Malaguti Madison3 250ie, Workshop Manual

Page 1: ...WORKSHOP MANUAL FRAME AND RUNNING GEAR ...

Page 2: ...ATURE SENSOR 18 HANDLEBAR LOWER COVER 19 SUB PANEL 20 ACCESSIBILITY 21 SPEEDOMETER SENSOR 22 FRONT BRAKE CALIPER 22 Checking front brake wear 22 FRONT WHEEL 23 FRONT BRAKE DISC 25 FRONT MUDGUARD 25 FRONT FAIRING 26 ACCESSIBILITY 28 MAIN SWITCH 29 REPLACING THE HEADLIGHT BULBS 30 Low beam high beam bulbs A 30 Parking light B 30 SIDE COVERS 30 RIDER SEAT 31 PILLION SEAT 31 ACCESSIBILITY 32 BATTERY 3...

Page 3: ...AR INDEX RADIATOR 62 RADIATOR assembly 64 HORN 65 BRAKE CALIPERS OVERHAUL 65 Overhaul of rear caliper 65 Overhaul of front caliper 67 BRAKE MASTER CYLINDERS 69 BLEEDINGTHE BRAKE SYSTEM 70 Rear brake caliper 70 Front brake caliper 70 SECURING CLAMPS 71 ...

Page 4: ... reserves the right to make any changes and modifications hereto it deems necessary without prior notice MANUAL UPDATES The updates will be sent by us in a reasonable time Every CD Rom you receive will supersede the one already in your possession The table of contents will be duly updated in the event that new pages are inserted which render the consultation of the manual difficult IMPORTANT The W...

Page 5: ...ts or safety recommendations They are therefore to be considered as me mory tags In case of any doubt as to their meaning consult the page in which they are fully descri bed UNITS OF MEASUREMENT All the dimensions in this Manual are shown in mm NOTE The letter V in the illustrations refers to fixing or adjusting screws The number following this letter refers to the number of the same type of screw...

Page 6: ...nch take care to proceed as shown in the figure Except in the case of occasional services prepare a work sheet for the customer on which to take a note of all the work performed and write memos relating to any future checks that may be required RECOMMENDATIONS Before carrying out any work on the vehicle wait for all the parts to cool down completely For operations requiring two mechanics make sure...

Page 7: ...int solvents to clean the vehicle components Never suck from or blow into the fuel pipe When welding make sure that there are no flammable liquids in the vicinity Always remove the fuel tank even if completely empty and disconnect the negative cable from the battery Never leave the engine running in closed or poorly ventilated areas Before any servicing make sure that the vehicle is perfectly stab...

Page 8: ...k described disconnect the battery negative cable RISK OF FIRE Indicates operations that may constitute a fire hazard EXPLOSION HAZARD Indicates operations that may constitute a risk of explosion TOXIC FUMES Indicates the risk of intoxication or inflammation of the respiratory tract NO Operations to be absolutely avoided SYMMETRICAL OPERATIONS Operations to repeat on both sides of the unit or comp...

Page 9: ...tomatic dry centrifugal clutch secondary drive gearbox and transmis sion housing with forced circulation cooling system FUEL SYSTEM Electronic injection with electric fuel pump Fuel unleaded petrol ELECTRONIC IGNITION High efficiency inductive coil integrated with injection va riable ignition advance and separate H T coil BRAKES Front 240 mm disk with hydraulic transmission and calliper with two p...

Page 10: ...f 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 Control dimension A must be 1220 mm with a tolerance of 2 mm Do not attempt to bend the frame to restore the original A measurement ...

Page 11: ... every 2 years Correct fitting and tightness of hoses Brake fluid circuit Wheel bearings Frame linkages Steering operation and play lubricate if necessary Operation and oil tightness of fork and shock absorbers Tightness of nuts and bolts Tightness of side and centre stands Pivot lubrication Operation of side stand switch Lubrication Throttle control Tyre pressure Tread wear Final check Condition ...

