MO Madison 3 250 IE Frame ENG.pdf - Luzeiro

FRAME AND RUNNING GEAR

WORKSHOP MANUAL

FRAME AND RUNNING GEAR MADISON 3 250 ie

INTRODUCTION INDEX

1 - INTRODUCTION

1

A

FRONT WHEEL . ....................................................

23

FRONT BRAKE DISC . ...........................................

25

INTRODUCTION. ....................................................

5

Manual updates ................................................................

5

FRONT MUDGUARD. .............................................

25

NOTES FOR EASY CONSULTATION. ....................

5

FRONT FAIRING . ...................................................

26

Modified pages ................................................................. Additional pages ............................................................... Configuration of the pages ................................................ Symbols ............................................................................ Abbreviations .................................................................... Units of measurement ....................................................... Recommendations ............................................................

5 5 5 6 6 6 7

ACCESSIBILITY. ....................................................

28

MAIN SWITCH. .......................................................

29

REPLACING THE HEADLIGHT BULBS. ................

30

Low beam / high beam bulbs (A) ...................................... Parking light (B) ................................................................

30 30

SIDE COVERS. .......................................................

30

GENERAL WORK PROCEDURES. ........................

7

RIDER SEAT. ..........................................................

31

Suggestions ......................................................................

7

PILLION SEAT . ......................................................

31

OPERATING SYMBOLS. ........................................

9

ACCESSIBILITY. ....................................................

32

BATTERY. ...............................................................

32

SEAT LOCK. ...........................................................

33

HELMET COMPARTMENT . ...................................

34

ACCESSIBILITY. ....................................................

35

REPLACING THE TAILLIGHT BULBS. ...................

36

Turn indicator bulb ............................................................ Rear taillight bulb ..............................................................

36 36

PILLION GRAB HANDLE. ......................................

36

REAR FAIRING. ......................................................

37

ACCESSIBILITY. ....................................................

38

INSTRUMENT PANEL. ...........................................

39

LOWER FAIRING AND FOOTBOARD. ..................

40

ACCESSIBILITY. ....................................................

43

MUFFLER. ..............................................................

43

EXHAUST MANIFOLD. ...........................................

44

REAR SHOCK ABSORBERS. ................................

45

REAR BRAKE CALIPER. .......................................

45

Check the disc and pads of the rear brake for wear .........

46

REAR WHEEL. ........................................................

46

REAR DISC. ............................................................

48

FILTER BOX. ...........................................................

49

ENGINE. ..................................................................

50

SIDE STAND. ..........................................................

54

Side stand switch ..............................................................

54

2 - GETTING TO KNOWYOUR SCOOTER TECHNICAL DATA. .................................................

10

Dimensions ....................................................................... Capacity ............................................................................ Engine: 4-valve single-cylinder Piaggio ............................ Spark plug ......................................................................... Transmission ..................................................................... Fuel system ....................................................................... Electronic ignition .............................................................. Brakes ............................................................................... Frame ................................................................................ Suspension ....................................................................... Battery ............................................................................... Tyres .................................................................................

10 10 10 10 10 10 10 10 10 10 10 10

DIMENSIONAL CHECK OF FRAME. .....................

11

3 - MAINTENANCE MAINTENANCE TABLE. .........................................

12

4 - DISASSEMBLY REAR-VIEW MIRRORS. .........................................

13

CENTRAL FAIRING. ...............................................

13

CHANGING THE FRONT TURN INDICATOR BULB. 14 WINDSHIELD. .........................................................

15

UPPER HANDLEBAR COVER. ..............................

16

ACCESSIBILITY. ....................................................

16

FUEL TANK. ............................................................

55

RIGHT-HAND CONTROL. ......................................

17

FUEL LEVEL SENSOR. .........................................

56

LEFT-HAND CONTROL. .........................................

17

HANDLEBAR. .........................................................

56

AMBIENT TEMPERATURE SENSOR. ....................

18

SUB-FAIRING. ........................................................

57

HANDLEBAR LOWER COVER. .............................

19

FRONT FORK. ........................................................

58

SUB PANEL . ..........................................................

20

FRONT DAMPER. ...................................................

59

ACCESSIBILITY. ....................................................

21

SPEEDOMETER SENSOR. ....................................

22

FRONT BRAKE CALIPER. .....................................

22

Checking front brake wear ................................................

22

Right .................................................................................. Left .................................................................................... Checking the oil level in the damper ................................. Changing the fork oil .........................................................

59 59 60 61

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A

1

MADISON 3 250 ie

INDEX

RADIATOR. .............................................................

62

RADIATOR (assembly) . ........................................

64

HORN . ....................................................................

65

BRAKE CALIPERS OVERHAUL. ...........................

65

Overhaul of rear caliper .................................................... Overhaul of front caliper ...................................................

65 67

BRAKE MASTER CYLINDERS . ............................

69

BLEEDING THE BRAKE SYSTEM. ........................

70

Rear brake caliper ............................................................ Front brake caliper ............................................................

70 70

SECURING CLAMPS. ............................................

71

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INTRODUCTION

1

A

INTRODUCTION • This Workshop Manual describes the main electrical/mechanical checks, the essential checks and the assembly of components supplied disassembled in order to deliver a brand new vehicle (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, complaints.

NOTE These manuals provide the necessary information and instructions for routine maintenance and servicing. Some 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. MANUAL UPDATES • The updates will be sent by us (in a reasonable time). Every CD-Rom you receive will supersede the one already in your possession. • The table of contents will be duly updated in the event that new pages are inserted, which render the consultation 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.

NOTES FOR EASY CONSULTATION CONFIGURATION OF THE PAGES A

X

X

Chapter Section title

W

Page N°

Z

Date of issue

Y

W

Y

Z

MODIFIED PAGES • Pages that have been modified will bear the same number as the same page of the previous edition, followed by a letter M and, in the relative box, the new date of issue. ADDITIONAL PAGES • Any additional pages shall bear the last number of the section to which they belong, followed by the letter A and the new edition date.

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A

1

MADISON 3 250 ie

INTRODUCTION

SYMBOLS • Symbols are provided for quick and easy reference (see the relevant heading), 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 “memory tags”. In case of any doubt as to their meaning, consult the page in which they are fully described.

ABBREVIATIONS

F Cs P Pr S Sc T V

Figure Tightening torque Page Paragraph Section Diagram Table Screw

UNITS OF MEASUREMENT All the dimensions in this Manual are shown in mm.

NOTE The letter V in the illustrations refers to fixing 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. A letter without a number indicates quantity 1. In case of different screws being referred to in the illustration, the letter V is followed by a number and a lower case letter. Example: (V4a). Unless otherwise specified, units and components are reassembled by proceeding in the reverse order of removal.

