Malaguti Centro 125 User manual

111/07
125i.e.-160i.e.
MALAGUTI S.p.A.
Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY
Tel.[phone] -Fax[phone]
e-mail:inf[email protected] -http:// www.malaguti.com
FOREWORD
• The present manual specifically addresses to specialised technical personnel (MALAGUTI authorised service centres and single motor mechanics) and contains all the
service interventions indicated by the Manufacturer until the publishing of this document.
•Some basic technical information has been intentionally omitted as it is considered to be common knowledge.
• Additional information is available in the SPARE PARTS CATALOGUES of each model.
• It is important toreadall thegeneralinformation beforegoingthrough themanualto thespecific topics andthe maintenanceoperationsto becarriedout onthemotor-bike in
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.
•Allchecks, maintenance,repairs orreplacements of spare parts inour motor-bikesare to beperformed byskilledand expert technicalpersonnel with specificexperience
instate-of-the-art technologyandfull knowledge ofthequickestand most rationalprocedures, technicalcharacteristics, settingvalues,tightening torques andinformation as
to which may only be properly and exhaustively provided by the manufacturer.
• It is important to adherestrictlytothe followinginstructions.Anyoperationcarriedoutcarelessly ornot carried outatall mayleadto personalinjury,damage tothe motorcycle
or simply to complaints.
MALAGUTI S.p.A. reserves the right to make any changes and modifications hereto it deems necessary without prior notice.
For further information and details, please contact MALAGUTI S.p.A.Servicing or Engineering Division.

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NOTES FOR EASY CONSULTATION
ABBREVIATIONS
EDITING SYMBOLS:
• Symbols have been provided for quick and easy reference,identifying situationsrequiringutmost attention orprovidingpractical suggestionsorsimple 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 which case they refer to all the topics 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 Torquewrench setting
DNut
Dx Right
FPicture
GGasket
PPage
RWasher
Sx Left
TTable
VScrew
TECHNICALDICTIONARY
V = (DC) Directcurrent(battery supply)
V ~ (AC) Alternatingcurrent(flywheel supply)
A :Ampere Unit of measurement of the electrical current
W:Watt Unitofmeasurementoftheelectrical power(productofVolts andAmperes;A xV=W)
ΩΩ
ΩΩ
Ω: OHM Unit of measurement of the electrical resistance
<Lower
≤≤
≤≤
≤Loweror equal
>Higher
≥≥
≥≥
≥Higheror equal
bar Unitofmeasurement ofpressure
N * m Newton/metre Unitofmeasurement of thetighteningtorque

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M
R
SYMBOL LIST
CAUTION!
Recommendationsand
precautionsregardingrider
safetyand motor vehicle
integrity.
WARNING! Situations
entailing the risk of personal
injury to maintenance or repair
mechanics, other workshop
personnel or third parties, or
damage to environment,
vehicle or equipment
FIREHAZARD.
Indicatesoperationswhich
mayconstitute a fire
hazard
RISK OF
EXPLOSION
Indicatesoperations
whichmay constitute a
riskof explosion
TOXIC FUMES
Indicatesapossibility of
intoxicationorinflammation
ofthe upper respiratory
tract
WARNING!
Dangerof crashing
arms
SAFETYGLOVES
Theseoperationsrequire
theuse of safetygloves
IMPORTANT
Thistopic requires special
attention
GENERALSERVICE
PERSONNEL
Skilledelectronicor
mechanicaltechnician.
MECHANICAL
MAINTENANCE
Operationsto be
performedonly by an
expertmechanic
ELECTRICAL
MAINTENANCE
Operationsbeperformed
onlyby an expert electrical/
electronictechnician
IGNITION KEY ON
(ONposition)
PRESENTMANUAL
Informationonthe
presentmanual
“ENGINE”SERVICE
MANUAL
Indicatesinformationwhich
maybeobtained by
referringtosaid catalogue
SPARE PARTS
CATALOGUE
Indicatesinformationwhich
maybeobtained by
referringtosaid catalogue
DISASSEMBLY
OPERATIONS
ASSEMBLY
OPERATIONS
SYMMETRICAL
OPERATIONS
Operationsthat must be
carriedout also on theother
sideof the unit or
component.
EMPTYTHECIRCUIT
REPLACEWITH NEW,
ORIGINALSPARE
PARTS
IDLING ENGINE
Switchontheengine, at
idlingspeed,toperfom
theseinterventions.
ENGINE OFF
Indicatesoperationsto
beperformedwith
engineoff
POWER OFF
Indicatesthatnegative
poleisto be disconnected
fromthe battery before
performingtheoperation
NO!
Operationsto be
absolutelyavoided
OIL
COOLANT
FUEL

