Malaguti Blog 126 Service Manual
  1. Manuals
  2. Brands
  3. Malaguti Manuals
  4. Motorcycle
  5. Blog 126
  6. Service manual

Malaguti Blog 126 Service Manual

Frame and running gear
Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Blog 126 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Malaguti Blog 126

Summary of Contents for Malaguti Blog 126

  • Page 2 125 - 160 cc 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.

  • Page 3: Description

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc NOTES FOR EASY CONSULTATION ABBREVIATIONS TECHNICAL DICTIONARY Torque wrench setting = (DC) Direct current (battery supply) ~ (AC) Alternating current (flywheel supply) Right...
  • Page 4 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc SYMBOL LIST CAUTION! IDLING ENGINE SAFETY GLOVES Recommendations and DISASSEMBLY Switch on the engine, at precautions regarding rider These operations require OPERATIONS idling speed, to perfom...
  • Page 5 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc 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 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc • 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: Table Of Contents

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc CONTENTS 1 2 3 1 2 3 DESCRIPTION 1 2 3 DESCRIPTION 1 2 3 1 2 3 1 2 3 TECHNICAL DATA SEAT...
  • Page 8 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: BATTERY Type ..................... MALAGUTI 03 Type 12V, 7Ah, no maintenance. MALAGUTI 04 TIRES n° Cylinders ...................... 1...

  • Page 9: Anti-Tampering Plate

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc IDENTIFICATION DATA: FRAME N° / ENGINE N° ANTI-TAMPERING PLATE • An anti-tampering plate, bearing all vehicle identification data required by Directive •...
  • Page 10 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc 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.
  • Page 11 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. 03/09...
  • Page 12 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc LUBRICANT TABLE NOTE - Use only recommended products. LUBRICANTS ENGINE OIL (4 STROKE) CLASS 10W 40 ENGINE TRANSMISSION OIL CLASS 10W 40 AIR FILTER LUBRICANT...
  • Page 13 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FUEL TANK • Insert the ignition key in the switch block and it into the lock on the left hand side of the seat (B). •...
  • Page 14 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc ENGINE OIL CHECK LEVEL every 2,000 km • The engine must be cold and the vehicle on level ground.

  • Page 15: Transmission Oil

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc TRANSMISSION OIL • After the first 1,000 Km CHECK LEVEL/ TOP UP CHANGE • Every 12,000 Km •...
  • Page 16 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc BLEED BRAKE SYSTEM FRONT CALIPER NOTE - Position the vehicle in a stabile manner and perfectly on level ground. •...

  • Page 17: Check Front/Back Brake Pads And Disks

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc CHECK FRONT/BACK BRAKE PADS AND DISKS • Check the condition of front and back brake pads and discs every 2,000 Km.

  • Page 18: Fork

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FORK • Remount the drain screw (V). CHANGE FORK OIL NOTE - When remounting, replace the copper washer located under the screw (V).
  • Page 19 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc DASHBOARD ELECTRIC/SERVICE MALFUNCTION WARNING LIGHT Speedometer When the starter key is turned in the switch in the Odometer position, without starting the engine, the war- ning light...

  • Page 20: Key Switch

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc KEY SWITCH HANDLEBAR CONTROLS Ignition inhibited (extractable key) LEFT CONTROLS RIGHT CONTROLS Horn button A) light switch: Preset starting position (non extractable key) right= off Turn signals switch.

  • Page 21: Lights

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc LIGHTS (12 V) HEADLIGHT (Quartz halogen lamps) A) High/Low beam lights: 55W (H7). B) Tail lights: 5W (W7y5).
  • Page 22 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc LIGHT BULB REPLACEMENT HEADLIGHT • In order to access the headlight bulbs, refer to the topics at page (33). TURN SIGNALS FRONT: See page (33).

  • Page 23: Fuses

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FUSES The electrical wiring includes 9 fuses, protecting the main components against faults. 8 are located in the glove compartment. F.

  • Page 24: Battery

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc BATTERY (12V - 9Ah) The battery housing is located in the central tunnel. BATTERY ASSEMBLY (PRE-DELIVERY OPERATION) •...

  • Page 25: Spark Plug

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc SPARK PLUG REPLACEMENT every 12,000 km Remove the spark plug when the engine is cold. Type of spark plug to be used: NGK DPR7EA9 •...