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INTRODUCTION

1

A

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. We therefore recommend observing such advice, recommendations and warnings scrupulously. SUGGESTIONS • Only use top quality tools and equipment. • Only use equipment conforming to EU Directives for lifting the vehicle. • During all operations keep tools close at hand, ideally in accordance with a predetermined sequence of use, and anyway never leave tools on the vehicle or in concealed or hard to reach positions. • 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 a “crosswise pattern” in successive “torquing steps”. • Preferably use open-end wrenches and tighten by exerting “pulling force” rather than “pushing force”. • Adjustable wrenches should only be used in case of emergency, i.e. when a properly sized wrench is not available. During the torquing stage the movable jaw tends to open thus risking damaging the screw head or achieving unreliable tightening torque values. In any case, when using an adjustable wrench, take care to proceed as shown in the figure. • Except in the case of occasional services, prepare a work sheet for the customer, on which to take a note of all the work performed and write memos relating to any future checks that may be required. RECOMMENDATIONS • Before carrying out any work on the vehicle wait for all the parts to cool down completely. • 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, oil seals, snap rings and cotters must be renewed at every refitting. • The torque settings specified in the manuals refer to the “final torque”, which must be reached progressively by steps. • Loosen and tighten aluminium alloy parts (covers) only after the engine has cooled down fully. • Only use screwdrivers of suitable sizes in relation 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 pliers 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 hex. • Never tap wrenches with a hammer (or other similar tools) to loosen or tighten screws and nuts. • Never attempt to increase leverage by attaching tubes, etc. to wrenches. 7

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MADISON 3 250 ie

INTRODUCTION

1

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 workshop floor. 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 fuel 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 vehicle is perfectly stable. The front wheel should preferably be anchored to fixture (A), which is integral with the lift platform.

A

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INTRODUCTION

1

A

OPERATING SYMBOLS IMPORTANT!

CAUTION! - Descriptions concerning operations that are potentially hazardous for the maintenance mechanic or repairman, other workshop personnel or extraneous persons, for the environment, for the vehicle, and for the tools and equipment.

DISCONNECT POWER - Before performing the work described, disconnect the battery negative cable.

RISK OF FIRE - Indicates operations that may constitute a fire hazard.

EXPLOSION HAZARD - Indicates operations that may constitute a risk of explosion.

TOXIC FUMES - Indicates the risk of intoxication or inflammation of the respiratory tract.

NO! - Operations to be absolutely avoided.

SYMMETRICAL OPERATIONS - Operations to repeat on both sides of the unit or component in question.

ENGINE WORKSHOP MANUAL - Information that can be found in the engine workshop manual.

FITTING AND ASSEMBLY OPERATIONS

REMOVAL AND DISASSEMBLY OPERATIONS

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A

GETTING TO KNOW YOUR SCOOTER

2

MADISON 3 250 ie

TECHNICAL DATA MALAGUTI SpA reserves the right to modify technical data at any time without prior notice. C

D

06039483

A B

DIMENSIONS wheel base (A), m ................................................. 1.410 max. length (B), m ................................................. 1.980 max. width (C), m .................................................. 0.790 max. height (D), m ................................................. 1.640 kerbside weight, Kg .................................................. 165 max. load with rider, pillion and luggage, Kg ............. 185

FUEL SYSTEM Electronic injection with electric fuel pump. Fuel: unleaded petrol.

CAPACITY engine oil, cc ........................................................ 1300* transmission oil cc .................................................. 250* fuel tank (reserve), l ........................................... 8.5* (3*)

BRAKES Front:

ELECTRONIC IGNITION High efficiency inductive coil integrated with injection, variable ignition advance and separate H.T. coil.

Rear:

* Guideline value

ENGINE: 4-VALVE SINGLE-CYLINDER PIAGGIO type .................................................................... M366M n° of cylinders ............................................................... 1 bore x stroke, mm ........................................... Ø 72 x 60 displacement, cm3 .................................................... 244 compression ratio ........................................... 11±0.5 : 1 cooling ................................................................... liquid starting system ........................................ electric starter lubrication system ........................................... wet sump SPARK PLUG type: ............................................. CHAMPION RG4 HP ........................................................... NGK CR8EB TRANSMISSION Expandable pulley automatic variator, V-belt, automatic dry centrifugal clutch, secondary drive gearbox and transmission housing with forced circulation cooling system.

10

240 mm disk with hydraulic transmission and calliper with two pistons 240 mm disk with hydraulic transmission and calliper

FRAME Frame made with single steel tube split at footboard level. SUSPENSION Front: Hydraulic fork Ø 36 mm - travel: 130 mm Rear: N.2 hydraulic shock absorbers with adjustable spring preload - travel: 75 mm. BATTERY Type: 12V, 12Ah; sealed unit. TYRES Front: ————— 120/70 - 14 55P Rear: ————— 140/60 - 14 64P It is possible to use tyres with load and speed indexes that are higher than or identical to those indicated. It is however necessary for speed indexes to be identical for both tyres.

05/06

FRAME AND RUNNING GEAR GETTING TO KNOW YOUR SCOOTER

MADISON 3 250 ie

A

DIMENSIONAL CHECK OF FRAME If the scooter has been involved in an accident and you suspect even slight distortion of the frame it is essential to perform the dimensional checking procedure before any further “repair or set-up” work. Control dimension (A) must be 1220 mm with a tolerance of ± 2 mm.

Do not attempt to bend the frame to restore the original “A” measurement.

A = 1220 ± 2 mm

A

06039484

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A

3

MADISON 3 250 ie

MAINTENANCE

MAINTENANCE TABLE = inspection

= clean

2

4

= first service 1

5

6

7

8

9

FIRST 1000 5000 km 10000 km 15000 km 20000 km 25000 km 30000 km 35000 km 40000 km 45000 km 50000 km 55000 km 60000 km 65000 km 70000 km 75000 km 80000 km km or or or or or or or or or or or or or or or or 10 months 20 months 30 months 40 months 50 months 60 months 70 months 80 months 90 months 100 months 110 months 120 months130 months 140 months 150 months160 months

CHECKS AND REPLACEMENT OPERATIONS Spark plug Engine oil and oil filter Gearbox oil Valves Drive belt Variator shoes / rollers Tightness of brake lines - Injection system Fuel pump filter Air filter Drive belt housing air filter Electrical system, battery and charge level Brake pads - condition and wear Level and density of coolant (change every 2 years) – Correct fitting and tightness of hoses Brake fluid circuit Wheel bearings Frame linkages Steering operation and play (lubricate if necessary) Operation and oil-tightness of fork and shock absorbers Tightness of nuts and bolts Tightness of side and centre stands – Pivot lubrication Operation of side stand switch - Lubrication Throttle control Tyre pressure – Tread wear Final check: Condition of tyres - Pressure – Lights Indicators - Switch functions - Road test

3

= change

= adjustment

* * * * * * * * * Every 2000 km

* * * * * * * * *

Every 20 months or 10000 km

*

If the periodic drive belt inspection (every 10000 km) reveals excessive wear in relation to the conditions of use, reduce the intervals between future services. The maintenance schedule is based on average riding conditions. Machines subject to severe use or ridden in unusually wet or dusty conditions or off the road require more frequent servicing. Certain simple checks, i. e. those marked with an asterisk, MAY be performed under the direct responsibility of technicians not specifically authorised by MALAGUTI.

