Malaguti PHANTHOM F12R User manual

107/07
MALAGUTI S.p.A.
Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY
Tel.[phone]-Fax[phone]
e-mail:[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 toread all the general informationbeforegoing through the manual tothe specific topics and themaintenance operations to be carriedouton the motor-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 inourmotor-bikesaretobe performed by skilled and experttechnical personnel with specificexperience
instate-of-the-art technology andfull knowledge of the quickestandmostrationalprocedures,technical characteristics, setting values,tighteningtorquesand information as
to which may only be properly and exhaustively provided by the manufacturer.
• It is important to adherestrictly to the followinginstructions.Anyoperationcarried out carelessly or notcarried out atallmay lead to personal injury,damagetothemotorcycle
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.

207/07
NOTES FOR EASY CONSULTATION
ABBREVIATIONS
EDITING SYMBOLS:
• Symbols have been provided for quick and easy reference,identifyingsituationsrequiring utmost attention orproviding practical suggestions orsimple 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 Torquewrenchsetting
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 Unitofmeasurementoftheelectricalpower(productofVoltsand Amperes;A xV=W)
ΩΩ
ΩΩ
Ω: OHM Unit of measurement of the electrical resistance
<Lower
≤≤
≤≤
≤Lowerorequal
>Higher
≥≥
≥≥
≥Higherorequal
bar Unitof measurement of pressure
N * m Unitofmeasurement ofthetighteningtorque

307/07
M
R
SYMBOL LIST
CAUTION!
Recommendationsand
precautionsregarding rider
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.
Indicatesoperations which
mayconstitute a fire
hazard
RISK OF
EXPLOSION
Indicatesoperations
whichmay constitute a
riskofexplosion
TOXIC FUMES
Indicatesa possibilityof
intoxicationor inflammation
oftheupper respiratory
tract
WARNING!
Dangerof crashing
arms
SAFETYGLOVES
Theseoperations require
theuseof safetygloves
IMPORTANT
Thistopic requires special
attention
GENERALSERVICE
PERSONNEL
Skilledelectronic or
mechanicaltechnician.
MECHANICAL
MAINTENANCE
Operationsto be
performedonly by an
expertmechanic
ELECTRICAL
MAINTENANCE
Operationsbe performed
onlyby an expertelectrical/
electronictechnician
IGNITION KEY ON
(ONposition)
PRESENTMANUAL
Informationon the
presentmanual
“ENGINE”SERVICE
MANUAL
Indicatesinformation which
maybe obtainedby
referringto saidcatalogue
SPARE PARTS
CATALOGUE
Indicatesinformation which
maybe obtainedby
referringto saidcatalogue
DISASSEMBLY
OPERATIONS
ASSEMBLY
OPERATIONS
SYMMETRICAL
OPERATIONS
Operationsthat mustbe
carriedout also onthe other
sideof the unitor
component.
REPLACEWITH NEW,
ORIGINALSPARE
PARTS
IDLING ENGINE
Switchon theengine, at
idlingspeed, toperfom
theseinterventions.
ENGINE OFF
Indicatesoperations to
beperformed with
engineoff
POWER OFF
Indicatesthat negative
poleis tobedisconnected
fromthe battery before
performingthe operation
NO!
Operationsto be
absolutelyavoided
OIL
FUEL
EMPTYTHECIRCUIT

407/07
F. 1
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,alwayskeep toolsandequipment athand,possibly layingthemout accordingtothe sequenceinwhich theyareto beused.Absolutely avoidputtingthem onthe
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 wrenchesby “pulling” and not “pushing”.
• The roller adjustable wrenches must be used only in case of emergency, that is to say when the right size wrench is not available.
In fact, when force is applied, the mobile vice tends to open and this may cause damage to the bolts and also result in a scarcely
reliabletightening torque. Always usethe wrenches as indicatedin Figure.

507/07 F. 2
•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 beenproperly mounted beforeproceeding with assembling 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 ornuts because,in addition tonot providing asufficient clampingforce, theymay also damagethe screw heador nuthexagon.
•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.

607/07
A
F. 3
Before 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.

