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CONTENTS
DESCRIPTION PAGE
INTRODUCTION 1
NOTES FOR EASY CONSULTATION 1
SPECIFICATIONS 2
MAIN COMPONENTS 3
IDENTIFICATION DATA: CHASSIS N° / ENGINE N° 3
ANTI-TAMPERING PLATE 3
TIRES 4
PRESSURE 4
FUEL TANK 5
FRONT LUGGAGE COMPARTMENT 5
REAR-VIEW MIRROR 5
HELMET COMPARTMENT 6
LUGGAGE HOOK 6
INSTRUMENT BOARD 6
HANDLEBAR CONTROLS 7
RIGHT HAND CONTROL (FIG. 17) 7
LEFT HAND CONTROL (FIG. 18) 7
CHECKS BEFORE USE 7
MAINTENANCE TABLE 8
TRANSMISSION OIL 8
ENGINE OIL 9
LUBRICANT TABLE 10
SPARK PLUG 10
THROTTLE FREE PLAY ADJUSTMENT 10
CHECKING THE PADS AND DISC OF THE FRONT BRAKE (CONDITION AND WEAR) 11
CHECKING THE REAR BRAKE 11
HEADLIGHT 11
FRONT TURN INDICATOR 11
TAIL LAMP (WITH STOP LIGHT) 12
FUSES 12
BATTERY (12V - 5Ar) 13
BATTERY RECHARGING 13
FAIRING 14
DISMANTLING THE FRONT HANDLEBAR COVER 15
REPLACING THE HEAD LIGHT BULB 15
DISMANTLING THE REAR HANDLEBAR COVER 16
DISMANTLING THE FRONT SHIELD 16
DISMANTLING THE SIDE COVERS 17
DISMANTLING THE TAIL LIGHT ASSY 17
DISMANTLING THE REAR HANDLE 18
DISMANTLING THE HELMET COMPARTMENT 19
DISMANTLING THE FAIRING 19
BATTERY BOX 20
DISMANTLING THE FOOT BOARD 21
DISMANTLING THE LOWER SHIELD AND INNER SHIELD 21
REPLACING THE PARK LIGHT AND TURN INDICATORS BULBS 22
DISMANTLING THE FRONT MUDGUARD 22
FRONT WHEEL 24
DISMANTLING THE FRONT WHEEL 25
DISMANTLING THE FRONT BRAKE CALLIPER 25
DISMANTLING THE BRAKE DISC 25
FRONT RIM CHECK (WHEEL REMOVED) 26
CHECKING THE FRONT WHEEL SPINDLE 26
I 03/10
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DESCRIPTION PAGE
DISMANTLING THE BRAKE PAD SET 26
FRONT FORK 28
DISMANTLING THE FORK 29
REPLACING CAPS AND STEERING CONES 29
DISMANTLING THE FORK 30
OIL LEVEL CHECK 30
MAIN IGNITION SWITCH 31
REAR WHEEL AND SHOCK ABSORBER 31
DISMANTLING THE REAR WHEEL 32
DISMANTLING THE BRAKE SHOES 32
DISMANTLING THE SHOCK ABSORBER 32
CHECKING THE BRAKE HUB 33
CHECKING BRAKE SHOES 33
CHECKING THE SHOCK ABSORBER 33
DISMANTLING THE MAIN STAND 34
REMOVING THE ENGINE FROM THE CHASSIS 34
CHECKING THE END COMPRESSION PRESSURE 39
ENGINE DISMANTLING 40
DISMANTLING THE CLUTCH COVER 40
DISMANTLING THE ASSY PRIMARY PULLEY 41
DISMANTLING THE REAR CLUTCH ASSY 41
DISMANTLING THE STARTER MOTOR 42
DISMANTLING THE ETC INTAKE MANIFOLD 42
DISMANTLING THE AIR CONVEYORS 42
DISMANTLING THE VALVE COVER 43
DISMANTLING THE SECONDARY AIR VALVE 43
DISMANTLING THE ROTOR 44
DISMANTLING THE STATOR AND PICK-UP 45
DISMANTLING THE CHAIN TENSIONER 45
DISMANTLING THE HEAD 46
DISMANTLING THE ROCKER ARMS 47
DISMANTLING VALVES AND VALVE STEM SEALS 47
DISMANTLING THE CYLINDER 48
DISMANTLING THE PISTON 49
DISMANTLING THE OIL SUMP 49
DISMANTLING THE OIL PUMP 50
DISMANTLING THE RIGHT CRANK CASE 51
DISMANTLING THE CRANK SHAFT 51
CHECK CONNECTING ROD ASSEMBLY 51
DISMANTLING THE TRANSMISSION COVER 52
ASSEMBLY 53
CRANKCASE ASSEMBLY 53
ASSEMBLE THE OIL SUMP 54
ASSEMBLING THE STATOR AND PICK-UP 55
ASSEMBLING THE PISTON RINGS 56
ASSEMBLING THE PISTON 56
ASSEMBLING THE CYLINDER 57
ASSEMBLING THE HEAD 57
TIMING 58
HEAD CYLINDER TIGHTENING 58
CHECKING TIMING 59
VALVE TIMING ADJUSTMENT 59
VARIOUS INTERVENTIONS 60
DISMANTLING THE STARTING SYSTEM 60
ASSEMBLING THE STARTING SYSTEM 60
II 03/10
DESCRIPTION PAGE
REPLACING CENTRIFUGAL ROLLERS 61
DISMANTLING THE CLUTCH ASSY 61
ASSEMBLING THE CLUTCH ASSY 62
DISMANTLING THE CARBURETTOR 62
DISMANTLING THE STARTER 62
DISMANTLING THE VALVE 63
DISMANTLING THE FLOAT, NEEDLE AND JET 64
REMOVE THE IDLE SCREW AND IDLING ADJUSTING SCREW 65
CYCLE TIGHTENING TORQUES 66
ENGINE TIGHTENING TORQUE 67
TIGHTENING TORQUE (GENERIC TABLE) 68
FRAME DIMENSION CHECKS 68
ELECTRICAL PART LOCATION 69
SWITCH CHECKS 71
CHECK FUEL LEVEL GAUGE 71
CHECK FUEL LEVEL SENSOR 72
IGNITION 72
HT COIL 72
SPARK PLUG CAP 72
STATOR (POWER 70W) 72
WIRING DIAGRAM 73
III 03/10
INTRODUCTION NOTES FOR EASY CONSULTATION
- MALBO Line makes on-going efforts to perfect all its For a quick and easy interpretation, symbols have been
vehicles as well as the manuals supplied with them. used to highlight situations requiring extra attention,
- MALBO Line reserves the right to modify its models practical advice or just information.
without notice; therefore, kindly check if the vehicle
meets your expectations before purchasing it. ATTENZION! Tips and precautions regarding
- All MALBO Line vehicles are designed and built with the safety of the rider (motorcycle user) and the
their common use in mind: therefore, any special use maintenance of vehicle integrity.
of MALBO Line vehicles is excluded unless expressly
approved in writing by MALBO Line. IMPORTANT! Subject matter for which you
- The vehicle observes the emission limits provided must pay special attention.
for by the European directive for motorcycles.
- Exclusively refuel your vehicle with: UNLEADED PET-
ROL.
The muffler irradiates heat even after the engine has just
been turned off. We therefore recommend you to careful-
ly read the following instructions:
- Always allow the engine and muffler to cool down be-
fore any maintenance operation, in order to avoid hot
surfaces.
- Make sure you do not park nor stop your vehicle on
grass, paper, deadleaves or other easily inflammable
materials.
- The passenger should get on and off the vehicle from
the opposite side of the muffler, in order to avoid hot
surfaces.
1 03/10
SPECIFICATIONS Ignition
Electronic.
MALBO Line reserves the right to modify the specifica-
tions at any time without prior notice. Brakes
Front brake:
disk type, Ø 155 mm
transmission and hydraulic calipers.
Rear brake:
drum Ø 110 mm
mechanical transmission.
Chassis
High resistance tubular steel frame.
Suspensions
Front: hydraulicall fork Ø 26 mm.
Rear: Swinging engine with hydraulic shock absorber
featuring helical spring.
Fig. 01 Battery
12V, 5Ah, maintenance-free.
Dimensions
Wheel base (A-Fig. 01) m .....................................1,200 Tires
Max. length (B-Fig. 01) m ......................................1,640 Front: .........3.50 - 10 42J (tubeless)
Max. width (C-Fig. 01) m ......................................0,685 Rear: .........3.50 - 10 42J (tubeless)
Max. height (D-Fig. 01) m ......................................1,075
Kerb weight kg ...........................................................85
Max. load with rider, passenger and luggage Kg .....160 It is possible to use tires with load-capacity and
speed indexes that are higher than or identical
Capacity to those indicated.
Engine oil cm3 ........................................................ 800* It is however necessary for the speed indexes
Transmission oil cm3 .............................................. 120* to be identical for both tires.
Fuel tank capacity (reserve) l .......................... 6,0 (1,5)*
Engine: single-cylinder - 4-stroke

