Malaguti XSM 50, Workshop Manual

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

Page 2: ......

Page 3: ...ght 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 Oil tank 3 28 Oil level probe 3 28 Oil pipe fitting with filter 3 28 Fuel tank 3 29 Fuel cock 3 29 Throttle cable 3 30 Carburettor 3 30 Engine 3 31 Radiator 3 31 Side stand 3 32 Front indicators 3 32 G...

Page 4: ...This 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 modifications hereto it deems necessary without prior notice For further information and details please contact the Malaguti S p A Service Division MANUAL UPDATES Updated pages of this publication w...

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 next to a text in which case they refer solely to the text itself next to a figure in which case they refer to the topic illustrated in the figure and to the relative text or at the top of the page in...

Page 6: ...rew 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 followed by a number and a small letter for instance V4a Unless otherwise specified units and components are reassembled by proceeding in the reverse order of re moval F Figure Cs Tightening torque P Page P...

Page 7: ...oceed 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 RECOMMENDATIONS Before carrying out any operation on the vehicle wait for all parts to cool down For operations requiring two mechanics make sure that the various steps to be performed by each of them ...

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 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 motorbike is perf...

Page 9: ...erations 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 corro sion F MECHANICALMAINTENANCE Operations to be performed only by an expert mechanic G ELECTRICALMAINTENANCE Operations be performed only by an expert electrical elec tronic technician H NO Operation...

Page 10: ...isplacement 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 TC TS C3 standards Total amount 1 1 L Transmission oil SAE 10W30 type SE Total amount 0 82 L Fuel Type RON 91 premium grade unleaded petrol Fuel tank capacity 6 5 L Reserve amount 1 8 L Carburettor Ty...

Page 11: ... 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 Ø240 mm hydraulic disk type Ø259 mm Calipers with two pistons Operation right hand operation Rear hydraulic disk type Ø218 mm hydraulic disk type Ø218 mm Calipers with two pistons Operation right foot operation Suspensions Front telescopic fork Max stroke 190 2 mm Rear swingarm Max stroke 44 ...

Page 12: ...se 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 tampering label A F 2i is located under the seat It bears all the vehicle registration data envis aged by the 97 24 CE Directive If you intend to replace the compartment under the seat make sure it is ...

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 cap 10 Rear brake pedal 11 Passenger foot rests 12 Passenger holder 13 Number plate light number plate holder SWITZERLAND only ...

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 the handlebar SWITZERLAND version only START SWITCH KEYS The main switch controls the ignition circuit and steering lock Up to chassis n 7086713 all electrical contacts are disconnected the contacts...

Page 15: ...el 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 comes on when the transmission is in neutral position 6 Oil level warning light This warning light comes on when the oil level is low 7 Low beam indicator light SWITZERLAND version only This indicator...

Page 16: ...0 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 the pressure type it therefore calls for no manual intervention Unscrew the cap and fill the tank Do not overfill the fuel tank T F 9i Immediately wipe off spilled fuel Use regular unleaded petrol w...

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 too much coolant to reach the recommended level or if you need to top up too frequently check the entire cooling system ENGINE OIL There is an electrical contact inside the tank that turns the red r...

Page 18: ...The 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 the cause BRAKE FLUID CHECK When checking the fluid level make sure that the top end of the main cylinder is horizontal when the handle bar is turned Make sure the brake fluid level of the rear brake...

Page 19: ...g 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 chain tightness loosen the wheel fixing nut B F 18i and the lock nut V F 18i and turn the adjustment screw C F 18i After adjusting tighten the lock nut V F 18i and nut B F 18i This operation must be ...

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 right TAIL SECTION Remove seat and left right rear side casing Undo fixing screws V2 F 3 and the screws V4 F 3b ...

Page 21: ...CHAPTER 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 screws V2 F 6 ...

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 screw V F 8 CAUTION Before removing make sure the muf fler has cooled down Remove the clamp C F 9 from the tube of the secondary air valve and detach the tube from its fitting Remove the spring D F 9 and...

