MALAGUTI MADISON 400 - Carl Salter

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Remove the INTAKE SHAFT including the centring bush CHECK THE INTEGRITY OF THE BUSH AND OF THE O-RING ON THE SHAFT. Démonter l’ARBRE D’ENTREE et la douille de retenue. CONTROLER L’ETAT DE LA DOUILLE ET DU JOINT TORIQUE SUR L’ARBRE. Quitar el EJE ENTRADA completo de casquillo centrador CONTROLAR LA INTEGRIDAD DEL BUJE Y DE LA JUNTA TORICA EN EL EJE WARNING!!! CHECK THE INTEGRITY OF THE ROLLER CAGES AND BEARINGS. ATTENTION ! CONTROLER L’ETAT DES CAGES A AIGUILLES ET DES ROULEMENTS. ¡ATENCION! CONTROLAR LA INTEGRIDAD DE LAS JAULAS DE RODILLOS Y DE LOS COJINETES Remove the UNDULATED SNAP RING. Remove the OIL RETAINER. Remove the SNAP RING. Heat the area around the bearing and extract the bearing WARNING!!! FOR REPLACING THE INTAKE SHAFT ROLLER BEARING ONLY. Démonter le JONC ONDULE Démonter la BAGUE PARE- POUSSIERE Démonter le JONC. Chauffer la zone du roulement et retirer le roulement. ATTENTION ! SEULEMENT POUR CHANGER LE ROULEMENT A GALETS DE L’ARBRE EN ENTREE. Quitar el SEEGER ONDULADO Quitar el GUARDAGOTAS Quitar el SEEGER Calentar la zona del cojinete y sacar el cojinete. ¡ATENCION! SOLO PARA CAMBIAR EL COJINETE DE RODILLOS DEL EJE DE ENTRADA 67 09/01
GRUPPO DISTRIBUZIONE LUBRIFICAZIONE E VOLA- NO MAGNETE ATTENZIONE!!! PRIMA DI PROCEDERE ALLO SMONTAGGIO ASSICURARSI CHE SIA STATO TOLTO L’OLIO MOTO- RE Smontare il TAPPO DELLA CAR- TUCCIA OLIO (1) e la CARTUCCIA OLIO (2) 1 2 SCHMIERMITTEL-VERTEI- LUNGSGRUPPE UND SCHWUNGMAGNETZÜN- DER ACHTUNG!!! VOR DER ABMONTAGE SICHERSTELLEN, DASS DAS MOTORÖL AUSGELASSEN WURDE. Den STOPFEN DES ÖLEINSATZES (1) und den ÖLEINSATZ (2) abmontieren. F. 37 Smontare il COPERCHIO DEL FIL- TRO OLIO (1), MOLLA (2) e FIL- TRO (3) 1 2 Den DECKEL DES ÖLFILTERS (1), die FEDER (2) und den FILTER (3) abmontieren. 3 F. 38 Rimuovere l’ANELLO SEEGER (1) di FISSAGGIO BY-PASS ATTENZIONE!!! MOLLA BY-PASS CARICATA 1 Den SEEGERRING (1) der BYPASS-BEFESTIGUNG entfernen. ACHTUNG!!! DIE BYPASS-FEDER IST GESPANNT! F. 39 Smontare GRUPPO BY-PASS Die BYPASS-GRUPPE abmontieren. F. 40 68 09/01
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MALAGUTI MADISON 400 1 09/01
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NOTE DI CONSULTA- ZIONE HINWEISE ZU
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MADISON 400 PRECONSEGNA - EINGRIFFE
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MADISON 400 S INDICE INHALT CONTENT
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MADISON 400 S INDICE INHALT CONTENT
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MADISON 400 A DATI TECNICI TECHNISC
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MADISON 400 A DISIMBALLO • Disimb
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MADISON 400 IDENTIFICATION DATA FRA
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MADISON 400 A IDENTIFICAZIONE ELEME
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MADISON 400 A HANDLEBAR CONTROLS Ri
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MADISON 400 A HANDLEBAR CONTROLS Le
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STARTER/KEYS • The main button (F
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MADISON 400 A CRUSCOTTO 1) Indicato
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MADISON 400 A MANCATO AVVIAMENTO
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MADISON 400 SERBATOIO CARBURANTE Pe
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COOLANT TANK • The expansion tank
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MADISON 400 MOTOR OIL TESTING • P
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MADISON 400 TRANSMISSION OIL LEVEL
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MADISON 400 A RABBOCCO OLIO FRENI
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MADISON 400 B REGOLAZIONE DEL MINIM
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MADISON 400 250 SHOCK ABSORBERS ADJ
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MADISON 400 STEERING LASH CONTROL
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MADISON 400 B SADDLE ADJUSTMENT •
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MADISON 400 C CARROZZERIA COMPOSIZI
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MADISON 400 WINDSCREEN ASSEMBLING P
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MADISON 400 SIDE MIRRORS ASSEMBLY N
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MADISON 400 C SIDE MIRRORS REMOVAL
