Malaguti Password 250 i.e., Workshop Manual

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

Page 2: ......

Page 3: ...TMENT 18 INSTRUMENT PANEL 19 DIGITAL INSTRUMENT PANEL 20 FUNCTION SELECTION ANDWARNING OR ALARM SIGNALS 21 Secondary menu or submenu 21 Main menu 23 Bar graph 23 Alarms function 24 MILES OR KILOMETRES SELECTION 25 HANDLEBAR CONTROLS 25 Right hand control 26 Left hand control 26 KEYSWITCH 27 HANDLEBAR LOCK 27 Locking 27 Unlocking 27 STANDS 28 Centre stand 28 Side stand 28 OWNER STOOLKIT 29 DIMENSIO...

Page 4: ... HORN 64 RIGHT AND LEFT LATERAL SUB PANELS 65 ACCESSIBILITY 66 VOLTAGE REGULATOR 67 CDI CONTROL UNIT 67 BATTERY COMPARTMENTTUNNEL COVER 68 RIGHT SIDE ACCESSIBILITY 69 LEFT SIDE ACCESSIBILITY 69 BATTERY 70 SUB FAIRING 71 LOWER FAIRING 72 FOOTBOARD 75 COOLANT EXPANSIONTANK 76 SIDE STAND 77 Side stand switch 77 CENTRE STAND 78 MAIN ELECTRICAL SYSTEM 79 RADIATOR 80 FAN UNIT 83 RADIATOR assembly 83 KEY...

Page 5: ...T DAMPER 116 Right 116 Left 116 Checking the oil level in the damper 117 Changing the fork oil 118 BRAKE CALIPERS 119 Removing the front caliper 119 Changing the front caliper 119 Overhaul 120 Removing the rear caliper 120 Replacing the rear caliper 120 Rear caliper disassembly 120 BRAKE SYSTEM 123 BLEEDINGTHE BRAKE SYSTEM 124 Front caliper 124 Rear caliper 124 ...

Page 6: ...erves 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 Works...

Page 7: ...eat basic technical concepts or safety recommendations They are therefore to be considered as memory tags In case of any doubt as to their meaning consult the page in which they are fully described ABBREVIATIONS 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 t...

Page 8: ...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 tha...

Page 9: ...ents 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 stable The f...

Page 10: ...ibed 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 component i...

Page 11: ...tion system wet sump SPARK PLUG type NGK DPR8EA9 TRANSMISSION Primary automatic speed variator with V belt Final gearbox Automatic centrifugal clutch FUEL SYSTEM Injection Fuel unleaded petrol IGNITION MORIC control unit 5HW MORIC start up coil 2JN BRAKES Front brake Ø 270 mm disc hydraulic caliper with double Ø 25 mm piston Rear brake Ø 240 mm disc hydraulic caliper with Ø 30 mm piston FRAME High...

Page 12: ...t 7 Fuel tank cap 8 Pillion grab handles 9 Rear turn indicators 10 Parking and stop lights 11 Number plate light 12 Number plate holder 13 Air filter 14 Centre stand 15 Side stand 16 Left hand pillion bracket 17 Bag hook 18 Glove compartment 19 Left hand mirror IDENTIFICATION OF MAIN COMPONENTS right hand side 20 Front turn indicator 21 Front parking light 22 Headlights 23 Radiator 24 Coolant tank...

Page 13: ... 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 Alteration of identification data is a criminal offence When ordering spare parts it is essential to quote the vehicle identification data ...

Page 14: ...ged cracks or cut have them replaced as soon as possible There are T W I marks all around the tyre sidewalls These correspond to tyre wear indicators situated in the tyre s tread if there is no difference between the thickness of the tyre wear indicators and the tread depth the tyre must be changed NOTE Minimum tread depth front and rear is 2 mm INFLATION PRESSURE Tyre inflation pressure must be a...

Page 15: ...om the scoot er body immediately since fuel may damage surface finishes The quantity of fuel and the use of the reserve fuel ca pacity are displayed by the relative function of the on board computer and the amber warning light on the right hand side of the instrument panel Use UNLEADED PETROL Guideline value Petrol is extremely inflammable avoid approaching the fuel filler also when refuelling wit...

Page 16: ...s never remove coolant tank cap B when the engine is hot Do not top up with water except in emergen cy situations in which case drain the tank completely and fill with the prescribed cool ant as soon as possible REAR VIEW MIRRORS The left and right rear view mirrors must be fitted to the specific locations on the handlebar and firmly secured in place Adjust the visual angle of the mirrors while si...

