Table Of Contents - Malaguti MADISON 400 Owner's Manual

Table of Contents

Symbols3
Abbreviations3
Pre-Delivery5
Desembalaje5
Table Of Contents7
Unpacking13
Identification Data15
Identification Of Main Components (Right Side)16
Elementos Principales16
Handlebar Controls19
Right Control19
Mandos En El Manillar19
Left Control21
Starter/Keys23
Starting23
Keys23
Steering Lock23
Seguro De Dirección23
Side Stand24
Caballete Lateral24
Dashboard25
Tablero De25
Digital Dashboard26
Functions "CHECK"26
Starting Failure27
El Motor27
Tubeless Tyres28
Pressure Control28
Neumáticos28
Fuel Tank29
Depósito29
Coolant Tank31
Level Control31
Olio Motore32
Motor Oil33
Testing33
Oil Change33
Aceite Motor33
Transmission Oil35
Level Checking35
Replacement35
Brakes Oil (Front And Rear)36
Aceite Frenos36
Brakes Oil Topping Up37
Frenos37
Lubricants38
Idling Speed Adjustment39
Ajuste39
Shock Absorbers Adjustment41
Tightening Controls41
Steering43
Lash Control43
Handlebar Inclination Adjustment43
Handlebar "Tightening" Control43
Saddle Adjustment45
Ajuste Enganche45
Body47
Fairing Components47
Windscreen49
Assembling Pre-Arrangement (Pre-Delivery Operations)49
Side Mirrors Assembly51
Side Mirrors Removal53
Desmontaje53
Plate Assembly54
(Pre-Delivery Operation)54
Handlebar Cover Removal55
Rear55
Front55
Shield Removal57
Svitare Le Viti (V2 - F. 15)58
Drainer Removal59
Dashboard Removal61
Brakes Lever Control61
Svitare Le Viti (V2 - F. 16)62
Handlebar Controls Removal63
Front Fender Removal65
Under-Shield Fender65
Leg-Mudguard Removal65
Svitare Le Viti (V2 - F. 17)68
Kickstand Removal69
Footboard Removal71
Helmet Compartment Removal71
Cs - Nm 2 ± 10% V72
Cs - Nm72
Abmontieren Des Frontschutzplattes74
Saddle Removal75
Rear Fairing Removal75
Die Schrauben (V2 - Abb. 17)76
Removing The Engine Case79
Removing The Case79
Rear Fender Removal79
"Tail" Removal81
Mud-Flap Removal81
Front Wheel Removal83
Rear Wheel Removal85
Brake Distributor Removal87
Brake Pumps Removal87
Desmontaje Distribuidor De87
Front Brake Caliper Unit Removal89
Rear Brake Caliper Unit Removal89
Front/Rear Brake Pads Wear Control91
Front Caliper Unit Replacement91
Control Desgaste Pastillas Freno91
Rear Caliper Unit Replacement93
Silencer Removal95
Desmontaje Silen Ciador De Escape95
Fork97
Fork Leg Removal97
Horquilla97
Leg Stripping99
Fork Oil99
Level Check99
Fork Oil Replacement101
Complete Fork Removal101
To Remove The Handlebar101
To Remove The Fork103
Key-Switch Removal103
Acoustic Alarm Removal103
Desmontaje Interruptor103
Fuel Tank Removal105
To Empty The Tank105
To Remove The Tank105
Floating Unit Removal107
Air Cleaner111
Engine Removal113
Dimensional Frame Check115
The Two Headlights117
Light Bulbs Replacement117
Luminous Beam Adjustment121
Tail Light121
Direction Indicators123
Front Direction Indicators123
Rear Direction Indicators123
Bulb Replacement123
Regulator125
Electric Fan Thermostat125
Spark Coil125
Battery127
Fuses127
Left Side Harnesses129
Right Side Harnesses130
Wiring Diagram131
Electric Cable Colour Coding132
Remoción136
Publication Updates137
Notes For Easy Consultation138
Page Layout138
Modified Pages139
Additional Pages139
Madison141
Ignition Coil143
Electric Starting145
Key Commutator145
Engine Stop Switch145
Side Stand Switch149
Starting Motor151
Check Tension In The Red Cable153
Check Ground In The White/Red153
Check "Start" Button155
Check Ground In The Black Cable Of The Harness Connector155