  • Page 26: Reassembly Notes

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc PROCEDURES FOR DISMANTLING AND WINDSCREEN SUPPORTS REMOVING COMPONENTS • V2. REASSEMBLY NOTE • Supports (A). WINDSCREEN •...

  • Page 27: Upper Handlebar Covers

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc UPPER HANDLEBAR COVERS • V2. • W2. F. 41 F. 40 • Release the upper • Disconnect the handlebar cover, connectors (C - D).

  • Page 28: Dashboard

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc • Disconnect the DASHBOARD connector (A). • V4. F. 45 F. 44 • V2. • V2/a. F.

  • Page 29: Lower Handlebar Covers

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc ACCESS (after removing the upper handlebar cover) 1) Front brake pump 2) Hydraulic front brake union 3) Front brake "stop"...

  • Page 30: Upper Shield

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc UPPER • Tapping slightly with the hand palm, SHIELD release the upper • V2. cover. 1 ± 10% F.

  • Page 31: Front Shield

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FRONT SHIELD • W. • V2. 1 ± 10% 1 ± 10% F. 53 F. 54 •...

  • Page 32: Access (Motorbike Parts - Shield Parts)

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc ACCESS (motorbike parts) 1) Radiator 2) Electric fan 3) Fork stem screw F. 57 (shield parts) 1) Turn signals 2) Tail lights 3) High/Low beam lights...

  • Page 33: Change Light Bulb

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc CHANGE LIGHT BULB TURN SIGNALS • Turn the bulb holder (A) anti-clockwise and remove the bulb (B). TAIL LIGHTS •...

  • Page 34: Front Fairing

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FRONT FAIRING • Remove the front fairing with • V2. care. • V. • V1. • V3. 2 ±...

  • Page 35: Side Struts

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc SIDE STRUTS • V4. • V3. • V. 1 ± 10% 1 ± 10% F. 64 F.

  • Page 36: Seat

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc • V. • Release the leg-fender with care, paying attention not to damage the sides (A). 1 ±...
  • Page 37 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc ACCESS • Rollover sensor (A). When reassembling the removed components, make sure that the tilt sensor is horizontal.

  • Page 38: Helmet Case

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc HELMET CASE • After undoing • Remove the cover (A). the screws (V2), open up the fairing, as shown in the figure.
  • Page 39 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc • V2. • Lift the helmet compartment. • Remove the seat lock unit (A). • Disconnect the connector (B).

  • Page 40: Access (After Removing The Helmet Compartment)

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc ACCESS (after removing the helmet compartment) A) Fuel level gauge B) Fuel Pump C) Pump connector D) Fuel tank 1) Injector connector 2) Temperature gauge (coolant)

  • Page 41: Fuel Level Sensor

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FUEL LEVEL SENSOR Do not smoke or use open flames, during operations on the fuel tank. •...

  • Page 42: Footbar

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FOOTBAR • V. 1 ± 10% • Remove the lids (A) by means of a screwdriver. •...
  • Page 43 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc ACCESS 1) Ignition coil 2) Horn 3) Voltage regulator 4) Rollover sensor 5) Regulator connector System connector 6) Electronic control unit F.
  • Page 44 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc IGNITION COIL • Connector (A). • Screw (V). • H.T. cable (C) • Remove the coil complete with the support staff. HORN •...

  • Page 45: Rear Fairing

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc REAR • By means of a screwdriver, release and remove the FAIRING upper cover (A). REAR HANDLE •...

  • Page 46: Tail Lights

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc TAIL LIGHTS • Disconnect the faston • V2. connectors and remove the complete tail light. • In order to replace the bulbs, it is not necessary to remove the complete tail light unit.

  • Page 47: Full Rear Fairing- Fairing Breakdown

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FAIRING BREAKDOWN • V2. • Release the electric cables from the hose rings (A). • V5. •...

  • Page 48: Seat Lock Unit

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc SEAT LOCK UNIT • V3. • Lift and remove the key • Lid (A). switch block lock clip. F.
  • Page 49 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc 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...
  • Page 50 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc 9) O2 sensor 11) Exhaust manifold 12) Spark plugs cap 10) Thermal unit 13) Starter motor ground cable F.