Page 12: ...9035_1 A V2 D A REAR VIEW MIRRORS Lift rubber boot then undo nut D and mirror A RIGHT HAND MIRROR is fitted by screwing it COUNTER CLOCKWISE LEFT HAND MIRROR is fitted by screwing it CLOCKWISE CENTRAL FAIRING Remove panels A by prising with a screwdriver Undo screws V2 DISASSEMBLY ...

Page 13: ..._1 06039032_1 06039029_1 B A B Disengage central fairing B and remove it from sco oter rotating it forwards CHANGING THE FRONT TURN INDICATOR BULB Remove panels A by prising with a screwdriver Turn bulb holder ringnut B counter clockwise and remove Extract bulb by pulling it ...

Page 14: ...15 A 4 05 06 MADISON 3 250 ie FRAME AND RUNNING GEAR DISASSEMBLY 06039045_1 V6 V6 A WINDSHIELD Remove central fairing Undo screws V6 Remove windshield A Recover the rubber grommets under the screws ...

Page 15: ...2b Remove upper handlebar cover A ACCESSIBILITY Removing the front handlebar cover provides access to the following components Handlebar screw A connector for LH handlebar control B ambient temperature sensor connector C RH control STOP switch D LH control STOP switch E rear brake master cylinder union F front brake master cylinder union G resistance connector H steering adjustment ringnuts S ...

Page 16: ...e opening A cables Use compressed air to reduce friction when removing and refitting the twist grip At time of reassembly shorter screw V2 must be located in UPPER part of control LEFT HAND CONTROL Remove rear view mirrors Remove upper handlebar cover Disconnect switch connector Undo screw V and remove counterweight Undo screws V2 and remove LH control Use compressed air to reduce friction when re...

Page 17: ...06039021_1 06039060_1 A B C AMBIENT TEMPERATURE SENSOR Remove rear view mirrors Remove upper handlebar cover Detach the 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 18: ...1 V2 V HANDLEBAR LOWER COVER Remove rear view mirrors Remove upper handlebar cover Remove right hand control Remove ambient temperature sensor Undo screws V2 Undo screw V Remove lower handlebar cover To remove handlebar cover completely di sconnect the two right hand control con nectors ...

Page 19: ...SON 3 250 ie FRAME AND RUNNING GEAR DISASSEMBLY 06039085_1 06039082_1 06039086_1 V V4a V4b A B SUB PANEL Remove footboards A Undo screw V Undo screws V4a and V4b Remove sub panel B Screws V4a are longer than screws V4b ...

Page 20: ...RAME AND RUNNING GEAR DISASSEMBLY 06039090_1 06039088_1 06039227_1 C D B A ACCESSIBILITY Removing the sub panel provides access to the following components Ignition coil A Bank angle sensor B Radiator drain plug C Side stand switch D ...

Page 21: ...ansmission and its gaskets When reassembling replace the gaskets of the hydraulic transmission Undo screws V2 and free the complete caliper After having removed the hydraulic tran smission and the caliper from its seat pla ce a recipient under it to collect the brake fluid Dispose of used brake fluid in com pliance with statutory legislation CHECKING FRONT BRAKE WEAR Take the opportunity to check ...

Page 22: ...039095_2 D V FRONT WHEEL Before disassembly support the frame at the centre to prevent the scooter from falling For this purpose remove sub panel and pla ce a stand under frame cradles as shown Undo the nut D Pull out the spindle V then remove the wheel Pay attention to spacers located on spindle V ...

Page 23: ... figure shows sequence of components for fitting wheel Pin A Washer B Right hand spacer C Left hand spacer D Washer E Nut F Do not operate the brake lever after remo ving the wheel since the pads would come into contact with each other When refitting the wheel be sure to refit the spacers C D and grease spindle A ...

Page 24: ...E DISC Remove speedometer sensor Remove front brake caliper Remove front wheel Undo screws V5 When reassembling use new screws and apply a high strength thread locker FRONT MUDGUARD Remove front wheel Undo screws V2a and V2b Pay attention to nut on screws V2b rear screws Remove cable guide ring A from mudguard B then remove mudguard ...