Page 17: ...he lights off note that using the socket reduces battery recharging and can reduce the battery charge level in certain circumstances Do not use the socket for appliances with an excessive power draw max power draw 30W The socket can also be used to recharge the battery by connecting it to a battery charger for sealed batteries when the engine is switched off Remember to refit the socket cap after ...

Page 18: ...t is fitted with a lock that can be opened with the ignition key turn the key clockwise The glove compartment contains the electrical system fuses B and relative spare fuses C are contained in a pocket in the door see the relative section in the manual Do not place heavy objects or temperature sensitive items lighters matches inflamma ble liquids perishable goods etc in the compartments Do not lea...

Page 19: ...w beam indicator light 6 Blue high beam indicator light 7 Green left hand turn indicator light 8 Green right hand turn indicator light 9 Fuel level indicator The warning light illuminates to indicate that the reserve fuel level has been reached 10 Injection warning light When on or blinking it indicates an anomaly in the injection system 11 This light is not used The engine is not equipped with a ...

Page 20: ...sappears the following appear 1 Secondary Menu or Submenu 2 Main Menu 3 Bar graph To select a function press the MODE button on the right hand control Operation of the MODE button is illustrated in the following diagrams by means of an arrow symbol accompanied by the time for which the button must be held down If the time is not specified momentary pressure on the button 1 sec is sufficient The av...

Page 21: ... functions are always accessible irrespective of the Main Menu that has been opened The choice of the speedometer unit of measurement km or miles can only be made from the relative selection menu when the battery is hooked up to the scooter When selecting the unit of measurement adhere strictly to the rules in force in your country SECONDARY MENU OR SUBMENU A TOD FUNCTION total km or miles Indicat...

Page 22: ...l Press the MODE button for 3 seconds until only the minutes and seconds are shown on the display Change the flashing number by pressing the MODE button briefly and repeatedly Holding down the button for a longer interval serves to switch to the next digit to change Not pressing the MODE button for 3 seconds serves to quit time setting mode E AIR TEMPERATURE FUNCTION Shows ambient temperature in d...

Page 23: ...CATOR FUNCTION Displays the level of fuel in the tank The quantity of fuel in the tank is displayed in graphic form by means of an 8 segment bar graph on the right hand side of the display When the second segment switches off this means the scooter is running on the reserve supply the corresponding amber warning light will illuminate B BATTERY LEVEL INDICATOR FUNCTION Vbatt Shows the battery charg...

Page 24: ... the message MIN if the battery is flat with the engine off this indication appears in flashing mode C OIL CHANGE ALARM Prompts the rider to execute a scheduled service The symbol appears with the message OIL CHA This indication will flash for 1 minute when the ignition key is turned on if the limit for a scheduled service see MAINTENANCE TABLE has been reached It is the responsibility of local Au...

Page 25: ...t This choice must be made every time the digital instrument panel remains without power for several minutes IMPORTANT Using a unit of measurement that differs from the one used in the country where you are driving may lead to incorrect calculations especially concerning road speed with consequent risk for the safety of the rider and others and liability to traffic offence fines D DISABLE OIL ALAR...

Page 26: ... the various digital instrument panel functions A Emergency switch engine stop Position Engine start Position Engine stop B Lights switch rh position off centralposition parkinglightsandinstrumentpanel lh position low beam high beam C Electric starter button LEFT HAND CONTROL 1 High beam flasher lever passing 2 Rear brake lever 3 Counterweight 4 Horn button 5 Turn indicator switch 6 Lights selecto...

Page 27: ...et compartment lock a Ignition disabled key can be removed b Ready to start position key cannot be re moved c Handlebar lock on ignition disabled key can be removed d Helmet compartment lock NOTE The scooter is supplied with two keys HANDLEBAR LOCK LOCKING Turn the handlebar all the way to the left insert the key press and turn it counter clockwise UNLOCKING Turn the key clockwise ...

Page 28: ...SIDE STAND The side stand is located on the left hand side of the scooter B and it is monitored by a microswitch that prevents the engine from starting unless the stand is properly closed Do not remove or tamper with this safety device We advise you to check the retaining system of both stands regularly The system is com posed of tension springs Irrespective of whether using the side stand or cent...

Page 29: ... C D E A 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 C Double insert PH2 Allen wrench size 4 to be used with handle B D Pliers E C spanner for shock absorber adjustment ...

