Malaguti XTM 50 Workshop Manual
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Malaguti XTM 50 Workshop Manual

Chassis
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CHASSIS
XTM - XSM
WORKSHOP MANUALS

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Summary of Contents for Malaguti XTM 50

  • Page 1 CHASSIS XTM - XSM WORKSHOP MANUALS...

  • Page 3: Table Of Contents

    - CHASSIS CHASSIS Introduction CHAPTER TABLE OF CONTENTS DISASSEMBLY INTRODUCTION Shock absorber Notes for easy consultation Shift lever Abbreviations Control unit General work procedures Oil tank Editing symbols Oil level probe Oil pipe fitting with filter GETTING TO KNOW YOUR MOTORBIKE Fuel tank Specifications Fuel cock...

  • Page 4: Manual Updates

    We therefore decline all responsibility for any error, omission or misrepresentation. MALAGUTI reserves the right to make any changes and modifications hereto it deems necessary without prior notice. For further information and details, please contact the Malaguti S.p.A. Service Division.

  • Page 5: Introduction 1

    - CHASSIS CHASSIS Introduction CHAPTER NOTES FOR EASY CONSULTATION PAGE LAYOUT Chapter Section title Page n° Date of issue (RIGHT HAND PAGE) MODIFIED PAGES • Modified pages shall bear the same number as those in the previous edition /pre-modified ones, followed by the letter M, with the date of issue appearing in the appropriate box.

  • Page 6: Abbreviations

    - CHASSIS CHASSIS Introduction CHAPTER ABBREVIATIONS Figure Tightening torque Page Paragraph Section Diagram Table Screw Note: the letter V in the illustrations refers to retaining or adjusting screws. The number following this letter refers to the number of the same type of screw in the unit or component described and illustrated. Letters not followed by a number indicate a single screw.

  • Page 7: General Work Procedures

    - CHASSIS CHASSIS Introduction CHAPTER GENERAL WORK PROCEDURES • The advice, recommendations and warnings 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. They should therefore be strictly adhered to.
  • Page 8 - CHASSIS CHASSIS Introduction CHAPTER 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.

  • Page 9: Editing Symbols

    - CHASSIS CHASSIS Introduction CHAPTER EDITING SYMBOLS CAUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity. WARNING! Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third par- ties, or damage to environment, vehicle or equipment. FIRE HAZARD Indicates operations which may constitute a fire hazard.

  • Page 10: Getting To Know Your Motorbike 2

    - CHASSIS CHASSIS CHAPTER Getting to know your motorbike SPECIFICATIONS Model: ENDURO SUPERMOTARD Dimensions: Length 2050 mm 2000 mm Width 850 mm Height 1160 mm 1115 mm Wheel base 1350 mm ± 20 Seat height 910 mm 880 mm Minimum ground clearance 345 mm 315 mm Minimum turning radius...
  • Page 11 - CHASSIS CHASSIS Getting to know your motorbike CHAPTER Model: ENDURO SUPERMOTARD Transmission: Primary reduction system helical gears Primary reduction ratio z71 / z20 (3,55) Secondary reduction system chain drive Secondary reduction ratio z50 / z11 (4,54) z48 / z11 (4,36) Transmission type mechanical, 6-speed Type...

  • Page 12: Unpacking

    Engine registration data (P - F.1i) is on the left crankcase. VEHICLE REGISTRATION NUMBER The vehicle’s registration number (I - F2i) is stamped on the steering rod. The vehicle registration number is used to identify the motorcycle. MARCHIO DI FABBRICA: MALAGUTI S.P.A. 1 - --------------------- 2 - ---------------------...

  • Page 13: Main Components

    - CHASSIS CHASSIS Getting to know your motorbike CHAPTER MAIN COMPONENTS (Left hand side) Headlight Oil tank Battery Air filter Shift pedal F.3i MAIN COMPONENTS (Right hand side) Radiator Owner’s tool bag Fuse Fuel tank cap Rear brake pedal Passenger foot rests Passenger holder Number plate light + number plate holder...

  • Page 14: Controls

    - CHASSIS CHASSIS CHAPTER Getting to know your motorbike CONTROLS Controls/Instruments Main switch Clutch lever Turn signal switch Digital, multifunction instrument board Manual starter lever Front brake pump Mode switch Front brake lever Throttle grip 24 25 Rear-view mirror (*) Horn switch Low beam/high beam light switch (**)

  • Page 15: Side Stand

    - CHASSIS CHASSIS Getting to know your motorbike CHAPTER KEYS The vehicle is supplied with two keys featuring a code number, which have the following functions: • Providing the ignition contact • Turning the lights on • Locking the steering system. STEERING LOCK Locking: turn the handlebar all the way to the right or left, push the key in and turn it counter-clockwise.