Type ................................................................ 139QMB
Cylinders ......................................................................1
Bore x stroke mm ........................................ Ø 39 x 41,4
Capacity cm3 ..............................................................49
Compression ratio ..............................................10,5 : 1
Cooling ............................................................forced air
Starting system ...................electrical and/or kickstarter
Lubrication system ........................... by wet crank case
Spark plug
Type ....................... NGK CR7HSA - A7RTC - LDA7TC
Transmission
Primary: automatic speed variator by V-belt.
Final: by gears.
Automatic centrifugal dry clutch.
Fuel system
Automatic starter
Fuel: unleaded petrol.
*Indicative Value
2 03/10
MAIN COMPONENTS
1 - Headlight 1 13
2 - Front turn indicator
3 - Passenger footboard 2 10
4 - Centre stand 6
5 - Battery - Protection fuses
6 - Helmet compartment
7 - Tail lamp
5 3
8 - Number plate holder
9 - Muffler
10 - Luggage hooks 4
11 - Front luggage compartment
12 - Ignition key Fig. 02
13 - Mirror 17 14
16 15
14 - Instrument board
15 - Twin seat 7
16 - Fuel tank cap 12
17 - Passenger handles 8
11
9
3 Fig. 03
IDENTIFICATION DATA: CHASSIS N° / ANTI-TAMPERING PLATE

ENGINE N° An anti-tampering plate (C-Fig. 06), bearing all vehicle
- The type approval and vehicle numbers (VIN) are identification data required by Directive 97/24/CE
stamped on the vehicle’s chassis in the positions Chap. 7, is fitted on the filter box. If you have the filter box
shown in the photos (A-Fig. 04). replaced, make sure the plate is fitted too.
- Engine identification data are visible on the left engine This label must be neither removed nor
crankcase (B-Fig. 05). changed.
Altering identification data will be punished ac-
cording to the law.
- When ordering spare parts, also quote the vehicle
identification data.
A B
Fig. 04 Fig. 05 C
Fig. 06
3 03/10
TIRES PRESSURE
Type: Tubeless (without inner tube)
The pressure of tires must be adjusted while

the tire is at ambient temperature.
X Y Pressure differing from that indicated can lead

to higher fuel consumption, irregular wear of
3.50-10 42J 3.50-10 42J Fig. 07 the tire, impaired vehicle performance and rid-
It is possible to use tires with load-capacity and ing conditions.
speed indexes that are higher than or identical
to those indicated.
It is however necessary for the speed indexes
to be identical for both tires.
USE ONLY HOMOLOGATED TIRES.
Check the tire conditions (before every journey): if they

are broken (cracked) or cut, have them replaced as soon
as possible.
“T.W.I.” marks are provided all around the tire side walls.
These correspond to tire wear indicators, which are situ-
ated in the tire’s tread; if there is no difference between
the thickness of these indicators and the tread depth it-
self, the tire must be replaced.
Minimum tread depth (front and rear) is 2 mm

(Fig. 08).
Fig. 08
4 03/10
FUEL TANK FRONT LUGGAGE COMPARTMENT
To gain access to the fuel tank, proceed as follows: This is located at the centre of the lower fairing (A-
- Place the vehicle on the centre stand. Fig. 11). It can be used for storage small and light ob-
jects.
- Take the ignition key out of the ignition barrel and in-
sert it into the lock on the left hand side of the seat (A- It is advisable not to leave any documents or
Fig. 09). valuables inside these compartments.
- Open seat by turning ignition key clockwise (Fig. 10).
- Remove the cap (B-Fig. 09) and fill the tank.
- After refuelling, immediately remove any possible trac-
es of fuel from the vehicle body, since fuel may deteri-
orate the vehicle’s outer surfaces.
- The quantity of fuel, as well as a low fuel level, are dis-
played by the corresponding indicator on the right
hand side of the instrument board (5-Fig. 16).
- Use UNLEADED PETROL.
Important: do not overfill the fuel tank. Over- A
flowing fuel may damage the vehicle.
Petrol is extremely inflammable; avoid ap- Fig. 11
proaching the fuel filler - also during filling -
with lit cigarettes or naked flames (for instance REAR-VIEW MIRROR
matches). Danger of fire!
The left hand rear view mirror must be fitted to the han-
dlebar, in its special seat and firmly secured in place.
Adjust the visual angle of the mirror, while you are sat in
riding position on the vehicle in riding order, by turning
the mirror until you obtain the best conditions of visibility
*Indicative value in litres (P-Fig. 12).
Objects that are visible in the mirror are actually closer
than they seem.
A Do not adjust rear-view mirror while driving. Al-
B
ways wait to stop at a traffic light, for example.
Fig. 09
Fig. 12
Fig. 10
5 03/10
HELMET COMPARTMENT INSTRUMENT BOARD
- This is located under the seat. The helmet compart- 1 - Analogue instruments, Speedometer
ment can contain a Jet helmet. Some types of helmet This indicates the current speed in kmh or mph.
may not fit into the compartment. Before purchasing 2 - Odometer
your helmet, make sure it fits into the compartment. This indicates the total distance travelled in km.
3 - Green turn indicator light
- To gain access to the helmet compartment, put the ve-
4 - Blue high beam indicator light
hicle on its stand; take the ignition key out of the switch
5 - Fuel level indicator
block and insert it into the lock on the left hand side of
This displays the level of fuel in the tank.
the seat (Fig. 13). Red zone: reserve - REFUEL!!
The helmet compartment can be used to carry To prevent damage, avoid washing instru-
light objects. They shall be stored in such a ments with pressurised system.
way as not to compromise the vehicle’s stabili-
ty while riding. Do not store objects which are
not temperature resistant (lighters, inflamma-
ble liquids, perishable goods, etc.). Do not
leave documents or valuables inside the hel-
1 3
met compartment.
2
5
4
Fig. 13 Fig. 14 Fig. 16
LUGGAGE HOOK
The vehicle is fitted with two luggage hooks (G-Fig. 15)
on which you can hang small objects or bags. One of the
hooks is located at the centre of the lower fairing, the oth-
er is in centre position, under the seat. They must be
used only for holding light and stable loads.
Never use these hooks for loads that alter your
riding position or put the vehicle’s stability at
risk. The load must never protrude from the
sides of the vehicle.
Fig. 15
6 03/10
HANDLEBAR CONTROLS LEFT HAND CONTROL (FIG. 18)
1) Rear brake lever
RIGHT HAND CONTROL (FIG. 17)
1) Throttle grip 2) Horn button.
2) Front brake lever 3) Turn indicator switch.
3) Engine stop:
4) Button for turning off indicator lights
right = Position - Engine stop
5) Light switch:
left = Position - Engine starting high beam
4) Electric starter button.
low beam
PASSING High beam “flash” lever
3
5
2
2
4 1 Fig. 17 1 Fig. 18
CHECKS BEFORE USE

