Malaguti f10 Service Manual
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Malaguti f10 Service Manual

50cc engine
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  • Page 2 125 i.e. - 160 i.e. 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.
  • Page 3 125 i.e. - 160 i.e. NOTES FOR EASY CONSULTATION ABBREVIATIONS TECHNICAL DICTIONARY Torque wrench setting = (DC) Direct current (battery supply) ~ (AC) Alternating current (flywheel supply) Right : Ampere Unit of measurement of the electrical current Picture : Watt Unit of measurement of the electrical power (product of Volts and Amperes;...
  • Page 4 SYMBOL LIST CAUTION! IDLING ENGINE Recommendations and SAFETY GLOVES 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 these interventions. integrity. WARNING! Situations entailing the risk of personal ENGINE OFF IMPORTANT...
  • Page 5 125 i.e. - 160 i.e. 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. •...
  • Page 6 125 i.e. - 160 i.e. • 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. •...
  • Page 7 Before any servicing, make sure that the vehicle is perfectly stable. It is absolutely forbidden to walk on the lifting device. The front wheel should preferably be anchored to fixture (A), which is integral with the lift platform. 03/08...

  • Page 8: Table Of Contents

    INDEX DESCRIZIONE DESCRIZIONE HELMET COMPARTMENT SPECIFICATIONS SEAT LOCKING DEVICE IDENTIFICATION DATA: FRAME N° / ENGINE N° PEDANA POGGIAPIEDI TYRES ACCESSES MAINTENANCE TABLE FUEL LEVEL PROBE LUBRICANT TABLE OIL TANK REAR MIRRORS FUEL TANK FAIRING RIGHT AND LEFT SWITCH UNIT UPPER HANDLEBAR COVER KEY SWITCH DASH WIRING HORN...

  • Page 9: Specifications

    SPECIFICATIONS Cooling ....................forced air Starting system..........electric starter and/or kick starter SPARK PLUG Type ................NGK BR8 ES - 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.

  • Page 10: Identification Data: Frame N° / Engine N

    IDENTIFICATION DATA: FRAME N° / ENGINE N° • The body number (A) is stamped on the central body tube and can be viewed by removing the cover (B). • Engine identification data are located on the left-hand engine crankcase (C). Any alteration to the vehicle identification data is pursued by the Law.

  • Page 11: Maintenance Table

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

  • Page 12: Lubricant Table

    LUBRICANT TABLE NOTE -Use only recommended products. • To fill, remove the inspection cover, unscrewing the screw (V) and cap (A), pulling outwards. • Pour in oil. 03/08...

  • Page 13: Rear Mirrors

    FAIRING REAR MIRRORS • Uncover and loosen the UPPER HANDLEBAR nut (D). COVER • Unscrew the arm holding • V3 the mirror. Cs - N * m 0,5 ± 20 % • Remove the upper handlebar cover by lighting hitting it upwards. F.10 DASH WIRING •...

  • Page 14: Accesses

    ACCESSES (after removing the front handlebar cover) (1) Blinking (2) Dashboard connector (3) Front brake “stop” switch (4) Rear brake “stop” switch (5) Right switch connector (6) Left switch connector (7) Front brake pump oil connection (8) Rear brake transmission (9) Dashboard protection condenser F.13 FRONT SHIELD...

  • Page 15: Gruppo Fari

    • Slightly spread the shield GRUPPO FARI and disconnect the connector (A). • V3 • Remove the shield • V (Vite regolazione fascio including the headlights luminoso). and blinkers. When reassembling, check correct OR positioning. • C (Plexiglas). F.16 Always replace the gasket before reassembling.

  • Page 16: Accesses

    ACCESSES (after removing the shield) (1) Regulator (2) Key switch connector (3) Connector for anti-theft device (4) Headlights connector (5) Handlebar nut and bult (6) 7.5 A light protection fuse (7) Horn (8) Twin gas mixer After removing the cables, reposition and anchor the cables with new straps, as described in the figure.

  • Page 17: Lower Side Panels

    LOWER SIDE PANELS • Foot rest mat (A). • V2 • V2 - Cs - N * m Cs - N * m 2 ± 10 % 2 ± 10 % • V1 - Cs - N * m F.21 2 ±...

  • Page 18: Coil

    FUSE DESCRIPTION COIL B) 10 A - General protection/Recharge NOTE - Remove: C) 7,5 A - Lights protection/Starter - Lower Side Panels FUSE REPLACEMENT (p.16). • V2 Always replace a fuse with another of same • Faston (A). capacity. Higher capacity may result in serious damage to the electric system, including the risk of fire.

  • Page 19: Leg Shield

    LEG SHIELD • Remove the wiring. • Remove the leg guard (B) NOTE - Remove: as indicated. - Front Shield (p.13). - Battery (p.17). • Unscrew the ring nut (A). • V3 Cs - N * m 5 ± 20 % F.30 F.29 SEAT...

  • Page 20: Rear Light

    • Faston (A), (B), (C), (D). REAR LIGHT When reassembling, the faston (B), pink • V2 wire, must be connected on the same side as the faston (D), black grounding wire. F.34 F.33 REAR FAIRING • Carefully remove the rear hood (A) NOTE - Remove: slighting spreading - Rear light (p.19).