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125i.e.-160i.e.
GENERAL WORK PROCEDURES
• The recommendations given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment
damage and idle times, and should therefore be strictly adhered to.
• Always listen with attention to the customer’s opinion and complaints about the motor-bike operation, asking specific questions in order to have a complete understanding of
all the symptoms and identify with good approximation the real causes of the trouble.The present manual provides the technical information and the basic indications on the
intervention procedures but these have to be integrated with the personal expertise.
• We suggest planning the service interventions in order to avoid any waste of time or downtime.Try to reduce as much as possible the operations necessary to reach the
componentsthatneeds repairing.
• Prepare the components that are likely to be replaced and all the original spare parts you may need.
• Use only the original spare parts.
• Mark the components that maybe 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 toolsand equipment athand, possibly layingthem out accordingto thesequencein which theyare to beused. Absolutely avoidputting themonthe
vehicle itself, out-of-sight or in poorly accessible places.
• Always keep the work area neat and clean.
• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progressive “pulls”using a“criss-cross”pattern.
• The torque settings specified in the manual refer to the “final torque”, which must be attained progressively by steps.
• Preferably use open-endbox wrenches by “pulling”and not“pushing”.
Before any servicing, make sure that the vehicle is perfectly stable.
The front wheel should be anchored to fixture, which is integral with the lift platform.

511/07
125i.e.-160i.e.
•Before carrying out any operation, wait for all parts to cool down.
• For operations requiring two mechanics, make sure that the various steps to be performed byeach of them are clearly defined and co-ordinated beforehand.
• Make sure that each componenthas been properly mounted before proceeding withassembling the next one.
•Always replace gaskets, O-rings, circlips and split pins at every refitting.
• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.
Never use open flames for any reason.
Never leave open containers or containers not suitable for holding fuel in passageways, close to heat sources, etc.
Never use petrol to clean the vehicle or the floor of the workshop. Always use 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 short circuit.
• Make sure that the vehicle is stable and not to have to take on awkward working positions.
• Never reuse old gaskets or circlips.
• Never use a screwdriver as a lever or chisel.
• Never use pincers to loosen ortighten screws or nuts because, in addition to notproviding a sufficient clamping force, they mayalso damage the screw head or nut hexagon.
•Never tap the wrench with a hammer or other similar tool to loosen or tighten screws and nuts.
•Never attempt to increase the lever arm by fitting a tube into the wrench.