Part Check
Fuel Enough fuel
Transmission oil - Engine oil Level within limits specified. Check for leaks
Tires Check pressure/wear/damage
Nuts, screws, bolts Check tightness
Steering Free movement from one end to the other
Front/Rear brakes Working properly and not worn; if necessary, adjust or replace
Throttle Operation should be smooth, if necessary lubricate or adjust
Lights and indicators Proper working conditions
Stand Operation of stand and return springs
Make sure loads and accessories (e.g. rear case) are firmly secured to
Loads
vehicle
7 03/10
MAINTENANCE TABLE
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 featuring an asterisk CAN also be carried out by technicians not author-
ised by MALBO Line or MALAGUTI, but under their direct responsibility.
TRANSMISSION OIL
Checking level/topping up every 5,000 km/3,120
miles or 12 months
1 - Park the vehicle on a level surface on its centre
stand.
2 - Unscrew the dipstick (A-Fig. 19) A
3 - If necessary, top up until it overflows.
4 - Refit and tighten the oil filling screw. Recommended
oil: Q8 T35 - 80W
Renew after the first 500/1,000 km (312/624 mi) and

every 10,000 km (6,240 mi) or 24 months
1 - Park the vehicle on a level surface on its centre B
stand.
2 - Put a container under the drain cap.
3 - Remove the oil filler screw (A-Fig. 19). Fig. 19
4 - Unscrew the oil drainage screw (B-Fig. 19) and
drain out the entire oil content.
5 - Clean the drainage screw and refit it. Perform this operation with the engine off and
6 - Fill with new oil of the recommended type until you cold.
notice oil overflowing. Prevent foreign matters from getting into trans-
Recommended oil: Q8 T35 - 80W mission crankcase during checks or oil chang-
Capacity: 120 cc. es. Prevent oil dripping on tires or wheels.
7 - Refit the oil filler screw and wrench in place.
8 03/10
ENGINE OIL Topping up
Before topping up, check the oil level and in no case
Check oil level EVERY 500 KM (310 MILES)
allow the level to rise above the MAX notch.
As far as four-stroke engines are concerned, engine oil is
used to lubricate distribution components, base bearings Never allow the level to rise above the MAX
and the thermal unit. An insufficient oil quantity or use mark! Excessive internal pressure can impair
a poor quality oil can seriously damage the engine. performance and cause malfunctioning or
In all four-stroke engines, deterioration of the oil and a damage to the engine.
certain consumption are to be considered normal. Con-
sumption, in particular, strictly relates to conditions of us- Change engine oil and clean the filtering net every
age (oil consumption increases if the vehicle is used with 2,500 km/1,560 miles or 6 months
the throttle fully open). 1 - Warm the engine up for a few minutes.
To prevent trouble, check the oil level more frequent- 2 - Stop the engine and put an oil container under the
ly with respect to the indications given in the MAIN- engine.
TENANCE TABLE, especially before long journeys. 3 - Remove the drainage plug of the filtering net (A-
Fig. 21-22) and the dipstick, then let oil flow out.
Checking the oil level
This check should be performed when the engine is cold,
as described below:
1 - Park the vehicle on flat ground and put it on its cen-
tre stand. C
2 - Stop the engine and wait a few minutes for the oil to
stabilise. B
3 - Unscrew the cap/dipstick (A-Fig. 20), dry it with a
clean cloth and refit it, without wrenching it.
4 - Remove the cap/dipstick and make sure the level A
falls between the MAX and MIN notches; if neces- A
sary, top up with Q8 CLASS 10W40 oil.
Fig. 21 Fig. 22
5 - Refit the cap/dipstick (A-Fig. 20).
4 - Clean the filtering net (C-Fig. 22) with a suitable
solvent and blow dry with compressed air.
5 - Refit the filtering net, a new O-ring (B-Fig. 22) and
the drain cap.
Max Make sure the O-ring is correctly seated.
Min
6 - Tighten the drain cap at the requested torque set-

ting: Tightening torque: 25-28 Nm/2.5-2.8 kgm
7 - Fill the engine with 800 cc of Q8 CLASS 10W40 oil
and top up if necessary. Refit the dipstick.
8 - Run the engine and let it warm up; check for any
leaks. If leaks are noted, stop the engine and locate
A
Fig. 20 their cause.
When checking the oil level, make sure the ve- Letting the engine run with an insufficient
hicle is upright; slight tilting may alter the read- amount of lubricant or with the wrong types of
ings. lubricant causes wear to moving parts and can
in the long run cause serious damage.
If you need to check the level when the engine
is warm, remember that the level line will be
lower. It is best to wait at least 10 minutes from
stopping the engine in order to have a correct
reading
9 03/10
LUBRICANT TABLE
NOTE - The vehicle’s life depends also on the care devoted to lubricating it.
SPARK PLUG
Replace every 5,000 km (3,120 mi) finger tight. Then, using the special spark plug
The spark plug is an essential component: wrench, wrench it to the recommended torque
1 - Proper care of the plug is important for maintaining wrench setting: 17.5 Nm / 1.75 kgm.
the engine in perfect working order. Spark plugs with a heat rating differing from
2 - For maintenance, remove the centre partition under
the recommended one may seriously damage
the seat (P-Fig. 23) , by unscrewing the three fixing
the engine.
screws (V-Fig. 24) (2 on the footboard and one
inside the helmet compartment) and raising the bot- It is imperative that any spark plug exhibiting
tom profile (with the aid of a screwdriver) sealed cracks on the insulator or corroded electrodes
onto the two teeth of the footboard. Carefully be replaced.
remove the cap by turning it clockwise and anti-
clockwise alternatively (C-Fig. 24); now, unscrew
the spark plug using the special wrench supplied
with the vehicle (all operations on the spark plug
must be performed when the engine is cold).
3 - Examine the spark plug conditions after a reasona-
bly long drive (10-15 km) and after letting the
engine cool down (at least 10-15 minutes), since
the sediments and the colour of the insulator can C
provide useful information about the heat rating of
the spark plug, carburetion, lubrication and general V
conditions of the engine. A light brown colour of the P
insulator, around the central electrode, indicates
good working order.
4 - After disassembling the spark plug, suitably clean
the electrodes and the insulator using a metal
brush. Adjust the electrode gap using a filler gauge: 0,5Ð²0,
the gap should range from 0,5 ÷ 0,6 mm.
5 - Blow onto it so as to prevent possible residues from Fig. 23 Fig. 24
entering the engine, then refit it, by wrenching until
THROTTLE FREE PLAY ADJUSTMENT

Check that the throttle grip idle stroke is 1-3 mm (meas-
ured on the end of the throttle grip).
10 03/10
CHECKING THE PADS AND DISC OF THE
FRONT BRAKE (CONDITION AND WEAR)
1 - We recommend you to check the front pads and disc
every 2,500 km (1,560 mi).
2 - The minimum thickness of the brake lining shall not
be less than 2 mm (Fig. 25). Check the thickness of
the brake pads as illustrated in Fig. 26.
3 - If the thickness of the pads is close to the lowest per-
mitted limit or if they are damaged, have them MIN. 2mm
replaced immediately.
Fig. 25 Fig. 26
CHECKING THE REAR BRAKE

- Check whether the lever’s stroke is as illustrated in
Fig. 27. The idle stroke of the lever is approximately 10
mm. NO
- To adjust the rear brake, turn the adjuster under the en- 10 mm
gine, as illustrated in Fig. 28.
OK
Fig. 27 Fig. 28
HEADLIGHT
To increase visibility at night, quartz (halogen) type head-
lights are fitted.
- Low beam / high beam (A-Fig. 29)
Bulb 12V - 25/25W
- Parking light bulb (B-Fig. 29)
Bulb 12V - 5W
NOTE - We advise you to check if the replaced bulb works
properly before refitting the headlight unit defini-
tively. A
FRONT TURN INDICATOR

- Front turn indicator (C-Fig. 29)
Orange lamp 12V - 10W B
The rate at which the turn indicator warning light

on the instrument board flashes will increase to
signal that one of the four indicators is not work-
ing.
C
Fig. 29
11 03/10
TAIL LAMP (WITH STOP LIGHT)
- Parking/Stop light (B-Fig. 30)
Bulb 12V - 21W/5W
- Rear turn indicator (E-Fig. 30)
Bulb 12V - 10W (R10W)
NOTE - Visually check if the stop light works properly, by B
pulling one of the two brake levers.
E
Fig. 30
FUSES
The electrical equipment includes a fuse protecting the
main components against faults. It is located close to the S
battery (F-Fig. 31).
REPLACING THE FUSE

