User manual MALAGUTI MADISON 180-200

[. . . ] The present warehouse manual includes all main electro-mechanical tests, indispensable controls and assembling of loose supplied spare parts in order to carry out delivery of this brand new motorbike (the sequence of operations to be carried out is not a difficult one). t s ey motn · I i v r i p r a t to carefully observe what described herewith. Interventions, which are superficially carried out, or even omitted, can cause injuries to buyer, damages to the motorbike, etc. OPERATIONS Idcts ta te oeain niae ht h prto must be repeated on the opposite side of the unit or component. [. . . ] Sooty black mat d p s t , dry (to the touch), are a sign that working temperature is too low, i. A whitish c l u o t e i s l t r i i d c t v o too lean a m x u e o o too low a heat range of the spark plug (ie, oor f h nuao s niaie f itr r f . If need be, adjust by acting only on the earth electrode electrode. Clean the electrodes and the insulator thoroughly by means of a wire brush. Remove any residual dirt with a strong jet of compressed ar i. Lubricate spark plug thread with engine oil or graphitized ges, adisali b hn utlfne tgt rae n ntl t y ad ni igr ih. Upon prescribed mileage being reached, always plug. When replacing exhausted spark plugs, visually inspect spark plug condition as described above to ascertain whether or not the engine is running properly. For removal of the engine from the frame, refer to the "cycle" shop manual which lists all the operations required. The manufacturer declines all responsibility for damage of any kind caused by disassembly and reassembly of the engine and its parts if unsuitable tools ar used. Rest for driving shaft inspection Heat gun rest Heat gun Oil pressure gauge Crankcase separation plate Sheath for driven pulley Band for piston installation (125 cc) Punch for valve oil seal Tester Immobilizer Vacuum pump MITY-VAC Stroboscopic lamp Speed indicator Single battery charger Multiple battery charger Magnetic support with test indicator Adapter 32x35 for installation of driven pulley shaft bearing Adapter 42x47 for hub bearings installation Adapter 52x55 for hub bearings installation 20 mm guide for hub bearings installation 25 mm guide for installation of ball bearing of driven pulley Stop wrench for driving pulley (125 cc) Adapter 28x30 for installation of ball bearing of driven pulley Handle for adapters Tool for valve disassembly Band for piston installation (180 cc) 15 mm guide for hub bearings installation 28 mm guide for hub bearings disassembly Clutch bell stop wrench Roller case punch of driven pulley Punch for oil seal installation on flywheel side Support fork for piston Support for piston projection Pressure gauge connector 17 mm guide for installation of shock absorber support bearing Water pump overhaul Driving pulley stop wrench (180 cc) Compressor tool for driven pulley Isalto to frpso pnlcs ntlain ol o itn i ok (180 cc) 10 mm guide Compass wrench Ple ulr Engine support Flywheel puller Exhaust gas analyser Support pour contrôle de l'arbre moteur Support pour pistolet thermique Pistolet thermique Manomètre pour le contrôle de la pression d lhie e 'ul Plaque de séparation du carter Gaine pour poulie conduite Gaine pour le montage du piston (125 cc) Pointeau pour pare-huile soupape Testeur immobilizer Pompe à vide MITY-VAC Lampe stroboscopique Compte-tours Chargeur de batterie simple Chargeur de batterie multiple Support magnétique avec comparateur Adaptateur 32x35 montage coussinet arbre poulie conduite Adaptateur 42x47 montage coussinets moyeu Adaptateur 52x55 montage coussinets moyeu Glissière de 20 mm montage coussinet moyeu Glissière de 25 mm montage coussinet à billes poulie conduite Clé d'arrêt de la poulie motrice (125 cc) Adaptateur 28x30 montage coussinet à billes poulie conduite Manchon pour adaptateurs Outil pour la dépose des soupapes Gaine pour le montage du piston (180 cc) Glissière de 15 mm montage coussinets moyeu Glissière de 28 mm montage coussinets moyeu Clé d'arrêt pour cloche d'embrayage Pointeau poche à rouleaux poulie conduite Pointeau pour le montage du pare-huile du côté du volant Fourche d'appui pour piston Support pour saillie de piston Raccord pour manomètre Glissière de 17 mm montage coussinet support amortisseur Révision de la pompe à eau Clé d'arrêt poulie motrice (180 cc) Outil compresseur poulie conduite Outil pour le montage des arrêts de l'axe (180 cc) Glissière de 10 mm Clé à compas Extracteur Support moteur Extracteur pour volant Analyseur des gaz d'échappement Main features Technical specifications General information and maintenance Egn oladolfle nie i n i itr Ollvl i ee inspection Oladolfle i n i itr change Hub oil level inspection and change Spark plug Tappet cover disassembly Timing inspection Inspection/adjustment of the valve clearance Tappet cover assembly Inspection of the end compression pressure Into tmn giin iig inspection Transmission Transmission cover