Page 25: ...LY 06039107_1 06039111_1 06039115_1 Vd V6e V2c V2b V2a V2b V2a FRONT FAIRING Remove central fairing Remove windshield Remove front wheel Remove front mudguard Undo screws V2a V2b and V2c Recover the bushes located under the screws V2a Undo screw Vd Undo screws V6e ...

Page 26: ... DISASSEMBLY 06039122_1 06039125_1 06039506_1 V4 V4 V4 V2g V5f V5f V5f Undo screws V5f and V2g Pay attention to screws V4 located UNDER ticket compartment cover UNDER cover of radiator expansion vessel access compart ment and UNDER glove compartment door ...

Page 27: ...subsequent reassembly engage front fairing with metal tab C ACCESSIBILITY Removing the front fairing provides access to the following components main switch A anti theft connector provision 3 way B headlight connectors C main switch connector 6 way D odometer sensor connector E 12V power socket connector protected by foam F 12V power socket fuse 5 A G autodiagnostic serial port H coolant expansion...

Page 28: ...ntral fairing Remove windshield Disengage front fairing from lower fairing and rest it on front mudguard taking care not to damage paintwork Remove keyswitch ringnut A rotating it counter clockwise through 1 4 of a turn Undo tamperproof screws V2 using a special 4 mm hex wrench P N 08601400 then extract keyswitch E ...

Page 29: ...g LOW BEAM HIGH BEAM BULBS A Remove the wiring connector rubber cap and spring change the bulb refit the spring rubber cap and wiring connector refit the upper fairing PARKING LIGHT B Remove the rubber bulb holder change the bulb refit the rubber bulb holder by pressing and refit the upper fairing SIDE COVERS Undo screws V2 Remove side covers A To remove side cover first rotate rear part upwards i...

Page 30: ...RIDER 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 PILLION SEAT Lift rider seat Undo screws V2 Remove the seat A resting it on a supporting surfa ce with the upholstery upwards ...

Page 31: ...provides access to the following compo nents main charge circuit fuse 30 A A Battery B BATTERY See Installing the battery Note that the RED leads must be connected to the battery PO SITIVE terminal the BLACK lead must be connected to the battery NEGATIVE terminal the battery terminals must be towards the FRONT of the scooter ...

Page 32: ... 3 250 ie FRAME AND RUNNING GEAR DISASSEMBLY 06039185_1 06039188_1 D2 B A SEAT LOCK Remove nut covers and unscrew nuts D2 Extract seat lock A by pulling downwards and then disengage it from transmission cable B and remove ...

Page 33: ...195_1 B C A D V2a V2b HELMET COMPARTMENT remove rider seat remove pillion seat Remove battery Remove seat lock Undo screws V2a Loosen the screws V2b Slightly lift helmet compartment A and then extract battery cables B and disconnect fuseholder C Extract seat transmission cable D from helmet com partment ...

Page 34: ...tached to cable guide F ACCESSIBILITY Removing the helmet compartment provides access to the following components flasher relay A starter motor contactor B fan contactor C injection charge contactor D voltage regulator E rear turn indicators F taillight G rubber boot containing connector of voltage regulator H throttle body with injection control unit I helmet compartment lock L cooling system air...

Page 35: ...ry Remove helmet compartment TURN INDICATOR BULB Turn bulb holder ringnut A counter clockwise and remove Extract bulb by pulling it REAR TAILLIGHT BULB Turn bulb holder ringnut B counter clockwise and remove Extract bulb by pulling it PILLION GRAB HANDLE Remove rider seat Remove pillion seat Remove battery Remove seat lock Remove helmet compartment Undo screws V3 and remove handle A ...

Page 36: ...IRING Remove rider seat Remove pillion seat Remove seat lock Remove battery Remove helmet compartment Remove pillion grab handle Undo screws V4 Open clamps B pulling them towards rear of scoo ter Detach the connector C Remove rear fairing pulling it towards rear of scoo ter Disengage rear fairing A lifting front part ...

Page 37: ...di sengaged it from supports E ACCESSIBILITY Removing rear fairing provides access to the following components Ground terminal A Fuel vapour venting valve B When renewing or refitting fuel vapour ven ting valve B note that it must be fitted with GREEN part connected to FREE hose C i e the hose connected to vehicle frame the other side of the valve must be connected to hose D from fuel tank ...