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MADISON 400 C RIMOZIONE COPRIMANUBR
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MADISON 400 SHIELD REMOVAL Note: in
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MADISON 400 • Unscrew the screws
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MADISON 400 DASHBOARD REMOVAL Note:
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MADISON 400 HANDLEBAR CONTROLS REMO
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MADISON 400 FRONT FENDER REMOVAL
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MADISON 400 • Open with the ignit
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MADISON 400 • Remove the kickstan
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MADISON 400 • Remove the cap (C)
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MADISON 400 SADDLE REMOVAL • Open
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MADISON 400 • Unscrew the central
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MADISON 400 REMOVING THE ENGINE CAS
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MADISON 400 “TAIL” REMOVAL Note
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MADISON 400 FRONT WHEEL REMOVAL •
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MADISON 400 REAR WHEEL REMOVAL Note
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MADISON 400 BRAKE DISTRIBUTOR REMOV
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MADISON 400 FRONT/REAR BRAKE PADS W
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MADISON 400 REAR CALIPER UNIT REPLA
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MADISON 400 SILENCER REMOVAL The si
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MADISON 400 FORK FORK LEG REMOVAL M
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MADISON 400 LEG STRIPPING • Clamp
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MADISON 400 FORK OIL REPLACEMENT
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MADISON 400 To remove the fork: •
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MADISON 400 FUEL TANK REMOVAL Petro
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MADISON 400 • Disconnect (from th
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MADISON 400 RADIATOR REMOVAL • Re
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MADISON 400 AIR CLEANER (maintenanc
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MADISON 400 ENGINE REMOVAL • To t
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MADISON 400 VERIFICA DIMENSIONALE D
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MADISON 400 THE TWO HEADLIGHTS •
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MADISON 400 PARKING LIGHT • Take
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MADISON 400 LUMINOUS BEAM ADJUSTMEN
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MADISON 400 DIRECTION INDICATORS FR
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MADISON 400 REGULATOR Note: to reac
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MADISON 400 BATTERY PRE-DELIVERY IN
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MADISON 400 CABLAGGI LATO SINISTRO
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MADISON 400 E IMPIANTO ELETTRICO EL
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MALAGUTI MADISON 400 cc IDENTIFICAZ
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PREMESSA • La presente pubblicazi
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NOTE DI CONSULTAZIONE HINWEISE NOTE
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Prima di ogni intervento accertarsi
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Madison 400 cc BOBINA ACCENSIONE
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Madison 400 cc AVVIAMENTO ELETTRICO
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Madison 400 cc B) Verificare la ten
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Madison 400 cc INTERRUTTORE CAVALLE
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Madison 400 cc MOTORINO D’AVVIAME
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Madison 400 cc VERIFICA 2° RELAIS
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Madison 400 cc C) Verifica pulsante
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Madison 400 cc VERIFICA RICARICA BA
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Madison 400 cc INDICATORE BENZINA N
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Madison 400 cc SPIA RISERVA BENZINA
