seat of the caps (C). Check the usage conditions and if necessary replace
C
them.

Grease and remount the fork unit.

Top bearings (Ø 3/16") n° 22

Lower bearings (Ø 1/4") n° 19
S
C
A 12 ± 10% B 140 ± 15%

F. 130

MUFFLER
Before operating on the muffler and the exhaust
pipe, ensure that the components are cool.

F. 131

• Loosen the clamp fixing screws (V)

of the muffler/exhaust pipe.
• V3. V3
• Remove the muffler.

V 24 ± 10%

V
F. 132

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EXHAUST
MANIFOLD
• Disconnect the O2 sensor • Loosen the O2 sensor (D).
connector (A). • D2.
• Remove the exhaust manifold
and related gaskets.

A
D
F. 133

D2
F. 134

2
D 45 ± 10%
D2 D
D2 30 ± 10%
REMOUNTING THE EXHAUST SYSTEM
1
• Screw the O2 sensor (D) on the exhaust connector (1).
• Position the collector (1) in correspondence with the engine, inserting
the gasket (2) that should be replaced if they are deteriorated. R V3
• Screw and tighten the nuts (D2).
• Insert the gasket (3).
• Insert the muffler (4) on the manifold exhaust. 4
• Screw and tighten the screws (V3), after having inserted the washers 3
(R ). F
• Tighten the clamps (F).

V3 42 ± 15%

F. 135
R V3

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SHOCK ABSORBERS Vs

Support the scooter

on the central part of
the chassis.

• Lower screws (Vi) • Nuts (D).

• Top screws (Vs)
D D
• Remove the shock
absorbers.

Vi 24 ± 15% Vs 45 ± 15% Vi

Vi

F. 136 F. 137

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REAR
MUDGUARD
Right side Left side
• V2. B • V.

V2 3,5 ± 20% V 3,5 ± 20%

V4
V2 V

F. 138 F. 139

REAR BRAKE CALIPER

Remove rear wheel beforehand as follows: unscrew the screws (V4) fixing the wheel to the hub, then
move the rear wheel until it hits the slider arm (B).
• Place an appropriate drain pan under the brake calliper. R
• Unscrew the hydraulic fitting (R).
Empty out the hydraulic circuit, pouring the fluid in a special container for disposal in accordance
with specific waste disposal laws.
• Unscrew the screws (V2) and remove the caliper, taking care not to damage the rim previously removed
from the hub.
Brake fluid is corrosive and can cause personal injury.

Remove the calliper, taking care that fluid line does not get damaged and the disc and pads V2
do not get dirty. When the removal and replacement operations are finished, check that there
are no losses, dry up any traces of fluid and bleed the system as indicated in page 16.

During reassembly, change the gaskets.

R 20 ± 10% V2 30 ± 20% F. 140

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REAR
WHEEL A F G
• Position the motorcycle on the
stand and place a suitable sup- V2
port under the engine.
H
• Remove beforehand:
- Muffler (page 58) E
- Rear mudguard (page 61)
- Rear brake calliper (page 61)
• Unscrew the lower screws (V) V2
of the right shock absorber. Ro-
tate and anchor the shock ab- V I
sorber up high. B C

F. 141 F. 142

• Unscrew the wheel nut (D). D 100 ± 20%

D
• Unscrew the fixing screws (V2) of the slider arm (B). V2 45 ± 15%

• Extract the external spacer (A).

• Remove the slider arm (B).
C
• Slide off the wheel pin the internal spacer (C).
• Check the wear conditions of the oil seals (E- F) and replace it if necessary.
• Check the condition of the silent-block (G).
• A appropriate puller must be used for bearing (H) replacement operations, after ha-
ving removed the Seeger ring (l).
• Slide off the wheel with care, ensuring that the vehicle is stable.

F. 143

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REAR BRAKE REAR

CALIPER WHEEL
• When removing the back • Before remounting the rear
wheel, check the state of wheel, grease the shaft in
use of the brake disc. In points A-B.
case of scoring or thick-
ness below the minimum
limit of 3.5 mm, remove it V4
by unscrewing the screws
(V4) and replace it.
A B

V4 11 ± 10% F. 145

Apply Loctite threa-

dlocker (Strong type)
F. 144
on the screw threa-
ding.