To replace the fuse, just open the battery compartment, ex-
tract the blown fuse and replace it with one of the same ca- F
pacity. Inside the fuse box, you will find a spare fuse (S-
Fig. 31). Check that the fuse you are using has the same
amperage of the fuse you are replacing.
Do not replace the fuse with one having a higher
capacity, as it could seriously damage the electri-
cal equipment and cause a fire on the vehicle in
the event of a short circuit.
Fig. 31
12 03/10
Battery (12V - 5Ar)
The battery compartment is located in the front section of
the vehicle. C B
Fitting battery
(operation performed before delivery)
To fit battery, proceed as follows:
- Take a previously charged battery.
V
- Remove the rubber mat.
- Loosen the four screws (V-Fig. 32) and remove the bat-
tery cover (C-Fig. 33). Fig. 32 Fig. 33
- Remove the 10A general protection fuse.
- Insert the battery (B-Fig. 33) and make sure it is cor- Do not use the vehicle if the battery has not
rectly seated. been fitted correctly and connected to its ca-
- Connect the battery wiring: bles.
- positive pole (+) to the RED - RED/BLUE cables
- negative pole (-) to the BLACK cables. This may cause failures and short circuit of the electrical
system and its components.
- Wrench down the battery terminals.
If the battery remains flat it will be seriously
- Refit the 10A general protection fuse previously re-
damaged.
moved.
- Check that the battery and the wiring harness are cor- We advise you to use protective gloves and
rectly installed. goggles while removing the battery from its
compartment, for example to recharge the bat-
- Refit the battery cover and the rubber mat. tery.
NEVER invert the cable connections.
BATTERY RECHARGING
- To perform this operation, it is recommended to take - The battery must always be kept completely charged.
the battery out of its compartment. During winter or when the vehicle is not used, charge
- Disconnect the cables. the battery at least once a month.
- It is good practice to recharge with amperage of 1/10 Danger of explosion! Never use open flames
with respect to that of the charged battery. (lighters, matches, etc.) to check the battery liq-
uid level.
- Refit the battery, being careful to connect the positive
cable (red) to the + pole and the negative cable (black)
to the - pole. The battery contains sulphuric acid, which is
- Wrench down the battery terminals. highly toxic. Avoid any contact with eyes, skin
or clothes.
13 03/10
FAIRING
Fig. 01
Nr. Item Nr. Item

1 Handlebar cover (front) 14 Rear fairing r/h
2 Handlebar cover (rear) 15 Rear fairing l/h
3 Front shield 16 Central fairing
4 Shield (lower) 17 Side cover r/h
5 Inner shield (upper) 18 Side cover l/h
6 Inner shield (lower) 19 Central fairing
8 VIN number cover 20 Helmet compartment
9 Foot board panel 21 Seat
10 Battery box 22 Rear handle
11 Battery cover 23 Plug
12 Mat set
13 Side cover mounting
14 03/10
DISMANTLING THE FRONT HANDLEBAR COVER
- Remove the RIGHT and LEFT mirrors (1)
1
Fig. 02
- Remove the front handlebar cover (2).
Fig. 03
- Disconnect the connector (3).
Fig. 04
REPLACING THE HEAD LIGHT BULB
- Disconnect the connector (1) and replace the light
bulb (2).
2
1
Fig. 05
15 03/10
DISMANTLING THE REAR HANDLEBAR COVER
- Remove the rear handlebar cover (1).
- Remove the speedometer cable (2).
Fig. 06
DISMANTLING THE FRONT SHIELD
- Remove the front shield (3).
Fig. 07
16 03/10
DISMANTLING THE SIDE COVERS
- Remove the central fairing (1).
1
Fig. 08
- Remove the right and left side covers (2).
Fig. 09
DISMANTLING THE TAIL LIGHT ASSY
- Unscrew the tail glass screws.
Fig. 10
17 03/10
- Release the tail cover glass by slighting pushing your
thumbs on the illustrated points.
NOTE - Be careful not to push too hard on the point (1); the
glass could break.
Fig. 11
- Tail light bulb (2).

- Turn indicator light bulbs (3).
2
3 3
Fig. 12
DISMANTLING THE REAR HANDLE
- Remove the plug (1).
1
Fig. 13
18 03/10
- Remove the rear handle (2).
2
Fig. 14
DISMANTLING THE HELMET COMPARTMENT
- Open the seat.
- Unscrew the illustrated screws and nuts. 1
- Remove the helmet compartment (1).
Fig. 15
DISMANTLING THE FAIRING
- Remove the mat set (1).
Fig. 16
- Remove the side cover mounting (2).
2
Fig. 17
19 03/10
- Unscrew the fuel tank cap (3).
3
- Before removing the fairing, release the seat opening
cable (4). 4
Fig. 18
- Remove the fairing (5).
Fig. 19
BATTERY BOX
- Remove the battery cover (1).
1
Fig. 20
- Remove the battery (2).
2
- Remove the 10 Ampere fuse box holder (3). 3
- Remove the CDI unit (4).
- Remove the starter relay (5).
4 5 Fig. 21
20 03/10
DISMANTLING THE FOOT BOARD
- Remove the battery (see specific chapter).
1
- Remove the foot board (1).
Fig. 22
DISMANTLING THE LOWER SHIELD AND INNER SHIELD
- Remove the ignition barrel cover (1).
- Remove the bag handle hook (2).
Fig. 23
- Remove the screws and remove the inner shield (3) and
lower shield (4).
4
NOTE - Before removing the lower shield (4), remove the
front wheel and front mudguard as indicated in the
specific chapters.
Fig. 24
21 03/10
REPLACING THE PARK LIGHT AND TURN INDICATORS BULBS
- Pack light bulb (1).
- Turn indicator light bulb (2).
Fig. 25
DISMANTLING THE FRONT MUDGUARD
- Release the two front mudguard halves (wheel side and
shield side).
- Remove the wheel as indicated in the specific chapter.
Fig. 26
- Release the two mudguard halves (wheel and shield

sides) from the bracket (1). 1
Fig. 27
22 03/10
- Remove the rear part (2) and front part (3).
2
Fig. 28
23 03/10
FRONT WHEEL
Fig. 29
Nr. Item Nr. Item

1 Front rim 7 Brake disc
2 Front tyre (Tubeless) 8 Bolt M8x24
3 Spacer 9 Spacer front brake
4 Bearing 6002 (ø15x32x9) 10 Nut M12
5 Bearing 6003 (ø17x35x10) 11 Front wheel spindle
6 Oil seal 12 Speedo drive
24 03/10
DISMANTLING THE FRONT WHEEL
Check perfect vehicle stability, positioned on the
main stand.
- Disconnect the speedometer cable (2).
- Unscrew the nut (1).
Cs - N*m
1 53
2
Fig. 30
DISMANTLING THE FRONT BRAKE CALLIPER

- Unscrew the front brake calliper screws (3).
- Lift the vehicle using the lift and remove the wheel.
3
Cs - N*m
3 26
Fig. 31
DISMANTLING THE BRAKE DISC

- Unscrew the 3 illustrated screws and remove the brake
disc.
Cs - N*m
V3 23
Fig. 32
25 03/10
FRONT RIM CHECK (WHEEL REMOVED)
Check front rim oscillation (Radial and Axial) and make
sure it does not exceed the service limit. If oscillation was
caused by the bearing, the rim may be reused after replac-
ing the bearing. Otherwise, replace with a new rim.
Oscillation limit = 2.0 mm
Fig. 33
CHECKING THE FRONT WHEEL SPINDLE
Check front shaft oscillation with a centesimal gauge and
replace it if it exceeds the service limit.
Measurement instrument: Micrometer
Linearity limit: 0,25 mm
Fig. 34
DISMANTLING THE BRAKE PAD SET
Do not pull the brake lever before installing the pad
set.
- Remove the screw (4).
- Rotate the calliper away from the cover.
- Remove the calliper cover.
Cs - N*m
4 26
Fig. 35
26 03/10
When reassembling:
- Mount the springs (5) as indicated.
- Mount the pad set (6) facing them in the indicated direc- 5
tions (flat side (7) facing towards the cover).
When reassembling the pad set, fully push the 6

piston into its housing.
After reassembling, pull the brake lever several

times to position the pad set in contact with the
brake disk.
7
Fig. 36
27 03/10
FRONT FORK
Fig. 37
Nr. Item Nr. Item

1 Handlebar 17 Plug
2 Bolt 18 O-Ring
3 Nut 19 Spring
4 Bolt 20 Piston tube
5 Screw 21 Seeger
6 Lock nut 22 Return spring
7 Lock washer 23 Fork tube
8 Adjustable cone 24 Dust seal
9 Steering ball cages N° 26 (ø 5/32) 25 Seeger
10 Upper washer 26 Oil seal
11 Lower washer 27 R/h fork leg assy
12 Steering ball cages (lower) N° 29 (ø 5/32) 28 Copper washer
13 Steering cone 29 Screw
14 Bottom yoke
15 Screw
16 L/h fork leg assy
Grease parts Nr. 8, 9, 10, 11, 12, 13, 26.

Tighten parts Nr. N. 3, 4, 15, 17, 29 to the specified tightening torque.
28 03/10
DISMANTLING THE FORK
- Remove the handlebar cover.
- Unscrew screw (1) and screw (2).
- Remove the front wheel.
- Remove the front mudguard.
- Remove the calliper.
- Remove the front shield
- Slide the handlebar off the fork tube.
1
Fig. 38
- Unscrew the steering lock nut (3).