  • Page 51: Fuel Tank

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FUEL TANK Do not smoke or use open flames, while operating on the fuel tank. • During the operation, screw the tank cap (A), to avoid that any foreign matter falls inside.

  • Page 52: Electric Fan And Radiator

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc ELECTRIC FAN AND RADIATOR Before any opera- • Position the engine tions on the cooling in a container system, check that suitable for collec- the fluid is below...

  • Page 53: Disassembling Radiator Unit - Cooling System Drainage

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc DISASSEMBLING RADIATOR UNIT • Disassemble the radiator unit, as shown in the figure. COOLING SYSTEM DRAINAGE The cooling system is "self-bleeding".

  • Page 54: Front Wheel

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FRONT WHEEL • Unscrew the nut (D), holding the wheel pin with a wrench (P). F. 118 F.

  • Page 55: Front Brake Caliper

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc 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 proper disposal in accordance with specific waste disposal laws.

  • Page 56: Handelbar Control - Brake Pump

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc HANDLEBAR CONTROLS ANDBRAKE PUMP • Disconnect the throttle transmission (A). • Disconnect the "faston" (F). F. 124 F.

  • Page 57: Handlebar

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc HANDLEBAR • Remove beforehand: - Upper handlebar covers (page 27) - Front shield (page 31). - Brake pump (page 56). - Right switch and left switch (M).

  • Page 58: Complete Fork

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FULL FORK • Upper ring nut (A) • Lower ring nut (A) NOTE - When extracting the fork unit, take care with the bearings (S) spilling out. •...

  • Page 59: Manifold Exhaust

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc EXHAUST MANIFOLD • Disconnect the O2 sensor • Loosen the O2 sensor (D). connector (A). • D2. •...

  • Page 60: Shock Absorbers

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc SHOCK ABSORBERS Support the scooter on the central part of the chassis. • Lower screws (Vi) •...

  • Page 61: Rear Mudguard - Rear Brake Caliper

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc REAR MUDGUARD Right side Left side • V2. • V. 3,5 ± 20% 3,5 ± 20% F.

  • Page 62: Rear Wheel

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc REAR WHEEL • Position the motorcycle on the stand and place a suitable sup- port under the engine. •...

  • Page 63: Rear Brake Disk

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc 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.

  • Page 64: Filter Box Unit

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FILTER BOX UNIT • Unhook the clamp (A). • Disconnect the tube (C ) "IDLE" valve- filter box sleeve. •...
  • Page 65 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc • Unscrew the fixing screws (V1) of the filter box- rear mudguard. • Unscrew the fixing screws (V) of the flexible air intake tube.

  • Page 66: Air Filter

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc AIR FILTER • Unscrew the screws (V5), remove the cover and take out the filtering element. F.

  • Page 67: Side Stand - Central Stand

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc SIDE CENTRAL STAND STAND • Springs (A - B). • Springs (A - B). • V. •...

  • Page 68: Frame Size Check

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc FRAME SIZE CHECK • In case of suspected deformation (even slight) of the frame following an acci- dent, perform a size check of the frame.

  • Page 69: Position Of Injection System Parts

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc POSITION OF INJECTION SYSTEM PARTS F. 159 Battery sensor (Lambda sensor) Inlet air temperature sensor Tilt sensor Ignition spark plug Starter motor ground cable H.T.
  • Page 70 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc 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...
  • Page 71 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc F. 161 Fuel injector Regulator connector system TPS sensor Fan relay (yellow) Stator three-phase connector regulator Radiator fan 03/09...

  • Page 72: Cable Positioning, "Pipe System" And Anchoring Ties

    B l o g B l o g B l o g B l o g B l o g 125 - 160 cc CABLE POSITIONING, "PIPE SYSTEM" AND ANCHORING TIES F. 162 03/09...
  • Page 73 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc F. 163 03/09...
  • Page 74 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc F. 164 03/09...
  • Page 75 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc F. 165 03/09...
  • Page 76 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc F. 166 03/09...
  • Page 77 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc F. 167 03/09...
  • Page 78 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc F. 168 03/09...
  • Page 79 B l o g B l o g B l o g B l o g B l o g 125 - 160 cc F. 192 03/09...

This manual is also suitable for:

Blog 150

Table of Contents

Save PDF