707/07
CONTENTS
DESCRIPTION P.
SPECIFICATIONS 8
IDENTIFICATION DATA: FRAME N° / ENGINE N° 9
TYRES 9
MAINTENANCETABLE 10
LUBRICANTTABLE 11
REARMIRRORS 12
FAIRING 12
FRONTHANDLEBARCOVER 12
DASHBOARDHOLDER 12
DASHBOARD 12
ACCESSES(after removingthe fronthandlebar cover) 13
FRONTSHIELD 13
HEADLIGHTS 15
DIRECTION INDICATORS 15
ACCESSES(after removingthe shield) 16
LOWERSIDEPANELS 17
FLOORBOARDS 17
BATTERYSEAT COVER 17
BATTERY 17
FUSEDESCRIPTION 18
FUSEREPLACEMENT 18
SEATCOVERSTORAGECOMPARTMENT 18
ACCESSES 19
LEGSHIELD 19
SEAT 20
SEAT LOCKING DEVICE 20
HELMETCOMPARTMENT 21
ACCESSES(afterremovingthehelmet compartment) 21
FUELLEVEL PROBE 22
COVER 22
ACCESSES(after removingthe cover) 22
REARFAIRING 23
NUMBERPLATEHOLDER 24
DESCRIPTION P.
CENTRALTUNNEL 24
OILTANK 25
FUELTANK 25
GASPEDAL CABLESPLITTER 27
REARMUDGUARD 28
FRONTMUDGUARD 28
HANDLEBARCOMMANDS 29
BRAKEPUMPS 29
HANDLEBAR 29
KEYSWITCH 30
HORN 30
ODOMETERSENSOR 30
FRONTWHEEL 31
FRONT BRAKE 32
CHECKINGLINING WEARANDBRAKEDISC 32
REPLACINGTHELININGS 32
BRAKECALIPER 32
FORK 33
WHEELSHAFT 33
OILLEVEL CHECK 33
OILREPLACEMENT (wheelshafts) 34
FORKASSY 34
REARWHEEL 35
REARDRUM BRAKE 35
CHECKING 36
BRAKELEVERADJUSTMENT 36
EXHAUSTSYSTEM 37
RADIATOR 37
AIR FILTER (Maintenance) (Removing) 38
ENGINE 39
FRAMEDIMENSION CHECK 41
CABLE POSITIONING,“PIPE SYSTEM”AND 42
LOCATION OF ANCHORING STRAPS
1234
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807/07
SPECIFICATIONS
DIMENSIONS
Wheelbase(A) m .......................................................................................1,300
Max.length (B) m........................................................................................1,830
Max.width (C) m .........................................................................................0,705
Max.height (D) m........................................................................................1,160
Kerb weightkg ...............................................................................................105
Max.load with rider,passengerandluggage kg..............................................175
CAPACITY
Engine oil cm3 ........................................................................................... 1400*
Transmission oil cm3 ................................................................................... 100*
Fuel tank (total)........................................................................................... l 9.5*
TWO-STROKEENGINE
Type...................................................................................................... CMA02C
Cylinders........................................................................................................... 1
Bore x stroke mm ............................................................................. Ø 40 x 39,2
Capacity cm3.................................................................................................. 49
Cooling............................................................................................................ air
Starting system. ............................................. electric starter and/or kick starter
SPARK PLUG
Type............................................................................................... NGK 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
Frontbrake: disk type, Ø 190 mm with transmission and hydraulic calipers
Rearbrake: drum type, Ø 110 mm with mechanical transmission.
CHASSIS
Steel tube single beam, split at the footrest.
SUSPENSIONS
Front: hydraulically controlled fork with two Ø 30 mm rods. Stroke: 88 mm.
Rear: hydraulic shock absorber.Stroke:60 mm.
BATTERY
Type12V,5Ah.
TYRES
Front: 130/60-13 53 J
Rear: 130/60-13 53 J
* Indicative Value
F. 4

907/07
F. 5 F. 6
F. 7
130/6013”53J 130/6013”53J
TYRES
Type:Tubeless
IDENTIFICATION DATA: FRAME N° / ENGINE N°
• Thevehicle’s identification number(VIN)(A)is located on the rear side of the
chassis, under the helmet compartment.
• Engineidentificationdata are located on the left-handenginecrankcase(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.
Itishowevernecessaryforspeedindexestobeidenticalforbothtyres.
Use only tyres with the relevant type approval.
Tyre inflation pressure must be adjusted while the tyre is at ambient temperature.