- Slide off the lock washer (4).
- Unscrew the adjustable cone (5).
3
- Slide out the fork, being careful of ball cages.
4
5
Fig. 39
REPLACING CAPS AND STEERING CONES
- Using a wrench, remove the steering caps.
- Using a chisel, slide off the steering cone (6).
6
Fig. 40
29 03/10
Install the following new parts:
- Fork cone (7).
- Steering caps (8).
7
Fig. 41
DISMANTLING THE FORK
- Lubricate the caps
13
- Install 26 ball cages (9) for the upper cap and 29 ball
cages (10) for the lower cap (ø 5/32). 11
- Insert the fork in the steering shaft.
- Install and tighten the adjustable cone (11). 9
12
- Loosen and re-tighten the adjustable cone.
- Position the lock washer (12).
- Install and tighten the steering lock nut (13).
10
Cs - N*m
13 30
Fig. 42
OIL LEVEL CHECK

- Insert a stick or gauge and check that oil is 110 ±5 mm
from the upper edge of the rod (move the rod to end
stop).
If necessary, top up with oil: Q8 FORK OIL
Quantity per tube ~ 40 cc
Fig. 43
30 03/10
MAIN IGNITION SWITCH
- Remove the front shield.
- Unscrew the fixing screws.
1
- Disconnect the connector.
- Remove the key switch (1).
Fig. 44
REAR WHEEL AND SHOCK ABSORBER
Fig. 45
Nr. Item Nr. Item

1 Rear rim 8 Nut M6
2 Rear tire 9 Washer
3 Brake shoes 10 Wheel nut
4 Spring 11 Shock absorber
5 Cam 12 Bolt M10x71
6 Brake lever 13 Nut
7 Bolt M6 x 28 14 Bolt M8x24
31 03/10
DISMANTLING THE REAR WHEEL
- Remove the exhaust.
- Unscrew the nut (D).
- Remove the rear wheel.
Cs - N*m D
D 120
Fig. 46
DISMANTLING THE BRAKE SHOES

- Remove the rear wheel.
- Unscrew the screw (V).
M
- Remove the brake shoes (1) being careful not to dam-
age the springs (M).
1
V
Fig. 47
DISMANTLING THE SHOCK ABSORBER
- Remove the rear fairing.
- Remove the air filter.
- Unscrew the screws (V2).
- Remove the rear shock absorber.
Cs - N*m
V2 29
V2
Fig. 48
32 03/10
CHECKING THE BRAKE HUB
Check the INTERNAL DIAMETER of the brake hub and re-
place the rim if the INTERNAL DIAMETER exceeds wear
limits.
Wear limit: 120.7 mm
Fig. 49
CHECKING BRAKE SHOES
Make sure brake shoes are not worn or damaged and re-
place the complete brake shoe set if necessary.
Fig. 50
CHECKING THE SHOCK ABSORBER
Make sure the shock absorber does not leak and that it is
not damaged. Replace if necessary.
Fig. 51
33 03/10
DISMANTLING THE MAIN STAND
Secure the vehicle so that it does not fall when the

main stand is removed.
- Remove the split pin (1).
Fig. 52
- Remove the spring (2).

- Slide out the pin (3) and remove the main stand.
3
2
Fig. 53
REMOVING THE ENGINE FROM THE CHASSIS
- Remove the helmet compartment (1).
1
Fig. 54
34 03/10
- Remove the right and left side covers (2).
Fig. 55
- Disconnect the carburettor starter connector (A) and

stator connector (B).
Fig. 56
- Release the throttle cable (3), the fuel hose (4) and de-
pression hose (5).
5
- Unscrew the filter box clamp (6).
4
Fig. 57
35 03/10
- Disconnect the positive and negative starter motor ca-
bles (7).
Fig. 58
- Remove the rear brake cable adjustment nut (8).
Fig. 59
- Remove the filter case (9).

9
Fig. 60
- Unscrew the rear shock absorber screw (10).
10
Fig. 61
36 03/10
- Slide off the spark plug cap (11).
- Remove the main stand (see specific chapter).
11
Fig. 62
- Unscrew the nut (12), slide off the engine pin and re-
move the engine from the frame.
12
Fig. 63
- Unscrew the screws (13).
Cs - N*m
13 24 13
13
Fig. 64
- Unscrew the exhaust manifold screws (14) and remove

the exhaust.
14
Cs - N*m
14 10
14
Fig. 65
37 03/10
- Unscrew the nut (15) and remove the rear wheel.
15
Fig. 66
38 03/10
CHECKING THE END COMPRESSION PRESSURE
- With the engine cold, remove the spark plug cap
- Remove the spark plug.
- Fit a compression testing pressure gauge in the spark plug seat with a spark plug fitting and tighten it.
- Run the engine using the starter motor and with the carburettor fully open, until the reading on the pressure gauge
is stable.
- If the pressure is normal, remove the device and reassemble the dismantled parts.
- If the pressure readings are below those indicated, check the rpm used for the test, if it is low, check the starter
system. If the number of rpm is perfect or slightly above, make sure the correct seal has been chosen for the cyl-
inder base and check the seals of the thermal part ( elastic bands- valves etc...)
IF YOU HAVE A HARD TIME INSERTING THE PRESSURE GAUGE FITTING, DISCONNECT THE ENGINE-
SWING ARM CONNECTION PIN AND PULL BACK THE ENGINE AS REQUIRED TO INSERT THE FITTING.
Technical specifications
Spark plug fitting

10 mm
Rpm
~ 800 rpm (starting speed).
Compression end pressure
14 ÷ 15 BAR
39 03/10
ENGINE DISMANTLING
- Place the engine on a suitable support.
Fig. 01
- Unscrew the engine oil tank cap (1).
- Unscrew the cap (2) and drain oil.
Note: the filtering net (3) must be cleaned and the
gasket replaced at each oil change.
Cs - N*m
2 20
Fig. 02
DISMANTLING THE CLUTCH COVER
- Unscrew the 8 cover fixing screws.
- Remove the clutch cover.
- Remove the gasket.
- Remove the 2 bushes.
Cs - N*m
V8 10
Replace the gasket each time the cover is disman-

tled.
Fig. 03
40 03/10
DISMANTLING THE PRIMARY PULLEY ASSY
- Unscrew the nut (1) and remove the washer (2).
- Remove the kick starter plate (3).
- Remove the fan (4).
- Remove the primary fixed half pulley (5).
Cs - N*m
1 50
Fig. 04
- Remove the V-belt.

- Remove the clutch assy (6) and bush (7).
- Remove the washer (8).
- Dismantle the starter pinion unit assy (9).
Fig. 05
DISMANTLING THE REAR CLUTCH ASSY
- Lock the clutch housing using the specific tool.
- Unscrew the nut (1).
- Dismantle the clutch housing and the rear clutch assy.
Cs - N*m
1 50
Fig. 06
41 03/10
DISMANTLING THE STARTER MOTOR
- Remove the 2 fixing screws (1).
- Remove the starter motor (2) after disconnecting the
positive wire.
Cs - N*m
1 10
Check starter motor O-Ring conditions.
Fig. 07
DISMANTLING THE ETC INTAKE MANIFOLD
- Unscrew the 2 intake manifold fixing nuts.
- Remove the intake manifold.
- Remove the two O-Rings.
Cs - N*m
1 10
If necessary, replace the O-Rings.
Fig. 08
DISMANTLING THE AIR CONVEYORS
- Remove the 4 fixing screws (1).
- Remove the conveyor (2).
- Unscrew the fixing screw (3).
Fig. 09
42 03/10
- Unscrew the 2 air conveyor fixing screws (4) on the
clutch side.
- Remove the air conveyors.
- Remove the gasket (5).
Fig. 10
DISMANTLING THE VALVE COVER
- Unscrew the 4 fixing screws (1).
- Unscrew the 2 secondary air hose screws (2).
- Remove the valve cover with its gasket.
Cs - N*m
1-2 10
The gasket must be replaced at each dismantling.
Fig. 11
DISMANTLING THE SECONDARY AIR VALVE
- Remove the secondary air filter.
- Unscrew the 2 screws (1).
- Unscrew the screw (2).
- Remove the air valve cover (3).
- Remove the air valve (4).
Fig. 12
43 03/10
DISMANTLING THE ROTOR
- Unscrew the fan fixing screws (V4).
- Remove the fan. V4
Cs - N*m
V4 10
Fig. 13
- Lock the rotor with the specific tool.
- Unscrew the nut (D).
Cs - N*m
D 50
Warning: using an unsuitable tool may deterio-

rate the magneto flywheel coils.
D
Fig. 14
- Screw in the flywheel extractor (E) on the rotor (2) and
screw in the central screw until the rotor detaches.
FLYWHEEL EXTRACTOR Code
64023700
Fig. 15
44 03/10
DISMANTLING THE STATOR AND PICK-UP
- Unscrew the 2 pick-up fixing screws (1) and two stator
fixing screws (2).
- Remove the stator and pick-up.
Cs - N*m
1 6
Cs - N*m
2 8
Fig. 16
DISMANTLING THE CHAIN TENSIONER