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Madison 400 cc INDICATORE TEMPERATU
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Madison 400 cc INDICATORE DI DIREZI
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Madison 400 cc VENTOLA DEL RADIATO-
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Madison 400 cc E) Verifica continui
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Madison 400 cc C) Verifica tensione
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Madison 400 cc LUCE ABBAGLIANTE, AN
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Madison 400 cc LUCE ABBAGLIANTE NON
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Madison 400 cc LUCE ANABBAGLIANTE N
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Madison 400 cc SPIA ABBAGLIANTE NON
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Madison 400 cc PULSANTE “PASSING
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Madison 400 cc LUCE FANALINO POSTER
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Madison 400 cc LUCE STOP NON FUNZIO
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Madison 400 cc STRUMENTO DIGIT NON
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Madison 400 cc STRUMENTO DIGIT NON
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Madison 400 cc C) Verifica continui
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Madison 400 cc CONTAGIRI NON FUNZIO
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Madison 400 cc C) Verifica continui
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Madison 400 cc FUNZIONE TEMPERATURA
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ALLARME OIL CHECK (OIL /CHANGE) - I
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Madison 400 cc PAGINA IN A/3 SCHEMA
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MADISON 400 CABLAGGI LATO SINISTRO
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IMPIANTO ELETTRICO ELEKTRISCHE ANLA
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MANUALI D’OFFICINA WERKSTATT-HAND
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INTRODUCTION • All checks, mainte
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NOTE DI CONSULTAZIONE HINWEISE NOTE
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Simbologia di redazione Verwendung
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Simbologia operativa Arbeitssymbole
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GENERAL WORK PROCEDURES • The adv
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WARNINGS • Before carrying out an
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• Make sure that the vehicle is s
Page 222 and 223: A F. 4 17 09/01
Page 224 and 225: CARATTERISTICHE TECNICHE DEL MOTORE
Page 226 and 227: SCHEDA DI MANUTENZIONE PERIODICA
Page 228 and 229: RIMOZIONE MOTORE • Per la rimozio
Page 230 and 231: BUSTE E TAMPONI / HÜLLEN UND PUFFE
Page 232 and 233: BUSTE E TAMPONI / HÜLLEN UND PUFFE
Page 234 and 235: COPPIE DI SERRAGGIO MOTORE FM400cc.
Page 236 and 237: CODICE / CODE / CODE / REF. / CÓDI
Page 238 and 239: CODICE / CODE / CODE / REF. / CÓDI
Page 240 and 241: CODICE/- CODE / CODE / REF. / CÓDI
Page 242 and 243: TABELLE CAUSE-EFFETTI - SOLUZIONI F
Page 244 and 245: D IFFICOLTA' DI AVVIAMENTO / SCHWIE
Page 246 and 247: S CARSA PRESSIONE DI LUBRIFICAZIONE
Page 248 and 249: MISCELA POVERA O MAGRA/ ARMES GEMIS
Page 250 and 251: C OMPRESSIONE BASSA / S CHWACHE KOM
Page 252 and 253: ECCESSIVO CONSUMO OLIO \ FUMO ALLO
Page 254 and 255: TENDENZA DEL MOTORE A FERMARSI ALLA
Page 256 and 257: SMONTAGGIO MOTORE FM400-4T-4V DEMON
Page 258 and 259: THERMAL UNIT Disassemble the SPARK
Page 260 and 261: Mark the intake and exhaust ROCKER
Page 262 and 263: Loosen the FASTENING NUTS on the HE
Page 264 and 265: STARTING MOTOR AND SPARK COIL Remov
Page 266 and 267: FRONT AND REAR VARIABLE SPEED DRIVE
Page 268 and 269: Remove the REAR VARIABLE SPEED DRIV
Page 270 and 271: REDUCTION GEAR GROUPE REDUCTEUR GRU
Page 274 and 275: TIMING SYSTEM, LUBRICATING CIRCUIT
Page 276 and 277: Remove the OIL CAP (1). Enlever le
Page 278 and 279: Remove the FASTENING NUT (1) on the
Page 280 and 281: Disassemble the OIL PUMP. It is ess
Page 282 and 283: OPENING THE CASE OUVERTURE DU CARTE
Page 284 and 285: INTAKE AND EXHAUST VALVES SOUPAPES
Page 286 and 287: FLYWHEEL COVER COUVERCLE DU VOLANT
Page 288 and 289: Disassemble the retainer PLATE of t
Page 290 and 291: MONTAGGIO MOTORE FM400-4T-4V MONTAG
Page 292 and 293: TRANSMISSION HALF- CASE WARNING!!!