  • Page 16: Tires

    - CHASSIS CHASSIS CHAPTER Getting to know your motorbike TIRES Dimensions: 80/90 - 21 48P (enduro, front) 110/80 - 18 58P (enduro, rear) 100/80 - 17 52S (supermotard, front) 130/70 - 17 62S (supermotard, rear) TIRE PRESSURE CHECK Tire pressure must be checked when the tires are cold. ENDURO: (psi) (29,0)

  • Page 17: Coolant

    - CHASSIS CHASSIS Getting to know your motorbike CHAPTER COOLANT CHECK 1. Remove the cap (T - F.10i) when the engine is cold and exhaust any residual pressure. 2. The coolant level must be checked on a cold engine since the level varies with engine temperature.

  • Page 18: Transmission Oil

    - CHASSIS CHASSIS CHAPTER Getting to know your motorbike TRANSMISSION OIL Replacement Park the vehicle on flat ground. 2.Start the engine and warm it up for several minutes. 3.Stop the engine. Place an oil pan under the engine and remove the filler cap (R - F.13i). 4.Remove the drain screw (S - F.13i) and the screw (F - F.13i) to drain oil.

  • Page 19: Adjustment Of Engine Idling Speed 2

    - CHASSIS CHASSIS Getting to know your motorbike CHAPTER ADJUSTMENT OF ENGINE IDLING SPEED Start the engine and warm it up for several minutes at about 1000-2000 RPM, while occasionally revving it to 4000-5000 RPM. The engine is warm when it quickly responds to the throttle.

  • Page 20: Seat

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER SEAT Loosen the screw (V - F.1) and release the seat from the chassis. Pull it out rearwards. F. 1 REAR SIDE CASINGS (rh / lh) (Remove seat) • Loosen the screws (V4 - F.2) and remove the rear side casing (left or right).

  • Page 21: Conveyor 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER CONVEYOR (right and left) (Remove seat) • Undo the screws (V2 - F.4), the side screws (V - F.5) and the front screws (V2 - F.6). 05.03 ISSUE PAGE SECTION 3 SECTION 2...

  • Page 22: Silencer 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER SILENCER (Remove seat and left hand side casing) • Remove the spring (D - F.9). Undo the screws (V2 - F.7) and remove the silenc- er by pulling it rearwards. CAUTION!!! Before removing, make sure the silenc- er has cooled down.

  • Page 23: Battery

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER BATTERY (Remove seat) • Remove the elastic band (A - F.10) and detach the battery cables (B and C - F.10b). F.10b F.10 Release the fuse carrier (D - F.11) from the clamp. Caution!!! When refitting the battery, pay attention to the exhaust pipe.

  • Page 24: Tail Light

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER TAIL LIGHT (Remove seat and tail section) • Disconnect the cables (A - F.13) and undo the screws (V2 - F.13b). Caution!!! When refitting, pay attention to the Fast-on sequence; (see wiring diagram).

  • Page 25: Filter Cartridge 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER FILTER CARTRIDGE (Remove seat and battery) • Undo the screws (V2 - F.16) and remove the filter cartridge. F.16 REGULATOR (Remove seat and rear right hand casing) • Detach the connector (C - F.17) and undo the screw (V - F.17).

  • Page 26: Rear Chassis 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER REAR CHASSIS (Remove seat, rear side casings, tail section, • shock absorber guard, battery, rear brake fluid tank,regulator, flashlight and silencer). Undo the screws (V4 - F.19). F.19 AIR FILTER SUCTION BOX (Remove seat, rear side casings, tail section, •...

  • Page 27: Shock Absorber

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER SHOCK ABSORBER (Remove the seat, rear left hand casing). • Undo the two screws holding the tank in place on the rear side, and remove the rubber protection. Undo the screws (V2 - F.22) and remove the shock absorber.

  • Page 28: Oil Tank

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER OIL TANK (Remove seat and front left conveyor). • CAUTION!!! Empty the tank before disassembly; to do so: 1. Put a pan under the oil tank. 2. Remove the pipe clamp (F - F.27) and detach the pipe from its fitting.