- Unscrew the screw, O-Ring and chain tensioner
spring (1).
- Unscrew the 2 chain tensioner screws (2).
Cs - N*m
1 8
Cs - N*m
2 10
Fig. 17
- Remove the chain tensioner and pull it by the lock

tab (A).
Fig. 18
45 03/10
DISMANTLING THE HEAD
- Remove the spark plug.
- Manually rotate the engine shaft in the operating direc-
tion to correctly align the rocker arm with the cam (A).
Fig. 19
- Loosen the 2 screws (1).
- Gradually loosen the four head nuts (2) in crossed order.
- Remove the 4 nuts, washers and 2 screws.
- Remove the valve rocker arm bracket (3).
Fig. 20
- Remove the timing chain (4).
- Slide out the cam shaft (5).
Fig. 21
- Remove the head, the head gasket (6) and 2 pins (7).
- Remove the timing chain sliding shoe (8) (located in the

cylinder on the exhaust side).
Fig. 22
46 03/10
DISMANTLING THE ROCKER ARMS
- Remove the 2 rocker arm pins (1).
- Remove the intake (2) and exhaust (3) rocker arms.
Fig. 23
DISMANTLING VALVES AND VALVE STEM SEALS

- Compress the valve spring using the specific tool.
- Remove the 2 valve stem halves (1).
- Decompress the spring and remove the tool.
Remove: Fig. 24
- Upper valve cup (2).
- Springs (3).
- Lower washer (4).
- Valve (5).
- Remove the second valve following the same proce-
dure.
Fig. 25
47 03/10
When one valve is removed, always replace the
relevant valve stem seals.
- Using a specific tool, install a new valve stem seal.
Fig. 26
- Reassemble valves, springs (7) and 2 valve stem
halves (6) in the upper valve cup.
When reassembled, thoroughly grease the rocker
arm shafts, cams and contact points between the
rocker arm and valve to avoid jamming when the
engine is started (use Molykote type grease).
Valve stem seals must be lubricated.
Fig. 27
DISMANTLING THE CYLINDER
- Remove the cylinder (1).
- Remove the base cylinder gasket (2) and 2 pins (3).
Fig. 28
- Remove the timing chain sliding shoe (5) screw (4).
- Slide out the timing chain sliding shoe.
Cs - N*m
4 10
Fig. 29
48 03/10
DISMANTLING THE PISTON
- Remove one of the seals (1).
- Remove the piston pin.
- Remove the piston (2).
Fig. 30
DISMANTLING THE OIL SUMP
- Unscrew the 4 screws (1) (85 mm).
- Unscrew the 4 screws (2) (100mm).
No tool is required to remove the oil sump.
Cs - N*m
1-2 10
Fig. 31
- Remove the oil sump (3).
- Remove the 2 pins (4) and the gasket (5).
Fig. 32
49 03/10
DISMANTLING THE OIL PUMP
- Lock the shaft.
- Unscrew the oil pump pinion nut (1).
- Remove the oil pump pinion (2).
Fig. 33
- Unscrew the 3 oil pump screws (3).

- Remove the oil pump.
Cs - N*m
3 10
Fig. 34
When the oil pump is removed, always replace the

2 O-Rings (3).
Before reassembling the oil pump, submerge it in
a container with specific engine oil.
Fig. 35
50 03/10
DISMANTLING THE RIGHT CRANK CASE
- Remove the two O-Rings (1).
- Remove the oil pump pin (2).
- Remove the fixing screw (3).
- Remove the right crankcase (4).
- Remove the 2 pins.
Cs - N*m
3 10
Fig. 36
DISMANTLING THE CRANK SHAFT

- Remove the crank shaft (1).
- Remove the timing chain, marking the rotation
direction (2).
Fig. 37
CHECK CONNECTING ROD ASSEMBLY
- Check connecting rod axial play using a thickness
gauge.
- Maximum admitted connecting rod axial play must not
exceed: 0.55 mm.
Fig. 38
51 03/10
- Eccentricity values read at the end of the crank shaft
must not exceed 0.10 mm.
- 35 mm transmission side (A).
- 27 mm flywheel side (B).
Fig. 39
DISMANTLING THE TRANSMISSION COVER
- Drain oil through the drain cap (1).
- Fill and check oil level through the cap (2).
Cs - N*m
2 12
Fig. 40

- Unscrew the screw (4) (35 mm).
3-4 Cs - N*m
5 12
Fig. 41
- Remove the transmission cover.
- Remove the 2 pins and the gasket.
Fig. 42
52 03/10
- Remove the spacer (1) and idle gear assy (2).
Fig. 43
- Remove the drive shaft assy (3).

- Remove the wheel axle (4).
- Remove the primary drive shaft (5).
Fig. 44
ASSEMBLY
CRANKCASE ASSEMBLY
The oil seals must be replaced each time the
crankcase is dismantled.
- Replace crankcase oil seals.
- Mount the engine shaft and timing chain in the left crank-
case.
Fig. 45
53 03/10
- Mount the 2 pins (1).
- Assemble the gasket (2).
Fig. 46
- Assemble the right crankcase with the left crankcase.
- Tighten the screw (3).
- Mount the oil pump pin (4) and 2 O-Rings (5).
Fig. 47
- Assemble the oil pump.

- Tighten the 3 screws.
- Assemble the oil pump pinion (6).
- Assemble the gasket and 2 pins.
Fig. 48
ASSEMBLE THE OIL SUMP
- Position the oil seal (1) using a suitable tool.
The oil seals must be replaced each time the
crankcase is dismantled.
Fig. 49
54 03/10
- Assemble the right crankcase (2).
- Tighten the 4 screws (3) (85 mm).
- Tighten the 4 screws (4) (100mm).
- Make sure the crank shaft freely rotates in the crank-
case.
Cs - N*m
3-4 10
Fig. 50
ASSEMBLING THE STATOR AND PICK-UP

- Position the stator as indicated.
- Tighten the 2 screws (1).
Cs - N*m
1 6
Cs - N*m
2 8
Fig. 51
Check correct woodruff key (3) position as indi-

cated in the figure, before mounting.
- Position the rotor on the crank shaft.
- Lock the rotor with the specific tool.
- Position and tighten the rotor nut to the indicated tight-
ening torque (Page 44 - Fig. 14).
Fig. 52
55 03/10
ASSEMBLING THE PISTON RINGS
- Position the spring (1) (no assembly direction).
- Position the 2 piston rings (2) next to the spring, offset-
ting the two openings (no assembly direction).
- Position the piston ring (3) with reference "A" facing up.
- Position the upper piston ring (4) with reference "A" fac-
ing up.
Fig. 53
ASSEMBLING THE PISTON
- Assemble the piston so that the "IN" reference is on the
intake side.
Fig. 54
Piston pin circlips must be replaced each time

the piston is dismantled.
- Piston pin circlip opening (1) must face either up or
down, but never to the side.
Fig. 55
56 03/10
ASSEMBLING THE CYLINDER
- Install a new base gasket and 2 pins on the crankcase.
- Position piston ring opening as follows.
- A. Upper seal piston ring opening
- B. Lower seal piston ring opening
- C. Upper piston ring opening.
- D. Lower piston ring opening
Fig. 56
Lubricate the cylinder.
- Pass the timing chain through the cylinder slot.

- Manually compress piston rings and individually mount
them in the cylinder.
- Mount the timing chain sliding shoe, fitting it in the cylin-
der housing (A) on the exhaust side.
Fig. 57
ASSEMBLING THE HEAD
- Position the 2 pins (1) and the cylinder head gasket (2)
on the cylinder.
- Pass the timing chain through the head slot.
Any intervention that requires head dismantling
requires always timing phase tuning.
Fig. 58
57 03/10
TIMING
- Position the rotor on the crank shaft, making sure it cor-
rectly fits on the key.
- Turn the magneto flywheel (1) to position the "T" refer-
ence in front of the crankcase stud (2) (clockwise).
- Position the cam shaft pinion references as on the refer-
ence (3).
Fig. 59
- Position the timing chain on the cam shaft pinion (5).

