Malaguti Centro 125 Manuel d'instructions
125 - 160cc 4T
Workshop Manual Engine
1
125 - 160 cc
C
WORKSHOP MANUAL
GENERAL INDEX
Assembling the piston ...................................................................37
Stripping down the cylinder head .................................................38
Checking valve springs ..................................................................................40
Checking valves ............................................................................................. 40
Checking and adjusting valve seating ..........................................42
Inspection ....................................................................................................... 42
Change ........................................................................................................... 42
Lapping ..........................................................................................................44
Installing the cylinder .....................................................................50
Installing the cylinder head ............................................................52
Installing the camshaft support .....................................................53
Checking engine timing .................................................................57
Fitting the valves cover ..................................................................58
SPEED VARIATOR-CLUTCH UNIT
..................................60
Trouble shooting .............................................................................61
Variator unit exploded view ..........................................................62
Clutch unit exploded view .............................................................63
Clutch pulley exploded view .........................................................64
Clutch shoes assy exploded view ................................................65
Removing the clutch cover ............................................................66
Assembly ........................................................................................................ 67
Primary pulley .................................................................................67
Disassembly ................................................................................................... 67
Checks .............................................................................................70
Drive belt ........................................................................................................ 70
Roller weights ................................................................................................. 71
Mobile primary pulley .....................................................................................71
OIL PUMP ASSY
...........................................................................3
Trouble shooting ............................................................................................... 4
Exploded view of oil pump ...............................................................5
Disassembly ......................................................................................6
Removing the oil pump ....................................................................................8
Oil pump body tolerances ................................................................................9
Clearance between oil pump inner and outer rotors ...................10
Clearance between front surfaces ................................................10
Assembly ......................................................................................... 11
CYLINDER HEAD, VALVES, CYLINDER, PISTON
.....15
Working precautions ......................................................................15
Trouble shooting .............................................................................18
Cylinder head exploded view .........................................................19
Cylinder compression pressure ...................................................20
Valve clearance adjustment ...........................................................21
Removing camshaft support .........................................................23
Removing the camshaft .................................................................26
Checks .............................................................................................27
Camshaft ....................................................................................................... 27
Rocker arms and rocker arm spindles ...........................................................28
Removing the cylinder head ..........................................................29
Removing the cylinder ...................................................................31
Removing the piston ......................................................................32
Cylinder / piston checks .................................................................34
Checking the cylinder ..................................................................................... 34
Checking the piston ........................................................................................ 34
2
125 -160 cc
C
WORKSHOP MANUAL
GENERAL INDEX
Installing the primary pulley ..........................................................73
Disassembling the clutch...............................................................76
Disassembling the clutch unit .......................................................77
Removing the secondary pulley ...................................................78
Checks .............................................................................................80
Clutch bell ...................................................................................................... 80
Clutch linings .................................................................................................. 80
Variator contrast spring .................................................................................81
Fixed secondary pulley ..................................................................................81
Mobile secondary pulley................................................................................. 82
Assembling the clutch....................................................................83
Installing the clutch bell .................................................................87
FINAL DRIVE GEARS
.............................................................88
Final drive exploded view...............................................................89
Removing the transmission cover ................................................90
Remove pulley shaft .......................................................................92
Transmission cover checks ...........................................................92
Removal and retting of transmission cover bearings
and oil seal.......................................................................................94
Removal and retting of clutch side engine casing bearings
and oil seals.....................................................................................96
Installing the transmission gears..................................................97
Installing the transmission cover..................................................98
FLYWHEEL COVER, FLYWHEEL MAGNETO,
WATER PUMP
............................................................................100
Exploded view of water pump......................................................101
Exploded view of ywheel cover.................................................102
Removing the ywheel cover.......................................................103
Removing the ywheel magneto .................................................................. 104
Removing the freewheel gear ...................................................................... 105
Removing the stator/pick-up assy ................................................................ 106
Removing the water pump impeller.............................................................. 106
Installing the water pump.............................................................107
Assembly procedure .................................................................................... 107
Installing the stator/pick-up assy ................................................108
Installing the freewheel gear and rotor.......................................109
Installing the ywheel cover ........................................................ 111
ENGINE CASING, CRANKSHAFT
.................................113
Removing the engine casings ..................................................... 114
Crankshaft checks ........................................................................ 115
Installing the engine casing......................................................... 117
3
125 - 160 cc
C
WORKSHOP MANUAL
• The oil pump must be serviced after having removed the flywheel cover.
