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FRAME AND RUNNING GEAR
WORKSHOP MANUAL
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MADISON 3
250 ie
INTRODUCTION
INDEX 1 A
1 - INTRODUCTION FRONT WHEEL . .................................................... 23
INTRODUCTION. .................................................... 5 FRONT BRAKE DISC . ........................................... 25

Manual updates ................................................................ 5 FRONT MUDGUARD. ............................................. 25
NOTES FOR EASY CONSULTATION. .................... 5 FRONT FAIRING . ................................................... 26
Modified pages ................................................................. 5 ACCESSIBILITY. .................................................... 28
Additional pages ............................................................... 5
MAIN SWITCH. ....................................................... 29
Configuration of the pages ................................................ 5
Symbols ............................................................................ 6 REPLACING THE HEADLIGHT BULBS. ................ 30
Abbreviations .................................................................... 6 Low beam / high beam bulbs (A) ...................................... 30
Units of measurement ....................................................... 6 Parking light (B) ................................................................ 30
Recommendations ............................................................ 7 SIDE COVERS. ....................................................... 30
GENERAL WORK PROCEDURES. ........................ 7 RIDER SEAT. .......................................................... 31
Suggestions ...................................................................... 7 PILLION SEAT . ...................................................... 31
OPERATING SYMBOLS. ........................................ 9 ACCESSIBILITY. .................................................... 32
BATTERY. ............................................................... 32
2 - GETTING TO KNOWYOUR SCOOTER
SEAT LOCK. ........................................................... 33
TECHNICAL DATA. ................................................. 10
HELMET COMPARTMENT . ................................... 34
Dimensions ....................................................................... 10
Capacity ............................................................................ 10 ACCESSIBILITY. .................................................... 35
Engine: 4-valve single-cylinder Piaggio ............................ 10 REPLACING THE TAILLIGHT BULBS. ................... 36
Spark plug ......................................................................... 10 Turn indicator bulb ............................................................ 36
Transmission ..................................................................... 10 Rear taillight bulb .............................................................. 36
Fuel system ....................................................................... 10 PILLION GRAB HANDLE. ...................................... 36
Electronic ignition .............................................................. 10
REAR FAIRING. ...................................................... 37
Brakes ............................................................................... 10
Frame ................................................................................ 10 ACCESSIBILITY. .................................................... 38
Suspension ....................................................................... 10 INSTRUMENT PANEL. ........................................... 39
Battery ............................................................................... 10
LOWER FAIRING AND FOOTBOARD. .................. 40
Tyres ................................................................................. 10
ACCESSIBILITY. .................................................... 43
DIMENSIONAL CHECK OF FRAME. ..................... 11
MUFFLER. .............................................................. 43
3 - MAINTENANCE EXHAUST MANIFOLD. ........................................... 44
REAR SHOCK ABSORBERS. ................................ 45
MAINTENANCE TABLE. ......................................... 12
REAR BRAKE CALIPER. ....................................... 45
Check the disc and pads of the rear brake for wear ......... 46
4 - DISASSEMBLY
REAR WHEEL. ........................................................ 46
REAR-VIEW MIRRORS. ......................................... 13
REAR DISC. ............................................................ 48
CENTRAL FAIRING. ............................................... 13
FILTER BOX. ........................................................... 49
CHANGING THE FRONT TURN INDICATOR BULB. 14
ENGINE. .................................................................. 50
WINDSHIELD. ......................................................... 15
SIDE STAND. .......................................................... 54
UPPER HANDLEBAR COVER. .............................. 16 Side stand switch .............................................................. 54
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 Right .................................................................................. 59
SPEEDOMETER SENSOR. .................................... 22 Left .................................................................................... 59
Checking the oil level in the damper ................................. 60
FRONT BRAKE CALIPER. ..................................... 22
Changing the fork oil ......................................................... 61
Checking front brake wear ................................................ 22
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RADIATOR. ............................................................. 62
RADIATOR (assembly) . ........................................ 64
HORN . .................................................................... 65
BRAKE CALIPERS OVERHAUL. ........................... 65
Overhaul of rear caliper .................................................... 65
Overhaul of front caliper ................................................... 67
BRAKE MASTER CYLINDERS . ............................ 69
BLEEDING THE BRAKE SYSTEM. ........................ 70
Rear brake caliper ............................................................ 70
Front brake caliper ............................................................ 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 serv-
icing.
Some information has been given to us by the engine manufacturers. We therefore decline all respon-
sibility 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
X Y
Y Chapter
X Section title
W Page N°
Z Date of issue
W 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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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 “me-
mory tags”. In case of any doubt as to their meaning, consult the page in which they are fully descri-
bed.
ABBREVIATIONS
F Figure
Cs Tightening torque
P Page
Pr Paragraph
S Section
Sc Diagram UNITS OF MEASUREMENT
T Table All the dimensions in this Manual are shown in mm.
V Screw
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 illus-
tration, 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 fit-
ted before proceeding with the next one.
• Lubricate all parts (where applicable) before reinstall-
ing them.
• Gaskets, oil seals, snap rings and cotters must be re-
newed 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 ve-
hicle 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.
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MADISON 3
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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.
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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 2 YOUR SCOOTER 250 ie
TECHNICAL DATA
MALAGUTI SpA reserves the right to modify technical data at any time without prior notice.
06039483
A
B
DIMENSIONS FUEL SYSTEM