STARTER
• Disconnect the "faston" from the connector (A).
• Unscrew the screws (V2).

V2 10 ± 10%

V2
A

F. 146

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FILTER BOX UNIT

• Unhook the clamp (A).
• Disconnect the tube (C ) "IDLE" valve- filter box sleeve. A
• Remove the clamps (B).
• Disconnect the vapour recovery tube (C).
• Cut the ties (E).
• Disconnect the connector (F) (Inlet air temperature sensor)
• Loosen the clamps (G).

C
B

C1

F. 147 F. 148

F E G

The ties that have been cut in order to remove various components must be replaced with identical ones, and placed in the original position.

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• Unscrew the fixing screws (V1) of the filter box- rear

mudguard.
V
• Unscrew the fixing screws (V) of the flexible air
intake tube.
• Unscrew the screws (V2).
V1
V
V1 5 ± 10%
V2

V2

F. 149

• Remove the whole air intake system.

• To remove the intake air sensor (A), unscrew the screws (V2A).
When remounting the inlet air
A V 2a sensor, check the condition of
B
the O-ring (B); replace if neces-
sary.

F. 150 F. 151
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AIR FILTER V5
• Unscrew the screws (V5), remove the cover and take out the filtering element.

F. 152

AIR FILTER MAINTENANCE

• Soak the filtering element (A) in a special solvent solution for filters, for a few
minutes. B
• Squeeze the filter (wearing rubber gloves) until all traces of the solvent are
eliminated. A
• Apply oil for air filters on the entire surface of the filter, eliminating any extra oil; C
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 filter unit, check that the filter casing seals (B)
and the filter cover are correctly inserted in the appropriate housing.

Position the cover and fasten it with screws (V5).

V5

F. 153
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SIDE CENTRAL
STAND STAND
• Springs (A - B). • Springs (A - B).
A
• V.
• Seeger (C). V
• V.

V 40 ± 10% V A
B 40 ± 10%

After having B
V tightened screws (V ) , C
insert seeger (C).
F. 154 F. 155

ENGINE
• Remove beforehand: D 45 ± 15%

- Rear fairing (page 45)

- Rear mudguard (page 61)
- Lower fixing screws, shock absorbers (page 60)
- Air filter unit (page 64)
- Slider arm (page 62)
• Nut (D). D
A
It is essential that all the tube and cable ties
are cut from the engine and all relevant con- F. 156 F. 157
nectors are disconnected.
After remounting the previously removed components, all cables, pipelines and ties should result as they were originally; in concern to this, carefully consult
the following pages.
Raise the rear part of the motorcycle before sliding off the engine pin (A). It is advisable 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.

The removal of parts and components that allow the engine to be separated from the frame includes a certain number of bands being cut. These must be replaced and
positioned as they were originally. For this purpose, consult the illustrations on the following pages.

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FRAME SIZE CHECK

• In case of suspected deformation (even slight) of the frame following an acci-
dent, perform a size check of the frame.

Check that the distance A = 1168 mm ( ± 2mm tolerance)

• If it results to be outside of the tolerance, replace the frame.

It is absolutely forbidden to deform the frame to restore the original

distance (A).

F. 158

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POSITION OF INJECTION SYSTEM PARTS

F. 159

Battery O2 sensor (Lambda sensor) Inlet air temperature sensor

Tilt sensor Ignition spark plug Starter motor ground cable
H.T. coil Idle control valve Side stand switch

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F. 160

Wiring ground cables RPM connector (Pick up) ECU (engine control unit)
Fuel pump Water temperature sensor Diagnosis plug
Injection system relay (red) Regulator Injection warnig light (orange)

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F. 161

Fuel injector Regulator connector system

TPS sensor Fan relay (yellow)
Stator three-phase connector regulator Radiator fan

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CABLE POSITIONING, "PIPE SYSTEM" AND ANCHORING TIES

F. 162
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F. 163
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F. 164
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F. 165
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F. 166
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F. 167
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F. 168
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F. 192
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