12

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DISASSEMBLY

REAR-VIEW MIRRORS

4

06039057_1

A

• Lift rubber boot then undo nut (D) and mirror (A).

D

RIGHT-HAND MIRROR is fitted by screwing it COUNTER-CLOCKWISE. LEFT-HAND MIRROR is fitted by screwing it CLOCKWISE.

CENTRAL FAIRING

06039029_1

A

• Remove panels (A) by prising with a screwdriver.

06039035_1

• Undo screws (V2).

V2

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A


A

4

MADISON 3 250 ie

DISASSEMBLY

• Disengage central fairing (B) and remove it from scooter, rotating it forwards.

06039041_1

B

CHANGING THE FRONT TURN INDICATOR BULB

06039029_1

• Remove panels (A) by prising with a screwdriver.

A

• Turn bulb-holder ringnut (B) counter-clockwise and remove.

06039032_1

B

• Extract bulb by pulling it.

14

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DISASSEMBLY

WINDSHIELD

4

A

06039045_1

• (Remove central fairing). • Undo screws (V6). • Remove windshield (A). • Recover the rubber grommets under the screws.

A

V6

15

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V6


A

4

MADISON 3 250 ie

DISASSEMBLY

UPPER HANDLEBAR COVER

06039048_1

• (Remove rear-view mirrors). • Undo screws (V2a) and (V2b). • Remove upper handlebar cover (A).

A

V2a

ACCESSIBILITY

06039059_1

G

Removing the front handlebar cover provides access to the following components: • • • • • • • • •

V2b

Handlebar screw (A); connector for LH handlebar control (B); ambient temperature sensor connector (C); RH control STOP switch (D); LH control STOP switch (E); rear brake master cylinder union (F); front brake master cylinder union (G); resistance connector (H); steering adjustment ringnuts (S).

F

D E A

S

06039060_1

C

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05/06

H

B


DISASSEMBLY

RIGHT-HAND CONTROL

A

4

06039385

• (Remove rear-view mirrors). • (Remove upper handlebar cover). • • • • •

Unscrew union (B). Undo screw (V) and remove counterweight. Disconnect wiring connectors. Undo screws (V2) and remove throttle control. Disconnect throttle opening (A) cables.

V

V2 A

Use compressed air to reduce friction when removing and refitting the twist grip.

B

At time of reassembly shorter screw (V2) must be located in UPPER part of control.

LEFT-HAND CONTROL

06039386

• (Remove rear-view mirrors). • (Remove upper handlebar cover).

V2

• Disconnect switch connector. • Undo screw (V) and remove counterweight. • Undo screws (V2) and remove LH control. Use compressed air to reduce friction when removing and refitting the twist grip. At time of reassembly shorter screw (V2) must be located in UPPER part of control.

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05/06

V


A

4

MADISON 3 250 ie

DISASSEMBLY

AMBIENT TEMPERATURE SENSOR

06039060_1

• (Remove rear-view mirrors). • (Remove upper handlebar cover). • Detach the connector (A).

A

• Remove sensor (B) from lower handlebar cover (C).

06039021_1

The sensor must be mounted EXTERNALLY to the lower handlebar cover, as shown in the figure.

B

18

05/06

C


DISASSEMBLY

HANDLEBAR LOWER COVER • • • •

06039062_1

V2

(Remove rear-view mirrors). (Remove upper handlebar cover). (Remove right-hand control). (Remove ambient temperature sensor).

• Undo screws (V2).

• Undo screw (V). • Remove lower handlebar cover.

06039061_1

To remove handlebar cover completely, disconnect the two right-hand control connectors.

V

19

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4

A


A

4

MADISON 3 250 ie

DISASSEMBLY

SUB PANEL

06039082_1

• Remove footboards (A).

A

• Undo screw (V).

06039085_1

V

• Undo screws (V4a) and (V4b). • Remove sub-panel (B).

06039086_1

V4b

Screws (V4a) are longer than screws (V4b).

V4a

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05/06

B


DISASSEMBLY

ACCESSIBILITY

A

4

06039088_1

Removing the sub panel provides access to the following components: • Ignition coil (A). • Bank angle sensor (B).

B

• Radiator drain plug (C).

A

06039090_1

C

• Side stand switch (D).

06039227_1

D

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A

MADISON 3 250 ie

DISASSEMBLY

4

SPEEDOMETER SENSOR

06039095_2

V

• Undo screw (V) ensuring the spacer does not fall. • Disconnect the electronic transmission connector. When refitting, use a feeler gauge, to check that the sensor - disc gap is 1÷2 mm. • Remove the sensor complete with the transmission.

FRONT BRAKE CALIPER

06039095_2

• Undo the screw of the hydraulic transmission (V) and remove the hydraulic transmission and its gaskets. When reassembling, replace the gaskets of the hydraulic transmission.

V

V

V2

20 ± 10%

• Undo screws (V2) and free the complete caliper. After having removed the hydraulic transmission and the caliper from its seat, place a recipient under it to collect the brake fluid. Dispose of used brake fluid in compliance with statutory legislation.

V2

30 ± 20%

2 mm

CHECKING FRONT BRAKE WEAR • Take the opportunity to check also wear of the brake disc. If they are scored or unevenly worn, they can be reground. If disc thickness has worn to less than 3.5 mm the discs must be changed. Minimum thickness of the pads is 2 mm.

Note

For overhauling the caliper, see the specific Chapter.

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DISASSEMBLY

FRONT WHEEL

4

06039093_1

Before disassembly, support the frame at the centre to prevent the scooter from falling. For this purpose, remove sub-panel and place a stand under frame cradles as shown.

• Undo the nut (D).

06039095_2

D

80 ± 10%

D

• Pull out the spindle (V); then remove the wheel.

