MALAGUTI MADISON 400 - Carl Salter

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<strong>MADISON</strong> <strong>400</strong> C CARROZZERIA COMPOSIZIONE DELLE CARENATURE KAROSSERIE AUFBAU DER SEITENVE- RKLEIDUNGEN 6 1 N° DESCRIZIONE BESCHREIBUNG 1 Parabrezza Windschutzscheibe 2 Scudo centrale Zentrale Frontschutzplatte 3 Scudo Frontschutzplatte 4 Parafango anteriore Schutzblech vorne 5 Parafango Schutzblech sottoscudo Frontschutzplatte 6 Coprimanubrio anteriore Lenkerverkleidung vorne 7 Coprimanubrio posteriore Lenkerverkleidung hinten 8 Coprimanubrio centrale Lenkerverkleidung Mitte 9 Cornice cruscotto Rahmen Armaturenbrett 10 Paragambe Beinschutz 11 Carena posteriore Heckverkleidung 12 Parafango posteriore Schutzblech hinten 13 Porta targa Kennzeichenschildträger 14 Codino paraspruzzi Spritzblech 15 Pedana appoggia piedi Fußbrett 16 Copritunnel dx - sx Tunneldeckel 17 Coprimotore posteriore Motordeckel hinten 18 Coprimotore anteriore Motordeckel vorne 19 Puntone Strebe 9 16 1 7 8 19 2 3 5 4 14 13 12 10 15 16 19 18 11 17 BODY FAIRING COMPONENTS CARROSSERIE COMPOSITION DU CARENAGE N° DESCRIPTION DESCRIPTION DESCRIPCION 1 Windscreen Pare-brise Parabrisas 2 Central shield Tablier central Escudo central 3 Shield Tablier Escudo 4 Front fender Garde-boue avant Guardabarros delantero 5 Under-shield fender Garde-boue sous tablier Guardabarros debajo del escudo 6 Front handlebar cover Protège-guidon avant Protector de manillar delantero 7 Rear handlebar cover Protège-guidon arrière Protector de manillar trasero 8 Central handlebar cover Protège-guidon central Protector de manillar central 9 Dashboard frame Encadrement tableau de bord Montura del tablero de instrumentos 10 Leg-mudguard Tablier avant Protección para las piernas 11 Rear fairing Carénage arrière Carenado trasero 12 Rear fender Garde-boue arrière Guardabarros trasero 13 Plate holder Porte plaque Soporte placa de matrícula 14 Rear mud-flap Bavette garde-boue Colín paragotas 15 Footboard Repose-pieds Plataforma para apoyar los pies 16 dx - sx tunnel cover Couvre-tunnel droit - gauche Cubretúnel der.-izq. 17 Rear engine cover Carter moteur arrière Cubierta de motor posterior 18 Front engine cover Carter moteur avant Cubierta de motor anterior 19 Kickstand Etrésillon Perfil carenado inferior F. 1 1 09/01 CARROCERIA COMPOSICION DE LOS CARENADOS
Page 1 and 2: MALAGUTI MADISON 400 1 09/01
Page 3 and 4: NOTE DI CONSULTA- ZIONE HINWEISE ZU
Page 5 and 6: MADISON 400 PRECONSEGNA - EINGRIFFE
Page 7 and 8: MADISON 400 S INDICE INHALT CONTENT
Page 9 and 10: MADISON 400 S INDICE INHALT CONTENT
Page 11 and 12: MADISON 400 A DATI TECNICI TECHNISC
Page 13 and 14: MADISON 400 A DISIMBALLO • Disimb
Page 15 and 16: MADISON 400 IDENTIFICATION DATA FRA
Page 17 and 18: MADISON 400 A IDENTIFICAZIONE ELEME
Page 19 and 20: MADISON 400 A HANDLEBAR CONTROLS Ri
Page 21 and 22: MADISON 400 A HANDLEBAR CONTROLS Le
Page 23 and 24: STARTER/KEYS • The main button (F
Page 25 and 26: MADISON 400 A CRUSCOTTO 1) Indicato
Page 27 and 28: MADISON 400 A MANCATO AVVIAMENTO
Page 29 and 30: MADISON 400 SERBATOIO CARBURANTE Pe
Page 31 and 32: COOLANT TANK • The expansion tank
Page 33 and 34: MADISON 400 MOTOR OIL TESTING • P
Page 35 and 36: MADISON 400 TRANSMISSION OIL LEVEL
Page 37 and 38: MADISON 400 A RABBOCCO OLIO FRENI
Page 39 and 40: MADISON 400 B REGOLAZIONE DEL MINIM