Page 30: ...e 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 1206 mm with a tolerance of 2 mm Do not attempt to bend the frame to restore the original A measurement ...

Page 31: ...h is set to OFF The OFF position of the emergency stop switch is signalled by a warning light on the digital instrument panel To start the engine before pressing the ignition button activate the start enable permissive switch by pulling the front or rear brake lever and keeping it pulled The fuel system is designed to manage engine starting on the basis of engine conditions cold warm and ambient t...

Page 32: ...every 24 months or 12000 km 3 INTRODUCTION WARNINGS For the safety of your customers and others and to ensure correct operation of the vehicle it is essential to carry out the routine maintenance operations within the scheduled times indicated in the relative table in this manual Failure to perform routine maintenance operations can impair operation of the vehicle with all the relevant consequence...

Page 33: ...of oil Recommended oil Q8 T35 80W Capacity 0 25l 7 Fit the filler cap Oil change after the first 1 000 km and every 12 000 km thereafter 1 Perform the operations described in points 1 2 3 4 5 2 Fill the crankcase with new oil of the recommended type Recommended oil Q8 T35 80W Capacity 0 25l 3 Fit the filler cap Perform this operation with the engine off and when it is cold NOTE Regularly check for...

Page 34: ...the scooter on flat ground and put it on its centre stand 2 Stop the engine and wait a few minutes for the oil level to stabilise 3 Unscrew the cap dipstick A dry the dipstick with a clean cloth and re insert it without screwing down the cap 4 Remove the cap dipstick and make sure the level is between the MAX and MIN marks if necessary top up with Q8 CLASS 10W 40 oil Maximum oil quantity 1 4 l Max...

Page 35: ...n changed Engine oil change and mesh strainer cleaning after the first 1000 km and every 3000 km or 6 months thereafter 1 Warm the engine up for a few minutes 2 Stop the engine Place an oil container under the en gine and remove the dipstick 3 Remove drain plug A and dipstick and allow the oil to flow into the container 4 Clean strainer B with solvent 5 Check O ring C and renew if damaged 6 Refit ...

Page 36: ...LANT The coolant expansion tank is located under the rubber mat on the right hand side The coolant level can be checked with reference to the MIN and MAX marks which are visible through the chassis number inspection window Check the coolant level in the tank when the engine is cool in order to avoid burns The coolant level is correct when it is between the MIN and MAX marks on the reservoir If it ...

Page 37: ...e to cool down and check that cooling surface of the radiator located between the headlights is not obstructed remove any debris that coolant is not leaking from the circuit see coolant level top up that the fan fuse has not blown change the fuse if necessary LUBRICANT TABLE The lifetime of the scooter depends on various factors including the execution of correct lubrication LUBRICANTS TYPE OF LUB...

Page 38: ...ter waiting at least 10 15 minutes for the engine to cool Any deposits on the plug and the colour of the insulator can provide useful information concern ing the heat rating the fuel air mixture and the general condition of the engine If the engine and spark plug are in good working order the insulator should dis play light brown discolouration around the central elec trode After removing the spar...

Page 39: ...hock absorbers to the same position Unbalanced adjustment will affect the stability of the scooter When travelling with pillion set the shock absorber spring to position 4 Wear gloves when adjusting the shock absorbers risk of abrasion injury ADJUSTING IDLING SPEED Engine idling speed should be adjusted whenever you notice that the engine is idling unevenly To check idle speed start the engine and...

Page 40: ... It is good practice to check the front rear pads and discs every 2 000 km Minimum thickness of the brake pads is 2 mm Inspect brake pad thickness as illustrated in points A and B If the thickness of the pads is close to the minimum limit or if they are damaged have them replaced immediately Worn brake discs and pads must be replaced as soon as possible ...

Page 41: ... unit ADJUSTINGTHE BEAM To check adjust the vertical beam angle proceed as follows position the scooter in running conditions at 10 metres from a wall switch on the low beam headlights and keep the scooter upright without a stand and without rider e g lean it against a side wall remove the two adjusting screw caps inside the glove compartment use a cross head screwdriver to turn the headlight adju...

Page 42: ...iring by undoing the 4 screws V 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 bulbholder change the bulb refit the rubber bulbholder by pressing and refit the upper fairing FRONT TURN INDICATOR Front turn indicator A 12V 16W bulb W16W ...