  • Page 21: Accesses

    ACCESSES (after removing the seat and rear hood) (1) Fuel level probe (2) Gas level probe connector (3) Electronic panel (4) Ignition relay (5) Flywheel connector (6) Engine oil probe connector (7) Engine oil probe F.37 03/08...

  • Page 22: Helmet Compartment

    HELMET COMPARTMENT SEAT LOCKING DEVICE NOTE - Remove: - Seat (p.18). NOTE - Remove: - Rear fairing (p.19). - Helmet compartment • (A). (p.21). • V2 • V2 Cs - N * m Cs - N * m 5 ± 20 % 5 ±...

  • Page 23: Accesses

    ACCESSES (after removing the seat, rear hood, foot rest and helmet case) (1) Seat locking device (2) Air filter case sleeve (3) Carburettor transmission (4) Mixer pipe (5) Electric carburettor starter connector FUEL LEVEL PROBE • V4 F.41 Cs - N * m 2 ±...

  • Page 24: Oil Tank

    OIL TANK NOTE - Remove: - Helmet compartment (p.21). • Connector (A). • Use pincers to release the strap and disconnect the pipe (C). • Insert a screw, which shall function as tap, in the tank exit connection. • V2 Cs - N * m 5 ±...

  • Page 25: Right And Left Switch Unit

    RIGHT AND LEFT SWITCH UNIT NOTE - Remove: - Upper handlebar Cover (p.12). • Connectors (A) and/or (B). • V2 Cs - N * m 1,6 ± 20 % • Remove the complete switch unit (C) and/or (D). FRONT BRAKE PUMP NOTE - Remove: - Upper handlebar Cover (p.12).

  • Page 26: Key Switch

    KEY SWITCH HORN NOTE - Remove: NOTE - Remove: - Front Shield (p.13). - Front Shield (p.13). • Remove the ring nut (A). • Faston (A). • V2 • V Cs - N * m Cs - N * m 10 ±...

  • Page 27: Front Brake

    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. •...

  • Page 28: Fork

    OIL LEVEL CHECK FORK • •Block the wheel shaft in a clamp, in vertical position. WHEEL SHAFT • •Remove: NOTE - Remove: - Cover (A) - Odometer return. - Seeger ring (B) - Front wheel (p. 25). - Propeller nut (C), complete with O-Ring (D) - Odometer sensor (for left shaft) - Spring (E) (let oil drip off it) (p.

  • Page 29: Oil Replacement

    OIL REPLACEMENT FORK ASSY (wheel shafts) To remove the complete fork, remove: • With the shaft blocked in a clamp, • Shield (p. 13). in vertical position, place a container beneath the screw (V). • Front wheel (p. 25). • V - •...

  • Page 30: Suspension

    EXHAUST SYSTEM The operations described below should be carried out only when the exhaust system has cooled down. • V2 Cs - N * m 8 ± 15 % • Gasket (to be replaced with a new one). • Remove the strap (A) and disconnect the secondary air supply pipe. •...

  • Page 31: Central Kick Stand

    CENTRAL KICK STAND Secure the vehicle so that it does not fall when the central kick stand is removed. • Split pin (A). • Pin (B). • Spring (C). When reassembling, secure the rear transmission wire to the support plate (D). F.60 FOOT REST RODS •...

  • Page 32: Rear Wheel

    REAR WHEEL NOTE - To remove the rear wheel, you must remove the exhaust system (p. 37). • Position the scooter on the stand and insert a suitable support beneath the engine. • D Cs - N * m 100 ± 20 % •...

  • Page 33: Checking

    CHECKING Materiale di attrito • Control the conditions of the brake shoes, verify the minimum thickness of the friction material, which should’t be thinner then mm 2, otherwise, replace the shoes. Drum • Clean carefully the inner part of the drum, verifying that there are no clearly visible scores or damages.

  • Page 34: Air Filter

    AIR FILTER • V3 - • Remove: (Maintenance) - Cover (A) • The air filter can be reached - Filtering element (B). by removing the lower side • Immerge the filtering panels (p. 16). element in a solution: • Release the spring (A) on solvent for filters, for a few the carburetor.

  • Page 35: Engine

    ENGINE • Remove the rear fairing (p. 19) and the lower side panels (p. 16). • Dismantle the muffler (p. 29) • Dismantle the tyre (p. 31) • Disconnect the ignition motor wires (A) • Disconnect the stator connector (B) •...
  • Page 36 • V - • Disconnect the carburettor accelerator • V2 - wire. • Lateral air conveyor, • Disconnect the mixer paying attention to the wire (A) from the cam hook element positioned (B) that drives the oil in the lower part of the mixer.

  • Page 37: Frame Dimension Check

    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 dangerous operation, and should be carried out with maximum care and attention in order to avoid crushing arms and legs and to protect the engine itself.

  • Page 38: Cable Positioning, "Pipe System" And Location Of

    CABLE POSITIONING, “PIPE SYSTEM” AND LOCATION OF ANCHORING STRAPS F.79 03/08...
  • Page 39 F.80 F.81 03/08...
  • Page 40 F.82 03/08...
  • Page 41 F.83 03/08...
  • Page 42 F.84 03/08...
  • Page 43 F.85 03/08...
  • Page 44 F.86 03/08...

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