10 07/07
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

11 07/07
LUBRICANTS
ENGINE TRANSMISSION OIL T35 - 80W
OILFOR MIXING CITY BIKE ULTRA (synthetic)
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 recommendedproducts.

12 07/07
REAR MIRRORS
• Uncoverand loosen the nut
(D).
• Unscrewthearmholding
themirror.
• Removethefronthandlebar,
includingthedashboard.
• Disconnect the dashboard
connector.
D
F. 9
F.11 F.12
DASHBOARDHOLDER
• V3 -
V3
V4
V31 ± 10%
DASHBOARD
• V4 -
F. 10
V3
V3
V31 ± 10%
FAIRING
FRONTHANDLEBAR
COVER
• V3 -

13 07/07
ACCESSES
(after removing the front handlebar cover)
1) Dashboardconnector
2) Front brake “stop”switch
3) Rear brake “stop”switch
4) Right switch connector
5) Left switch connector
6) Frontbrakepump oil connection
7) Rear brake transmission
8) Dashboard protection condenser
F. 13
F. 14
FRONTSHIELD
• Position adequatesupport beneath the scooter.
NOTE - Remove:
-Front mudguard (p.28)
-Front wheel (p.31).
F. 15
V
V5 ± 20%
V32 ± 10%
V3
•V-
• V3 -
6
2
87
3
154

14 07/07
• Gently separate the shield and disconnect the connector (A).
• Removethe shield, including the
headlightsand the direction indicators.
F. 17
F. 16
• V6 -
V62 ± 10%
V6
F. 18
A

15 07/07
HEADLIGHTS
•V2
• V2a
• V - (regulation screws for the
beamof light)
• Gutter(A)
• Shell(D)
• Faston(C)
DIRECTION
INDICATORS
• Shell(D)
•V1
F. 19
V2a
F. 20
B
C
V2
A DD B
F. 21
V
V1

16 07/07
ACCESSES
(after removing the shield)
NOTE - Cut the strap (A - F. 12) and remove the sheath
(B) to access connectors (F.12/a).
1) Odometer transmission connector
2) Key switch connector
3) Connector for anti-theftdevice
4) Headlights connector
5) Fuse box connections
6) Steering wheel allowanceregulationringnut
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.

17 07/07
LOWER SIDE PANELS
• V2 -
• V3 - (F. 24)
F. 25 F. 26
V2
V32 ± 10%
V
FLOORBOARDS
(after removing the
lower side panels)
•V-
• V2 -
V2
V3
V2V
F. 24
V25 ± 20%
BATTERY SEAT
COVER
•V
• Cover(A)
BATTERY
•V1
• Stop battery (B)
• Removebattery
• Disconnect the vent
pipe(C)
• Disconnectthe cables;
firstly the cable
connectedto
mass
C
V1
B
A
-
F. 23
V2

18 07/07
F. 29
F. 30
FUSE DESCRIPTION
A) 10 A - General protection/
Recharge
B) 5 A - Stop protection/
Directionindicators/
Horn
C) 7,5 A - Lights protection/
Starter
A
B
C
FUSE REPLACEMENT
Always replace a fuse with
another of same 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-
stratedinthefigure;connect
the positive cable first.
Do not invert cable
connection.
+
SEAT COVER
STORAGE COMPARTMENT
•V-
• Cover(A).
AV

19 07/07
LEG SHIELD
• V - (F. 31)
• V1 -
V15 ± 20%
• Removethe cover
(A - F. 31) of the key
switch.
F. 32
F. 33 F. 34
B
F. 31
ACCESSES
• Socketforbatteryrecharging
(B)(max. 5 Ah).
V5 ± 20% V
B
A
V1
C
• Remove the Fastons (B) on
the back of the fuse box.
Write down the
positions of the
Fastonsbefore
disconnecting them.
• Openthetwo wire
clamps(C).