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Summary of Contents for Malaguti Password 250
- Page 1 FRAME AND RUNNING GEAR WORKSHOP MANUAL...
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Page 2: Table Of Contents
FRAME AND RUNNING GEAR TABLE OF CONTENTS PASSWORD 250 1 - INTRODUCTION KEYSWITCH ............27 HANDLEBAR LOCK ..........27 Manual updates ..............Locking ................NOTES FOR EASY CONSULTATION ..... Unlocking ................Configuration of the pages ..........STANDS ..............28 Modified pages .............. - Page 3 FRAME AND RUNNING GEAR TABLE OF CONTENTS PASSWORD 250 5 - ACCESSORIES KEYSWITCH ............91 SEAT ............... 92 ACCESSORIES AVAILABLE ........51 HELMET COMPARTMENT ........92 6 - DISASSEMBLY SEAT LOCK ............93 ACCESSIBILITY ............. 94 INSTRUMENT PANEL WINDSHIELD ..... 52 FUEL LEVEL SENSOR ..........
- Page 4 FRAME AND RUNNING GEAR TABLE OF CONTENTS PASSWORD 250 7 - SYSTEMS MAIN ELECTRICAL SYSTEM ........ 132 Under the instrument panel ..........133 Behind the radiator ............133 Alongside the keyswitch ............ 134 Connectors under the footboard ........135 Left stanchion ..............135 Under the battery tunnel ...........
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Page 5: Introduction
Some information has been given to us by the engine manufacturers. We therefore decline all respon- sibility for any error, omission or misrepresentation. MALAGUTI reserves the right to make any changes and modifications hereto it deems necessary without prior notice. -
Page 6: Symbols
FRAME AND RUNNING GEAR TABLE OF CONTENTS INTRODUCTION PASSWORD 250 SYMBOLS • Symbols are provided for quick and easy reference (see the relevant heading), 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). -
Page 7: General Work Procedures
FRAME AND RUNNING GEAR INTRODUCTION TABLE OF CONTENTS PASSWORD 250 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. We therefore recommend observing such advice, recommendations and warnings scrupulously. - Page 8 FRAME AND RUNNING GEAR INTRODUCTION TABLE OF CONTENTS INDICE PASSWORD 250 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 workshop floor. Always use low flash point solvents to clean the vehicle components.
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Page 9: Operating Symbols
FRAME AND RUNNING GEAR TABLE OF CONTENTS INTRODUCTION INDICE PASSWORD 250 OPERATING SYMBOLS IMPORTANT! CAUTION! - Descriptions concerning operations that are potentially hazardous for the maintenance mechanic or repairman, other workshop personnel or extraneous persons, for the environment, for the vehicle, and for the tools and equipment. -
Page 10: Getting To Know Your Scooter
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 TECHNICAL DATA MALAGUTI SpA reserves the right to modify technical data at any time without prior notice. DIMENSIONS FUEL SYSTEM wheel base (A), m ..........1,484 Carburettor: KEIHIN 4MSA. -
Page 11: Identification Of Main Components (Left-Hand Side)
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 IDENTIFICATION OF MAIN COMPONENTS (left-hand side) 1) Instrument panel 2) Windshield 3) Right-hand mirror 4) Keyswitch 5) Fuses 6) Twin seat 7) Fuel tank cap 8) Pillion grab handles... -
Page 12: Identification Data: Frame N° / Engine N
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 IDENTIFICATION DATA: FRAME N° / ENGINE N° • To gain access to the vehicle identification number (VIN) (A), lift the right-hand rubber floor mat and remove the cover. • Engine identification data are located on the left-hand engine crankcase (B). -
Page 13: Tyres
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 TYRES Type: Tubeless NOTE 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 T.W.I. -
Page 14: Fuel Tank
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 FUEL TANK To access the fuel tank, proceed as follows: • Place the scooter on the centre stand. • Open the seat by turning the ignition key counter-clock- wise. -
Page 15: Coolant Tank
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 COOLANT TANK To access the engine coolant tank lift up the rubber mat on the right-hand side. Owing to the position of the tank, the level of coolant with respect to the “MIN”... -
Page 16: Helmet Compartment
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 HELMET COMPARTMENT • The helmet compartment is under the pillion seat. To gain access to the compartment, put the scooter on its stand and turn the ignition key counter-clockwise to release the seat lock. -
Page 17: Glove Compartment
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 GLOVE COMPARTMENT The glove compartment is located in the central part of the lower fairing (A) and is suitable for accommodating small personal belongings. It is fitted with a lock that can be opened with the ignition key: turn the key clockwise. -
Page 18: Instrument Panel
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 INSTRUMENT PANEL Green left-hand turn indicator light Multifunction digital instrument panel To set up the various functions refer to the relative heading in the manual. Green right-hand turn indicator light Analogue instruments. -
Page 19: Digital Instrument Panel
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 DIGITAL INSTRUMENT PANEL The digital instrument panel provides data for the rider to enable optimum management of the scooter. When the ignition key is set to , all displays on the instrument panel will illuminate for approximately 3 seconds to check that they are working correctly;... -
Page 20: Function Selection And Warning Or Alarm Signals
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 FUNCTION SELECTION AND WARNING OR ALARM SIGNALS To make the display easier to understand, functions are divided into menus and submenus. Menus Submenus Warning and alarm signals appear automatically whenever the necessity arises. - Page 21 FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 C) AVE FUNCTION (Average Speed): • This indicates the average speed during a journey. The value is in km/h or mph. The calculation does not take account of stops (speed = 0). To reset, press the MODE button when the scooter is stopped and hold it down until the display shows 0.