06039096_1

Pay attention to spacers located on spindle (V).

V

23

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A


A

4

MADISON 3 250 ie

DISASSEMBLY

The figure shows sequence of components for fitting wheel. • • • • • •

06039098_1

C

E

Pin (A). Washer (B). Right-hand spacer (C). Left-hand spacer (D). Washer (E). Nut (F). A

D

B

F

Do not operate the brake lever after removing the wheel, since the pads would come into contact with each other. 06039487

When refitting the wheel be sure to refit the spacers (C-D) and grease spindle (A).

A C

B

D

E F

24

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DISASSEMBLY

FRONT BRAKE DISC

4

06039360_1

V5

• (Remove speedometer sensor). • (Remove front brake caliper). • (Remove front wheel) • Undo screws (V5). When reassembling, use new screws and apply a high strength thread locker.

V5

11 ± 10%

FRONT MUDGUARD

06039102_1

V2b

V2a

• (Remove front wheel) • Undo screws (V2a) and (V2b). Pay attention to nut on screws (V2b) (rear screws).

• Remove cable guide ring (A) from mudguard (B) then remove mudguard.

06039104_1

A

B

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A


A

4

MADISON 3 250 ie

DISASSEMBLY

FRONT FAIRING • • • •

06039107_1

(Remove central fairing). (Remove windshield). (Remove front wheel). (Remove front mudguard).

V2b

V2b

V2a

V2a

• Undo screws (V2a), (V2b) and (V2c). Recover the bushes located under the screws (V2a). V2c

• Undo screw (Vd).

06039111_1

Vd

06039115_1

• Undo screws (V6e).

V6e

26

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DISASSEMBLY

• Undo screws (V5f) and (V2g).

4

A

06039122_1

V2g

V5f

V5f

V5f

Pay attention to screws (V4) located UNDER ticket compartment cover, UNDER cover of radiator expansion vessel access compartment and UNDER glove compartment door.

06039125_1

V4

V4

06039506_1

V4

27

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A

4

MADISON 3 250 ie

DISASSEMBLY

• Rotate front fairing (A) forwards then disconnect headlight connectors (B). • Remove front fairing (A).

06039499

B

A

During subsequent reassembly, engage front fairing with metal tab (C).

06039133_1

C

ACCESSIBILITY

06039500

Removing the front fairing provides access to the following components: • main switch (A); • anti-theft connector (provision) (3-way) (B); • headlight connectors (C); • main switch connector (6-way) (D); • odometer sensor connector (E); • 12V power socket connector, protected by foam (F); • 12V power socket fuse (5 A) (G); • autodiagnostic serial port (H); • coolant expansion tank (I); • fuse connections (L).

G A B C

C

F

28

H

05/06

D

E

I

L


DISASSEMBLY

MAIN SWITCH

4

06039256_1

• (Remove central fairing). • (Remove windshield).

A

• Disengage front fairing from lower fairing and rest it on front mudguard, taking care not to damage paintwork. • Remove keyswitch ringnut (A), rotating it counterclockwise through 1/4 of a turn.

• Undo tamperproof screws (V2) using a special 4 mm hex wrench (P/N 08601400); then extract keyswitch (E).

06039142_1

E

V2

29

05/06

A


A

4

MADISON 3 250 ie

DISASSEMBLY

REPLACING THE HEADLIGHT BULBS

06039137_1

• Disengage front fairing and rest it on front mudguard, protecting paintwork from scratches. (See “Removing front fairing”).

LOW BEAM / HIGH BEAM BULBS (A) • • • •

Remove the wiring connector, rubber cap and spring; change the bulb; refit the spring, rubber cap and wiring connector; refit the upper fairing.

A

B

A

PARKING LIGHT (B) • Remove the rubber bulb holder; • change the bulb; • refit the rubber bulb holder (by pressing) and refit the upper fairing.

SIDE COVERS

06039165_1

• Undo screws (V2). • Remove side covers (A).

To remove side cover, first rotate rear part upwards in such a way as to disengage interlocking tabs.

V2

30

05/06

A

V2


DISASSEMBLY

RIDER SEAT

A

4

06039168_1

• Release the seat lock with the key and tip it to its open position. • Unscrew nuts (D2) and remove the seat, resting it on a supporting surface with the upholstery upwards.

D2

PILLION SEAT

D2

06039179_1

A

• Lift rider seat. • Undo screws (V2). • Remove the seat (A), resting it on a supporting surface with the upholstery upwards.

V2

V2

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A

4

MADISON 3 250 ie

DISASSEMBLY

ACCESSIBILITY

06039180_1

Removing seat provides access to the following components: • main charge circuit fuse (30 A) (A); • Battery (B).

A

B

BATTERY

06039180_1

(See “Installing the battery”.) Note that: - the RED leads must be connected to the battery POSITIVE “+” terminal; - the BLACK lead must be connected to the battery NEGATIVE “-” terminal; - the battery terminals must be towards the FRONT of the scooter.

32

A B

A

05/06


DISASSEMBLY

SEAT LOCK

4

06039185_1

D2

• Remove nut covers and unscrew nuts (D2).

• Extract seat lock (A) by pulling downwards and then disengage it from transmission cable (B) and remove.

06039188_1

B

33

05/06

A

A


A

4

MADISON 3 250 ie

DISASSEMBLY

HELMET COMPARTMENT • • • •

06039180_1

(remove rider seat). (remove pillion seat). (Remove battery). (Remove seat lock).

V2a

• Undo screws (V2a).

• Loosen the screws (V2b).

06039180_1

V2b

• Slightly lift helmet compartment (A) and then extract battery cables (B) and disconnect fuseholder (C).

• Extract seat transmission cable (D) from helmet compartment.

06039192_1

B

C

06039195_1

D

34

05/06

A


DISASSEMBLY

• Disengage electrical cable (E) for helmet compartment light from cable guide (F), then disconnect connector (G).

A

4

G

E

When reassembling, electrical cable (E) must be reattached to cable guide (F). F

06039196_1

ACCESSIBILITY

E

Removing the helmet compartment provides access to the following components: • • • • • • • • • • • • • •

flasher relay (A); starter motor contactor (B); fan contactor (C); injection charge contactor (D); voltage regulator (E); rear turn indicators (F); taillight (G); rubber boot containing connector of voltage regulator (H); throttle body with injection control unit (I); helmet compartment lock (L); cooling system air bleed screw (M); injection connector (N); temperature sensor connector (O); fuel level sensor (P).