• When the values measured are outside the service limits, renew the oil pump.
• Ensure that no foreign material enters the engine when the oil pump is removed.
• Check for oil leaks once the pump has been installed.
Standard
Oil quantityFor oil change 800 cc.
Total capacity 1000 cc.
Recommended oil
temperature and viscosity
(temperature)
- 10° 0° 10° 20° 30° 40°C
SAE 20W /40
SAE 10W / 50
SAE 10W / 40
SAE 10W / 30
SAE 10W-40 20W-50 Special
for 4-stroke engines
When using alternative oils, select from the following range
API: type SE or SF engine oil
SAE: select from the table alongside on the basis of the outdoor
temperature.
cont’d
OIL PUMP ASSY
07028005
4
125 - 160 cc
C
WORKSHOP MANUAL
OIL PUMP ASSY
Standard Service limit
Oil pump rotor Radial clearance between
inner and outer rotors
0.15 mm 0.20 mm
Pump body radial clearance 0.15 - 0.23 mm 0.25 mm
Front clearance between
surfaces
0.05 - 0.10 mm 0.12 mm
Tightening torques
Pump body screws 10 N*m ± 15%
Pump cover screws 2 N*m ± 15%
Protection plate A assy 10 N*m ± 15%
Protection plate B 10 N*m ± 15%
Trouble shooting
Low oil level; possible causes:
1) Normal consumption (check scheduled service has been performed).
2) Oil leaks.
3) Wear or incorrect fitting of piston rings.
4) Wear of valve guide or valve stem.
5) Valve seat rings damaged.
5
125 - 160 cc
C
07028001
7
1
6
3
4
5 2
WORKSHOP MANUAL
OIL PUMP ASSY
Exploded view of oil pump
1) Pump cover
2) Pump shaft
3) Inner rotor
4) Outer rotor
5) Pump body
6) Locating dowel
7) Screw
6
125 - 160 cc
C
A
C
07028101
07028102
WORKSHOP MANUAL
Ensure that no foreign material enters the engine when the
oil pump is removed and refitted.
Disassembly
Remove:
• flywheel cover.
• rotor and freewheel gear.
• chain guard (A) and oil pump assembly.
Remove circlip (C) from shaft.
OIL PUMP ASSY
7
125 - 160 cc
C
D
E
B
07028103
07028104
WORKSHOP MANUAL
OIL PUMP ASSY
Remove chain ring (D) and chain (E).
Check chain for damage or excessive wear.
Remove chain guard (B).
8
125 - 160 cc
C
GF
C V
07028100
DSCN8392
WORKSHOP MANUAL
OIL PUMP ASSY
Remove pump assy (F) and pump shaft (G).
Check pump for possible damage or excessive wear.
Removing the oil pump
Undo screw (V) and remove pump cover (C).
9
125 - 160 cc
C
Q M
L N
M N
07028105
07028106
WORKSHOP MANUAL
OIL PUMP ASSY
Remove inner rotor (L) and outer rotor (M) from pump body (N), paying
attention to locating dowel (Q).
Oil pump body tolerances
Measure outside diameter of outer rotor (M) and inside diameter of pump
body (N) with callipers and inside micrometer; the difference between the
two values is the “radial clearance” of the pump body.
Service limit: 0.25 mm
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1
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