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Page 22: Main Menu
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 MAIN MENU To access Main Menu function selection mode, hold the down the “MODE” button for 3 sec. when “—” (F) is dis- played in the Submenu. A) INSTANTANEOUS SPEED FUNCTION: •... -
Page 23: Alarms Function
(see MAINTENANCE TABLE) has been reached. It is the responsibility of local Authorised MALAGUTI Service Centres to reset the warning lights and counters once the relative service operations have been completed. -
Page 24: Miles Or Kilometres Selection
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 MILES OR KILOMETRES SELECTION When riding in countries where different measurement systems are used, you can change the unit of measurement of the distance travelled and recorded road speeds (instantaneous and average) from kilometres to miles or vice versa. -
Page 25: Handlebar Controls
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 HANDLEBAR CONTROLS RIGHT-HAND CONTROL 1) Counterweight 2) Throttle grip 3) Front brake lever 4) MODE button: selects the various digital instrument panel functions A) Emergency switch, engine stop. Position - Engine start... -
Page 26: Keyswitch
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 KEYSWITCH • The keyswitch controls the ignition circuit, the handle- bar lock and the seat/helmet compartment lock. Ignition disabled (key can be removed) ‘Ready to start’ position (key cannot be re-... -
Page 27: Stands
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 STANDS CENTRE STAND • The centre stand position is not electronically monitored; you can therefore turn the engine on while the scooter is on the stand. To set the scooter on the stand push on spur (A) and lift the vehicle onto the stand using the rear grab rail. -
Page 28: Owner's Toolkit
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 OWNER’S TOOLKIT The scooter is equipped with a tool bag stowed under the seat. The bag contains the following tools: A Spark plug wrench B Handle for tool inserts. -
Page 29: Dimensional Check Of Frame
FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER PASSWORD 250 DIMENSIONAL CHECK OF FRAME If the scooter has been involved in an accident and you suspect even slight distortion of the frame it is essential to perform the dimensional checking procedure before any further “repair or set-up” work. -
Page 30: Instructions For Use
INSTRUCTIONS FOR USE FRAME AND RUNNING GEAR INSTRUCTIONS FOR USE PASSWORD 250 STARTING THE ENGINE The scooter is equipped with an ignition disabling system controlled by the side stand and by the emergency stop switch. The engine cannot be started if the side stand is down or if the emergency stop switch is set to OFF. -
Page 31: Maintenance
The maintenance schedule is based on average riding conditions. Machines subject to severe use or ridden in unusu- ally wet or dusty conditions or off the road require more frequent servicing. NOTE Certain simple checks, i.e. those marked with an asterisk, MAY be performed under the direct respon- sibility of technicians not specifically authorised by MALAGUTI. 09/05... -
Page 32: Transmission Oil
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE TRANSMISSION OIL LEVEL CHECK 1) Park the scooter on flat ground and set it on its centre stand. 2) Put a container under the engine crankcase. 3) Unscrew oil filler cap (A) and drain plug (B), and allow the oil to flow out. -
Page 33: Engine Oil
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 ENGINE OIL ENGINE OIL LEVEL CHECK In four-stroke engines the engine oil is used to lubricate timing components, the main bearings, and the thermal unit. Insufficient oil can cause serious damage to the engine. -
Page 34: Oil Top-Up
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE OIL TOP-UP Check the oil level before topping up. Never exceed the “MAX” level when topping up with oil. The difference between the “MIN” and “MAX” marks corresponds to approximately 300 cc. The oil level must never be above the “MAX” mark! Overfilling with oil may seriously damage the engine due to excessive internal pressure. -
Page 35: Front/Rear Brake Fluid
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 FRONT/REAR BRAKE FLUID Check: every 30 days • Visual inspection is to be performed through sight glass (S) of the brake fluid reservoirs: front brake (A) and rear brake (B), when the scooter is on level ground and per- fectly upright. -
Page 36: Coolant Temperature Indicator
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE COOLANT TEMPERATURE INDICATOR Coolant temperature is shown on the left-hand side of the display by a specific Bar Graph function. If the temperature is too high, an alarm condition is signalled by a flashing symbol and warning light on the display on the left-hand side of the instrument panel. -
Page 37: Spark Plug
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 SPARK PLUG Replacement: every 6000 km Recommended type of spark plug: NGK DR8EA The spark plug is an important engine component. • Proper care of the spark plug is essential to maintain the engine in perfect working order. -
Page 38: Adjusting
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE ADJUSTING THE REAR SHOCK-ABSORBERS • The rear shock absorbers feature a spring preload ad- justment facility that allows you to adjust suspension performance in relation to the load, type of riding, and road conditions. -
Page 39: Checking The Pads And Discs Of The Front/Rear Brakes (Condition And Wear)