Fan case Intake disassembly Bearing of the driven pulley shaft Assembly of the bearing of the driven pulley shaft Bl rl et ol Roll disassembly Roll reassembly Disassemly of the engine driven pulley Clutch bell inspections Clutch disassembly Pins stop cla olr Bearings of the fixed driven half-pulley Fixed driven halfpulley Mobile driven halfpulley Assembly of the bearings of the fixed die hl-uly rvn afple Montage du couvercle Montaje cárter des poussoirs de soupape empujaválvulas Contrôle de la pression de fin de compression Contrôle de l'avance à l'allumage Transmission Couvercle de la transmission Petit carter du rotor Dépose de la bouche d'aspiration Coussinet de support arbre poulie conduite Montage du coussinet de support arbre poulie conduite Rouleau d'appui courroie Dépose du rouleau Assembly of the driven pulley Spring Clutch assembly Diigbl rvn et Mobile driving hl-uly afple Assembly of the fixed diig hl-uly rvn afple Assembly of the mobile halfpulley and bush Assembly of the fixed driving pulley Cluch bell assembly Assembly of the transmission cover Rear hub Disassembly of the wheel axle Bearings of the hub case Coussinets boîte moyeu Cojinetes tapacubo Disassembly of the wheel axle bearing on the cover Disassembly of the driven pulley shaft Assemble of hub case bearings Assemble of the bearing of the driven pulley axle Inspection of the hub cover Assembly of the wheel axle bearing on the cover Iseto o npcin f te hb sat h u hfs Assembly of hub gears Assembly of the hub cover Flywheel Disassembly of the Dépose du couvercle complete flywheel cover complet du volant Flywheel disassembly Stator disassembly Stator inspection Inspection of the oil Contrôle de l'interrupteur de Control interruptor de minimum pressure switch pressione minimale de l'huile presión mínima aceite Pick-Up inspection Assembly of the complete flywheel cover Lubrication Oil pressure inspection Oil pan disassembly Removal of the presDépose du bipasse de sure adjustment by-pass reglage de la pression By-Pass inspection Oil pump disassembly Cylinder, head and timing system Disassembly of the intake manifold Thermostat disassembly Disassembly of the timing system control Disassembly of the camshaft and rocker arms Head disassembly Valve removal Cylinder and piston removal Small end inspection Piston pin diameter Piston Seal rings Pso isalto itn ntlain Check of the piston position Assembly of seal rings Cylinder assembly Head inspection Inspection of the valve wear Inspection of the wear of the valve seatings Valve inspection Valve Tightness ts et Inspection of the springs of the cotters Valve installation Inspection of the timing components Camshaft inspection Installation of head and timing components Assembly of the timing components Thermostat assembly Assembly of the intake manifold Crankcase and driving shaft Opening of the engine crankcase Inspection of the driving Contrôle de l'alignement shaft alignment de l'arbre moteur Inspection of the engine Contrôle du demi-carter half casing du moteur Journal brasses inspection Closing of the engine crankcase Assembly of the starting motor Fuel system and carburetor Air cleaner Carburetor disassembly Carburetor assembly Level inspection Inspection of the depression valve and of the conical pin Inspection of the automatic satr tre Il de adjusting Cooling system Water pump disassembly Components inspection Water pump assembly Thermostat inspection Microprocessor from 10° ±1 to 2000 r/1' 30° ±1 from 4000 to 7000 r/1' 35° over 7000 r1. OIL LEVEL INSPECTION -Start the engine and take it to the operative temperature. 5 ÷ 10 minutes until the oil flows into t eo lp n h i a. -Remove the cap/rod and clean it , te srwi tgt hn ce t ih. -Remove the cap/rod and check that the oil level is between the MIN and MAX reference marks (F. OIL AND OIL FILTER CHANGE Note - The engine oil has to be changed when the engine is warm. -Drain the oil removing the drain plug and/or the plug which gives access t t ep e f l e ( . -Remove and clean the pre-filter with compressed air. -Lubricate them and install again the p e f l e a dt ep u , t g t n n i t r-itr n h lg iheig t o the specified torque. -Install a new cartridge filter and do not forget to lubricate the O-ring before the installation; screw to the gasket contact point, tightening by hand. Ls h i ilr lg -Start the engine in order to load the filter and the lubrication system. -To change the oil, remove the drain plug shown in the picture and let oil completely flow. [. . . ] Much higher values may result from the engine misfire due to a too weak mixture (low CO), to ignition defects, to an incorrect timing or to a dump valve stumbled or unsealed. WATER PUMP DISASSEMBLY -In case of noise due to bearings or if you notice fluid blow-by from the exhaust hole inside the cover, inspect the water pump. -Remove the flywheel cover complete with water pump. -Position the flywheel cover on the ring base which is part of the tool, drawing n 19. [. . . ]