wheel base (A), m ................................................. 1.410 Electronic injection with electric fuel pump.
max. length (B), m ................................................. 1.980 Fuel: unleaded petrol.
max. width (C), m .................................................. 0.790
max. height (D), m ................................................. 1.640 ELECTRONIC IGNITION
kerbside weight, Kg .................................................. 165 High efficiency inductive coil integrated with injection, va-
max. load with rider, pillion and luggage, Kg ............. 185 riable ignition advance and separate H.T. coil.
CAPACITY BRAKES
engine oil, cc ........................................................ 1300* Front: 240 mm disk with hydraulic transmission and
transmission oil cc .................................................. 250* calliper with two pistons
fuel tank (reserve), l ........................................... 8.5* (3*) Rear: 240 mm disk with hydraulic transmission and
* Guideline value calliper
ENGINE: 4-VALVE SINGLE-CYLINDER PIAGGIO FRAME

type .................................................................... M366M Frame made with single steel tube split at footboard level.
n° of cylinders ............................................................... 1
bore x stroke, mm ........................................... Ø 72 x 60 SUSPENSION
displacement, cm3 .................................................... 244 Front: Hydraulic fork Ø 36 mm - travel: 130 mm
compression ratio ........................................... 11±0.5 : 1 Rear: N.2 hydraulic shock absorbers with adjusta-
cooling ................................................................... liquid ble spring preload - travel: 75 mm.
starting system ........................................ electric starter
BATTERY
lubrication system ........................................... wet sump
Type: 12V, 12Ah; sealed unit.
SPARK PLUG
TYRES
type: ............................................. CHAMPION RG4 HP
Front: ————— 120/70 - 14 55P
........................................................... NGK CR8EB
Rear: ————— 140/60 - 14 64P
TRANSMISSION It is possible to use tyres with load and speed indexes that
Expandable pulley automatic variator, V-belt, automatic dry are higher than or identical to those indicated. It is howe-
centrifugal clutch, secondary drive gearbox and transmis- ver necessary for speed indexes to be identical for both
sion housing with forced circulation cooling system. tyres.
10 05/06
MADISON 3 GETTING TO KNOW
250 ie YOUR SCOOTER 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
06039484
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MAINTENANCE TABLE
= first service = inspection = clean = adjustment = change
1 2 3 4 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
CHECKS AND REPLACEMENT OPERATIONS 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
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 Every 2000 km
Level and density of coolant (change every 2 years) –
Correct fitting and tightness of hoses
Brake fluid circuit * Every 20 months or 10000 km
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 *
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 unu-
sually 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 re-
sponsibility of technicians not specifically authorised by MALAGUTI.
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DISASSEMBLY 4 A
REAR-VIEW MIRRORS 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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• Disengage central fairing (B) and remove it from sco- 06039041_1