Page 23: ...ATTERY 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 exhaust pipe REAR INDICATORS Undo the screw V F 1 Remove the glass cover and detach the lamp sock et cables Undo the fixing screw V F 12 ...

Page 24: ...AIL 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 side casings and tail section Cut the cable clamp F F 14 Undo the screws V2 F 14 and the screws V4 F 15 on both sides Undo the screws V3 F 14b ...

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 remember to reconnect the earth cables M F 17 FLASHLIGHT Remove seat and rear right hand casing Detach the connector and open the snap lock I F 18 ...

Page 26: ...EAR 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 rear side casings tail section battery rear wing silencer and rear chassis Undo the screws V3 F 20 F 21 and loosen the clamp F F 21b ...

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 shock ab sorber and tighten the screws V2 to the established torque setting SHIFT LEVER Undo the screw V F 23 and remove the lever CONTROL UNIT Remove seat and rear right hand casing Undo the self tappi...

Page 28: ...F 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 release the tank from the chassis Detach the probe s connector C F 25 from the main wiring OIL PIPE FITTING WITH FILTER Caution Before removing the fitting release the tank from the chassis Loosen the ...

Page 29: ...front 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 probe connec tor S F 28 CAUTION Empty the tank FUEL COCK Remove seat and fuel tank CAUTION Make sure the tank is empty Loosen the clamp F F 28b and remove the cock ...

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 pipe clamps and detach the pipes T F 31 Detach the carburettor from the suction manifold after loosening the spring Caution If you are removing the en gine only the carburettor can be left attached ...

Page 31: ...isconnect 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 pump radiator L F 33 couplings Remove the pinion cover CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over Remove the lock nut and pull out the fork pin Lo...

Page 32: ...t 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 Undo the screw V F 1 Remove the glass cover and detach the lamp sock et cables Undo the fixing screw V F 36 GUARD FRONT WING Remove front indicators Undo the screws V4 F 37 of the front wing Caution Re...

Page 33: ...onnector 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 Remove the knob M F 40 Undo the screws V2 F 40 and remove the throt tle control Caution To reduce friction during knob removal and refitting use com pressed air FRONT BRAKE PUMP Detach the fast ons o...

Page 34: ...1 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 place Caution When refitting remember to tighten the front screws first FRONT BRAKE CALIPER Loosen the screws V2 F 43 and disconnect the pipe T F 43 after loosening the hydraulic trans mission screw V ...

Page 35: ...METER 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 between the sen sor and the fork REMOVING THE FRONT BRAKE CALIPERS ENDURO model REMOVING THE FRONT BRAKE CALIPERS MOTARD model ...

Page 36: ...TION 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 after tighten ing the pin P F 45 remember to the tighten the screws V2 F 45b FRONT BRAKE DISC Remove front wheel Loosen the screws V6 F 46 Caution When refitting use thread locker ...

Page 37: ...nd 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 guard P F 47 and pull out the fork CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over FOOT RESTS right and left Remove the split pin C F 48 pull out the pin P...

Page 38: ...d 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 Caution When refitting remember to replace the copper gaskets and bleed using the relevant equipment REARWHEEL CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling ov...

Page 39: ...e 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 the copper gaskets and bleed using the relevant equipment REAR DISC BRAKE Remove front wheel and rear caliper Undo the screws V3 F 53 Caution When refitting use thread locker REMOVING THE REAR BRAKE CA...

Page 40: ...screws 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 the vehicle falling over Caution When refitting follow the in structions provided in section 2 in AD JUSTING TRANSMISSION CHAIN TIGHTNESS ...

Page 41: ...1 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 Front wheel pin fixing element Front brake caliper Muffler side coupler Rear engine fixing screws Fork pin Front engine fixing screws Front pump clamp Rear wheel Clamps Top shock absorber Bottom shock ...

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