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 CHECKING THE PADS AND DISCS OF THE FRONT/REAR BRAKES (condition and wear) • It is good practice to check the front/rear pads and discs MIN 2 mm every 2,000 km. • Minimum thickness of the brake pads is 2 mm. -
Page 40: Headlight
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE HEADLIGHT • To increase night-time visibility the scooter is equipped with quartz (halogen) headlight bulbs. • Low beam/high beam (A) 12V - 35/35 W halogen bulb (HS1) • Parking light (B) 12V - 5W bulb (W5W) For details on the light controls refer to the relative head- ing. -
Page 41: Front Turn Indicator
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 REPLACING THE HEADLIGHT BULBS Replacing low beam / high beam headlight bulbs and parking light bulb • Remove upper fairing by undoing the 4 screws (V). Low beam / high beam bulbs (A) •... -
Page 42: Changing The Front Turn Indicator Bulb
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE CHANGING THE FRONT TURN INDICATOR BULB • Undo screw (V) (right or left, depending on which bulb you need to replace) responsible for securing the handlebar casings; • use both hands to separate the two casings;... -
Page 43: Replacing The Taillight Bulbs
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 REPLACING THE TAILLIGHT BULBS • Remove the taillight cover (D) by undoing the 2 screws (V). Take care not to scratch the cover. Parking light (A) • Remove the bulbholder from the inside of the taillight;... -
Page 44: Number Plate Light
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE NUMBER PLATE LIGHT • Number plate light (A) 12V - 5W bulb (W5W) To check that number plate light (A) is working, set the light switch (on the right-hand side handlebar control) to its central position and turn the key to starting position. -
Page 45: Fuses
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 FUSES • The electrical equipment includes eight fuses protect- ing the main components against faults. The fuses are located in the glove compartment. Fuses: A) 15 A Lights B) 7.5 A Brake light+Indicators... -
Page 46: Battery (12V - 12Ah)
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE BATTERY (12V - 12AH) The battery housing is in the central channel. INSTALLING THE BATTERY • Take a fully charged battery; • apply the adhesive strip supplied with the scooter as shown in figure, removing the two protective films from the ends of the adhesive area, as shown by the arrow in the drawing (A);... -
Page 47: Removing The Battery
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 • fit the battery and ensure it is correctly seated; • connect the battery cables; • connect: the positive pole (+) to the RED cables ; the negative pole (-) to the BLACK cables;... -
Page 48: Troubleshooting
FRAME AND RUNNING GEAR PASSWORD 250 MAINTENANCE TROUBLESHOOTING • If the scooter malfunctions, perform the checks and operations proposed by this Manual. FAULTY BRAKE SYSTEM Scooter fails to brake or excess lever travel. • For both hydraulic brakes, check the fluid level in the master cylinder reservoirs on the handlebars, and if necessary, top up or bleed the circuit. -
Page 49: Cleaning
FRAME AND RUNNING GEAR MAINTENANCE PASSWORD 250 CLEANING To keep all parts of your scooter in perfect working order it is important to clean it properly. • Before cleaning, protect the exhaust pipe terminal and make sure that the spark plug is fitted and the fuel and oil tank caps are properly closed. -
Page 50: Accessories
Authorised MALAGUTI Centres. • MALAGUTI Spa is released from all liability for damage to the vehicle or to the user due to installation of non-original accessories. Likewise, MALAGUTI Spa is released from all liability for damage to the vehicle or harm to the user due to improper installation of accessories (including genuine original accessories). -
Page 51: Disassembly
REMOVAL FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 INSTRUMENT PANEL WINDSHIELD • Remove the two covers (A) taking care not to snap off the tabs holding them in place. • Undo screws (V4) and remove the windshield. • Recover the rubber grommets under the screws. -
Page 52: Instrument Panel
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Remove the handlebar cover (A) upwards complete with the instrument panel. Take care not to damage instrument panel connector cable (B). INSTRUMENT PANEL • (Remove windshield). • (Remove upper handlebar cover). • Detach the connector (B). -
Page 53: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ACCESSIBILITY Removing the front handlebar cover and instrument panel provides access to the following components: • Instrument panel connector (A). • Connector for LH handlebar control (B). • Connector for RH handlebar control (C). -
Page 54: Ambient Temperature Sensor
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 AMBIENT TEMPERATURE SENSOR • (Remove windshield). • (Remove upper handlebar cover). • Detach connector (A). • Remove sensor (B) from lower handlebar cover (C). The sensor must be mounted EXTERNAL- LY to the lower handlebar cover as shown in the figure. -
Page 55: Right-Hand Control
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 RIGHT-HAND CONTROL • (Remove windshield). • (Remove upper handlebar cover). • Disconnect throttle opening (A) and closing (B) cables. • Undo screw (V) and remove counterweight. • Undo screws (V2) and remove throttle control. -
Page 56: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Grip front fairing (A) and lift the lower part slightly and disconnect connector (B); now remove the fairing. When refitting take care not to pinch the headlight cable. ACCESSIBILITY Removing the front fairing provides access to the follow- ing components: •... -