- Make sure the cam shaft references (3) are parallel to
the head level (4).
- Position the valve rocker arm bracket.
Fig. 60
HEAD CYLINDER TIGHTENING
- This operation is performed in several steps:
- Slightly grease the stud bolts.
- Position the 4 washers.
- Snugly fit the 4 nuts (6) and 2 screws (7).
- Tighten the 4 nuts in crossed order.
Cs - N*m
6 18
Cs - N*m
7 8
Fig. 61
58 03/10
- Position the chain tensioner and 2 fixing screws (8).
- Position the spring (9).
- Position the screw (10) and gasket (11) (checking gas-
ket conditions, replacing it if necessary).
Cs - N*m
8 10
Cs - N*m
10 8
Fig. 62
CHECKING TIMING
- Rotate the crank shaft 2 turns in the engine rotation di-
rection (clockwise).
- Turn the magneto flywheel (12) to position the "T" refer-
ence in front of the crankcase stud (13).
- Make sure the cam shaft references (14) are parallel to
the head level (15).
If references are not aligned, repeat the timing
procedure.
Fig. 63
VALVE TIMING ADJUSTMENT
- Manually rotate the crank shaft in the operating direction
to correctly align the rocker arm with the cam (A).
Fig. 64
- Loosen the rocker arm adjusting screw locknut (1).
- With a thickness gauge, adjust timing on each valve, us-
ing the rocker arm adjusting screw (2).
Timing:
• 0.10 mm intake.
• 0.10 mm exhaust.
- Lock the rocker arm adjusting screw.
- Tighten the locknut.
Fig. 65
59 03/10
VARIOUS INTERVENTIONS
DISMANTLING THE STARTING SYSTEM
- Unscrew the 8 clutch cover screws.
- Remove the gear cover.
Cs - N*m
V8 10

tled.
Fig. 66
- Manually start the kick starter shaft (1), removing the

washer and pinion (2).
- Remove the kick starter screw (3).
- Remove the kick starter (4).
- Remove the seeger.
- Remove the washer, the kick starter shaft (1) and the
spring (5) from the gear cover.
- Remove the roller bearing (6).
Fig. 67
ASSEMBLING THE STARTING SYSTEM
- Position the spring (1), hook the longer side on the cover
pin (A).
- Position the roller bearing (2).
- Position the kick starter shaft (3) in the previously
greased housing.
- Hook the other side of the spring (B) to the kick starter
shaft.
- Load the spring until the kick starter shaft is positioned
on the cover lock (C).
- Turn the cover, position the seeger and washer on the
kick starter shaft.
- Position the washer on the bush housing.
- Load the kick starter shaft about 1/8 a turn and position
the starter pinion (4).
- Position the starter spring (5) on the notch (D) protruding
from the cover.
Fig. 68
60 03/10
REPLACING CENTRIFUGAL ROLLERS
- Unscrew the 8 cover screws.
- Remove the gear cover.

tled.
- Unscrew the nut (1) and remove the washer (2).

- Remove the kick starter plate (3) and fan (4).
- Remove the primary fixed half pulley (5).
- Remove the V-belt.
- Remove the clutch assy (6) and bush (7). Fig. 69
- Remove the washer (8).
Cs - N*m
1 50
- Remove the 3 plate (10) screws (9).

- Remove the plate (10).
- Remove the housing cap (11) and 3 dowels (12).
- Remove the 6 centrifugal rollers (13).
Centrifugal rollers must be replaced if abnormally
worn.
Assembly:
- Proceed in reverse dismantling order without greasing
the centrifugal rollers.
Fig. 70
DISMANTLING THE CLUTCH ASSY
- Unscrew the 8 cover screws.
- Remove the clutch cover.

tled.
- Lock the clutch housing using the specific tool.

- Unscrew the nut.
- Remove the clutch housing, rear clutch assy and fan
belt.
- Compress the rear clutch assy using the specific tool
and insert it in the clamp.
- Unscrew the nut (1). Fig. 71
- Decompress the specific tool.
61 03/10
- Remove the clutch assy (2), the spring holder cup (3),
spring (4) and pulley side cup.
- Slide out the guide pins (6).
- Separate the secondary fixed pulley (7) and secondary
mobile pulley (8).
Fig. 72
ASSEMBLING THE CLUTCH ASSY
- After ensuring that the 2 oils seals (1-Fig. 73) and mo-
bile pulley O-Rings (2) are in good conditions, grease
the 3 guide pins (6) and install parts in reverse disman-
tling order.
- Tighten the nut (1-Fig. 72).
Cs - N*m
1 50
Fig. 73
DISMANTLING THE CARBURETTOR

DISMANTLING THE STARTER
- Remove the starter cover (1).
- Remove the screw (2) and starter plate (3).
- Remove the starter (4) marking its direction.
Fig. 74
62 03/10
- Remove the 2 starter mounting screws (5).
- Remove the starter mounting and relevant gasket.
Fig. 75
DISMANTLING THE VALVE
- Remove the 2 valve cover screws (1).
- Remove the valve cover (2).
- Remove the spring.
- Remove the needle, valve and diaphragm.
Fig. 76
- Remove the needle lock (1) and relevant spring (2) ro-
tating it ¼ a turn.
- Remove the needle and relevant washer (3).
The needle position is adjusted by the manufac-
turer and cannot be modified.
Fig. 77
63 03/10
DISMANTLING THE FLOAT, NEEDLE AND JET
- Remove the 3 float chamber screws (1).
- Remove the float chamber (1) and relevant O-Ring.
Fig. 78
- Remove the float (2), relevant float pin (3) and needle
(4).
Fig. 79
- Remove the idle jet (5) (Ø 30).

- Remove the max jet (6) (Ø 78).
- Remove the atomizer (7).
Fig. 80
64 03/10
Check the conditions of the needle and its hous-
ing (A).
Check chamber O-Ring conditions.
Fig. 81
REMOVE THE IDLE SCREW AND IDLING ADJUST-
ING SCREW
- Turn the idle screw (1) clockwise, counting the number
of turns until stop.
This operation allows it to be replaced in the same
regulation position when reassembled.
Fig. 82
- Turn the screw (2) clockwise, counting the number of
turns until stop.
This operation allows it to be replaced in the same
regulation position when reassembled.
Fig. 83
- Clean the carburettor and parts with specific solvents.
- Spray all carburettor body ducts and its jets with com-
pressed air.
Do not use metallic tools which could ruin ducts
or some elements.
Fig. 84
65 03/10
CYCLE TIGHTENING TORQUES
Fig. 85 Fig. 86
Fig. 87 Fig. 88
Fig. 89 Fig. 90
Fig. 91 Fig. 92
66 03/10
Fig. 93 Fig. 94
Nr. Item Nm Kgm Figure

1 Front wheel spindle 53 5,3 85
2 Handlebar screw 49 4,9 86
3 Front fork nut 30 3,0 86
4 Handlebar positioning screw 25 2,5 86
5 Fork leg screw (botton yoke) 45 4,5 87
6 Brake pump jumper screw 10 1,0 88
7 Brake hose bolt 23 2,3 89
8 Caliper screw 26 2,6 90
9 Clamp drain valve 7,5 0,75 90
10 Front disc screw 23 2,3 90
11 Rear wheel nut 120 12 91
12 Shock absorber screw 29 2,9 92
13 Rear brake lever nut 11 1,1 93
14 Engine mount pivot 98 9,8 94
15 Engine pivot 80 8,0 94
ENGINE TIGHTENING TORQUE

Item Nm Kgm Figure
Cylinder head screw 10 1,0 -
Cam shaft nut 18 1,8 -
Rocker arm nut 10 1,0 -
Crankcase cover screw 10 1,0 -
Clutch housing nut 50 5,0 -
Clutch assy nut 50 5,0 -
Kick starter screw 10 1,0 -
Rotor nut 50 5,0 -
Stator screw 8 0,8 -
67 03/10
Item Nm Kgm Figure
Pick-up screw 6 0,6 -
Oil pump gear nut 10 1,0 -
Oil filter cap 20 2,0 -
Starter motor screw 10 1,0 -
Gear motor oil level screw 12 1,2 -
Gear motor crankcase screw 12 1,2 -
Oil pump screw 10 1,0 -
Crankcase screw 10 1,0 -
Cylinder stud bolt 25 2,5 -
Cooling fan screw 8 0,8 -
Intake manifold screw 10 1,0 -
Spark plug 18 1,8 -
TIGHTENING TORQUE (GENERIC TABLE)

