Malaguti XTM 50, Workshop Manual

Page 1: ...XTM XSM A WORKSHOP MANUALS CHASSIS...

Page 2: ......

Page 3: ...ht 3 24 Rear wing 3 24 Filter cartridge 3 25 Regulator 3 25 Flashlight 3 25 Rear chassis 3 26 Air filter suction box 3 26 S P DISASSEMBLY 3 20 Shock absorber 3 27 Shift lever 3 27 Control unit 3 27 Oi...

Page 4: ...his information has been given to us by the engine manufacturers We therefore decline all responsibility for any error omission or misrepresentation MALAGUTI reserves the right to make any changes and...

Page 5: ...Symbols have been provided for quick and easy reference see page 9 identifying situations requiring utmost attention or providing practical suggestions or simple information These symbols may appear n...

Page 6: ...ew in the unit or component described and illustrated Letters not followed by a number indicate a single screw In case of different screws being referred to in the illustration the letter V is followe...

Page 7: ...ceed as shown in Figure 1 Except for occasional customers always make out and deliver to the customer a work sheet specifying the operations performed withnotesastoanyfuturecheckseventuallyrequired RE...

Page 8: ...low flash point 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 tank ev...

Page 9: ...rations which may constitute a fire hazard D RISK OF EXPLOSION Indicates operations which may constitute a risk of explo sion E TOXIC FUMES Indicates a possibility of intoxication inflammation or corr...

Page 10: ...splacement 49 cm3 Bore x stroke 40 3 x 39 mm Compression ratio 12 1 0 5 Starting system Kickstarter Lubricating system separate lubrication Type of oil Engine oil semi synthetic oil according to API T...

Page 11: ...r 0 90 kg 2 2 bar Front 90 kg max load 2 0 bar Rear 90 kg max load 2 2 bar Brakes Front hydraulic disk type 240 mm hydraulic disk type 259 mm Calipers with two pistons Operation right hand operation R...

Page 12: ...e VEHICLE REGISTRATION NUMBER The vehicle s registration number I F2i is stamped on the steering rod The vehicle registration number is used to identify the motorcycle ANTI TAMPERING LABEL The anti ta...

Page 13: ...1 2 3 5 4 12 F 3i F 4i 13 MAIN COMPONENTS Left hand side 1 Headlight 2 Oil tank 3 Battery 4 Air filter 5 Shift pedal MAIN COMPONENTS Right hand side 6 Radiator 7 Owner s tool bag 8 Fuse 9 Fuel tank ca...

Page 14: ...light switch GREAT BRITAIN version the rear view mirror is on the right hand side of the handlebar SWITZERLAND version there are two rear view mirrors one on the right and one on the left hand side of...

Page 15: ...l tank 4 Coolant temperature warning light This light comes on when the temperature of the coolant is too high When this light comes on stop the engine at once 5 Neutral indicator light N This light c...

Page 16: ...80 18 58P enduro rear 100 80 17 52S supermotard front 130 70 17 62S supermotard rear TIRE PRESSURE CHECK Tire pressure must be checked when the tires are cold FUEL TANK The tap of the fuel tank is of...

Page 17: ...low add coolant 4 Refit the cap REPLACEMENT Changing the coolant 1 Park the vehicle on a level surface and put a pan under the radiator 2 Remove the clamp F F 11i 3 Detach the pipe U F 11i If you need...

Page 18: ...he use of SAE 10W 30 oil is recommended Start the engine and let it warm up for a few minutes While it is warming up check for oil leakage If oil is leaking immediately turn off the engine and locate...

Page 19: ...cable SHOCK ABSORBER ADJUSTMENT The vehicle s seat can be lowered by moving the lower fixing element M F 17i double hole in the bottom fixing bracket ADJUSTING TRANSMISSION CHAIN TIGHTNESS To adjust...

Page 20: ...F 3 V4 F 3b SEAT Loosen the screw V F 1 and release the seat from the chassis Pull it out rearwards REAR SIDE CASINGS rh lh Remove seat Loosen the screws V4 F 2 and remove the rear side casing left or...

Page 21: ...HAPTER PAGE ISSUE CHASSIS ENGLISH SECTION 2 Disassembly XTM XSM SECTION 3 A CHASSIS F 4 F 5 F 6 V2 V V2 CONVEYOR right and left Remove seat Undo the screws V2 F 4 the side screws V F 5 and the front s...

