Malaguti XTM 50 Manuel d'instructions

XTM - XSM

WORKSHOP MANUALS

CHASSIS

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INTRODUCTION 1 4

Notes for easy consultation 1 5

Abbreviations 1 6

General work procedures 1 7

Editing symbols 1 9

GETTING TO KNOW YOUR MOTORBIKE 2 10

Specifications 2 10

Unpacking 2 12

Appearance check 2 12

Registration data 2 12

Anti-tampering label 2 12

Main components 2 13

Controls 2 14

Start switch/keys 2 14

Side stand 2 15

Display 2 15

Tires 2 16

Fuel tank 2 16

Coolant 2 17

Engine oil 2 17

Transmission oil 2 18

Brake fluid 2 18

Adjustment of engine idling speed 2 19

Shock absorber adjustment 2 19

Adjusting transmission chain tightness 2 19

DISASSEMBLY 3 20

Seat 3 20

Rear side casings 3 20

Tail section 3 20

Conveyor 3 21

Silencer 3 22

Muffler 3 22

Battery 3 23

Rear indicators 3 23

Tail light 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

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

Guard/front wing 3 32

Headlight 3 33

Display 3 33

Throttle control 3 33

Front brake pump 3 33

Clutch control 3 34

Handlebar 3 34

Front brake caliper 3 34

Removingthefrontbrakecalipers 3 35

Speedometer sensor 3 35

Front wheel 3 36

Front brake disc 3 36

Fork head 3 37

Fork 3 37

Foot rests (lh/rh) 3 37

Rear brake lever 3 38

Rear brake pump 3 38

Rear wheel 3 38

Rear brake calipers 3 39

Removingtherearbrakecalipers 3 39

Rear disc brake 3 39

Chain crankcase 3 40

Fork 3 40

ASSEMBLY 4 41

Chassis torque wrench settings 4 41

TABLE OF CONTENTS

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INTRODUCTION

•This Workshop Manual describes the main electrical/mechanical checks, the essential checks, and the as-

sembly of components supplied disassembled, in order to deliver a brand new motorcycle (the sequence of

operations is not binding).

•It is essential to follow the instructions with great care. Work carried out carelessly or, worse still, work that has

not been accomplished, can cause injuries and damage or, in the less serious cases, tiresome complaints.

“Schedules” (frequency of operations to accomplish during the guarantee period).

Note:

These manuals provide the necessary information and instructions for routine maintenance and servicing. 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 will be delivered by us (in a reasonable time) already punched and therefore

ready to be incorporated in the Manual. The superseded sheets should not be removed from the manual as they

remain applicable to the servicing of pre-modified engines.

• The table of contents will be duly updated in the event that new pages are inserted, which render the consulta-

tion of the manual difficult.

•IMPORTANT! The Workshop Manuals are to be considered as essential tools to be properly kept up-to-date so

as to maintain their “validity” over time.

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NOTES FOR EASY CONSULTATION

MODIFIED PAGES

• Modified pages shall bear the same number as those in the previous edition /pre-modified ones,

followed by the letter M, with the date of issue appearing in the appropriate box.

• Modified pages may contain new illustrations; in this case, the added illustration (or illustrations) will bear the

number of the illustration on the former page, followed by a letter.

ADDITIONAL PAGES

• Any additional pages shall bear the last number of the section to which they belong, followed by the letter Aand

the date of issue.

EDITING SYMBOLS

• 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 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. They are therefore to be considered as veritable “memory tags”. In case

of any doubt as to their meaning, consult the page in which they are fully described.

YChapter

XSection title

WPage n°

ZDate of issue

(RIGHT HAND PAGE)

PAGE LAYOUT

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ABBREVIATIONS

Note:

the letter V in the illustrations refers to retaining or adjusting screws. The number following this letter refers to the

number of the same type of screw 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 Vis

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.

FFigure

Cs Tightening torque

PPage

Pr Paragraph

SSection

Sc Diagram

TTable

VScrew

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F. 1

F. 3

F. 2

GENERAL WORK PROCEDURES

• The advice, recommendations and warnings 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. They

should therefore be strictly adhered to.