oter, rotating it forwards.
CHANGING THE FRONT TURN INDICATOR 06039029_1
BULB
• Remove panels (A) by prising with a screwdriver.
• Turn bulb-holder ringnut (B) counter-clockwise and 06039032_1
remove.
B
• Extract bulb by pulling it.
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DISASSEMBLY 4 A
WINDSHIELD 06039045_1
• (Remove central fairing).
• Undo screws (V6). A

• Remove windshield (A).
• Recover the rubber grommets under the screws.
V6 V6
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A 4 DISASSEMBLY
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UPPER HANDLEBAR COVER 06039048_1
• (Remove rear-view mirrors).
• Undo screws (V2a) and (V2b). A

• Remove upper handlebar cover (A).
V2a V2b
ACCESSIBILITY 06039059_1
G F
Removing the front handlebar cover provides access to
the following components:
• Handlebar screw (A);

• connector for LH handlebar control (B);
• ambient temperature sensor connector (C);
• RH control STOP switch (D); D
• LH control STOP switch (E);
E
• rear brake master cylinder union (F);
• front brake master cylinder union (G);
• resistance connector (H); A S
• steering adjustment ringnuts (S).
06039060_1
C H B
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DISASSEMBLY 4 A
RIGHT-HAND CONTROL 06039385

• (Remove upper handlebar cover).
• Unscrew union (B).

V
• Undo screw (V) and remove counterweight.
• Disconnect wiring connectors.
• Undo screws (V2) and remove throttle control.
V2
• Disconnect throttle opening (A) cables.
Use compressed air to reduce friction when A

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). V2 V

• 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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AMBIENT TEMPERATURE SENSOR 06039060_1

• Detach the connector (A).
• Remove sensor (B) from lower handlebar cover (C). 06039021_1
The sensor must be mounted EXTERNAL-

LY to the lower handlebar cover, as shown
in the figure.
B C
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DISASSEMBLY 4 A
HANDLEBAR LOWER COVER 06039062_1
• (Remove rear-view mirrors). V2

• (Remove right-hand control).
• (Remove ambient temperature sensor).
• Undo screw (V). 06039061_1
• Remove lower handlebar cover.
To remove handlebar cover completely, di-

sconnect the two right-hand control con-
nectors.
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A 4 DISASSEMBLY
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SUB PANEL 06039082_1
• Remove footboards (A).
• Undo screw (V). 06039085_1
• Undo screws (V4a) and (V4b). 06039086_1
• Remove sub-panel (B). V4b
Screws (V4a) are longer than screws (V4b).
V4a B
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DISASSEMBLY 4 A
Removing the sub panel provides access to the following

components:
• Ignition coil (A).

• Bank angle sensor (B).
B A
• Radiator drain plug (C). 06039090_1
• Side stand switch (D). 06039227_1
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SPEEDOMETER SENSOR 06039095_2
• Undo screw (V) ensuring the spacer does not fall. V

• 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. V2 V
V 20 ± 10%
• Undo screws (V2) and free the complete caliper.
After having removed the hydraulic tran-

smission and the caliper from its seat, pla-
ce a recipient under it to collect the brake
fluid. Dispose of used brake fluid in com-
pliance 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 4 A
FRONT WHEEL 06039093_1
Before disassembly, support the frame at the

centre to prevent the scooter from falling.
For this purpose, remove sub-panel and pla-
ce a stand under frame cradles as shown.
• Undo the nut (D). 06039095_2
D 80 ± 10%
• Pull out the spindle (V); then remove the wheel. 06039096_1
Pay attention to spacers located on spindle