Page 57: Headlights
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 HEADLIGHTS • (Remove front fairing). • Undo screws (V6) and remove headlights. To change the bulbs refer to “Replacing headlight bulbs” (page 42) GRILLE • (Remove front fairing). • Undo screws (V4) and remove grille (B). -
Page 58: Front Mudguard
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FRONT MUDGUARD • Undo screw (V) and remove nut (D) responsible for securing hydraulic hose clamp (A). • Unscrew screws (V4) on the underside of the mud- guard. • Remove the mudguard, sliding it through the forks and taking care to protect from scratching. -
Page 59: Speedometer Sensor
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 SPEEDOMETER SENSOR • Undo screw (V) ensuring the spacer does not fall. • Disconnect the electronic transmission connector (See “Systems” section). When refitting, use a feeler gauge to check that the sensor - disc gap is 1¸2 mm. -
Page 60: Checking Front Brake Wear
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 CHECKING FRONT BRAKE WEAR • Use this opportunity to check the brake discs for wear. If they are scored or unevenly worn, they can be re- ground. If disc thickness has worn to less than 4.5 mm the discs must be changed. -
Page 61: Front Wheel
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FRONT WHEEL Before disassembly, support the frame at the centre to prevent the scooter from fall- ing. • (Remove speedometer sensor). • (Remove front brake calliper). • Loosen screw (V). • Unscrew and remove wheel spindle (A), paying atten- tion to spacer (B). -
Page 62: Front Brake Disc
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FRONT BRAKE DISC • (Remove speedometer sensor). • (Remove front brake calliper). • (Remove front wheel). • Undo screws (V6). When reassembling, use new screws and apply a high strength threadlocker. 11 ± 10%... -
Page 63: Left And Right Half Shield
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 LEFT AND RIGHT HALF SHIELD • (Remove front fairing). • Remove rubber mats (A). • Undo screws (V4). 09/05... - Page 64 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Undo screws (V4). • Undo screw (V1). Pay attention: screw (V1) is internal and con- cealed by the fairing. Remove the half shield. 09/05...
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Page 65: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ACCESSIBILITY Removing the right-hand half shield provides access to the following components: • Fuse connections (A). • Horn (B). • Keyswitch connector (C). • Connector (D): provision for anti-theft system. • Odometer sensor connector (E). -
Page 66: Horn
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 Removing the left-half shield provides access to the fol- lowing components: • Coolant hoses (F). HORN • (Remove right-hand half shield). • Undo screw (V) and disconnect the cables. For subsequent reassembly, connect BLUE... -
Page 67: Right And Left Lateral Sub Panels
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 RIGHT AND LEFT LATERAL SUB PANELS • (Remove rubber mats). • Undo screws (V2). • Grasp lateral sub panel (A) and disengage it from foot- board attachment point (B) by turning it outwards. -
Page 68: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ACCESSIBILITY Removing the right-hand sub panel provides access to the following components: • Seat lock transmission (A). NOTE If you need to open the helmet compartment WITHOUT the key, remove rubber protection (B) and then pull the two control cable sheaths. -
Page 69: Cdi" Control Unit
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 Removing both sub panels provides access to the follow- ing components: • “CDI” control unit (D) • Voltage regulator (E) “CDI” CONTROL UNIT • Free connector (A) by pulling purple tab (B); then dis- connect the connector. -
Page 70: Voltage Regulator
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 VOLTAGE REGULATOR • Disconnect connector (A) by pressing the tab. • Undo screws (V2) and remove regulator (B). 09/05... -
Page 71: Battery Compartment Tunnel Cover
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 BATTERY COMPARTMENT TUNNEL COVER • Undo screws (V4). • Gently pull tunnel cover (A) towards the front of the scooter to remove it. 09/05... -
Page 72: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ACCESSIBILITY Removing the tunnel cover provides access to the fol- lowing components: • Starter motor relay (A). • Flasher unit (B). • Starter motor disconnection relay (C) (WHITE). • Fuel pump relay (D) (BLACK). -
Page 73: Battery
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 BATTERY See “Installing the battery”. Note that: - the battery leads are routed through opening (A) in the rear of the cover; - cover (B) can be removed ONLY if all battery leads are disconnected;... -
Page 74: Sub-Fairing
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 SUB-FAIRING • (Remove half shields). • (Remove front mudguard). • Undo screws (V2a). • Undo screws (V2b). • Undo screw (Vc). Screws (V2a) and (Vc) are equipped with bushes that must be recovered when the screws are removed. -
Page 75: Lower Fairing
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 LOWER FAIRING • (Remove upper fairing). • (Remove front half fairings). • (Remove sub-fairing). • Remove keyswitch cover (A), rotating it counter-clock- wise through ¼ of a turn. • Open the luggage compartment and undo fusebox screws (V2). - Page 76 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Undo bag hook screws (V2). • Undo screw (V). • Undo screw (V). 09/05...