Page 294 and 295: FLYWHEEL HALF-CASE WARNING!!! The h
Page 296 and 297: FLYWHEEL COVER WARNING!!! The half-
Page 298 and 299: Assemble the bottom SPRING cap. Mon
Page 300 and 301: Fasten the TOP COVER with the COTTE
Page 302 and 303: Assemble the THERMOSTAT COVER (1) a
Page 304 and 305: PRE-ASSEMBLY OF PISTON AND CYLINDER
Page 306 and 307: PRE-ASSEMBLY OF FLYWHEEL COVER Fill
Page 308 and 309: Assemble the OIL LEVEL INSPECTION P
Page 310 and 311: ASSEMBLING THE LUBRICATION SYSTEM M
Page 312 and 313: FREEWHEEL ON FLYWHEEL ROTOR Fit the
Page 314 and 315: COLD DRIVING + ASSEMBLING VARIOUS P
Page 316 and 317: Drive the engine coupling ROLLER CA
Page 318 and 319: BUSHES Drive the BUSHES into place
Page 320 and 321: ASSEMBLING THE ENGINE ASSEMBLAGE DU
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Fit the DRIVING SHAFT (1) into the
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Place the OIL PUMP GASKET (1) in it
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ASSEMBLING THE REDUCTION GEAR ASSEM
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Assemble the CENTRING BUSH (1) on t
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Assemble the INTAKE SHAFT OIL RETAI
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ASSEMBLING THE LUBRICATING SYSTEM (
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ASSEMBLING THE LUBRICATING SYSTEM (
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ASSEMBLING THE COUNTERSHAFT GEAR Fi
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ASSEMBLING THE TIMING SYSTEM ASSEMB
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Assemble the STARTING RING GEAR (1)
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ASSEMBLING THE THERMAL UNIT + TIMIN
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Before the CYLINDER makes contact,
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Oil the THREADS OF THE STUD BOLTS M
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Assemble the HALF RING (1) on the H
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Assemble the CENTRING FRAME (1) and
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Apply Threebond paste to the GASKET
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ELECTRIC STARTER Grease the startin
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FRONT VARIABLE SPEED DRIVE AND CLUT
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Assemble the CLUTCH HOUSING COVER u
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STARTING TRANSMISSION + COMPLETE FL
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ASSEMBLING FLYWHEEL COVER THE ASSEM
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Flywheel cover fastening SCREWS M6
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CONTROLLO - RIPARAZIONE - MANUTENZI
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Accoppiamenti Cilindro-Pistone/ Ver
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Controllo sedi valvola sulla testa
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CONTROLLI / KONTROLLEN / CONTROLES
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Piston pin - Measure the outer diam
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Opening the oil pump - Remove the t
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Check rotor-pump case clearance - M
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Checking the driving shaft - Check
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Livello olio motore - A motore fred
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IMPIANTO DI LUBRIFICAZIONE / SCHMIE
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CARBURATORE /VERGASER /CARBURETTOR
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31 LEVA COMANDO ACCELERATORE / BESC
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MALAGUTI MADISON 400 - Carl Salter

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