Page 43: ...bholder by turning it clockwise Secure the handlebar casing The rate at which the turn indicator warning light on the instrument panel flashes will increase to signal that one of the four indicators is not working When performing the operations described above take care not to damage parts in the vicinity transmissions wiring seals etc TAILLIGHT with brake light Parking light A 12V 5W bulb W5W Bra...

Page 44: ...t A Remove the bulbholder from the inside of the taillight replace the bulb refit the rubber bulbholder by pressing and the cover Brake light B and turn indicator C Remove the coloured cap secured by means of 2 clips from the taillight replace the bulb refit the coloured cap and cover When performing the operations described above take care not to damage parts in the vicinity transmissions wiring ...

Page 45: ...ontrol to its central position and turn the key to starting position REPLACINGTHE NUMBER PLATE LIGHT BULB To replace the number plate light bulb remove the number plate light cover B by undoing screw V remove the rubber bulbholder from the plastic cover replace the bulb refit the bulbholder and the cover When performing the operations described above take care not to damage parts in the vicinity t...

Page 46: ...in fuse F 10 A PUMP I E Fuel pump G 7 5 A Fan H 30 A CHARGE Battery charge protection To change a fuse simply open the lower fairing cover and remove the blown fuse replacing it with an identi cally rated fuse Several spare fuses A are provided on the inside of the cover Check that the fuse you intend to fit is identi cally rated to the one you are replacing Do not replace fuses with others of hig...

Page 47: ...ve films from the ends of the adhesive area as shown by the arrow in the drawing A remove the two sponge vibration dampers from the orig inal battery you have just removed and apply them to the new battery Procure new vibration dampers if nec essary remove the 30A main fuse remove the rubber mats B undo the 4 screws V remove the centre partition un der the seat C remove the elastic band D and the ...

Page 48: ...is action may cause faults and short circuits on the electrical system and its components NEVER invert battery cable connection polarity If the battery is allowed to discharge completely and allowed to remain in this condition it will deteriorate rapidly NOTE Use protective gloves and goggles when removing the battery e g for recharging RECHARGING THE BATTERY It is good practice to remove the batt...

Page 49: ...NSTRUMENT 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 UPPER HANDLEBAR COVER Undo screws V2 Undo screws V4 V4 V4 A V2 V2 V4 V4 ...

Page 50: ... 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 Undo screws V4 and screw V then detach instru ment panel from upper handlebar cover ...

Page 51: ...ent panel provides access to the following components Instrument panel connector A Connector for LH handlebar control B Connector for RH handlebar control C RH control STOP switch D LH control STOP switch E Rear brake master cylinder union F Front brake master cylinder union G Turn indicators connector H Ambient temperature sensor connector L ...

Page 52: ... handlebar cover C The sensor must be mounted EXTERNAL LY to the lower handlebar cover as shown in the figure A C RIGHT HAND CONTROL Remove windshield Remove upper handlebar cover Disconnect throttle transmission A Undo screw V and remove counterweight Undo screws V2 and remove throttle control Use compressed air to reduce friction when removing and refitting the twist grip V V2 A B ...

Page 53: ...DISASSEMBLY 5 Remove upper handlebar cover Undo screw V and remove counterweight Undo screws V2 and remove LH control Use compressed air to reduce friction when removing and refitting the twist grip FRONT FAIRING Undo screws V2 Undo screws V2 V2 V2 V V2 ...

Page 54: ... 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 Radiator and relative cap A Fan connector B Coolant hoses with clamps C ...

Page 55: ...UNNING GEAR DISASSEMBLY 5 V6 V6 V4 B V6 V6 V4 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 56: ...ONT MUDGUARD Undo screw V and remove nut D responsible for securing hydraulic hose clamp A Unscrew screws V4 on the underside of the mudguard Remove the mudguard sliding it through the fork and taking care to protect from scratching Pay attention to the four bushes B located under the screws ...

Page 57: ...cer 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 Remove the sensor complete with the transmission FRONT BRAKE CALIPER Undo screws V2 and free the complete caliper When refitting insert the longest screw in the top fitting ...

Page 58: ...hydraulic circuit and drain the fluid into a container so that it may be disposed of in compliance with statutory environmental and waste disposal legislation When removing the caliper take care to pro tect the hydraulic line disc and brake pads from damage After working on the brake system make sure that the brake fluid line is not twisted that the discs and pads are not contaminated with oil or ...

