Malaguti PHANTHOM F12R, Sevice Manual

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Page 2: ...n order to make sure the topics the technical and safety concepts are clearly understood and the manual can be used as a sure reference text All checks maintenance repairs or replacements of spare parts in our motor bikes are to be performed by skilled and expert technical personnel with specific experience in state of the art technology and full knowledge of the quickest and most rational procedu...

Page 3: ...s dealt with in the page NOTE The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations Cs Torque wrench setting D Nut Dx Right F Picture G Gasket P Page R Washer Sx Left T Table V Screw TECHNICAL DICTIONARY V DC Direct current battery supply V AC Alternating current flywheel supply A Ampere Unit of measuremen...

Page 4: ...an MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technician IGNITION KEY ON ON position PRESENT MANUAL Information on the present manual ENGINE SERVICE MANUAL Indicates information which may be obtained by referring to said catalogue SPARE PARTS CATALOGUE Indicates information whic...

Page 5: ...re parts you may need Use only the original spare parts Mark the components that may be mis placed during re assembly operations Only use quality tools and equipment Only use equipment conforming to EU Directives for lifting the vehicle During operations always keep tools and equipment at hand possibly laying them out according to the sequence in which they are to be used Absolutely avoid putting ...

Page 6: ... low flash point solvents to clean the vehicle components When welding make sure that there are no flammable liquids in the vicinity Never suck from or blow into the fuel pipe Never leave the engine running in closed or poorly ventilated areas Do not use fuses with a higher rated capacity than indicated this may cause severe damages to the electrical system and burn a fire as a conse quence of sho...

Page 7: ...re any servicing make sure that the vehicle is perfectly stable The front wheel should preferably be anchored to fixture A which is integral with the lift platform It is absolutely forbidden to walk on the lifting device ...

Page 8: ...E SPLITTER 27 REAR MUDGUARD 28 FRONT MUDGUARD 28 HANDLEBAR COMMANDS 29 BRAKE PUMPS 29 HANDLEBAR 29 KEY SWITCH 30 HORN 30 ODOMETER SENSOR 30 FRONTWHEEL 31 FRONT BRAKE 32 CHECKING LINING WEAR AND BRAKE DISC 32 REPLACINGTHE LININGS 32 BRAKECALIPER 32 FORK 33 WHEEL SHAFT 33 OIL LEVEL CHECK 33 OIL REPLACEMENT wheel shafts 34 FORK ASSY 34 REARWHEEL 35 REAR DRUM BRAKE 35 CHECKING 36 BRAKE LEVER ADJUSTMEN...

Page 9: ...BR7 ES TRANSMISSION Automatic speed variator with expandable pulleys V belt automatic dry centrifuge clutch reduction gear FUEL SYSTEM Carburettor make type GURTNER PY 12 automatic starter Fuel unleaded petrol IGNITION Electronic BRAKES Front brake disk type Ø 190 mm with transmission and hydraulic calipers Rear brake drum type Ø 110 mm with mechanical transmission CHASSIS Steel tube single beam s...

Page 10: ...um tread depth is 2 mm There are T W I marks all around the tyre sides 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 replaced 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 ...

Page 11: ...he vehicle is used in rainy weather in dusty places or on rough terrain Due to their simplicity checks with no asterisk CAN also be carried out by technicians not authorised by MALAGUTI but under their direct responsibility Nr coupon check clean adjust replace MAINTENANCE TABLE ...

Page 12: ...c DAILY SUPER semi synthetic AIR FILTER LUBRICANT AIR FILTER OIL BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4 FORK ROD OIL FORK OIL F 8 A OIL TANK Litres TOTAL TANK CAPACITY RESERVE To fill up the oil tank remove the cover A by pulling its side flap LUBRICANT TABLE NOTE Use only recommended products ...

Page 13: ...he nut D Unscrew the arm holding the mirror Remove the front handlebar including the dashboard Disconnect the dashboard connector D F 9 F 11 F 12 DASHBOARDHOLDER V3 V3 V4 V3 1 10 DASHBOARD V4 F 10 V3 V3 V3 1 10 FAIRING FRONT HANDLEBAR COVER V3 ...

Page 14: ...e stop switch 4 Right switch connector 5 Left switch connector 6 Front brake pump oil connection 7 Rear brake transmission 8 Dashboard protection condenser F 13 F 14 FRONT SHIELD Position adequate support beneath the scooter NOTE Remove Front mudguard p 28 Front wheel p 31 F 15 V V 5 20 V3 2 10 V3 V V3 6 2 8 7 3 1 5 4 ...

Page 15: ...14 07 07 Gently separate the shield and disconnect the connector A Remove the shield including the headlights and the direction indicators F 17 F 16 V6 V6 2 10 V6 F 18 A ...