(V).
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A 4 DISASSEMBLY
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The figure shows sequence of components for fitting 06039098_1

wheel.
C E
• Pin (A).
• Washer (B).
• Right-hand spacer (C).
• Left-hand spacer (D).
• Washer (E).
• Nut (F).
A B D F
Do not operate the brake lever after remo-
ving the wheel, since the pads would come
into contact with each other.
06039487
When refitting the wheel be sure to refit the A
spacers (C-D) and grease spindle (A). C
D
E
F
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DISASSEMBLY 4 A
FRONT BRAKE DISC 06039360_1
V5
• (Remove speedometer sensor).
• (Remove front brake caliper).
• (Remove front wheel)
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 06039104_1
remove mudguard.
A
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FRONT FAIRING 06039107_1

V2b V2b
• (Remove windshield).
• (Remove front wheel).
• (Remove front mudguard).
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
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DISASSEMBLY 4 A
• Undo screws (V5f) and (V2g). 06039122_1
V2g
V5f
V5f
V5f
Pay attention to screws (V4) located UNDER 06039125_1

ticket compartment cover, UNDER cover of
radiator expansion vessel access compart-
ment and UNDER glove compartment door.
V4
V4
06039506_1
V4
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A 4 DISASSEMBLY
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• Rotate front fairing (A) forwards then disconnect hea- 06039499

dlight connectors (B).
• Remove front fairing (A).
During subsequent reassembly, engage 06039133_1

front fairing with metal tab (C).
ACCESSIBILITY 06039500
Removing the front fairing provides access to the following

components: G
• main switch (A);
• anti-theft connector (provision) (3-way) (B); A H
• headlight connectors (C);
• main switch connector (6-way) (D); B
• odometer sensor connector (E);
C
• 12V power socket connector, protected by foam (F);
• 12V power socket fuse (5 A) (G);
• autodiagnostic serial port (H);
C
• coolant expansion tank (I);
• fuse connections (L).
F D E I L
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DISASSEMBLY 4 A
MAIN SWITCH 06039256_1

• (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 counter-
clockwise through 1/4 of a turn.
• Undo tamperproof screws (V2) using a special 4 mm 06039142_1

hex wrench (P/N 08601400); then extract keyswitch
(E).
E
V2
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A 4 DISASSEMBLY
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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
• Remove side covers (A).
To remove side cover, first rotate rear part

upwards in such a way as to disengage in-
terlocking tabs.
V2 A V2
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DISASSEMBLY 4 A
RIDER SEAT 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 D2
PILLION SEAT 06039179_1
A
• Lift rider seat.
• Remove the seat (A), resting it on a supporting surfa-
ce with the upholstery upwards.
V2
V2
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250 ie
Removing seat provides access to the following compo-

nents:
A
• main charge circuit fuse (30 A) (A);
• Battery (B).
B
BATTERY 06039180_1
(See “Installing the battery”.)
Note that: A
- the RED leads must be connected to the battery PO-
SITIVE “+” terminal; B
- the BLACK lead must be connected to the battery
NEGATIVE “-” terminal;
- the battery terminals must be towards the FRONT of A
the scooter.
32 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
SEAT LOCK 06039185_1
• Remove nut covers and unscrew nuts (D2). D2
• Extract seat lock (A) by pulling downwards and then 06039188_1

disengage it from transmission cable (B) and remove.
B A
33 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
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 06039192_1

battery cables (B) and disconnect fuseholder (C). B C A
• Extract seat transmission cable (D) from helmet com- 06039195_1

partment.
34 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
• Disengage electrical cable (E) for helmet compartment
light from cable guide (F), then disconnect connector E G
(G).
When reassembling, electrical cable (E)

must be reattached to cable guide (F).
06039196_1
ACCESSIBILITY
E H F
Removing the helmet compartment provides access to
the following components: D
C
• flasher relay (A); B
A
• starter motor contactor (B);
• fan contactor (C);
G
• injection charge contactor (D);
• voltage regulator (E);
• rear turn indicators (F);
• taillight (G);
• rubber boot containing connector of voltage regulator
(H); 06039200_1
• throttle body with injection control unit (I);