Page 59: ...he scooter from fall ing Remove speedometer sensor Remove front brake caliper Loosen screw V Unscrew and remove wheel spindle A paying atten tion to spacer B Remove wheel assembly Do not operate the brake lever after remov ing the wheel since the pads would come into contact with each other When refitting the wheel be sure to refit the spacer and grease spindle A ...

Page 60: ... RUNNING GEAR DISASSEMBLY 5 60 11 06 V5 11 10 V5 V5 V5 FRONT BRAKE DISC Remove speedometer sensor Remove front brake caliper Remove front wheel Undo screws V5 When reassembling use new screws and apply a high strength threadlocker ...

Page 61: ...61 11 06 A PASSWORD 250 i e FRAME AND RUNNING GEAR DISASSEMBLY 5 LEFT AND RIGHT HALF SHIELD Remove front fairing Remove rubber mats A Undo screws V4 V4 V4 V4 A ...

Page 62: ...A PASSWORD 250 i e FRAME AND RUNNING GEAR DISASSEMBLY 5 62 11 06 Undo screws V4 Undo screw V1 Pay attention screw V1 is internal and con cealed by the fairing Remove the half shield V4 V4 V1 ...

Page 63: ...FRAME AND RUNNING GEAR DISASSEMBLY 5 A B ACCESSIBILITY Removing the right hand half shield provides access to the following components Fuse connections A Horn B Saddle opening transmission cable gland C Side stand connector D C D ...

Page 64: ...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 wire A to the horn INTERNAL terminal and ORANGE wire B to the EXTERNAL termi nal F V B A ...

Page 65: ... 250 i e FRAME AND RUNNING GEAR DISASSEMBLY 5 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 V2 A B ...

Page 66: ...l 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 Removing the left hand sub panel provides access to the following components Side stand and relative switch C A ...

Page 67: ...tage regulator D CDI control unit E VOLTAGE REGULATOR Disconnect connector A by pressing the suitable tab Undo screws V2 and remove regulator D CDI CONTROL UNIT Disconnect connector B by pressing the suitable tab Undo screws V2 and remove CDI control unit E To unscrew the screws V2 you must use a fool proofing TORX wrench T 25 E B E D V2 A ...

Page 68: ...A PASSWORD 250 i e FRAME AND RUNNING GEAR DISASSEMBLY 5 68 11 06 BATTERY COMPARTMENT TUNNEL COVER Undo screws V4 Gently pull tunnel cover A towards the front of the scooter to remove it V4 V4 A V4 ...

Page 69: ...nnector D Starter motor disconnection relay C WHITE E Fan relay YELLOW F Injection loads relé RED G Battery compartment H Spark plug drop tube The spark plug cable must always be in the position represented in the picture NOTE Relay disposition may vary from the one represented in the figure Before removing relays remember to write down their original disposition LEFT SIDE ACCESSIBILITY I Coil L C...

Page 70: ...e 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 the RED leads must be connected to the battery POS ITIVE pole the BLACK lead must be connected to the battery NEGATIVE pole the battery poles must be towards the REAR of the scooter ...

Page 71: ...RD 250 i e 5 SUB FAIRING Disassemble the front leg shield Remove half shields Remove front mudguard Undo screws V2a Undo screws V2b Undo screw V Screws V2a V2b and V are equipped with bushes that must be recovered when the screws are removed V V2a V V2b ...

Page 72: ...RING Remove upper fairing Remove front half fairings Remove sub fairing Remove keyswitch cover A rotating it counter clock wise through of a turn Open the luggage compartment and undo fusebox screws V2 When reassembling note that the LIGHT BLUE 15A fuse must be uppermost A V2 ...

Page 73: ...73 A FRAME AND RUNNING GEAR DISASSEMBLY 11 06 PASSWORD 250 i e 5 Undo bag hook screws V2 Undo screw V Undo screw V V V2 V ...

Page 74: ...rds 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 There is a 12V socket in the luggage com partment the Faston connectors must be disconnected from the socket before the lower fairing can be removed C B D Undo screws V2 V2 V2 ...

Page 75: ...BLY 11 06 PASSWORD 250 i e 5 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 A V4 V4 ...

Page 76: ...S Before proceeding make sure that the cool ant temperature is lower than 50 C Undo the radiator cap Place a 2 l recipient under expansion tank A Open clamp B and slide down the hose now slide out hose C wait for all the coolant to drain out from both the hose and the tank Undo screws V3 and remove tank A A B C A V3 V3 ...