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CONTENTS
DESCRIPTION P.
ACCESS-SEAT- HELMETCASE 30
SEATLOCKINGDEVICE 31
ACCESS 32
FUELLEVELSENSOR-FUELPUMPSENSOR 33
FUELTANK 34
BATTERYCASECOVER -ACCESS-SIDESTRUTS 35
ACCESS 36
REARFAIRING 37
REARHANDLE 38
NUMBERPLATELIGHTHOUSING-REARLIGHTSASSEMBLY 39
FULLREARFAIRING 40
ACCESS(RIGHT SIDE) 41
(LEFTSIDE) 42
ELECTRONICCONTROLUNIT-VOLTAGEREGULATOR 43
IGNITIONCOIL-ROLLOVERSENSOR 43
REARFAIRINGBREAKDOWN 44
LEGSHIELD 45
ACCESS 46
KEYSWITCH-HORN 47
FRONTWHEEL-FRONTBRAKEDISC 47
SEQUENCEOFFRONTWHEELREASSEMBLY 48
FRONTBRAKECALIPER 48
FRONTMUDGUARD-FRONTSHIELD 49
BACKHANDLEBARCOVER-HANDELBARCONTROL-BRAKE PUMP 50
HANDLEBAR-ELECTRICFANANDRADIATOR 51
EXPANSIONTANK 53
FORK-FORKLEG-COMPLETEFORK 54
MUFFLER-OXYGENSENSOR 55
MANIFOLDEXHAUST-REASSEMBLY OFEXHAUSTSYSTEM 56
SHOCKABSORBERS-REMOUNTINGTHESHOCKABSORBERS 56
REARMUDGUARD 57
AIRINTAKEASSEMBLY 58
AIRFILTER 59
AIRFILTER MAINTENANCE-STARTER 60
REARBRAKECALIPER 61
REARWHEEL 62
REARBRAKEDISK-REARWHEEL-ENGINE 63
FRAMESIZECHECK 64
CABLEPOSITIONING,"PIPESYSTEM" ANDPOSITIONOFCLAMPS 65
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DESCRIPTION P.
TECHNICALDATA 7
IDENTIFICATION INFORMATION:FRAMEN°/ENGINEN°-TIRES 8
MAINTENANCECHART 9
LUBRICANTCHART 10
FUELTANK -COOLANTRESERVOIR 11
MOTOROIL 12
LEVELCHECK/CHANGE 12
TRANSMISSIONOIL 13
CHECKLEVEL/TOPPINGUP-CHANGE 13
BRAKEFLUID 13
CHECK-CHANGE 13
BLEEDINGTHEBRAKESYSTEM 14
FRONTCALIPER-REARCALIPER 14
CHECKFRONT/BACKBRAKEPADSANDDISKS 15
REPLACEPADS 15
FRONTBRAKES-REARBRAKES 15
FORK 16
CHECKOIL LEVELINTHEFORKLEG 16
CHANGEFORKOIL 16
SHOCKABSORBERADJUSTMENTS 16
LOCATIONOFTHEMAINELECTRICALANDELECTRONICELEMENTS 17
DASHBOARD 19
ELECTRIC/SERVICEWARNINGLIGHT-DIGITALCLOCK 19
KEYSWITCH-HANDLEBARCONTROLS 20
LEFTCONTROL-RIGHTCONTROL 20
ENGINESTARTER 20
LIGHTS 21
HEADLIGHT-LIGHTBEAMADJUSTMENT-TURNSIGNALS 21
TAIL-LIGHT-NUMBERPLATELIGHT 22
FUSES-FUSEREPLACEMENT 23
BATTERY 24
BATTERYASSEMBLY-CHARGEBATTERY 24
SPARKPLUG 25
REPLACEMENT 25
DISMANTLINGANDREMOVALPROCEDURESFORCOMPONENTS 26
REASSEMBLYNOTES-REAR-VIEWMIRROR-UPPERCOVER 26
FRONTHANDLEBARCOVERS 27
ACCESS 28
FRONTSHIELD 29