- Page 77 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Disengage the tab that secures the lower fairing to the footboard, pull lower edge (B) of the lower fairing to- wards the front of the scooter; also disengage screw inserts (C). • Make sure the luggage compartment is CLOSED; now rotate lower fairing (D) slightly towards the rear of the scooter and remove by lifting upwards.
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Page 78: Footboard
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FOOTBOARD • (Remove the battery compartment tunnel cover). • (Remove the battery). • (Remove the sub-panels). • (Remove right/left half fairings). • (Remove lower fairing). • Undo screws (V4). • Rotate footboard (A) upwards and remove. -
Page 79: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ACCESSIBILITY Removing the footboard provides access to the following components: • Coolant expansion tank (A). • Fuel pump (B). • Side stand switch connector (C). • Fuel pump connector (D). 09/05... -
Page 80: Coolant Expansion Tank
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 COOLANT EXPANSION TANK • (Remove upper fairing). • (Remove upper half fairings). • (Remove mudguard). • (Remove sub-fairing). • (Remove lower fairing). • (Remove footboard). DANGER OF BURNS! Before proceeding, make sure that the cool- ant temperature is lower than 50°C. -
Page 81: Side Stand
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 SIDE STAND • Detach springs (A) and undo screw (V). 20 ± 15% SIDE STAND SWITCH • Undo screws (V2). 5 ± 20% • Disconnect connector (A) under the footboard on the right-hand side of the scooter. -
Page 82: Centre Stand
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 CENTRE STAND Prop up the centre of the scooter to prevent it from falling. • Detach two springs (A). • Remove snap ring (B), washer (C) then remove pin (D). When reassembling, ALWAYS insert washer (C) UNDER the snap ring. -
Page 83: Fuel Pump
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FUEL PUMP • (Remove upper fairing). • (Remove upper half fairings). • (Remove mudguard). • (Remove sub-fairing). • (Remove lower fairing). • (Remove footboard). Obtain two Ø 5 mm plugs. DANGER During this procedure do not use heat and keep sparks and naked flames well clear of the scooter. -
Page 84: Radiator
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 RADIATOR • (Remove upper fairing). • (Remove upper half fairings). • (Remove sub-fairing). • (Remove lower fairing). DANGER OF BURNS! Before proceeding, make sure that the cool- ant temperature is lower than 50 °C. - Page 85 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Undo screws (V4). • Undo screws (V2). • Remove clamps (C). NOTE For the subsequent assembly phase the clamps must be positioned immediately be- hind the point at which the metal pipe diame- ter increases.
- Page 86 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 NOTE Use pliers (Beta 1472 FS) to remove the clamps. • Detach rubber hoses (D) from metal pipes. NOTE To facilitate this operation prise the hose by inserting a screwdriver under it while simul- taneously pulling it.
- Page 87 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Disconnect fan connector (H). • Remove the radiator by pulling it downwards. • Detach Faston connectors from the two thermal switch- es (M). • Remove also radiator support partition(L). The two thermal switches (M) are marked...