Page 77: ...GEAR DISASSEMBLY 11 06 PASSWORD 250 i e 5 V 20 15 V2 5 20 SIDE STAND Detach springs A and undo screw V SIDE STAND SWITCH Undo screws V2 Disconnect the connector A of the side stand located under the right semi shield V A V2 A ...

Page 78: ...BLY 11 06 PASSWORD 250 i e 5 A C D B 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 79: ...79 A FRAME AND RUNNING GEAR DISASSEMBLY 11 06 PASSWORD 250 i e 5 MAIN ELECTRICAL SYSTEM ...

Page 80: ...ture is lower than 50 C Remove radiator cap A Place a 5 l recipient under the scooter Remove screw V and wait for ALL the coolant to flow out When refitting screw V renew the copper washer NOTE When reassembling follow the procedure outlined at the end of the heading Empty the tank of coolant Open clamp B and free the fan cable Disconnect the fan connector C At the time of reassembly remember to s...

Page 81: ...ASSEMBLY 11 06 PASSWORD 250 i e 5 V4 V2 V2 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 C ...

Page 82: ...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 Remove radiator cap E and lift the edges F of radia tor support partition G to disengage the radiator at tachment points Remove the radiator by sliding it downwards D F E F G ...

Page 83: ...ition the fan as shown in the figure and position clamp A under the screw as indicated V A V3 V3 A 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 ALLTHE AIR to escape now tighten screw V ...

Page 84: ...ed for a few minutes then switch off and unscrew the bleed screw again to vent any residual air Now retighten the bleed screw KEYSWITCH Remove sub fairing Remove front half fairings Remove lower fairing Detach connector A and disconnect transmission B now undo screws V2 NOTE Use aTORKS T 25 wrench for tamperproof screws to unscrew screws V2 Or a foolproof Allen wrench size 4 ...

Page 85: ...esting it on a supporting surface with the upholstery upwards HELMET COMPARTMENT Remove seat Undo screws V2 and V4 Remove fuel tank cap B remove gasket C discon necting it from the drip hose then refit the cap Screw the fuel tank cap back on immediate ly after removing the gasket The helmet compartment is still attached to the scooter via the seat lock transmission cable D2 D2 V2 V2 V4 C B ...

Page 86: ...cable C from metal clamp D NOTE Make a mental note of the path followed by transmission cable C thereby making sure you refit in the correct position at the time of reassembly Unscrew screws V2 ensuring you recover the relative nuts NOTE You can now remove the helmet compart ment from the scooter NOTE If the seat lock jams or if you lose the key refer to the section on accessibility after re movin...

Page 87: ...uel probe C Fuel pump D Suction air temperature sensor connector E Engine stepper F TPS sensor butterfly valve position G Suction air pressure sensor H Injector I Water temperature sensor L Roll over protection sensor M Depression valve cap throttle body The regulation screw N on the throttle body must never be tampered with under no conditions D M N L G H E F I A C B ...

Page 88: ...3 Suction air pressure sensor 4 Suction air pressure sensor shaft 5 Engine stepper connector step by step scooter 6 TPS sensor connector 7 TPS sensor butterfly valve position 8 Accelerator cable 9 Air filter box clamp 10 Throttle body clamp 11 Throttle body 12 Injector connector 13 Fuel pipe support 14 Injection unit 15 Suction collector 16 Suction collector joint 12 14 11 9 2 4 3 1 8 5 7 6 10 13 ...

Page 89: ...level sensor fitted for a prolonged peri od plug the hole to prevent the accumula tion of petrol vapour in the workshop Remove sensor C When removing the sensor take care when the float is being extracted through the hole in the tank When reassembling MAKE SURE the float is facing the FRONT of the scooter A V4 V4 V4 B C FUEL PUMP Disconnect the connector A Use an open end wrench and apply pressure...

Page 90: ...15 V2 43 15 PILLION GRAB HANDLE Remove seat Remove helmet compartment Remove seat lock Undo screws V2 and V and remove handle A When refitting the grab handle pay atten tion to seat lock cable A which must fol low the route indicated with respect to the grab handle V2 V A ...

Page 91: ... 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 ACCESSIBILITY Removing the taillight provides access to the following components Number plate light connectors A ...

Page 92: ... 5 B C A 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 Now reconnect connector C ...

Page 93: ...GHT 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 Disconnect connectors B When reassembling pay attention to the wire colour coding A ...