Page 16: ...15 07 07 HEADLIGHTS V2 V2a V regulation screws for the beam of light Gutter A Shell D Faston C DIRECTION INDICATORS Shell D V1 F 19 V2a F 20 B C V2 A D D B F 21 V V1 ...

Page 17: ...dometer transmission connector 2 Key switch connector 3 Connector for anti theft device 4 Headlights connector 5 Fuse box connections 6 Steering wheel allowance regulation ring nut 7 Horn 8 Fork F 22 B A 5 8 2 3 1 F 12 4 7 6 After removing the cables reposition and anchor the cables with new straps as described in the figure ...

Page 18: ...2 10 V FLOORBOARDS after removing the lower side panels V V2 V2 V3 V2 V F 24 V2 5 20 BATTERY SEAT COVER V Cover A BATTERY V1 Stop battery B Remove battery Disconnect the vent pipe C Disconnect the cables firstly the cable connected to mass C V1 B A F 23 V2 ...

Page 19: ...ame capacity Higher capacity may result in serious damage to the electric system including the risk of fire F 27 F 28 When reassembling the battery do not forget to insert the vent pipe Make sure it exits the battery seat without bending or strangling BATTERY Connect the cables as illu strated in the figure connect the positive cable first Do not invert cable connection SEAT COVER STORAGE COMPARTM...

Page 20: ...A F 31 of the key switch F 32 F 33 F 34 B F 31 ACCESSES Socket for battery recharging B max 5 Ah V 5 20 V B A V1 C Remove the Fastons B on the back of the fuse box Write down the positions of the Fastons before disconnecting them Open the two wire clamps C ...

Page 21: ... 36 V2 F 37 D2 SEAT D2 D2 3 20 D2 F 40 R2 F 40 V2 3 20 SEAT LOCKING DEVICE V2 D Remove the cables from the battery from the front part Gently separate the leg shield and disconnect the connector D of the recharge socket D2 ...

Page 22: ...oil probe B Low fuel warning light C Engine oil probe connector D Low fuel warning light sensor connector E Fuel level probe connector F Rear light connector G HELMET COMPARTMENT V V4 Cover A Gasket B Cover C Gasket D V V4 5 20 F 39 V4 C D B V4 A V F 40 R2 D2 B E C B V4 F A G D F 41 ...

Page 23: ...ing the cover CDI unit A Tension regulator B Flasher relays C Start relay D Mass rope E COVER V FUEL LEVEL PROBE V4 F 41 NOTE During reassembly insert the float 1 so that the probe con nector is turned as shown in F 42 V4 2 10 V D B A 1 C F 45 E ...

Page 24: ...V2 Rear light frame A NOTE In these conditions the lamp can be replaced To replace the lamp of the indicators loosen the screws V V2 V2 5 20 Remove the side flanks by sliding them towards the rear part of the scooter Gently separate the side flanks V2 ...

Page 25: ...er NUMBER PLATE HOLDER V2 B F 51 F 50 V V 5 20 Free the anchoring notches A of the fairing Gently remove the fairing itself being careful with the cabling of the rear lights F 54 V4 V4 A V A F 53 CENTRALTUNNEL V4 Release the tunnel A from the hooks and let it slide in the direction indicated by the arrow V2 ...

Page 26: ... exit connection Disconnect the connector C V3 V3 2 20 OIL TANK F 56 E V4 F 55 V3 C B A D FUEL TANK After removing the oil tank Disconnect the connector D F 55 Disconnect the connector E Disconnect the fuel supply pipe V4 V4 5 20 NOTE In order to reach the oil tank and the fuel tank it is necessary to remove the rear fairing ...

Page 27: ...ld you need to replace the pipe B of the mixer oil pointed out in yellow position and anchor it according to the illustrations below If not properly fixed the pipe may interfere with the exhaust gas pipe F 57 F 58 F 59 B ...

Page 28: ...SPLITTER V Disconnect the clamp cables A NOTE Selective transmissions cables C one is connected to the carburetor and the other to the oil pump F 61 F 60 V C A NOTE The ignition coil B is positioned under the left footbord C B ...

Page 29: ...28 07 07 REARMUDGUARD V2 V2 5 20 V2 and relative bushs V2 3 20 During re assembly insert the removed parts both outside and inside the fender FRONTMUDGUARD V2 V2 3 20 F 64 F 62 V2 F 63 V2 V2 ...

Page 30: ...nect the connectors A Disconnect the accelerator transmission T V2 1 6 20 V2 a 28 20 V 20 20 D 50 20 HANDLEBAR Remove Front handlebar cover p 12 Front shield p 13 V2 b V1 Loosen nut D and slide the handlebar off being careful not to damage cables or pipes V2 b 10 10 F 65 a F 65 V2 a B V A V V2 A V2 C V1 T V2 b D ...