B

C

H

F

D

A G

06039200_1

L

P N I M

O

06039224_1

35

05/06


A

MADISON 3 250 ie

DISASSEMBLY

4

REPLACING THE TAILLIGHT BULBS B

• • • •

(Remove rider seat). (Remove pillion seat). (Remove battery). (Remove helmet compartment).

TURN INDICATOR BULB • •

A

Turn bulb-holder ringnut (A) counter-clockwise and remove. Extract bulb by pulling it. 06039220_1

REAR TAILLIGHT BULB • •

Turn bulb-holder ringnut (B) counter-clockwise and remove. Extract bulb by pulling it.

PILLION GRAB HANDLE • • • • •

(Remove rider seat). (Remove pillion seat). (Remove battery). (Remove seat lock). (Remove helmet compartment).

•

Undo screws (V3) and remove handle (A).

V3

V3

43 ± 15%

06039206_1

36

05/06


DISASSEMBLY

REAR FAIRING • • • • • •

4

06039229_1

(Remove rider seat). (Remove pillion seat). (Remove seat lock). (Remove battery). (Remove helmet compartment). (Remove pillion grab handle). V4

•

Undo screws (V4).

•

Disengage rear fairing (A), lifting front part.

06039234_1

A

• • •

Open clamps (B), pulling them towards rear of scooter. Detach the connector (C). Remove rear fairing, pulling it towards rear of scooter.

37

06039236_1

B

05/06

C

B

A


A

4

MADISON 3 250 ie

DISASSEMBLY

In the event of breakage of rubber protection (D), it can be removed after having disengaged it from supports (E).

06039229_1

E

D

ACCESSIBILITY A

Removing rear fairing provides access to the following components: • Ground terminal (A).

06039242_1

•

Fuel vapour venting valve (B)

D

When renewing or refitting fuel vapour venting valve (B), note that it must be fitted with GREEN part connected to FREE hose (C), i.e. the hose connected to vehicle frame; the other side of the valve must be connected to hose (D) from fuel tank.

06039270_1

38

05/06

B

C


DISASSEMBLY

INSTRUMENT PANEL • •

4

06039245_1

(Remove central fairing). (Remove windshield). V2

V2

•

Disengage upper part of front fairing (see “Removing front fairing”.

•

Undo screws (V4).

06039247_1

V4

•

A

Disconnect connector (A), open clamp (B); then remove dashboard.

06039254_1

V4 A

To detach the digital instrument from the dashboard undo screws (V4). When refitting dashboard re-secure electrical cable under clamp (B). B

V4

39

05/06


A

4

MADISON 3 250 ie

DISASSEMBLY

LOWER FAIRING AND FOOTBOARD

06039256_1

A

• • • • • • • • • • • • •

(Remove rider seat). (Remove pillion seat). (Remove seat lock). (Remove battery). (Remove helmet compartment). (Remove pillion grab handle). (Remove rear fairing). (Remove central fairing). (Remove windshield). (Remove front wheel). (Remove front mudguard). (Remove upper fairing). (Remove dashboard).

•

Remove main switch cover (A), rotating it counterclockwise through ¼ of a turn. Open the luggage compartment and undo fuse box screws (V2a).

•

06039255_1

When reassembling note that LIGHT BLUE 15A fuse must be positioned on LEFT. •

Undo screw (Vb).

V2a

•

Vb

Undo screw (V5c).

V5c

06039257_1

40

05/06

FRAME AND RUNNING GEAR MADISON 3 250 ie •

DISASSEMBLY

Remove foam (A) from 12V power socket and detach connectors (B).

4

06039152_1

B

When reassembling note that foam (A) must be refitted to protect connectors and socket. A

• •

Open hatch (C). Remove fuel tank cap (D), remove gasket (E), disconnecting it from the drip hose, then refit the cap.

06039260_1

D C

Screw the fuel tank cap back on immediately after removing the gasket.

•

Undo screws (V3d) and disengage coil (F) from footboard.

06039262_1

V3d

If no further parts are to be removed, it is not necessary to detach the coil wires.

F

41

05/06

A

A


A •

4

MADISON 3 250 ie

DISASSEMBLY

Temporarily remove flasher unit (G) from vehicle.

06039264_1

G

•

Remove lower fairing and footboard unit (H) from vehicle, turning front part upwards, then slide out towards rear of vehicle.

06039267_1

H

•

To detach lower fairing (L) from footboard (M) undo screws (V4e) and screw (Vf).

06039280_1

L

Vf

V4e

M

42

05/06


DISASSEMBLY

ACCESSIBILITY

A

4

06039286_1

A

B

Removing lower fairing and footboard provides access to the following components: • Fuel tank (A). • Side stand switch connector (B).

MUFFLER

06039327_1

V3b

Before working on the silencer and the exhaust manifold wait until all the component shave cooled down and always wear suitable protective gloves. • •

Loosen screw (V) of clamp (A). Undo the screws (V3b); then remove the entire silencer (B). B

V3b

V

V3b

25 ± 15%

Pay attention to spacers (C) located under washers (D) on screws (V3b). When refitting silencer always renew gasket between silencer and exhaust manifold (see “Removing exhaust manifold”).

06039328_1 06039328_1

V3b

D

43

05/06

C

A


A

MADISON 3 250 ie

DISASSEMBLY

4

EXHAUST MANIFOLD • •

06039326_1

(Remove silencer). (Remove helmet compartment).

A

Before working on the silencer and the exhaust manifold wait until all the component shave cooled down and always wear suitable protective gloves. •

Disengage Lambda probe connector (A) from its support and disconnect it. Note that connector (A) must always be secured to its support to ensure correct operation of the Lambda probe.

•

Cut clamp (B), unscrew nuts (D2) then extract manifold (C) including Lambda probe.

06039339_1

B

D2

30 ± 10% D

•

D2

If necessary, unscrew Lambda probe (D) from manifold.

D

C

45 ± 10%

The procedure for disassembling the components of the exhaust unit is illustrated in the figure.

E

When refitting the silencer always renew gasket (E) and check the condition of gasket (F) (change, if necessary). F

06039488

44

05/06


DISASSEMBLY

4

A

REAR SHOCK ABSORBERS Before disassembly, support the frame at the centre to prevent the scooter from falling. •

First undo lower screw (Vi); then upper screw (Vs).

Vi/s

Vs

45 ± 15% A

•

Remove shock-absorber (A).

Vi

06039332_1

REAR BRAKE CALIPER • •

Undo screws (V2). Undo brake fluid line screw (V) and detach brake line from caliper.

V

A

When reassembling, renew the gaskets of the brake fluid line screw.