Page 41 and 42: MADISON 400 250 SHOCK ABSORBERS ADJ
Page 43 and 44: MADISON 400 STEERING LASH CONTROL
Page 45: MADISON 400 B SADDLE ADJUSTMENT •
Page 49 and 50: MADISON 400 WINDSCREEN ASSEMBLING P
Page 51 and 52: MADISON 400 SIDE MIRRORS ASSEMBLY N
Page 53 and 54: MADISON 400 C SIDE MIRRORS REMOVAL
Page 55 and 56: MADISON 400 C RIMOZIONE COPRIMANUBR
Page 57 and 58: MADISON 400 SHIELD REMOVAL Note: in
Page 59 and 60: MADISON 400 • Unscrew the screws
Page 61 and 62: MADISON 400 DASHBOARD REMOVAL Note:
Page 63 and 64: MADISON 400 HANDLEBAR CONTROLS REMO
Page 65 and 66: MADISON 400 FRONT FENDER REMOVAL
Page 67 and 68: MADISON 400 • Open with the ignit
Page 71 and 72: MADISON 400 • Remove the kickstan
Page 73 and 74: MADISON 400 • Remove the cap (C)
Page 75 and 76: MADISON 400 SADDLE REMOVAL • Open
Page 77 and 78: MADISON 400 • Unscrew the central
Page 79 and 80: MADISON 400 REMOVING THE ENGINE CAS
Page 81 and 82: MADISON 400 “TAIL” REMOVAL Note
Page 83 and 84: MADISON 400 FRONT WHEEL REMOVAL •
Page 85 and 86: MADISON 400 REAR WHEEL REMOVAL Note
Page 87 and 88: MADISON 400 BRAKE DISTRIBUTOR REMOV
Page 91 and 92: MADISON 400 FRONT/REAR BRAKE PADS W
Page 93 and 94: MADISON 400 REAR CALIPER UNIT REPLA
Page 95 and 96: MADISON 400 SILENCER REMOVAL The si
Page 97 and 98:
MADISON 400 FORK FORK LEG REMOVAL M
Page 99 and 100:
MADISON 400 LEG STRIPPING • Clamp
Page 101 and 102:
MADISON 400 FORK OIL REPLACEMENT
Page 103 and 104:
MADISON 400 To remove the fork: •
Page 105 and 106:
MADISON 400 FUEL TANK REMOVAL Petro
Page 107 and 108:
MADISON 400 • Disconnect (from th
Page 109 and 110:
MADISON 400 RADIATOR REMOVAL • Re
Page 111 and 112:
MADISON 400 AIR CLEANER (maintenanc
Page 113 and 114:
MADISON 400 ENGINE REMOVAL • To t
Page 115 and 116:
MADISON 400 VERIFICA DIMENSIONALE D
Page 117 and 118:
MADISON 400 THE TWO HEADLIGHTS •
Page 119 and 120:
MADISON 400 PARKING LIGHT • Take
Page 121 and 122:
MADISON 400 LUMINOUS BEAM ADJUSTMEN
Page 123 and 124:
MADISON 400 DIRECTION INDICATORS FR
Page 125 and 126:
MADISON 400 REGULATOR Note: to reac
Page 127 and 128:
MADISON 400 BATTERY PRE-DELIVERY IN
Page 129 and 130:
MADISON 400 CABLAGGI LATO SINISTRO
Page 131 and 132:
MADISON 400 E IMPIANTO ELETTRICO EL
Page 133:
MALAGUTI MADISON 400 cc IDENTIFICAZ
Page 136 and 137:
PREMESSA • La presente pubblicazi
Page 138 and 139:
NOTE DI CONSULTAZIONE HINWEISE NOTE
Page 140 and 141:
Prima di ogni intervento accertarsi
Page 142 and 143:
Madison 400 cc BOBINA ACCENSIONE
Page 144 and 145:
Madison 400 cc AVVIAMENTO ELETTRICO
Page 146 and 147:
Madison 400 cc B) Verificare la ten
Page 148 and 149:
Madison 400 cc INTERRUTTORE CAVALLE
Page 150 and 151:
Madison 400 cc MOTORINO D’AVVIAME
Page 152 and 153:
Madison 400 cc VERIFICA 2° RELAIS
Page 154 and 155:
Madison 400 cc C) Verifica pulsante
Page 156 and 157:
Madison 400 cc VERIFICA RICARICA BA
Page 158 and 159:
Madison 400 cc INDICATORE BENZINA N
Page 160 and 161:
Madison 400 cc SPIA RISERVA BENZINA
Page 162 and 163:
Madison 400 cc INDICATORE TEMPERATU
Page 164 and 165:
Madison 400 cc INDICATORE DI DIREZI
Page 166 and 167:
Madison 400 cc VENTOLA DEL RADIATO-
Page 168 and 169:
Madison 400 cc E) Verifica continui
Page 170 and 171:
Madison 400 cc C) Verifica tensione
Page 172 and 173:
Madison 400 cc LUCE ABBAGLIANTE, AN
Page 174 and 175:
Madison 400 cc LUCE ABBAGLIANTE NON