Page 31: ... 07 V3 F 66 HORN Disconnect the Fastons A V F 67 KEY SWITCH Separate the front shield p 13 Disconnect the connector V3 foolproof screws V3 10 15 ODOMETER SENSOR V1 F 74 Connector C A V V1 10 20 V 7 10 F 68 C ...

Page 32: ...port beneath the lower side panels When reassembling the wheel pin insert the spacers A B F 72 B F 71 A Slide the wheel pin off P Do not activate the brake lever while the wheel is off Remove the front mudguard p 28 Unscrew the nut D preventing it from falling by using a wrench for the wheel pin D 45 15 ...

Page 33: ...NGWEAR AND BRAKE DISC Check the wear of the linings by looking from the front part of the fork In case of doubt regarding their validity remove them and replace them Check also the state of the brake disc In case of excessive wear or anomaly replace it Minimum thickness of linings should be 2 mm Minimum thickness of disc should be 3 5 mm F 73 F 74 V1 R V2 30 20 R 20 20 V2 every 2 000 km approx 1 2...

Page 34: ...ft downwards A OIL LEVEL CHECK Block the wheel shaft in a clamp in vertical position Remove Cover A Seeger ring B Propeller nut C complete with O Ring D Spring E let oil drip off it Bring the shaft F to its end of travel position F 76 F 77 Insert a measuring pin or a caliber and make sure the oil is at a depth of 110 mm approx 3 93 inches from the upper rim of the shaft If necessary fill up with o...

Page 35: ...ms regarding special garbage disposal Tighten the screw V with its relative gasket Carefully pour new oil in the shaft 90 cc right left Check oil level as described above Reassemble the parts V 24 10 FORK ASSY To remove the complete fork remove Shield p 13 Front mudguard p 28 Front wheel p 31 Brake caliper p 32 Odometer sensor p 30 Handlebar p 29 To release the fork Upper lock nut A Lower lock nut...

Page 36: ...ver A Grasp with both hands the two sectors of the rear brake shoes A open them out vigorously in order to separate them from cam pin E The high strength of the springs B may cause the crushing of your fingers Loosen the nut D1 F 83 and remove the lever C F 83 paying attention to the torsion spring with which is connected Extract the cam pin E Clean and grease only the central part of the cam pin ...

Page 37: ...fter the adjustment verify that the adjustment nut thread is not completely employed up to the end of the thread itself that would mean that the brake shoes are completely worn out NOTE Rear brake transmission is secured in the lower part of the motorcycle by the screw V CHECKING Friction material Control the conditions of the brake shoes verify the minimum thickness of the friction material which...

Page 38: ...a 8 15 F 91 EXHAUST SYSTEM The operations described below should be carried out only when the exhaust system has cooled down V2 see removing the rear mudguard p 28 F 90 Remove the strap A and disconnect the secondary air emission pipe B V2 b V2 b 30 20 F 92 F 89 D V V2 V2 a V2 b B A ...

Page 39: ...ntil all solvent is eliminated Spread oil for air filter on the entire surface of the filter eliminating any excessive material in fact the filter must be uniformly impregnated without dripping In case the filtering element is damaged replace with a new original one When reassembling the air filter unit make sure the container contact surfaces are perfectly adherent to avoid aspiration of non filt...

Page 40: ... mass pipe B of the start engine Disconnect the flywheel connector C and the three faston connectors F Engine oil tank p 25 Disconnect the engine oil outlet pipe C and use a screw to close it Pull off the spark plug lead D Use the spring E to release the air filter from the carburetor Remove the air filter unit p 38 F 98 F 99 B A C D E F 97 a C F ...

Page 41: ...yor itself V V2 Disconnect the first accelerator cable from the carburetor Disconnect the second accelerator cable A from the cam B which operates on the oil mixer Disconnect the carburetor starter connector C page 41 F 103 Remove the muffler p 37 Release the rear brake transmission cable by operating on the nut D Remove the rear wheel p 35 Unscrew the lower locking screw V of the shock absorber R...

Page 42: ...original configuration Before removing the engine shaft you must lift the scooter from its rear part For this operation it is advisable to have another operator help you Removing the engine from the frame is a dangerous operation and should be carried out with maximum care and attention in order to avoid crushing arms and legs and to protect the engine itself Removing the pieces and parts which al...

Page 43: ...42 07 07 F 106 F 108 F 107 CABLE POSITIONING PIPE SYSTEM AND LOCATION OF ANCHORING STRAPS ...

Page 44: ...43 07 07 F 109 ...

Page 45: ...44 07 07 F 110 ...