V

20 ± 10%

V2

30 ± 20% V2

Pay attention to spring washer (B) between screw (V) and washer (C). •

Remove calliper (A). 06039349_1

B

After having removed the hydraulic transmission and the caliper from its seat, place a recipient under it to collect the brake fluid. Dispose of used brake fluid in compliance with statutory legislation. 06039346_1

45

05/06

C


A

MADISON 3 250 ie

DISASSEMBLY

4

CHECK THE DISC AND PADS OF THE REAR BRAKE FOR WEAR •

2 mm

Take the opportunity to check also wear of the brake disc. If the disc is badly damaged or the thickness less than 3.5 mm, it must be renewed. Minimum thickness of the pads is 2 mm.

Note

05053576

For overhauling the caliper, see the specific Chapter.

06039489

REAR WHEEL • • •

(Remove silencer). (Remove right-hand rear shock-absorber). (Remove rear brake caliper).

• •

Straighten split pin (A). Turn wheel until pin (A) is aligned with pocket, then extract split pin. Extract vibration damper ring (B) and nut cover (C), then unscrew underlying nut (D).

•

D •

A

B

C D E

100 ± 10%

Remove spacer (E) from the wheel spindle.

06039341_1

When refitting the wheel spacer (E) must be positioned with the largest diameter side towards the wheel bearing, as shown in the photo.

C

B 06039344_1 06039496

E

46

05/06


DISASSEMBLY

4

A

Undo screws (V2b) and the screw (Va). Va

F

Watch out for the bush under the screw (Va).

• •

Slightly lift rear mudguard (F). Remove swing arm (G). V2b

There is a spacer behind the swing arm similar to the spacer IN FRONT of the arm; the spacer must be refitted with the smallest diameter side facing the arm.

V2b

23 ± 10%

G 06039349_1

NOTE To replace bearing (H) located inside the swing arm use a puller tool after having removed snap ring (L).

H

L

06039498

•

Remove rear wheel (M). M

06039358_1

47

05/06


A

MADISON 3 250 ie

DISASSEMBLY

4

Before reassembling, grease shaft (N) abundantly, especially on the splines.

N

06039362_1

REAR DISC • • • •

(Remove silencer). (Remove rear brake caliper). (Remove right-hand shock absorber). (Remove rear wheel).

V5

•

V5

Undo screws (V5).

V5

11 ± 10%

When reassembling, use new screws and apply a high strength thread locker.

48

05/06

06039360_1

The thickness of the rear brake disc must NEVER be less than 3.5 mm; otherwise, RENEW THE DISC.


DISASSEMBLY

4

A

FILTER BOX V9c

• • • • • •

(Remove rider seat). (Remove pillion seat). (Remove pillion grab handle). (Remove helmet compartment). (Remove rear fairing). (Remove rear wheel).

•

Undo screws (V3a), screw (Vb) and screws (V9c); now remove cover (A) from airbox.

Vb

V3a A

Pay attention to nut located behind screw (Vb) and bushings located under screws (V3a) and (Vb). 06039367_1

Use a TORX wrench T20 for screws (Vc).

• •

Loosen clamp screw (B) and disconnect hose (C). Loosen screw of clamp (D).

06039373_1

B

C

D

• •

Undo screws (V3d). Remove airbox (E) from vehicle, prising gently in connection point with throttle body.

E

V3d

49

05/06


A

4

MADISON 3 250 ie

DISASSEMBLY

The sequence for disassembling the filter box components is shown in the figure.

06039495

ENGINE • • • • • • •

(Remove helmet compartment). (Remove fairing). (Remove silencer). (Remove exhaust manifold). (Remove shock absorbers). (Remove rear wheel). (Remove filter box).

V

A

Before disassembly, support the frame at the centre to prevent the scooter from falling. • •

•

Disconnect flywheel connectors (A). Undo screw (V) and detach the ground cables from the frame.

06039242_1

Disconnect cap from spark plug (B). 06039339_1

B

50

05/06


DISASSEMBLY

4

Disconnect wires (C) from starter motor.

C

06039382_1

• • •

Undo screw (Vb), disengage hose (D) and underlying wiring. Disconnect injection control unit connector (E). Disconnect hoses (D) and (F), injector connector (G), engine temperature thermistor connector (H).

E

F G

Vb

D

H

•

Disconnect connector of oil pressure switch (I). I

51

05/06

A


A • •

4

MADISON 3 250 ie

DISASSEMBLY

Disconnect throttle cable (L). Undo screw (Vb) and disengage clamp from engine. L

Vb

06039374_1

•

Detach hose (M) from water pump. Before disconnecting hose (M), empty the cooling system (see “Removing the radiator”).

06039358_1

M

•

Disconnect coolant return hose (N). Before disconnecting hose (N), empty the cooling system (see “Removing the radiator”).

52

N

05/06


DISASSEMBLY

4

Temporarily fit rear wheel on its spindle and lock temporarily with its nut. This operation will facilitate removal of engine from scooter.

•

Undo the nut (D).

D

68 ± 10%

D

• •

Unhook spring (M). Remove pin (P) and extract engine towards rear of vehicle. M

P

53

05/06

A


A

MADISON 3 250 ie

DISASSEMBLY

4

SIDE STAND •

Detach springs (A) and undo screw (V).

V

20 ± 15% V

06039228_1

A

SIDE STAND SWITCH •

Undo screws (V2). V2

5 ± 20%

06039228_1

V2

•

Disconnect connector (A) under the footboard on the right-hand side of the scooter.

A

06039286_1

54

05/06


DISASSEMBLY

4

A

FUEL TANK • • • • • • • •

(Remove upper fairing). (Remove rider seat). (Remove pillion seat). (Remove pillion grab handle). (Remove helmet compartment). (Remove fairing). (Remove lower fairing and footboard). (Remove fuel level sensor). DANGER During this procedure do not use heat and keep sparks and naked flames well clear of the scooter. Make sure the tank is empty. Before emptying the tank, wait for the engine to cool down. Use a manual pump.

A

B

•

Remove fuel tank cap, remove gasket (A), disconnecting it from the drip hose, then refit the cap. Screw the fuel tank cap back on immediately after removing the gasket.

•

Disconnect fuel pump hoses (B) and fuel pump connector (C).

C 06039393_1

•

Undo screws (V4) and remove tank (D). There is a bushing (D) under each screw (V4).

•

D

The tank support must rest on a rubber Silent Block (F); ensure the rubber mount does not fall.

V4 V4

E 06039316_1

F 06039497

55

05/06


A

MADISON 3 250 ie

DISASSEMBLY

4

FUEL LEVEL SENSOR • • •

(Remove rider seat). (Remove pillion seat). (Remove helmet compartment).