Check Continuity In The White/Red Cable155
Check The Battery Recharge157
Check Charging Tension157
Check The Resistance Of The Charging Coil157
The Fuel Indicator Does Not Work159
Check Fuel Indicator159
Check The Instrument Panel Indicator159
Check Continuity In The Gray Cable159
Low Fuel Warning Light161
The Temperature Indicator Does Not Work163
Check The Temperature Indicator163
Check The Temperature Indicator Of The Instrument Panel163
The Left/Right Indicator Lights Do Not Work165
Check the "Turn" Indicator Switch165
Check The Intermittent Tension165
Check The Continuity Of The Brown/Black165
The Radiator's Fan Does Not Work167
Check The Thermic Switch167
The Acoustic Alarm Does Not Work169
12 Volt Outlet Does Not Work171
The High Beam, The Low Beam, The Running Light, The Instrument Board Light And The Rear Light Do Not Work173
The High Beam Does Not Work175
The Low Beam Does Not Work177
The High Beam Led Does Not Work179
The "Passing" Button (Right Commutator) Does Not Work181
The Tail-Light And The Instrument Panel Lighting System Do Not Work183
The Stop Light Does Not Work185
The Digit Device Does Not Work187
Check Tension187
Check Ground In The Black Cable187
The Digit Device Does Not Change Function189
Check "Mode" Button189
Check the Supply of the "Mode" Button189
The Digit Clock Does Not Work191
The Revolution Counter Does Not Work193
The Digital And Analog Km-Indicators Do Not Work193
Only The Analog Km-Indicator Does Not Work195
Air Temperature Function197
"Ice" Pilot Light197
Oil Check Pilot Light199
Oil Pressure Indicator Pilot Light199
Location Of Electrical Components201
Workshop Manuals206
Editing Symbols212
General Work Procedures216
Advice216
Warnings218
Periodical Maintenance Schedule226
Engine Disassembly228
Special Tools229
Casing And Buffers230
Thermal Unit258
Transmission Halfcase292
Flywheel Half-Case294
Countershaft Bearing294
Clutch Housing Cover294
Flywheel Cover296
Pre-Assembly Of Head296
Pre-Assembly Of Piston And Cylinder304
Pre-Assembly Of Flywheel Cover306
Assembling The Lubrication System310
Freewheel On Flywheel Rotor312
Cold Driving314
Bushes318
Clutch Half-Case318
Assembling The Engine320
Assembling The Reduction Gear326
Graphite Grease326
Intake Shaft326
Assembling The Lubricating System332
Assembling The Countershaft Gear336
Assembling The Timing System338
Assembling The Thermal Unit + Timing System342
Electric Starter354
Front Variable Speed Drive And Clutch356
Starting Transmission + Complete Flywheel Rotor360
Assembling Flywheel Cover362
Checks – Repairs – Maintenance366
Table Cylinder - Piston367
Small End Of Connecting Rod-Piston Pin Coupling367
Cylinder-Piston Coupling368
Selection Check Points368
Valves369
Checking Valve Seats On Head370
Checks371
Cylinder372
Piston372
Piston Pin374
Small End Of Connecting Rod374
Piston Rings374
Assembling The Rings On The Piston374
Opening The Oil Pump376
Removing The Oil Pump Snap Ring376
Check Outer Rotor Clearance376
Check Clearance Between Rotors376
Check Rotor-Pump Case Clearance378
Inner Rotor Spindle378
Closing The Oil Pump378
Oil Pump378
Checking The Driving Shaft380
Check The Radial Clearance380
Check Permitted Misalignment Of Driving Shaft380
Running Clearance Between Assembled Bushing And Shaft381
Engine Oil Level382
Changing The Oil383
Lubricating System384
Spark Advance385
Carburettor386
Front Variable-Speed Drive389
Disassembling The Mobile Half-Pulley389
Assembly389