Page 22: ...pulling it rearwards CAUTION Before removing make sure the silenc er has cooled down MUFFLER Remove seat and left hand side casing Remove the springs A and B F 8 fastened to the cylinder Undo the scre...

Page 23: ...TTERY Remove seat Remove the elastic band A F 10 and detach the battery cables B and C F 10b Release the fuse carrier D F 11 from the clamp Caution When refitting the battery pay attention to the exha...

Page 24: ...IL LIGHT Remove seat and tail section Disconnect the cables A F 13 and undo the screws V2 F 13b Caution When refitting pay attention to the Fast on sequence see wiring diagram REAR WING Remove seat si...

Page 25: ...seat and battery Undo the screws V2 F 16 and remove the filter cartridge REGULATOR Remove seat and rear right hand casing Detach the connector C F 17 and undo the screw V F 17 Caution When refitting r...

Page 26: ...AR CHASSIS Remove seat rear side casings tail section shock absorber guard battery rear brake fluid tank regulator flashlight and silencer Undo the screws V4 F 19 AIR FILTER SUCTION BOX Remove seat re...

Page 27: ...screws V2 F 22 and remove the shock absorber CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over Caution Check the direction in which you are fitting the sho...

Page 28: ...27 and detach the pipe from its fitting Undo the screws V2 F 25 detach the probe connector C F 25 and release the tank pin P F 26 from the chassis OIL LEVEL PROBE CAUTION Before removing the probe re...

Page 29: ...ront con veyors Undo the front fixing screw V F 28 and the rear fixing screws V2 F 28 Disconnect the vacuum pipe D F 28 and the petrol pipe B F 28 from the fuel cock Raise the tank and detach the fuel...

Page 30: ...cable C F 30 from the pump body P F 30 CARBURETTOR Remove seat side casings fuel tank Remove the throttle cable coupler G F 31 and the starter coupler S F 31 by loosening the screws V2 F 31 Remove the...

Page 31: ...sconnect the trans mission Remove the mixer pump by loosening the two Allen screws Empty the coolant circuit by means of the drain age screw on the pump body V F 33 Remove the head radiator B F 32 and...

Page 32: ...be performed with the side stand in its idle position Release the screws M F 35 and undo the screw V F 35 Caution When reassembling use a high strength threadlocker FRONT INDICATORS right and left Un...

Page 33: ...nnector C F 39 and unscrew the fixing screws V2 F 39 THROTTLE CONTROL Remove the MODE button P F 40 by unscrew ing the fixing screw Remove the front cover C F 40 and release the throttle cable G F 40...

Page 34: ...and the left hand knob Loosen the screws V2a F 41 and remove the left hand control HANDLEBAR Remove right and left controls Loosen the screws V4 F 42 to remove the U bolts holding the handlebar in pl...

Page 35: ...ETER SENSOR Loosen the screw V F 44 and remove the sen sor release the cable from the U bolts and detach the connector under the headlight Caution When refitting pay attention to the shim washer betwe...

Page 36: ...ION Before disassembly hold the centre chassis section to prevent the vehicle falling over Loosen the screw V2 F 45b Unscrew the pin P F 45 and remove it Remove the front wheel Caution When refitting...

Page 37: ...d remove the fork head FORK Remove front indicators guard digital instru ment board front wheel speedometer sensor front caliper handlebar and fork head Unscrew the ring nut G F 47 remove the dust gua...

Page 38: ...remove the rear brake oil tank To remove the pump disconnect the cable from the rear stop switch I F 50 and unscrew it Undo the fixing screws V2 F50 paying attention to the eye adjustment plaque Caut...

Page 39: ...T F 52 from the caliper Release the calipers from the fork CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over Caution When refitting remember to replace th...

Page 40: ...crews V3 F 54 FORK Remove rear wheel rear brake caliber shock absorber chain crankcase Unscrew the nut D F 55 and remove the pin CAUTION Before disassembly hold the centre chassis section to prevent t...

Page 41: ...69 20 26 5 7 72 98 2 4 38 52 38 52 18 24 18 24 25 34 16 24 6 10 CHASSIS TORQUE WRENCH SETTINGS Greasing grease TORQUE WRENCH SETTINGS TABLE TOURQUE WRENCH SETTINGS N m Kg m Remarks Front wheel pin Fr...

Page 42: ...A 42 05 03 CHAPTER PAGE ISSUE CHASSIS ENGLISH SECTION 2 Disassembly XTM XSM SECTION 3 A CHASSIS...