Page 38: ...MENT PANEL Remove central fairing Remove windshield Disengage upper part of front fairing see Removing front fairing Undo screws V4 Disconnect connector A open clamp B then re move dashboard To detach the digital instrument from the dashboard undo screws V4 When refitting dashboard re secure electri cal cable under clamp B ...

Page 39: ...lmet compartment Remove pillion grab handle Remove rear fairing Remove central fairing Remove windshield Remove front wheel Remove front mudguard Remove upper fairing Remove dashboard Remove main switch cover A rotating it counter clockwise through of a turn Open the luggage compartment and undo fuse box screws V2a When reassembling note that LIGHT BLUE 15A fuse must be positioned on LEFT Undo scr...

Page 40: ...bling note that foam A must be refitted to protect connectors and soc ket Open hatch C Remove fuel tank cap D remove gasket E discon necting it from the drip hose then refit the cap Screw the fuel tank cap back on immedia tely after removing the gasket Undo screws V3d and disengage coil F from foot board If no further parts are to be removed it is not necessary to detach the coil wires ...

Page 41: ...06039267_1 06039280_1 V4e L Vf M G H Temporarily remove flasher unit G from vehicle Remove lower fairing and footboard unit H from vehi cle turning front part upwards then slide out towards rear of vehicle To detach lower fairing L from footboard M undo screws V4e and screw Vf ...

Page 42: ...ank A Side stand switch connector B MUFFLER Before working on the silencer and the exhaust manifold wait until all the compo nent shave cooled down and always wear suitable protective gloves Loosen screw V of clamp A Undo the screws V3b then remove the entire silen cer B Pay attention to spacers C located under washers D on screws V3b When refitting silencer always renew gasket between silencer an...

Page 43: ...ctive gloves Disengage Lambda probe connector A from its sup port and disconnect it Note that connector A must always be se cured to its support to ensure correct ope ration of the Lambda probe Cut clamp B unscrew nuts D2 then extract mani fold C including Lambda probe If necessary unscrew Lambda probe D from mani fold The procedure for disassembling the components of the exhaust unit is illustrat...

Page 44: ...pper screw Vs Remove shock absorber A REAR BRAKE CALIPER Undo screws V2 Undo brake fluid line screw V and detach brake line from caliper When reassembling renew the gaskets of the brake fluid line screw Pay attention to spring washer B between screw V and washer C Remove calliper A After having removed the hydraulic tran smission and the caliper from its seat pla ce a recipient under it to collect...

Page 45: ...ewed Minimum thickness of the pads is 2 mm Note For overhauling the caliper see the specific Chapter REAR WHEEL Remove silencer Remove right hand rear shock absorber Remove rear brake caliper Straighten split pin A Turn wheel until pin A is aligned with pocket then extract split pin Extract vibration damper ring B and nut cover C then unscrew underlying nut D Remove spacer E from the wheel spindle...

Page 46: ... for the bush under the screw Va Slightly lift rear mudguard F Remove swing arm G There is a spacer behind the swing arm si milar to the spacer IN FRONT of the arm the spacer must be refitted with the smal lest diameter side facing the arm NOTE To replace bearing H located inside the swing arm use a puller tool after having re moved snap ring L Remove rear wheel M ...

Page 47: ...e shaft N abundan tly especially on the splines REAR DISC Remove silencer Remove rear brake caliper Remove right hand shock absorber Remove rear wheel The thickness of the rear brake disc must NEVER be less than 3 5 mm otherwise RENEWTHE DISC Undo screws V5 When reassembling use new screws and apply a high strength thread locker ...

Page 48: ...rtment Remove rear fairing Remove rear wheel Undo screws V3a screw Vb and screws V9c now remove cover A from airbox Pay attention to nut located behind screw Vb and bushings located under screws V3a and Vb Use a TORX wrench T20 for screws Vc Loosen clamp screw B and disconnect hose C Loosen screw of clamp D Undo screws V3d Remove airbox E from vehicle prising gently in con nection point with throt...