•

Detach connector (A) and undo screws (V4).

06039400_1

B

During this procedure do not use heat and keep sparks and naked flames well clear of the scooter. If the tank remains without the fuel level sensor fitted for a prolonged period, plug the hole to prevent the accumulation of petrol vapour in the workshop. •

V4

A V4

Remove sensor (B).

HANDLEBAR B

• • • • •

(Remove central fairing). (Remove windshield). (Remove upper handlebar cover). (Remove lower handlebar cover). (Remove front/rear brake master cylinders).

• •

Cut all cable and hose ties. Loosen nut (D) then extract the handlebar upwards.

D

D

50 ± 20% 06039315_1

56

05/06


DISASSEMBLY

A

4

SUB-FAIRING •

Loosen all screws (V4) and remove one for each bracket (A); then turn latter until to align them with opening in sub-fairing (B).

A

V4

B

V4 06039402_1

•

Undo screw (V) and remove sub-fairing (B) passing slider stanchion tubes through relative opening. B

V

06039404_1

57

05/06


A

4

MADISON 3 250 ie

DISASSEMBLY

FRONT FORK 06039315_1

• • • • • • • • •

(Remove front fairing). (Remove windshield). (Remove upper fairing). (Remove upper handlebar cover). (Remove handlebar). (Remove mudguard). (Remove front brake caliper). (Remove speedometer sensor). (Remove front wheel). A

Before disassembly, support the frame at the centre to prevent the scooter from falling. •

• • •

B

Sever all the electrical cable ties; to proceed with the operation position the brake caliper and the brake line to BEHIND the frame. Undo and remove ring nut (A). Undo and remove underlying ring nut (B). Remove the fork assembly in a downward direction. A

Support the fork to prevent them falling. • • •

B

Pay attention because balls (C) may fall from their races. Clean away any grease, including the grease in the ball races. Check for wear and renew if necessary. Grease and refit.

C

Upper race: 22 balls (Ø 3/16") Lower race: 19 balls (Ø 1/4")

C

06039490

58

05/06


DISASSEMBLY

4

FRONT DAMPER RIGHT • • • •

(Remove mudguard). (Remove upper fairing). (Remove wheel). (Remove sub-fairing).

LEFT • • • • • •

(Remove mudguard). (Remove upper fairing). (Remove wheel). (Remove brake caliper). (Remove odometer pick-up). (Remove sub-fairing). Before disassembly, support the frame at the centre to prevent the scooter from falling.

06039407_1

To proceed with the operation, position the brake caliper and brake line BEHIND the scooter frame. •

Undo screws (V2c).

V2c

V2c

• •

30 ± 20%

Remove snap ring (C). Remove damper tube (D) downwards by pulling and twisting.

C

D

06039408_1

59

05/06

A


A

4

MADISON 3 250 ie

DISASSEMBLY

CHECKING THE OIL LEVEL IN THE DAMPER A

If the front suspension bottoms out or makes anomalous noises, check the oil level in the dampers as follows: • Remove upper cover (A); • Remove circlip (B), using a screwdriver to press downwards on cap (C) complete with O-ring (D); • Carefully remove spring (E) and allow the oil in which it was immersed to drip off; • Bring the damper (F) to its bottom travel limit while keeping it in a perfectly vertical position.

C

B D F E

06039491

•

With the aid of a rule or a gauge rod, check the oil level. The correct level is 80 mm from the upper edge of the damper. Top up with Q8 FORK OIL if necessary

80 mm

•

05053605

60

05/06


DISASSEMBLY

4

CHANGING THE FORK OIL • • • •

Place a container under the damper and remove screw (V). Allow as much oil as possible to drain out. Disassemble the dampers as described above. Turn the damper upside down to drain out the residual oil.

06039492

Hydraulic fluid is corrosive and can cause serious personal injury. Spent oil must be disposed of in compliance with local legislation. •

V

Refit drain screw (V).

NOTE When reassembling renew copper washer under screw (V).

V • • •

Quantity of oil for damper: 178 ± 4 cc

17 ± 15%

Carefully pour new oil into the damper Check the oil level as described above. Reassemble the damper components and then refit the dampers to the scooter.

61

05/06

A


A

4

MADISON 3 250 ie

DISASSEMBLY

RADIATOR • •

(Remove upper fairing). (Remove lower fairing and footboard). DANGER OF BURNS! Before proceeding, make sure that the coolant temperature is lower than 50 °C.

•

Open expansion vessel cap (A).

A

06039410_1

• •

Place a 5 l recipient under the scooter. Remove screw (V) and wait for ALL the coolant to flow out. If you need to empty coolant system WITHOUT having to remove radiator (e.g. when dropping engine) drain out liquid by detaching one of the hoses from the pump.

V 06039415_1

62

05/06

FRAME AND RUNNING GEAR MADISON 3 250 ie • •

DISASSEMBLY

4

Use a felt-tip pen to mark position of screw (V) with respect to its hole. Remove rubber protection then undo screw (V) and allow coolant to continue to flow from radiator cap. Marking position of screw (V) eliminates risk of overtightening it at time of reassembly.

V

06039380_1

•

Disconnect hoses (C) from radiator and also disconnect fan connector. C

C

06039493

•

Undo screws (V2b) and remove the radiator (E).

E

V2b

V2b 06039415_1

63

05/06

A


A

4

MADISON 3 250 ie

DISASSEMBLY

When reassembling remember to insert ground cable (D) under right-hand screw (V2b).

06039090_1

V2b D

06039410_1

RADIATOR After having refitted the radiator and filled the cooling system by pouring coolant into filler point (A), bleed air from the system as follows: loosen screw (V) and allow ALL THE AIR to escape; now tighten screw. Do not tighten screw (V) past the mark you have made with pen or thread may be damaged. • •

A

Replenish the radiator coolant and then close filler cap (A). Start the engine and run it at IDLE speed for a few minutes then switch off and unscrew the bleed screw again to vent any residual air. Now retighten the bleed screw.

06039380_1

V

64

05/06


DISASSEMBLY

4

A

HORN 06039412_1

• •

(Remove upper fairing). (Remove sub-fairing).

•

Undo screw (V) and disconnect the cables. For subsequent reassembly, connect BLUE wire to the horn INTERNAL terminal and ORANGE wire to the EXTERNAL terminal.

V

BRAKE CALIPERS OVERHAUL B

OVERHAUL OF REAR CALIPER •

Remove retaining ring (A) of brake pad pin (B).

A

06039501

• •

Remove pad pin (B). EsRemove spring (C) and the two pads (D).

NOTE Note that the minimum thickness of the pads is 2 mm.