  • Page 29: Fuel Tank

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER FUEL TANK (Remove seat and top screw of the front con- • veyors) Undo the front fixing screw (V - F.28) and the rear fixing screws (V2 - F.28). Disconnect the vacuum pipe (D - F.28) and the petrol pipe (B - F.28) from the fuel cock.

  • Page 30: Throttle Cable 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER THROTTLE CABLE / MIXER Undo the screws (V2 - F.29) and remove the pump cover. Release the cable (C - F.30) from the pump body (P - F.30). F.29 F.30 CARBURETTOR (Remove seat, side casings, fuel tank) •...

  • Page 31: Engine 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER ENGINE (Remove seat, tank, side conveyors and muf- • fler) Detach the two pipes of the cylinder head heater (R - F.32), remove the suction manifold screws and detach the spark plug cap (P - F32). Detach the white/green cable from the thermistor (F - F.32).

  • Page 32: Side Stand 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER SIDE STAND CAUTION!!! Before disassembly, hold the centre chassis section to prevent the vehi- cle falling over. This operation must be performed with the side stand in its idle position. Release the screws (M - F.35) and undo the screw (V - F.35).

  • Page 33: Headlight 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER HEADLIGHT (Remove guard) • Remove the fast-ons of the wiring (A - F.38) and remove the headlight by folding the tabs outwards (L2 - F.38). To access the lamp, open the clip (C - F.38). Caution!!! When reassembling, pay attention to the fast-on assembly se- quence (see wiring diagram).

  • Page 34: Clutch Control 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER CLUTCH CONTROL Detach the clutch cable (F - F.41) and the starter cable (S - F.41) and remove the mirror (A - F.41). Loosen the screws (V2b - F.41), remove the start- er lever body (L - F.41) and the left hand knob.

  • Page 35: Removing The Front Brake Calipers 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER REMOVING THE FRONT BRAKE CALIPERS (MOTARD model). F.43A REMOVING THE FRONT BRAKE CALIPERS (ENDURO model). F.43B SPEEDOMETER SENSOR Loosen the screw (V - F.44) and remove the sen- sor; release the cable from the U-bolts and detach the connector under the headlight.

  • Page 36: Front Wheel

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER FRONT WHEEL (Remove front caliper and speedometer sensor) • CAUTION!!! Before disassembly, hold the centre chassis section to prevent the vehicle falling over. Loosen the screw (V2 - F.45b). Unscrew the pin (P - F.45) and remove it. Remove the front wheel.

  • Page 37: Fork Head

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER FORK HEAD (Remove front indicators, guard, digital instru- • ment board and handlebar) Unscrew the Allen screws (V2 - F.47) Unscrew the nut (D - F.47) and remove the fork head. F.47 FORK (Remove front indicators, guard, digital instru- •...

  • Page 38: Rear Brake Lever 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER REAR BRAKE LEVER Remove the stick (A - F.49), by pulling out the pin (P - F.49); loosen the screw (V - F.49) and remove: the pedal, the spring, the bushing and the plastic washer.

  • Page 39: Rear Brake Calipers 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER REAR BRAKE CALIPER (Remove rear wheel) • Loosen the hydraulic transmission screw (V - F.52) and detach the pipe (T - F.52) from the caliper. Release the calipers from the fork. CAUTION!!! Before disassembly, hold the centre chassis section to prevent the vehicle falling over.

  • Page 40: Chain Crankcase 3

    - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER CHAIN CRANKCASE Undo the screws (V3 - F.54). F.54 FORK (Remove rear wheel, rear brake caliber, shock • absorber, chain crankcase) Unscrew the nut (D - F.55) and remove the pin. CAUTION!!! Before disassembly, hold the centre chassis section to prevent the vehicle falling over.

  • Page 41: Chassis Torque Wrench Settings

    - CHASSIS CHASSIS Assembly XTM - XSM CHAPTER CHASSIS TORQUE WRENCH SETTINGS TORQUE WRENCH SETTINGS TABLE TOURQUE WRENCH SETTINGS Kg*m Remarks Front wheel pin 38 - 52 3.8 - 5.2 Front wheel pin fixing element 17 - 23 1.7 - 2.3 Front brake caliper 24 - 36 2.4 - 3.6...
  • Page 42 - CHASSIS CHASSIS Disassembly XTM - XSM CHAPTER 05.03 PAGE ISSUE SECTION 3 SECTION 2...

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Xsm 50

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