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Malaguti MADISON Series User Manual

Malaguti MADISON Series
146 pages
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1 05/02
MALAGUTI MADISON 180-200MALAGUTI MADISON 180-200
MALAGUTI MADISON 180-200MALAGUTI MADISON 180-200
MALAGUTI MADISON 180-200
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Malaguti MADISON Series Specifications

General IconGeneral
TransmissionAutomatic CVT
Front SuspensionTelescopic Fork
Width740 mm
Engine Options125cc
Engine TypeSingle-cylinder, 4-stroke
Fuel SystemCarburetor
Front BrakeDisc
Rear BrakeDrum

Summary

Introduction and General Information

General Notes and Precautions

Provides important notes on adherence to descriptions, potential damages, and warranty time standards.

Pre-Delivery Operations

1. Unpacking and Aesthetic Control

Lists initial pre-delivery tasks including unpacking and visual checks.

2. Critical Tightenings

Checks for critical fastening points on the motorcycle, ensuring proper torque.

3. Level Checks

Procedures for checking various fluid levels, including coolant and oil.

4. Adjustments

Instructions for performing various adjustments on the motorcycle's components.

Pre-Delivery Operations (Continued)

5. Various Controls

Performing miscellaneous checks and controls on the vehicle's systems.

6. Assembly

Instructions for assembling specific parts and components of the motorcycle.

7. Road Test

Performing a road test to ensure the motorcycle operates correctly.

8. General Cleaning

Guidelines for performing general cleaning of the motorcycle.

Technical Data

General Characteristics

Key physical and general specifications of the motorcycle, including dimensions and weight.

Engine Specifications

Detailed technical specifications related to the engine, such as cylinders, bore, stroke, and displacement.

Technical Data (Continued)

Chassis and Suspension

Specifications for the motorcycle's frame, suspension system, and related components.

Brakes and Transmission

Technical details regarding the braking system and transmission, including fluid types and capacities.

Electrical System Components

Information on electrical parts like battery, generator, lights, and indicators.

Initial Procedures

Unpacking Procedure

Step-by-step guide for unpacking the motorcycle from its packaging.

Aesthetic Control Procedure

Instructions for visually inspecting the motorcycle for scratches or marks.

Identification Data

Frame and Engine Identification

Procedures for locating and reading the frame and engine identification numbers.

Handlebar Controls

Right and Left Handlebar Controls

Details the functions and layout of all handlebar controls.

Ignition and Key System

Starter and Ignition Switch Operation

Explains the main switch functions and operation for starting and unlocking.

Steering Lock Operation

Instructions for engaging and disengaging the steering lock mechanism.

Key Management

Information about the provided keys and their functions.

Side Stand Operation

Side Stand Checks and Functionality

Instructions to check the side stand's fastening, mobility, and micro-switch function.

Instrument Panel Overview

Dashboard Indicators and Functions

Explains the various indicators and their meanings on the digital dashboard.

Digital Dashboard Functions

System Check Procedure

Describes how to initiate and interpret the system check function on the digital dashboard.

Oil Change Indicator Reset

Procedure to reset the motor oil change reminder light after maintenance.

Tyre Specifications and Maintenance

Tyre Dimensions and Pressure Control

Provides tubeless tyre sizes and guidelines for checking and adjusting tyre pressure.

Fuel Tank Access and Refilling

Fuel Tank Access and Refilling Procedure

Step-by-step instructions on how to access the fuel tank for refilling.

Coolant System Maintenance

Coolant Level Check and Refilling

Instructions on locating the coolant tank, checking, and refilling the coolant.

Engine Oil Maintenance

Engine Oil Level Check

Procedure for checking the engine oil level using the dipstick and recommended oil type.

Engine Oil Change Procedure

Step-by-step instructions for changing the engine oil, including filter replacement.

Transmission Oil Maintenance

Transmission Oil Level Check and Change

Instructions for checking and changing the transmission oil, including drain and refill steps.

Brake Fluid Maintenance

Brake Fluid Level Check

Visual check of brake fluid level through the window, ensuring it's at the correct level.

Brake Fluid Top Up Procedure

Instructions on how to top up brake fluid, including safety precautions and fluid type.

Engine Idle Speed Adjustment

Idle Speed Adjustment Procedure

Steps to adjust the engine's idle speed, including preliminary checks and warm-up.

Rear Shock Absorber Adjustment

Shock Absorber Adjustment and Tightening Checks

Instructions on how to adjust the spring pre-load and check tightening of rear shock absorbers.

Steering System Checks and Adjustments

Steering Play Check and Adjustment

Procedure to check and adjust play in the steering system by manipulating nuts and torque settings.

Handlebar Inclination Adjustment

Procedure to adjust the handlebar's inclination angle for rider comfort.

Seat Latch Adjustment

Seat Latch Adjustment Procedure

Steps to adjust the seat latch mechanism for proper closing and to eliminate play.

Bodywork and Fairing Components

Front and Rear Fairing Components

Lists and identifies components of the front and rear fairings and bodywork.

Windscreen Installation

Windscreen Preparation and Mounting

Instructions for removing and installing the windscreen, including related components.

Side Mirror Installation

Side Mirror Assembly and Removal

Step-by-step guide for installing and removing the side mirrors, including wiring and fastening.

License Plate Mounting

License Plate Installation Procedure

Procedure for mounting the license plate holder and plate before delivery.

Handlebar Cover Removal

Handlebar Cover Removal Procedure

Steps to remove the handlebar cover, including mirror and switch removal.