Page 49: ...in the figure ENGINE Remove helmet compartment Remove fairing Remove silencer Remove exhaust manifold Remove shock absorbers Remove rear wheel Remove filter box Before disassembly support the frame at the centre to prevent the scooter from fal ling Disconnect flywheel connectors A Undo screw V and detach the ground cables from the frame Disconnect cap from spark plug B ...

Page 50: ... D H G Vb I Disconnect wires C from starter motor Undo screw Vb disengage hose D and underlying wiring Disconnect injection control unit connector E Disconnect hoses D and F injector connector G engine temperature thermistor connector H Disconnect connector of oil pressure switch I ...

Page 51: ... Disconnect throttle cable L Undo screw Vb and disengage clamp from engine Detach hose M from water pump Before disconnecting hose M empty the cooling system see Removing the radia tor Disconnect coolant return hose N Before disconnecting hose N empty the cooling system see Removing the radia tor ...

Page 52: ... DISASSEMBLY D 68 10 M P D Temporarily fit rear wheel on its spindle and lock tem porarily with its nut This operation will facilitate removal of en gine from scooter Undo the nut D Unhook spring M Remove pin P and extract engine towards rear of vehicle ...

Page 53: ...RUNNING GEAR DISASSEMBLY V 20 15 06039228_1 V A 06039228_1 V2 5 20 V2 06039286_1 A SIDE STAND Detach springs A and undo screw V SIDE STAND SWITCH Undo screws V2 Disconnect connector A under the footboard on the right hand side of the scooter ...

Page 54: ...eat and keep sparks and naked flames well clear of the scooter Make sure the tank is empty Before emp tying the tank wait for the engine to cool down Use a manual pump Remove fuel tank cap remove gasket A discon necting it from the drip hose then refit the cap Screw the fuel tank cap back on immedia tely after removing the gasket Disconnect fuel pump hoses B and fuel pump con nector C Undo screws ...

Page 55: ... heat and keep sparks and naked flames well clear of the scooter If the tank remains without the fuel level sensor fitted for a prolonged pe riod plug the hole to prevent the accumula tion of petrol vapour in the workshop Remove sensor B HANDLEBAR Remove central fairing Remove windshield Remove upper handlebar cover Remove lower handlebar cover Remove front rear brake master cylinders Cut all cabl...

Page 56: ... 06039402_1 A B 06039404_1 V B V4 V4 SUB FAIRING Loosen all screws V4 and remove one for each brac ket A then turn latter until to align them with ope ning in sub fairing B Undo screw V and remove sub fairing B passing slider stanchion tubes through relative opening ...

Page 57: ...re to prevent the scooter from fal ling Sever all the electrical cable ties to proceed with the operation position the brake caliper and the brake line to BEHIND the frame Undo and remove ring nut A Undo and remove underlying ring nut B Remove the fork assembly in a downward direction Support the fork to prevent them falling Pay attention because balls C may fall from their races Clean away any gr...

Page 58: ... LEFT Remove mudguard Remove upper fairing Remove wheel Remove brake caliper Remove odometer pick up Remove sub fairing Before disassembly support the frame at the centre to prevent the scooter from falling To proceed with the operation position the brake caliper and brake line BEHIND the scooter frame Undo screws V2c Remove snap ring C Remove damper tube D downwards by pulling and twisting ...

Page 59: ...ws Remove upper cover A Remove circlip B using a screwdriver to press downwards on cap C complete with O ring D Carefully remove spring E and allow the oil in which it was immersed to drip off Bring the damper F to its bottom travel limit while keeping it in a perfectly vertical position With the aid of a rule or a gauge rod check the oil level The correct level is 80 mm from the upper edge of the...

Page 60: ...he damper upside down to drain out the resi dual oil Hydraulic fluid is corrosive and can cause serious personal injury Spent oil must be disposed of in complian ce with local legislation Refit drain screw V NOTE When reassembling renew copper washer under screw V Carefully pour new oil into the damper Check the oil level as described above Reassemble the damper components and then refit the dampe...