ADVICE:

• Only use quality tools and equipment.

• Only use equipment conforming to EU Directives for lifting the vehicle.

• During operations, always keep tools and equipment at hand, possibly laying them out according to the sequence in which

they are to be used. Absolutely avoid putting them on the vehicle itself, out-of-sight or in poorly accessible places.

• Always keep the work area clean and tidy.

• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progressive “pulls”

in accordance to a “criss-cross” pattern.

• Preferably use open-end box wrenches by “pulling” and not “pushing”.

• Adjustable wrenches (F. 1) should only be used in case of emergency, i.e. when a properly sized wrench is not available.

they should preferably not be used as the movable jaw tends to open thus risking damaging or not properly tightening the

bolt to the correct torque.In any case, when using an adjustable wrench, take care to proceed as shown in Figure 1.

• Except for occasional customers, always make out and deliver to the customer a work sheet specifying the operations

performed, with notes as to any future checks eventually required.

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 are

clearly defined and coordinated beforehand.

• Make sure that each component has been properly fitted before proceeding with the next one.

• Lubricate all parts (where applicable) before reinstalling them.

• Gaskets, O-rings, circlips and split pins must be replaced at every refitting.

• The torque settings specified in the manuals refer to the “final torque”, which must be attained progressively by

steps.

• Loosen and tighten aluminium alloy parts (covers) only after the engine has fully cooled down.

• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.

•Work in a comfortable position and ensure that the vehicle is stable.

• Never use a screwdriver as a lever or chisel.

• Never use pincers to loosen or tighten screws or nuts because, in addition to not providing a sufficient clamping

force, they may also damage the screw head or nut hexagon.

•Never tap the wrench with a hammer or other similar tools to loosen or tighten screws and nuts (F. 2).

•Never attempt to increase the lever arm by fitting a tube into the wrench (F. 3).

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F. 4

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.

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 perfectly stable.

The front wheel should preferably be anchored to the equipment (A - F.4) integral with the lifting board.

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EDITING SYMBOLS

A) CAUTION!

Recommendations and precautions regarding rider safety and

motor vehicle integrity.

B) WARNING!

Situations entailing the risk of personal injury to maintenance

or repair mechanics, other workshop personnel or third par-

ties, or damage to environment, vehicle or equipment.

C) FIRE HAZARD

Indicates operations 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) MECHANICAL MAINTENANCE

Operations to be performed only by an expert mechanic.

G) ELECTRICAL MAINTENANCE

Operations be performed only by an expert electrical/elec-

tronic technician.

H) NO!

Operations to be absolutely avoided.

I) ENGINE SERVICE MANUAL

Indicates information which may be obtained by referring to

said manual.

L) SPARE PARTS CATALOGUE

Indicates information which may be obtained by referring to

said catalogue.

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SECTION 2

Getting to know your motorbike

SECTION 2

A- CHASSIS

SPECIFICATIONS

ENDURO SUPERMOTARD

Dimensions:

Length 2050 mm 2000 mm

Width 850 mm

Height 1160 mm 1115 mm

Wheel base 1350 mm ± 20

Seat height 910 mm 880 mm

Minimum ground clearance 345 mm 315 mm

Minimum turning radius 2320 mm 2240 mm

Front wheel stroke 190 mm

Rear wheel stroke 220 mm

Weight:

Kerb weight 104 kg

Maximum load 160 kg

Engine:

Type 2-stroke, liquid-cooled

Cylinder arrangement single-cylinder, vertical

Displacement 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:

Type PHBN 16

Manufacturer DELL’ORTO

Chassis:

Chassis welded steel tubular bar.

Caster angle 28°

Spark plug:

Type BR9ES

Manufacturer NGK

Electrode gap 0.6 ~ 0.7 mm

Clutch mechanical, multiple disc, oil-bath type

Air filter sponge, 45ppi

Cooling system

Type water-cooled

Antifreeze-water mixture ratio 1:1

Total amount 0.55 L

Model:

Ce manuel convient aux modèles suivants

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