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Page 88: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ACCESSIBILITY Removing the radiator and relative support partition pro- vides access to the following components: • Keyswitch connector (A). • Odometer pickup connector (B). • Headlights connector (C). • Anti-theft system connector (D) (provision). -
Page 89: Radiator (Assembly)
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 RADIATOR After having refitted the radiator and filled the cooling system by pouring coolant into filler point (A), bleed air from the system as follows: loosen screw (V) and allow ALL THE AIR to escape; now tighten screw (V). -
Page 90: Keyswitch
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Replenish the radiator coolant and then close filler cap (A). • Start the engine and run it at IDLE speed for a few minutes then switch off and unscrew the bleed screw again to vent any residual air. -
Page 91: Seat
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 SEAT • Release the seat lock with the key and tip it to its open position. • Unscrew nuts (D2) and remove the seat, resting it on a supporting surface with the upholstery upwards. -
Page 92: Seat Lock
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 SEAT LOCK • (Remove seat). • (Remove helmet compartment). • Raise rear of helmet compartment (A) slightly. • Remove nut covers (B) and disengage transmission cable (C) from metal clamp (D). NOTE Make a mental note of the path followed by... -
Page 93: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ACCESSIBILITY Removing the helmet compartment provides access to the following components: • Fuel tank (A). • Fuel level sensor (B). • Fuel suction filter (C). • Carburettor valve cover (D). • Automatic choke connector (E). -
Page 94: Fuel Level Sensor
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FUEL LEVEL SENSOR • (Remove seat). • (Remove seat lock). • (Remove helmet compartment). • Open clamp (A) and free the electrical cable; discon- nect connector (B) and undo screws (V4). During this procedure do not use heat and keep sparks and naked flames well clear of the scooter. -
Page 95: Pillion Grab Handle
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 PILLION GRAB HANDLE • (Remove seat). • (Remove helmet compartment). • (Remove seat lock). • Undo screws (V2) and (V) and remove handle (A). 43 ± 15% 43 ± 15% When refitting the grab handle, pay atten-... -
Page 96: Taillight
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 TAILLIGHT See “Replacing the taillight bulb” (page 44) To remove the complete unit first free the electrical cables from cable tie (A); now de- tach connector (B) located under the pillion grab handle (see “Pillion grab handle”). - Page 97 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 TAILLIGHT • Insert the electrical cable through opening (A). • Fit the taillight unit, paying attention to attachment point (B) in the scooter number plate holder rear fairing; the attachment point must interlock with tab on the tail- light.
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Page 98: Number Plate Light
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 NUMBER PLATE LIGHT See “Replacing the number plate light bulb” (page 45). • (Remove taillight). • Open clamp (A) and free the electrical cable. At the time of reassembly the electrical ca- ble must be restrained in the clamp again. -
Page 99: Rear Fairing
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 REAR FAIRING • (Remove seat). • (Remove helmet compartment). • (Remove seat lock). • (Remove taillight). • (Remove pillion grab handle). • (Remove battery compartment tunnel). • Undo screws (V2). • Undo screws (V4). - Page 100 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 The figure shows the rear fairing with an indication of ALL the screws to be removed. 09/05...
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Page 101: Accessibility
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ACCESSIBILITY Removing the rear fairing provides access to the follow- ing components: • Fuel filter (A). • Flywheel connectors (B). • Ground terminal (C). 09/05... -
Page 102: Fuel Tank
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FUEL TANK • (Remove battery compartment tunnel). • (Remove seat). • (Remove helmet compartment). • (Remove pillion grab handle). • (Remove rear fairing). • (Remove fuel level sensor). DANGER During this procedure do not use heat and keep sparks and naked flames well clear of the scooter. - Page 103 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Undo screws (V4). There is a bushing (C) under each screw (V4). The tank support must rest on a rubber SilentBlock (D); ensure the rubber mount does not fall. Fit the electrical cable ties under the two rear screws when refitting the fuel tank.
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Page 104: Silencer
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 SILENCER Before working on the silencer and the ex- haust manifold wait until all the components have cooled down and always wear suita- ble protective gloves. • Undo exhaust manifold nuts (D2). 30 ± 10% •... - Page 105 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 The procedure for disassembling the components of the exhaust unit is illustrated in the figure. When refitting the silencer always renew gasket (A) and check the condition of gas- ket (B). Note that before separating the silencer from the exhaust pipe you must FIRST remove the wire heat shield (C).
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Page 106: Rear Shock Absorbers
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 REAR SHOCK ABSORBERS Before removing the rear shock absorbers support the centre of the frame to prevent the scooter from falling. • First undo lower screw (Va); then upper screw (Vb). 24 ± 15% 45 ±... -
Page 107: Rear Mudguard
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 REAR MUDGUARD • Undo screws (V2). 3,5 ± 20% • Undo screw (V). • Undo screw (V) then remove mudguard towards rear of scooter. 09/05... -
Page 108: Rear Brake Calliper
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 REAR BRAKE CALLIPER • Undo screws (V2). • Undo brake fluid line screw (V) and detach brake line from calliper. When reassembling, renew the gaskets of the brake fluid line screw. 20 ± 10% 30 ±... -
Page 109: Rear Wheel
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 REAR WHEEL • (Remove silencer). • (Remove right-hand rear shock-absorber). • (Remove mudguard). • (Remove rear brake calliper). • Undo nut (D) with washer and screws (V2). 45 ± 15% 135 ± 15% •... - Page 110 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 NOTE To replace bearing (D) located inside the swin- garm use a puller tool after having removed snap ring (E). • Remove rear wheel (F). Spacer (H) is located on shaft (G) behind the wheel.