Page 61: ...OF BURNS Before proceeding make sure that the coo lant temperature is lower than 50 C Open expansion vessel cap A Place a 5 l recipient under the scooter Remove screw V and wait for ALL the coolant to flow out If you need to empty coolant system WITHOUT having to remove radiator e g when dropping engine drain out liquid by detaching one of the hoses from the pump ...

Page 62: ...position of screw V with respect to its hole Remove rubber protection then undo screw V and allow coolant to continue to flow from radiator cap Marking position of screw V eliminates risk of overtightening it at time of reassembly Disconnect hoses C from radiator and also discon nect fan connector Undo screws V2b and remove the radiator E ...

Page 63: ...ystem by pouring coolant into filler point A bleed air from the system as follows loosen screw V and allow ALLTHE AIR to escape now tighten screw Do not tighten screw V past the mark you have made with pen or thread may be da maged 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...

Page 64: ...reassembly connect BLUE wire to the horn INTERNAL terminal and ORANGE wire to the EXTERNAL terminal BRAKE CALIPERS OVERHAUL OVERHAUL OF REAR CALIPER Remove retaining ring A of brake pad pin B Remove pad pin B EsRemove spring C and the two pads D NOTE Note that the minimum thickness of the pads is 2 mm Spring C and pads D are marked with an arrow to show the position of the disc with respect to the...

Page 65: ...ll Remove wiper seal H and oil seal L in both caliper halves taking care not to damage the relative grooves Check that the plungers and their seats are undama ged Clean the parts thoroughly and flush with exclusively alcohol Always fit new wiper seals and new oil seals Refit the plungers the O rings the retaining rings and the wiper seals lubricating the parts with brake fluid NOTE After working o...

Page 66: ... NOTE The brake pads can be removed and chan ged without having to disassemble the brake calipers from the scooter Undo screws V2 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 caliper body Excessive air pressure will result in exces sively violent ejection of the two plungers A ...

Page 67: ...exclusively alcohol Always fit new wiper seals and oil seals Refit the plungers oil seals C and wiper seals B lubri cating with brake fluid After terminating the inspection cleaning and replace ment procedures refit all the parts in reverse sequence with respect to the sequence of disassembly NOTE After working on the braking system always check that the brake fluid lines are not damaged cru shed ...

Page 68: ...s of the scooter Remove upper handlebar cover Unscrew and remove union A Remove brake fluid line B and gaskets C Disconnect brake light switch S Undo screws V2 and remove U clamp D Remove master cylinder unit E To refit the master cylinder first start the lower screw using a long T handle wrench without tightening it and then start the upper screw then tighten both screws to the prescribed torque ...

Page 69: ... the rubber tube Replenish the brake fluid level in the reservoir While bleeding the brakes ensure that no brake fluid comes into contact with the sco oter bodywork risk of damage In addition while bleeding the brake calipers avoid con tamination of brake discs or pads with brake fluid Failure to comply with this prescrip tion will have a negative effect on the effi ciency of the brake system If t...

Page 70: ...gether with an indication of the component they fasten in some cable harnesses the position of the clamp is shown by means of coloured adhesive tape 1 Handlebar wiring harnesses RH switch Lh switch 2 Handlebar wiring harnesses front brake hydraulic fluid line rear brake hydraulic fluid line 3 Breather tube to expansion tank 4 Throttle transimission 5 Sidestand switch wiring 6 Fuel tank air breathe...

Page 71: ...EAR DISASSEMBLY 06039285_1 5 2 2 3 1 06039286_1 1 1 2 4 06039288_1 1 Main wiring harness 2 Rear brake hydraulic fluid line 3 Fuel pump delivery and return tubes 4 Rubber boot protecting voltage regulator connector 5 Frame right hand side wiring fixing ...

Page 72: ...73 A 4 05 06 MADISON 3 250 ie FRAME AND RUNNING GEAR DISASSEMBLY 06039339_1 1 2 06039320_1 3 1 Lambda sensor wiring 2 Coil cable Sidestand switch wiring 3 Bank angle sensor wiring ...