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DIMENSIONS
Wheelbase(A) m .......................................................................................1,360
Max.length(B) m........................................................................................2,050
Max.width(C) m.........................................................................................0,735
Max. height (D) m ......................................................................................1,180
Kerb weightkg ...............................................................................................140
Max.loadwith rider,passenger andluggagekg..............................................180
CAPACITY
Engine oil cm3 ........................................................................................... 1000*
Transmission oil cm3 ................................................................................... 150*
Fuel tank (total) l ................................................................................. 8,2*(3,0*)
ENGINE: 2 valve - 4 stroke single cylinder:
Type .............................................................................................. MALAGUTI01
MALAGUTI02
n°Cylinders ...................................................................................................... 1
Bore x stroke mm .......................................................................... Ø 52,4 x 57,8
Ø 58,0 x 57,8
Capacity cm3.................................................................................................125
153
CompressionRatio.................................................................................. 10,6 : 1
11,3 :1
Cooling........................................................................................................ liquid
Starting system............................................................................. electric starter
lubrication system................................................................................ wet sump
SPARK PLUG
Type ............................................................................................NGK DPR7EA9
TRANSMISSION
Primary drive:automatic transmission byV-belt speed changegear
Final:by gears.Automatic centrifugal dry clutch.
FUELSYSTEM
Electronicfuelinjection withelectricfuel pump.
Fuel: unleaded petrol.
IGNITION
Digital
BRAKES
Frontbrake: disk type Ø 245 mm double piston hydraulic caliper Ø 25 mm
Rearbrake: disk type Ø 220 mm double piston hydraulic caliper Ø 34 mm
CHASSIS
High-tensilesteeltubes
SUSPENSIONS
Front: hydraulically fork Ø 33 mm; Stroke:88 mm.
Rear: Swingingenginewithdoublehydraulicshockabsorber.Stroke:74 mm.
BATTERY
Type 12V, 9Ah, maintenance free.
TYRES
Front: 100/80-16 50P (tubeless)
Rear: 120/80-16 60P (tubeless)
* Indicative Value
SPECIFICATIONS
F. 1

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125i.e.-160i.e.
F. 2
F. 3
F. 4120/80 - 16” - 60P 100/80 - 16” - 50P
2.0 2.0 2.1
(29.0) (29.0) (30.5)
2.2 2.3 2.3
(31.9) (33.4) (33.4)
B
A
TYRES
Type:Tubeless (wiithoutinnertube)
IDENTIFICATION DATA: FRAME N° / ENGINE N°
• Thevehicle’sidentification number(VIN) (A)is locatedonthe rearside ofthe
chassis, under the helmet compartment.
• Engineidentificationdata arelocated ontheleft-hand enginecrankcase(B).
Any alteration to the vehicle identification data is pursued by the
Law.
Minimum tread depth is 2 mm.
• There areT.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.
Itishowever necessaryfor speed indexesto beidentical for bothtyres.
Use only tyres with the relevant type approval.
Tyre inflation pressure must be adjusted while the tyre is at ambient
temperature.

911/07
125i.e.-160i.e.
NOTE - Maintenance operations should be performed more frequently if the 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

10 11/07
125i.e.-160i.e.
LUBRICANT TABLE
NOTE - Useonly recommended products.
LUBRICANTS
ENGINEOIL (4STROKE)CLASS 10W 40
ENGINE TRANSMISSION OIL CLASS 10W 40
AIR FILTER LUBRICANT AIR FILTER OIL
RADIATOR FLUID TOP FLUID
BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4
FORK ROD OIL FORK OIL

11 11/07
125i.e.-160i.e.
FUEL TANK
• The fuel tank cap (A) is accessible by raising the seat, using
the ignition key and turning it clockwise.
• Checkthefluid levelinthe inspectionwindow(C) found
undertheshield.
If it needs to be topped up, use the product
specified in the lubricants chart.
Use unleaded fuel.
A
Do not remove the cap when the motor is hot.
F. 5
F. 6
F. 7
COOLANT TANK
• Open the case with the ignition key.
• Removetheplastic protectionpiece(B). B
C