Item Nm Kgm
M5 nut and bolt 4 0,4
FRAME DIMENSION CHECKS

If even slight frame deformation is suspected after an acci-
dent, check frame dimension.
Control quota A = 750 mm (tolerance ± 5 mm)
If a quota is found out of tolerance, replace the frame.
Deforming the frame to return the quota (A) to its
original settings is strictly prohibited.
Fig. 95
68 03/10
ELECTRICAL PART LOCATION
8
9
1
5
Fig. 96
Legend
1 - Ignition switch 6 - Front stop switch
2 - Regulator 7 - Rear stop switch
3 - Horn 8 - Right switch connector
4 - Resistance 9 - Left switch connector
5 - Relay
69 03/10
10
11
19
17
12 13
18
20
14
15
16
Fig. 97
Legend:
10 - Battery 16 - Tail light wiring connector
11 - Fuse box holder (10 A) 17 - Flywheel connectors
12 - CDI unit 18 - HT coil
13 - Starter relay 19 - Starter motor wire connector (+)
14 - Fuel level gauge 20 - Ground wire
15 - Fuel level gauge connector
70 03/10
SWITCH CHECKS
Engine stop button Start
White/ Red/ Yel-
Position Yellow/
Black Black Position low/
Green
Red
- Off
- On
Push
Light switch
White/ Horn
Position Blue White Black
Blue Light
Position Black
green
High beam
Low beam
Push
Passing
Front/rear brake switch

Indicator switch Green/
Light Position Black
Position Orange Grey yellow
Blue
Off - lever idle
L
On - lever pulled
R
Main ignition switch
Position B-N VR VR R N
Key “OFF”
Key “ON”
CHECK FUEL LEVEL GAUGE

- Disconnect the fuel level sensor connector (1).
- Bridge the White/Black wire with the Yellow/White
1
wire.
- Turn the key to "ON". The fuel level gauge should be po-
sitioned on the "F" symbol (FUEL). If the gauge remains
on "E", check Yellow/White wire and White/Black wire
(GROUND) continuity If necessary, replace the dash-
board
NOTA - The White/Blue wire controls the fuel reserve
warning signal
Fig. 98
71 03/10
CHECK FUEL LEVEL SENSOR
- Remove the helmet case.
- Disconnect the fuel level sensor connector. 1
- Remove the sensor (1) from the tank.
Fig. 99
- Measure sensor resistance as per the table.

Float position Resistance
"F" position 6-10 Ω
"E" position 90-100 Ω F

If the measured values are different, replace the
sensor.
Fig. 100
IGNITION
Ignition type: Advance variable
HT COIL STATOR (POWER 70W)
Winding 0,45Ω ± 10% Component Resistance

Primary at 25°C Pick-up (Blue/yellow wire) 153Ω ± 10%
Resistance
Winding 3KΩ ± 20% Coil (Red/Black wire) 420Ω ± 10%
Secondary at 25°C
Light supply
0,9 Ω
(Yellow wire)
Battery charge
SPARK PLUG CAP 1Ω
(White wire)
Resistance 5KΩ ± 20%

Battery charge voltage 14 ± 0,5V
72 03/10
WIRING DIAGRAM
2
1 7
3 4 5 6
N
B GR 10 W 5 W 35 35 10 W
L
W
E
B/N
GL/B
M/B
N
VR
AZ
B/BL
AR
B/N
AR
GL
B/N
VR
BL
VR
AZ
AZ
VR
B
B/N
AR
B/N
GL
B/N
B/N
BL
AZ
10
GL/V
9 11
8
B/BL
B
BL
N
14
12 N/R 16
R
B/BL GL
B B N/R
AR B/N
BL BL B/N
GR
AR AR GL/R 15
AZ B/N
GR GR 17
ON
0FF
AZ AZ
13
ON
0FF
N N GL/R
N VC VC GL/V
VC
GL/B
GL/V
B/BL
GL
GL/R
N/R
B/N
AR
18
AZ
GL
VC
N
19
OFF
ON
VC GL/R
GL/B
GL/V
AR
AZ
VC
N/R
B/BL
B/N
GL
B/N B-N
N
N/R
B/N VR
B/N VR
GL/B GL/B R
B/BL B/BL R
N
20 VR B/N +12V
N
21
22
N GL/BL
B/N GL/N
N/R N/R
N/R GL/BL
N/R GL/BL
GL
B
GL/N GL/N
GL
B
B/N
23 R
-
+
R
B
B/N
24 R
10A
GL
B/N
5 - 5W
VR
GL
VR/N
GL/R
25
GL/V
B/N
AZ
GL
AR
R
GL
VR
GL/V
AZ
VR
AR
GL/V
B/R
B/N
GL/N
W
VR
N
W 10 21 5 W 10
26 27 28 29
30 31
Fig. 101
73 03/10
Colour legend Component legend
Code Colour 1 - Flasher relay
AR Orange 2 - Dashboard
3 - Left turn indicator
AZ Light Blue 4 - Park light
B White 5 - High/low beam
B/N White/Black 6 - Right turn indicator
7 - Stop switch
B/BL White/Blue 8 - Light switch
B/R White/Red 9 - Passing
BL Blue 10 - High beam
11 - Low beam
GL Yellow 12 - Indicators
GL/B Yellow/White 13 - Horn
GL/BL Yellow/Blue 14 - Left switch
15 - Right switch
GL/N Yellow/Black 16 - Engine Stop
GL/V Yellow/Green 17 - Start
GL/R Yellow/Red 18 - Ignition switch
19 - Horn
GR Grey 20 - Fuel level sensor
M Brown 21 - Flywheel
N Black 22 - CDI unit
23 - Regulator
N/R Black/Red 24 - Battery
R Red 25 - Starter resistance
VR Green 26 - Electric starter
27 - Left turn indicator
VC Light green 28 - Stop light
29 - Right turn indicator
30 - Coil
31 - Starter motor
74 03/10

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Engine: single-cylinder - 4-stroke

IDENTIFICATION DATA: CHASSIS N° / ANTI-TAMPERING PLATE

Type: Tubeless (without inner tube)

The pressure of tires must be adjusted while

X Y Pressure differing from that indicated can lead

Check the tire conditions (before every journey): if they

Minimum tread depth (front and rear) is 2 mm

Fig. 13 Fig. 14 Fig. 16

PASSING High beam “flash” lever

CHECKS BEFORE USE

Renew after the first 500/1,000 km (312/624 mi) and

6 - Tighten the drain cap at the requested torque set-

THROTTLE FREE PLAY ADJUSTMENT

CHECKING THE REAR BRAKE

FRONT TURN INDICATOR

The rate at which the turn indicator warning light

REPLACING THE FUSE

Nr. Item Nr. Item

- Remove the front handlebar cover (2).

- Disconnect the connector (3).

- Remove the speedometer cable (2).

- Remove the right and left side covers (2).

- Tail light bulb (2).

- Release the two mudguard halves (wheel and shield

Nr. Item Nr. Item

DISMANTLING THE FRONT BRAKE CALLIPER

DISMANTLING THE BRAKE DISC

When reassembling the pad set, fully push the 6

After reassembling, pull the brake lever several

Nr. Item Nr. Item

Grease parts Nr. 8, 9, 10, 11, 12, 13, 26.

- Unscrew the steering lock nut (3).

OIL LEVEL CHECK

If necessary, top up with oil: Q8 FORK OIL

Quantity per tube ~ 40 cc

REAR WHEEL AND SHOCK ABSORBER

Nr. Item Nr. Item

DISMANTLING THE BRAKE SHOES

Wear limit: 120.7 mm

Secure the vehicle so that it does not fall when the

- Remove the split pin (1).

- Remove the spring (2).

- Disconnect the carburettor starter connector (A) and

- Remove the rear brake cable adjustment nut (8).

- Remove the filter case (9).

- Unscrew the rear shock absorber screw (10).

- Unscrew the screws (13).

- Unscrew the exhaust manifold screws (14) and remove

Spark plug fitting

Replace the gasket each time the cover is disman-

- Remove the V-belt.

Check starter motor O-Ring conditions.

If necessary, replace the O-Rings.

The gasket must be replaced at each dismantling.

Warning: using an unsuitable tool may deterio-