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Page 111: Rear Disc
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 REAR DISC • (Remove silencer). • (Remove rear brake calliper). • (Remove right-hand shock absorber). • (Remove rear mudguard). • (Remove rear wheel). The thickness of the rear brake disc must NEVER be less than 3.5 mm; otherwise, RENEW THE DISC. -
Page 112: Filter Box
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FILTER BOX • (Remove seat). • (Remove helmet compartment). • Open the clamp and disconnect oil vapour recovery hose (A). • Open the clamp and disconnect hose (B) for “A.I.S.” valve (Air Induction System). - Page 113 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Undo screw (V). • Undo screw (V) working through opening (D). 09/05...
- Page 114 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Remove filter box (E) from the scooter, prising gently in carburettor connection point (F). • Undo screws (V7) to open the filter box. • The sequence for disassembling the filter box compo- nents is shown in the figure.
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Page 115: Pillion Footrest
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 PILLION FOOTREST • Undo screws (V2) and remove plastic cover (A). • Remove ring (B) and withdraw pivot pin (C). • Remove footrest (D). • To remove rubber covers (E) undo screws (V2). -
Page 116: Engine
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 ENGINE • (Remove silencer). • (Remove rear mudguard). • (Remove number plate holder rear fairing). • (Remove rear wheel). • (Remove filter box). • (Remove fuel tank). Before proceeding with the disassembly op- eration prop up the centre of the frame to prevent the scooter falling. - Page 117 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Unscrew clamp (F). • Detach hose (G) from water pump (P). Before disconnecting hose (G), empty the cooling system (see “Removing the radia- tor”). • Disconnect cap from spark plug (H). • Disconnect wires (L) from starter motor.
- Page 118 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Insert a jack under the engine and raise it until it is in contact with the engine; now unscrew nut (M) and re- move engine mounting bolt (N). • Lower the engine by acting on the jack and then re- move it from the rear of the scooter.
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Page 119: Brake Master Cylinders
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 BRAKE MASTER CYLINDERS Empty the brake fluid circuit, draining the fluid into a suit- able container for disposal in compliance with statutory environmental legislation. Beware of possible spills and splashes of brake fluid. Brake fluid is highly corrosive and can cause personal injury and damage painted parts of the scooter. -
Page 120: Handlebars
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 HANDLEBARS • (Remove windshield). • (Remove upper handlebar cover). • (Remove front/rear brake master cylinders). • Cut all cable and hose ties. • Disconnect connectors (A). • Disconnect cables from brake light switches (B). -
Page 121: Front Forks
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FRONT FORKS • (Remove windshield). • (Remove upper handlebar cover). • (Remove handlebars). • (Remove mudguard). • (Remove front brake calliper). • (Remove front wheel). • (Remove sub-fairing). Before proceeding with the forks disassem- bly operation, prop up the centre of the frame to prevent the scooter falling. -
Page 122: Front Stanchion
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 FRONT STANCHION RIGHT • (Remove mudguard). • (Remove wheel). LEFT • (Remove mudguard). • (Remove wheel). • (Remove brake calliper). • (Remove odometer pick-up). Before proceeding with the disassembly operation, prop up the centre of the frame to prevent the scooter falling. -
Page 123: Checking The Oil Level In The Stanchion
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 CHECKING THE OIL LEVEL IN THE STANCHION If the front suspension bottoms out or makes anomalous noises, check the oil level in the stanchions as follows: • Undo upper plug (A). • Carefully remove spring (B) and allow the oil in which it was immersed to drip off. -
Page 124: Changing The Forks Oil
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 CHANGING THE FORKS OIL • Place a container under the stanchion and remove screw (V). • Allow as much oil as possible to drain out. • Disassemble the stanchions as described above. • Turn the stanchion upside down to drain out the resid- ual oil. -
Page 125: Brake Callipers
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 BRAKE CALLIPERS Anomalous resistance or a spongy feel when operating the brake lever denote impaired operation of the brake system. NOTE The minimum thickness of the pads (front and rear brakes) is 2 mm. -
Page 126: Overhaul
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 OVERHAUL • Undo screws (V2). 20 ± 20% • Apply a low pressure jet of compressed air to the oil- way in which the brake fluid union was fitted in order to cause the two plungers to be ejected from the brake calliper body. -
Page 127: Removing The Rear Calliper
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 REMOVING THE REAR CALLIPER • Undo screws (V2). • Remove calliper assy. (A) complete with the brake hose. 30 ± 20% REPLACING THE REAR CALLIPER • Undo screw (V) and remove union (B) and relative gaskets. - Page 128 FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 • Apply a low pressure jet of compressed air to the oil- way (E) in which the brake fluid union was fitted in or- der to cause the two plungers to be ejected from their seats in the two halves of the calliper;...