12 11/07
125i.e.-160i.e.
every2,000 km
CHECKLEVEL
• Theenginemust becoldand thevehicle
onlevel ground.
• The level is shown on the cap/ dipstick
(A).
Top with the oil specified in the
lubricant chart.
F. 8
F. 9 F. 10
A
1
3
2
A
S
F
ENGINE OIL
• Placeanappropriate drain panunder the engine(withthe vehicleonflat
ground).
• Pull out the cap/ dipstick (A).
• Unscrew the drain plug (S) and let all the used oil drain out.
• Removethefilter/plug(F).
• Wash the screen (1) with solvent or if it is damaged, replace it.
• Checkthewear conditionsofthe O-Ring(3)and replace ifnecessary.
• Reassembly:O-Ring (3)-Spring(2)- Screen(1)and tightenthefilter/plug.
• Screw on and tighten the drain plug (S).
• Top up the engine with 800 cc of Q8 CLASS 10W40 oil and replace the cap/
dipstick.
Start the engine;leave it running for a few minutes, and check that there
are no leaks.
Dispose of used oil in accordance with current laws in force.
CHANGE
Warm up the engine for a few minutes and then shut it off.
• After the first 1,000 Km
• Every 4,000 KM

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125i.e.-160i.e.
CHECKLEVEL/TOP UP
• Coldengine
• Vehicle onlevelground.
• Placeadrip panunderthe engine.
• Unscrew the oil filler screw (A).
• If necessary, top up with oil specified in the lubricant
chart until the oil starts to overflow.
• Screw on the screw (A).
F. 11
TRANSMISSION OIL
CHANGE
If there is any debris or water in the brake fluid, it is essential that it be completely changed and the brake system must be bled. Excessive elasticity in the
brake lever is usually an indication that air is in the system.
CHANGE • After the first 1,000 Km
• Every 12,000 Km
• Coldengine
• Vehicle onlevelground
• Placeadrip panunderthe engine.
• Unscrew the oil filler screw (A).
• Unscrewthedrain screw(B)
• Drain out all the used oil.
• Clean the threads of the drain screw and screw back on.
• Refill the crankcase with oil specified in the lubricant
chart until the oil starts to overflow.
• Screw back on the screw (A).
CHECK
• Visually check by way of the warning signal (S) located on the front and back
brake reservoir, withthevehicleonlevelgroundand perfectly straight.
• The fluid levelmust be 3mm fromthe lower limitofthe warning signal.
BRAKE FLUID
A
B
SS
F. 12
every 30 days
Every 12,000 Km or 24 months
Do not mix different oil types when topping off.

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125i.e.-160i.e.
C
V
V
C
• Repeattheoperation, untilonly liquidcomesout of
therubbertube.
BLEED BRAKE SYSTEM
FRONTCALIPER
NOTE - Position the vehicle in a stabile manner and
perfectlyonlevel ground.
• Removethe(rightside)oil pumpreservoircover(A),
unscrewing the relative screws (V"), in order to be
able to top off the fluid.
• Fill the right brake fluid reservoir (B) to the highest
level.
• Remove the rubber hood (C) of the bleeder screw
(V) and insert a rubber tube to recover the brake
fluid.
• Pump the right brake lever (D), prime it and bring
the system in pressure.
• Keepingthebrakeleverpumped,loosenthebleeder
screws (V), to allow air to escape. Then, tighten
thebleederscrew (V) F.13 F.14
F. 15
F. 16
V12 ± 16%
REARCALIPER
• Tobleed therearcaliper,followthe sameoperation
above,butpump theleft brake lever(S).
AV2
B
S
B
D
V2A
• Topupthe brakefluid levelin the reservoir(B).

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125i.e.-160i.e.
F. 20
CHECK FRONT/BACK BRAKE PADS AND DISKS
• Check the condition of front and back brake pads and discs
every 2,000 Km.
• Carry out a visual check on the thickness of the brake pads as
shown in the illustration.The minimum thickness of the brake
pad friction material must not be less than 2mm.
• Replace the pads if they are close to the allowed limit, or if they
aredamaged.
F. 21
REPLACING PADS
F. 19
REARBRAKE
F.17 F.18
FRONTBRAKE
NOTE - The procedures for replacing front and back brake pads
canbededucedfrom the illustrationshownbelow.