Front Shield Removal

Front Shield Removal Procedure

Detailed steps for removing the front shield, including related components.

Drainer Removal

Instructions for removing the drainer, which requires prior shield removal.

Instrument Panel Removal

Instrument Panel Removal Procedure

Steps to remove the instrument panel assembly, including disconnecting harnesses and screws.

Brake Lever Checks and Removal

Brake Lever Control and Removal

Checks for free play and smooth operation of brake levers, and removal instructions.

Handlebar Controls Removal

Instructions for removing electric controls and counterweights from the handlebar.

Front Fender Removal

Front Fender and Under-shield Fender Removal

Steps to remove the front fender and under-shield fender, including related screws and clips.

Leg Guard Removal

Leg Guard Removal Procedure

Steps to remove the leg guard, involving the glove compartment, battery, and screws.

Strut Removal

Strut Removal Procedure

Steps to remove the strut, including loosening screws and careful handling.

Rear Fender Removal

Rear Fender Removal Procedure

Instructions to remove the rear fender, noting its attachment to the air filter housing.

Footboard Removal

Footboard Removal Procedure

Steps to remove the footboard, requiring removal of the seat, helmet compartment, battery, and screws.

Helmet Compartment Removal

Helmet Compartment Removal Procedure

Steps to remove the helmet compartment, involving lifting the seat, fuel tank cap, and related components.

Seat Removal

Seat Removal Procedure

Instructions for removing the seat, including opening the fuel tank cover and disconnecting the shock absorber pivot.

Rear Fairing Removal

Rear Fairing Removal Procedure

Steps to remove the rear fairing, requiring prior removal of tunnel covers and helmet compartment.

Muffler Removal

Muffler Removal Procedure

Steps to remove the muffler, including loosening screws and disconnecting from the exhaust manifold.

Front Wheel Removal

Front Wheel Removal Procedure

Steps to remove the front wheel, including fender, caliper, and speed indicator gear.

Rear Wheel Removal

Rear Wheel Removal Procedure

Steps to remove the rear wheel, requiring silencer removal and brake caliper detachment.

Brake Pump Maintenance

Front Brake Pump Removal

Steps to remove the front brake pump unit, including draining fluid and disconnecting lines.

Rear Brake Pump Removal

Steps to remove the rear brake pump unit, including draining fluid and disconnecting lines.

Brake Pad Wear Check and Replacement

Brake Pad Wear Check

Procedure to check brake pad wear and disc condition.

Brake Caliper Unit Replacement

Steps for replacing front or rear brake caliper units, including fluid draining and part replacement.

Muffler Removal

Muffler Removal Procedure

Steps to remove the muffler, including loosening screws and disconnecting from the exhaust manifold.

Front Fork Removal and Maintenance

Complete Fork Removal

Steps to remove the entire front fork assembly, requiring engine support and removal of related parts.

Fork Oil Replacement

Procedure for checking and replacing the fork oil, including disassembly and reassembly.

Direction Indicators

Front Indicator Maintenance

Steps to replace the bulb in the front direction indicators, including cover removal.

Rear Indicator Maintenance

Steps to replace the bulb in the rear direction indicators, involving cover removal.

Fuel Tank Removal and Emptying

Fuel Tank Removal Procedure

Steps to remove the fuel tank, requiring prior removal of seat, helmet compartment, and rear fairing.

Radiator Removal

Radiator Removal Procedure

Steps to remove the radiator, including shield, leg guard, and coolant draining.

Air Filter Box Removal

Air Filter Box Removal Procedure

Steps to remove the air filter box, including loosening screws and clamps.

Air Filter Maintenance

Air Filter Cleaning and Replacement

Instructions for cleaning or replacing the air filter element and housing.

Component Reassembly Warnings

Reassembly Precautions and Checks

Important warnings and checks to perform before reassembling components, especially regarding wear and proper fitment.

Engine Removal

Engine Removal Procedure

Comprehensive steps for removing the engine, including disconnecting various systems and components.

Rear Shock Absorber Removal

Left Rear Shock Absorber Removal

Steps to remove the left rear shock absorber, including loosening the pivot pin.

Frame Dimensional Check

Frame Dimensional Check Procedure

Procedure to check the frame dimensions for distortion after an accident, specifying tolerances.

Front Headlight Assembly and Bulb Replacement

Front Headlight Bulb Replacement

Steps to replace the bulbs in the front headlights, including accessing them through the shield.

Parking Light Maintenance

Parking Light Bulb Replacement

Instructions for removing the shield and replacing the parking light bulb.

Headlight Beam Adjustment

Headlight Beam Adjustment Procedure

How to adjust the headlight beam by turning a knob or nut, depending on the model.

Front Direction Indicators

Front Indicator Bulb Replacement

Steps to replace the bulb in the front direction indicators, including cover removal.

Rear Direction Indicators

Rear Indicator Bulb Replacement

Steps to replace the bulb in the rear direction indicators, involving cover removal.

Electrical Unit Components

Voltage Regulator and Electronic Unit Access

How to access the voltage regulator and electronic unit by removing the lower fairing.

Coil Access

Steps to access the coil by removing the helmet compartment under the seat.

Thermostat and Electric Fan Access

How to access the thermostat by removing the lower fairing.

Battery Pre-Delivery Service

Battery Preparation and Installation

Instructions for preparing the battery with electrolyte, charging, and installing it, including cable connections.

Fuse Identification and Replacement

Table of fuses, their ratings, and warnings about using higher capacity fuses.

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