Page 176 and 177:
Madison 400 cc LUCE ANABBAGLIANTE N
Page 178 and 179:
Madison 400 cc SPIA ABBAGLIANTE NON
Page 180 and 181:
Madison 400 cc PULSANTE “PASSING
Page 182 and 183:
Madison 400 cc LUCE FANALINO POSTER
Page 184 and 185:
Madison 400 cc LUCE STOP NON FUNZIO
Page 186 and 187:
Madison 400 cc STRUMENTO DIGIT NON
Page 188 and 189:
Madison 400 cc STRUMENTO DIGIT NON
Page 190 and 191:
Madison 400 cc C) Verifica continui
Page 192 and 193:
Madison 400 cc CONTAGIRI NON FUNZIO
Page 194 and 195:
Madison 400 cc C) Verifica continui
Page 196 and 197:
Madison 400 cc FUNZIONE TEMPERATURA
Page 198 and 199:
ALLARME OIL CHECK (OIL /CHANGE) - I
Page 200 and 201:
Madison 400 cc PAGINA IN A/3 SCHEMA
Page 202 and 203:
MADISON 400 CABLAGGI LATO SINISTRO
Page 204 and 205:
IMPIANTO ELETTRICO ELEKTRISCHE ANLA
Page 206 and 207:
MANUALI D’OFFICINA WERKSTATT-HAND
Page 208 and 209:
INTRODUCTION • All checks, mainte
Page 210 and 211:
NOTE DI CONSULTAZIONE HINWEISE NOTE
Page 212 and 213:
Simbologia di redazione Verwendung
Page 214 and 215:
Simbologia operativa Arbeitssymbole
Page 216 and 217:
GENERAL WORK PROCEDURES • The adv
Page 218 and 219:
WARNINGS • Before carrying out an
Page 220 and 221:
• 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 272 and 273:
Remove the INTAKE SHAFT including t
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
Page 322 and 323:
Fit the DRIVING SHAFT (1) into the
Page 324 and 325:
Place the OIL PUMP GASKET (1) in it
Page 326 and 327:
ASSEMBLING THE REDUCTION GEAR ASSEM
Page 328 and 329:
Assemble the CENTRING BUSH (1) on t
Page 330 and 331:
Assemble the INTAKE SHAFT OIL RETAI
Page 332 and 333:
ASSEMBLING THE LUBRICATING SYSTEM (
Page 334 and 335:
ASSEMBLING THE LUBRICATING SYSTEM (
Page 336 and 337:
ASSEMBLING THE COUNTERSHAFT GEAR Fi
Page 338 and 339:
ASSEMBLING THE TIMING SYSTEM ASSEMB
Page 340 and 341:
Assemble the STARTING RING GEAR (1)
Page 342 and 343:
ASSEMBLING THE THERMAL UNIT + TIMIN
Page 344 and 345:
Before the CYLINDER makes contact,
Page 346 and 347:
Oil the THREADS OF THE STUD BOLTS M
Page 348 and 349:
Assemble the HALF RING (1) on the H
Page 350 and 351:
Assemble the CENTRING FRAME (1) and
Page 352 and 353:
Apply Threebond paste to the GASKET
Page 354 and 355:
ELECTRIC STARTER Grease the startin
Page 356 and 357:
FRONT VARIABLE SPEED DRIVE AND CLUT
Page 358 and 359:
Assemble the CLUTCH HOUSING COVER u
Page 360 and 361:
STARTING TRANSMISSION + COMPLETE FL
Page 362 and 363:
ASSEMBLING FLYWHEEL COVER THE ASSEM
Page 364 and 365:
Flywheel cover fastening SCREWS M6
Page 366 and 367:
CONTROLLO - RIPARAZIONE - MANUTENZI
Page 368 and 369:
Accoppiamenti Cilindro-Pistone/ Ver
Page 370 and 371:
Controllo sedi valvola sulla testa
Page 372 and 373:
CONTROLLI / KONTROLLEN / CONTROLES
Page 374 and 375:
Piston pin - Measure the outer diam
Page 376 and 377:
Opening the oil pump - Remove the t
Page 378 and 379:
Check rotor-pump case clearance - M
Page 380 and 381:
Checking the driving shaft - Check
Page 382 and 383:
Livello olio motore - A motore fred
Page 384 and 385:
IMPIANTO DI LUBRIFICAZIONE / SCHMIE
Page 386 and 387:
CARBURATORE /VERGASER /CARBURETTOR
Page 388 and 389:
31 LEVA COMANDO ACCELERATORE / BESC
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MALAGUTI MADISON 400 - Carl Salter

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