16 11/07
125i.e.-160i.e.
FORK
CHECKOILLEVEL INTHE
FORKLEG
• Remove the fork leg.
If a "limit switch" of the fork is
found, or if they produce
abnormal sounds, the oil level
inside the pins must be
checked. Removal of the legs
can be seen in F.22.
• Insertaruler orgauge and
check that the oil is at least
75mm fromtheupper edge
of the leg.
• If necessary, top up with oil:
FORK OIL
F. 22
Adjust both shock absorbers using these instructions.
Uneven adjustment can compromise the stability of the vehicle.
F. 23
A
V
Perform adjustments using the special key equipped on the ring nut (A), located on the upper part of the shock absorbers;
turning it anti- clockwise will increase the strength of the spring (increase in load)
SHOCK ABSORBER
ADJUSTMENTS
5)adjustmentpositions areincluded:
1)driveronly (to75kg)
2)driveronly(over75 kg)
3)driverandcase
4)driver andpassenger
5)driver,passenger,andcase.
CHANGEFORK OIL
• Placeanappropriatedrippan underthe sliderandremove thescrews
(V).
• Drain out as much oil as possible.
• Proceed to dismantle the fork legs, as previously described.
• Turnthefork legs upside-down,tolet theremainingoil drain out.
Hydraulic oil is corrosive and may cause personal injury.
Do not improperly dispose of used oil in the environment.
• Remountthedrain screw(V).
NOTE - Whenremounting,replace thecopperwasher locatedunder the
screw(V).
• Checktheoil level,aspreviously described.
• Reassemble the fork components and the fork on the motorcycle.
• Carefully pour the "new" oil in the fork.
Quantity per fork 90 cc.
V17 ± 15%

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125i.e.-160i.e.
LOCATION OF THE MAIN ELECTRICAL AND ELECTRONIC ELEMENTS
F. 24

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125i.e.-160i.e.
F. 25

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125i.e.-160i.e.
ELECTRIC/SERVICE MALFUNCTION WARNING
LIGHT
When the starter key is turned in the switch in the
position, without starting the engine, the
warning light (as well as the warning light )
will remain on for a few seconds to verify the
functioning, and it will normally shut off after this.
If it stays on longer (fully and/or flickering) it means:
• Electrical Malfunction (blinking light): indicates a
malfunction in the electrical system.
• SERVICE (15 short blinking lights): indicates the
needtoperformprogrammedmaintenance (seethe
MaintenanceCharton page9).
In both cases, reset the signal after performing the
necessaryoperations.
The warning light interval of the SERVICE
sign of the may have different
meanings as shown in the Maintenance
Chart,depending onthe vehiclesconditions
of use.
DIGITALCLOCK
• Date and month readout
Press the top button once (after a few seconds the clock will automatically reappear).
• Seconds readout
Press the top button twice; to restore the initial configuration, press the button again.
To set theclock andcalendar, usethetwo buttonsonthe right handsideof thedial, starting withthetime display.
• Setting the month
Press the lower button twice;and then with the top button select the exact number.
• Setting the date
Press the lower button three times;and then using the top button select the exact number.
• Setting the time
Press the lower button four times, and then using the top button select the exact number.
• Setting the minutes
Press the lower button four times, and then using the top button select the exact number.
Pressthelowerbuttononce againtoreturn tothe time display.Confirmmodificationsbypressingthe topbutton.
DASHBOARD
1) Speedometer
2) Odometer
3) Turn signal warning light (green)
4) High beams warning light (blue)
5) Electric/SERVICE Malfunction warning light
(orange)
6) coolant temperature too high warning light
(red)
7) Fuel gauge indicator
8) Coolant temperature indicator (red zone:
temperature too high)
9) Digital clock
F. 26
9
8
7
6
5
4
3
2
1