D

Spring (C) and pads (D) are marked with an arrow to show the position of the disc with respect to the wheel.

C B 06039502

65

05/06


A •

MADISON 3 250 ie

DISASSEMBLY

4

Apply a low pressure jet of compressed air to the oilway (E) in which the brake fluid union was fitted in order to cause the two plungers to be ejected from their seats in the two halves of the caliper; now undo and remove screws (V2).

V2

E

V2

V2

20 ± 20%

06039503

•

Separate the two caliper halves, ensuring that the two plungers (F) and gaskets (G) do not fall.

F

G 06039504

• • •

Remove wiper seal (H) and oil seal (L) in both caliper halves, taking care not to damage the relative grooves. Check that the plungers and their seats are undamaged. Clean the parts thoroughly and flush with exclusively alcohol.

H

Always fit new wiper seals and new oil seals. Refit the plungers, the O-rings, the retaining rings, and the wiper seals, lubricating the parts with brake fluid. NOTE After working on the braking system, always check that: • the brake fluid lines are not damaged, crushed, or twisted; • the disc and pads are not contaminated with oil or grease; • all screws and unions are fully tightened; • there are no leaks from any of the unions.

66

06039505

05/06

L


DISASSEMBLY

A

4

OVERHAUL OF FRONT CALIPER •

Unscrew pins (V2) from their seats (C) and remove pads (D).

V2

C

20 ± 20%

V2

NOTE The brake pads can be removed and changed without having to disassemble the brake calipers from the scooter.

D AGF00019

•

Undo screws (V2).

V2

20 ± 20%

V2 V2

•

Apply a low pressure jet of compressed air to the oil way in which the brake fluid union was fitted in order to cause the two plungers to be ejected from the brake caliper body. Excessive air pressure will result in excessively violent ejection of the two plungers (A).

A AGF00020

67

05/06


A •

4

MADISON 3 250 ie

DISASSEMBLY

Remove wiper seal ring (B) and oil seal ring (C) relative to both plunger cylinders. B

During this procedure take care not to damage the wiper seal and oil seal grooves. • •

B

Check the pistons and their cylinders for any signs of scoring. Clean the parts thoroughly and flush with exclusively alcohol. Always fit new wiper seals and oil seals. Refit the plungers, oil seals (C) and wiper seals (B), lubricating with brake fluid.

AGF00021

After terminating the inspection, cleaning and replacement procedures, refit all the parts in reverse sequence with respect to the sequence of disassembly. NOTE After working on the braking system, always check that: • the brake fluid lines are not damaged, crushed, or twisted; • the discs and pads are not contaminated with oil or grease; • all screws and unions are fully tightened; • there are no leaks from any of the unions

68

C

05/06

C


DISASSEMBLY

A

4

BRAKE MASTER CYLINDERS Empty the hydraulic circuit and drain the fluid into a container so that it may be disposed of in compliance with statutory environmental and waste disposal legislation.

C

Beware of possible spills and splashes of brake fluid. Brake fluid is highly corrosive and can cause personal injury and damage painted parts of the scooter. • • • •

A

Remove upper handlebar cover. Unscrew and remove union (A). Remove brake fluid line (B) and gaskets (C). Disconnect brake light switch (S).

B

S

06039059_1

• • •

Undo screws (V2) and remove U clamp (D). Remove master cylinder unit (E). To refit the master cylinder first start the lower screw (using a long “T” handle wrench) without tightening it and then start the upper screw, then tighten both screws to the prescribed torque.

V2 E D

After assembling the brake master cylinders (front/rear), fit brake line banjo union (B), interposing two new gaskets (C) and tighten the union screw (A) to the prescribed torque.

C

B 06039494_1

A

20 ± 10%

V2

28 ± 15%

NOTE Always fill the brake circuit with new brake fluid after refitting a master cylinder.

69

05/06

A


A

MADISON 3 250 ie

DISASSEMBLY

4

BLEEDING THE BRAKE SYSTEM A

REAR BRAKE CALIPER NOTE Position the scooter so that it is stable and perfectly level. •

• •

Remove master cylinder reservoir cover (A) (left-hand side), unscrewing the relative two screws, so that you can replenish the brake fluid. Fill the brake fluid reservoir to the max. level. Remove rubber cap (B) from bleed screw (C) and fit a rubber tube to recover escaping brake fluid.

06039059_1

C

12 ÷16 06039349_1

• •

• •

Pull the left-hand brake lever to pressurise the brake circuit. Keeping the lever pulled, loosen the bleed screw to allow any air in the circuit to escape. Now tighten bleed screw (C).

B C

Repeat this procedure until brake fluid only flows out of the rubber tube. Replenish the brake fluid level in the reservoir. While bleeding the brakes ensure that no brake fluid comes into contact with the scooter bodywork (risk of damage). In addition, while bleeding the brake calipers avoid contamination of brake discs or pads with brake fluid. Failure to comply with this prescription will have a negative effect on the efficiency of the brake system. If the escaping brake fluid continues to contain air bubbles during the bleed operation, check all unions carefully: if the unions are perfectly tight, check the gaskets on the master cylinder and the caliper plungers for the possible ingress of air. When performing the bleed operation brake fluid may leak from the bleed screw and contaminate the caliper or the disc: in this case, dry the caliper thoroughly and degrease the disc.

B C

•

06039095_1

FRONT BRAKE CALIPER To bleed the front caliper, follow the procedure outlined above, but using the right brake lever.

70

05/06


DISASSEMBLY

4

A

SECURING CLAMPS 06039315_1

The following description contains a list of the main securing clamps on the vehicle, together with an indication of the component they fasten (in some cable harnesses the position of the clamp is shown by means of coloured adhesive tape).

1

1. Handlebar wiring harnesses - RH switch - Lh switch

2

2. Handlebar wiring harnesses - front brake hydraulic fluid line - rear brake hydraulic fluid line

3. Breather tube to expansion tank 4. Throttle transimission 5. Sidestand switch wiring 6. Fuel tank air breather tube

3

6

4

5

06039316_1

71

05/06

4


A

4

MADISON 3 250 ie

DISASSEMBLY

1. Main wiring harness

06039286_1

1

2. Rear brake hydraulic fluid line 3. Fuel pump delivery and return tubes

3

2

4. Rubber boot protecting voltage regulator connector 4

1

1

2

06039288_1

5. Frame right-hand side wiring fixing

5

2 06039285_1

72

05/06


DISASSEMBLY

1. Lambda sensor wiring

4

A

06039339_1

2. Coil cable Sidestand switch wiring

1

2

3. Bank angle sensor wiring

06039320_1

3

73

05/06