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Page 129: Bleeding The Brake System
FRAME AND RUNNING GEAR DISASSEMBLY PASSWORD 250 BLEEDING THE BRAKE SYSTEM FRONT CALLIPER NOTE Position the scooter so that it is stable and perfectly level. • Remove master cylinder reservoir cover (A) (right-hand side), unscrewing the relative two screws, so that you can replenish the brake fluid. -
Page 130: Systems
SYSTEMS FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 MAIN ELECTRICAL SYSTEM BRAKE SYSTEM COOLANT SYSTEM FUEL SYSTEM THROTTLE TRANSMISSION AND HELMET COMPARTMENT LOCK NOTE The introductory figure for all systems contains a series of numbers: the numbers correspond to illustra- tions and a description of the parts in question. -
Page 131: Main Electrical System
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 MAIN ELECTRICAL SYSTEM UNDER THE INSTRUMENT PANEL UNDER THE BATTERY TUNNEL BEHIND THE RADIATOR UNDER THE HELMET COMPARTMENT ALONGSIDE THE KEYSWITCH UNDER THE REAR FAIRING UNDER THE FOOTBOARD - CONNECTORS UNDER THE HELMET COMPARTMENT... -
Page 132: Under The Instrument Panel
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 UNDER THE INSTRUMENT PANEL A - instrument panel B - front brake (switch) C - rear brake (switch) D - LH switch E - temperature sensor F - RH switch G - RH switch... -
Page 133: Alongside The Keyswitch
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 ALONGSIDE THE KEYSWITCH A - keyswitch B - anti-theft connector (provision) C - odometer pick-up data transmission connector MAIN ELECTRICAL SYSTEM 09/05... -
Page 134: Connectors Under The Footboard
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 CONNECTORS UNDER THE FOOTBOARD A - “CDI” control unit (page 70) B - voltage regulator (page 71) C - fuel pump (page 84) D - side stand switch (page 82) LEFT STANCHION A - speedometer sensor... -
Page 135: Under The Helmet Compartment
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 UNDER THE HELMET COMPARTMENT A - carburettor choke B - thermistor MAIN ELECTRICAL SYSTEM 09/05... -
Page 136: Under The Rear Fairing
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 UNDER THE REAR FAIRING A - 2-way flywheel connector (pick-up) B - 3-way flywheel connector (battery charge) C - ground terminals group UNDER THE HELMET COMPARTMENT A - fuel level sensor B - taillights/rear indicators... -
Page 137: Brake System
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 BRAKE SYSTEM FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER REAR CALLIPER FRONT CALLIPER 09/05... -
Page 138: Front Brake Master Cylinder
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 FRONT BRAKE MASTER CYLINDER (pages 56 and 120) A - washers B - brake fluid line C - brake fluid line screw REAR BRAKE MASTER CYLINDER (pages 55 and 120) A - washers... - Page 139 FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 BRAKE SYSTEM 09/05...
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Page 140: Rear Calliper
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 REAR CALLIPER (pages 109 and 128) A - calliper B - brake fluid line C - washers D - brake fluid line screw FRONT CALLIPER (pages 61 and 126) A - calliper B - brake fluid line... -
Page 141: Coolant System
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 COOLANT SYSTEM UNDER THE HELMET COMPARTMENT UNDER THE FOOTBOARD UNDER THE FOOTBOARD ENGINE LEFT SIDE 09/05... -
Page 142: Under The Helmet Compartment
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 UNDER THE HELMET COMPARTMENT A - engine/radiator hose B - air bleed screw (page 90) UNDER THE FOOTBOARD A - water pump/radiator hose B - engine/radiator hose 09/05... - Page 143 FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 COOLANT SYSTEM 09/05...
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Page 144: Under The Footboard
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 UNDER THE FOOTBOARD A - expansion tank (page 81) B - radiator/expansion tank hose ENGINE LEFT SIDE A - radiator/water pump hose B - coolant drain screw (page 90) C - water pump... -
Page 145: Fuel System
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 FUEL SYSTEM UNDER THE HELMET COMPARTMENT UNDER THE REAR FAIRING UNDER THE FOOTBOARD 09/05... -
Page 146: Under The Helmet Compartment
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 UNDER THE HELMET COMPARTMENT A - fuel suction line with filter B - tank/filter hose C - fuel level sensor (page 95) D - drip recovery hose E - fuel pump/carburettor hose F - fuel tank (page 103) -
Page 147: Throttle Transmission And Helmet Compartment Lock
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 THROTTLE TRANSMISSION AND HELMET COMPARTMENT LOCK THROTTLE CONTROL CARBURETTOR HOSE CLAMP SEAT LOCK BLOCK 09/05... -
Page 148: Throttle Control
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 THROTTLE CONTROL A - throttle opening cable B - throttle closing cable C - adjusters CARBURETTOR A - throttle opening cable B - throttle closing cable 09/05... - Page 149 FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 THROTTLE TRANSMISSION AND HELMET COMPARTMENT LOCK 09/05...
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Page 150: Hose Clamp
FRAME AND RUNNING GEAR SYSTEMS PASSWORD 250 HOSE CLAMP A - control cable B - cable gland C - clamp SEAT LOCK BLOCK A - control cable B - seat lock (page 93) C - clamp 09/05...