Page 94: ...aillight Remove pillion grab handle Remove battery compartment tunnel Undo screws V2 Undo screws V2A Undo screws V4 NOTE To remove screws V4 use a screwdriver with a 90 angled blade Slide out the fairing towards the rear of the scooter The figure shows the rear fairing with an indication of ALL the screws to be removed V4 V4 V2 V2 V4 V2 V2a ...

Page 95: ...EMBLY 11 06 PASSWORD 250 i e 5 ACCESSIBILITY Removing the rear fairing provides access to the follow ing components Left side Drip container pipe A Right side Flywheel connectors B Ground terminal C Saddle opening cable junction A B D C ...

Page 96: ...t and keep sparks and naked flames well clear of the scooter If the tank remains without the fuel level sensor fitted for a prolonged peri od plug the hole to prevent the accumula tion of petrol vapour in the workshop Make sure the tank is empty Before emptying the tank wait for the en gine to cool down Use a manual pump Open clamps A At the time of reassembly the rear clamps must restrain the ele...

Page 97: ... 250 i e 5 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 V4 V4 V4 C D ...

Page 98: ...until all the components have cooled down and always wear suitable protective gloves Undo the screws V2a and remove the protection G Loosen the clamp screw F Undo screws V2 Undo the screw V while holding the silencer remove it from the scooter NOTE To identify all components please refer to the Spare Parts Catalogue Table I V V2a F V2a G V2 25 15 ...

Page 99: ...nnector C Unscrew the Lambda probe D D 45 10 DISCHARGE COLLECTORS Unscrew the nuts D2 which fix the collectors Remove the discharge collector During reassembling replace the gasket on theenginesideandthegasketonthesilencer side with new original ones The parts to be replaced can be found in the Spare Parts Catalogue D2 30 10 B D C A D2 ...

Page 100: ...6 PASSWORD 250 i e 5 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 Remove shock absorber A Va 24 15 Vb A Va Vb 45 15 ...

Page 101: ...101 A FRAME AND RUNNING GEAR DISASSEMBLY 11 06 PASSWORD 250 i e 5 V 3 5 20 REAR MUDGUARD Undo screws V2 Undo screw V Undo screw V then remove mudguard towards rear of scooter V V V2 ...

Page 102: ...aged or the thickness less than 3 5 mm it must be renewed Minimum thickness of the pads is 2 mm REPLACING THE REAR CALIPER Empty the brake fluid circuit draining the fluid into a sui table container for disposal in compliance with statutory environmental legislation When removing the caliper beware of the risk of damaging the brake fluid line the disc and the brake pads After working on the brakin...

Page 103: ...o nut D with washer and screws V2 Remove spacer B from the wheel spindle When refitting the wheel spacer B must be positioned with the largest diameter side towards the wheel bearing as shown in the photo Remove swingarm C There is a spacer behind the swingarm sim ilar to the spacer IN FRONT of the arm the spacer must be refitted with the smallest di ameter side facing the arm See also follow ing ...

Page 104: ...ring E Remove rear wheel F Spacer H is located on shaft G behind the wheel ASSEMBLY OF REAR WHEEL Before reassembling grease shaft G abundantly especially on the splines The layout of the following components is shown in the figure A nut B spacer H spacer L washer M spacer The arm must be positioned between the two spacers B and M the wheel must be positioned between spa cers M and H ...

Page 105: ... must NEVER be less than 3 5 mm otherwise RENEWTHE DISC Undo screws V5 When reassembling use new screws and ap ply a high strength threadlocker NUMBER PLATE HOLDER REAR FAIRING Remove seat Remove helmet compartment Remove battery compartment tunnel cover Remove rear fairing Remove taillight Disconnect cables C Undo screws V4 There is a metal bushing under each screw NOTE At the time of reassembly ...

Page 106: ...move helmet compartment Disconnect sensor connector A for suction air temperature Open the clamp and disconnect oil vapour recovery hose B Open the clamp and disconnect hose C throttle body valve depression Cut the clamp D Loosen clamp E securing the filter box to the throttle body A B C E D ...

Page 107: ...107 A FRAME AND RUNNING GEAR DISASSEMBLY 11 06 PASSWORD 250 i e 5 Undo screw V Undo the Allen screw V accessible from opening F V F ...

Page 108: ...F Remove filter box E from the scooter prising gently in throttle body connection point F Undo screws V7 to open the filter box To unscrew the screws V7 you must use a fool proofing TORX wrench T 15 The sequence for disassembling the filter box compo nents is shown in the figure ...

Page 109: ... PASSWORD 250 i e 5 A V2 B C D E V2 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 NOTE Note that each screw V2 is threaded into a bushing ...

Page 110: ...e silencer including collector and lambda probe Remove filter box Before proceeding with the engine disassembly operation prop up the centre of the frame to prevent the scooter from falling Disconnect flywheel connectors A Undo screw V and detach the ground cables from the frame Disconnect all electric connections related to the engine ...

Page 111: ...screw clamp F Detach hose G from water pump P Before disconnecting hose G empty the cooling system see Removing the radia tor Disconnect wires L from starter motor Disconnect cap from spark plug H The spark plug cable must always be in the position represented in the picture H ...

Page 112: ...SWORD 250 i e 5 M 45 20 N M 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 ...

Page 113: ...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 After assembling the brake master cylinders front rear...

Page 114: ...d left connectors Cut all cable and hose ties Disconnect connectors A Disconnect cables from brake light switches B Remove throttle cables C Undo screws V4 Undo screw V1 Loosen nut D then extract the handlebars upwards and disengage the lower handlebar cover l from the handlebars When removing the handlebars pay attention to the electrical connectors and all the other parts affected by the operati...

Page 115: ... scooter falling Sever all the electrical cable ties to proceed with the operation position the brake calliper and the brake line to BEHIND the scooter frame Undo and remove ring nut A Undo and remove underlying ring nut B Remove the forks assembly in a downward direction Support the forks to prevent them falling Pay attention because balls C may fall from their rac es Clean away any grease includ...

Page 116: ...re proceeding with the disassembly operation prop up the centre of the frame to prevent the scooter falling To proceed with the operation position the brake calliper and brake line BEHIND the scooter frame Remove circlip A Undo screws V2 Remove stanchion tube B downwards by pulling and twisting V2 30 20 NOTE The composition of the oil group of the fork can be found in the Spare Parts Catalogue B A...

Page 117: ... the upper cap A Remove the seeger ring B by using a screw driver to press the cap C downwards complete with O ring D Carefully remove the spring E and let oil drip completely from it Bring the shaft F to control stop below F keeping it perfectly vertical With the aid of a rule or a gauge rod check the oil level The correct level is 110 mm from the upper edge of the stanchion Top up with Q8 FORK O...

Page 118: ...wn to drain out the resid ual oil Hydraulic fluid is corrosive and can cause serious personal injury Spent oil must be disposed of in compliance with local legislation Refit drain screw V NOTE Before refitting renew the copper washer under screw V Carefully pour new oil into the stanchion Quantity per stanchion 165 4 cc Check the oil level as described above Reassemble the stanchion components and...

Page 119: ...e brake fluid Dispose of used brake fluid in compliance with statutory legislation Do not operate the brake lever after removing the callipers This action may cause the plungers to come out of their pistons resulting in spillage of brake fluid Note that brake fluid is highly corrosive and can cause serious personal injury CHANGINGTHE FRONT CALLIPER After removing the front brake calliper undo scre...

Page 120: ...t to dam age the wiper seal and oil seal grooves Check the pistons and their cylinders for any signs of scoring Clean the parts thoroughly and flush with exclusively alcohol Always fit new wiper seals and oil seals Refit the plungers oilseals C andwiperseals B lubricatingwithbrakefluid After terminating the inspection cleaning and replacement procedures refit all the parts in reverse sequence with...

Page 121: ...tive gaskets After having removed the calliper from its seat place a recipient under it to collect the brake fluid Dispose of used brake fluid in compliance with statutory legislation REAR CALLIPER DISASSEMBLY Remove retaining ring A of brake pad pin B Remove pad pin B Remove 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...

Page 122: ...d gasket G do not fall Remove wiper seal H and oil seal L in both calliper halves taking care not to damage the relative grooves Check that the plungers and their seats are undam aged 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 on the braking system make sure that the b...

Page 123: ...A FRAME AND RUNNING GEAR DISASSEMBLY 123 PASSWORD 250 i e 5 11 06 1 2 3 4 1 2 3 4 BRAKE SYSTEM FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER REAR CALIPER FRONT CALIPER ...

Page 124: ...r recovery tube Replenish the brake fluid level in the reservoir While bleeding the brakes ensure that no brake fluid comes into contact with the scooter bodywork risk of damage In addi tion while bleeding the brake callipers avoid contamination of brake discs or pads with brake fluid Failure to comply with this pre scription will have a negative effect on the efficiency of the brake system If the...