• helmet compartment lock (L);
• cooling system air bleed screw (M); L P
• injection connector (N); N
• temperature sensor connector (O);
I
• fuel level sensor (P).
M
06039224_1
35 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
REPLACING THE TAILLIGHT BULBS

B
• (Remove rider seat).
• (Remove pillion seat).
• (Remove helmet compartment).
TURN INDICATOR BULB A
• Turn bulb-holder ringnut (A) counter-clockwise and

remove.
06039220_1
REAR TAILLIGHT BULB
• Turn bulb-holder ringnut (B) counter-clockwise and

remove.
PILLION GRAB HANDLE

V3
• (Remove seat lock).
• Undo screws (V3) and remove handle (A).
V3 43 ± 15%
06039206_1
36 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
REAR FAIRING 06039229_1

• (Remove pillion grab handle).
V4
• Disengage rear fairing (A), lifting front part. 06039234_1
• Open clamps (B), pulling them towards rear of scoo- 06039236_1

ter. B C B
• Detach the connector (C).
• Remove rear fairing, pulling it towards rear of scoo-
ter.
37 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
In the event of breakage of rubber protec- 06039229_1
tion (D), it can be removed after having di- E

sengaged it from supports (E).
ACCESSIBILITY
A
Removing rear fairing provides access to the following
components:
• Ground terminal (A).
06039242_1
• Fuel vapour venting valve (B)

D B C
When renewing or refitting fuel vapour ven-

ting 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
MADISON 3
250 ie
DISASSEMBLY 4 A
INSTRUMENT PANEL 06039245_1

V2 V2
• Disengage upper part of front fairing (see “Removing 06039247_1

front fairing”.
V4
• Disconnect connector (A), open clamp (B); then re- 06039254_1

move dashboard. V4
A
To detach the digital instrument from the
dashboard undo screws (V4).
When refitting dashboard re-secure electri-
cal cable under clamp (B).
V4
39 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
LOWER FAIRING AND FOOTBOARD 06039256_1
A
• (Remove rear fairing).
• (Remove front mudguard).
• (Remove upper fairing).
• (Remove dashboard).
• Remove main switch cover (A), rotating it counter- 06039255_1

clockwise through ¼ of a turn.
• Open the luggage compartment and undo fuse box
screws (V2a).
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
MADISON 3
250 ie
DISASSEMBLY 4 A
• Remove foam (A) from 12V power socket and detach 06039152_1
connectors (B).
B
When reassembling note that foam (A) must

be refitted to protect connectors and soc-
ket.
A
• Open hatch (C). 06039260_1
• Remove fuel tank cap (D), remove gasket (E), discon- D A

necting it from the drip hose, then refit the cap.
C
Screw the fuel tank cap back on immedia-

tely after removing the gasket.
• Undo screws (V3d) and disengage coil (F) from foot- 06039262_1
board. V3d
If no further parts are to be removed, it is

not necessary to detach the coil wires.
41 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
• Temporarily remove flasher unit (G) from vehicle. 06039264_1
• Remove lower fairing and footboard unit (H) from vehi- 06039267_1
cle, turning front part upwards, then slide out towards
rear of vehicle.
• To detach lower fairing (L) from footboard (M) undo 06039280_1
screws (V4e) and screw (Vf).
V4e Vf
42 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
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 compo-
nent shave cooled down and always wear
suitable protective gloves.
• Loosen screw (V) of clamp (A).

• Undo the screws (V3b); then remove the entire silen-
cer (B).
B
V3b 25 ± 15%
V3b V A
Pay attention to spacers (C) located under 06039328_1

washers (D) on screws (V3b).
06039328_1
When refitting silencer always renew gasket
between silencer and exhaust manifold (see
“Removing exhaust manifold”).
V3b
D C
43 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
EXHAUST MANIFOLD 06039326_1
• (Remove silencer).
A
Before working on the silencer and the

exhaust manifold wait until all the compo-
nent shave cooled down and always wear
suitable protective gloves.
• Disengage Lambda probe connector (A) from its sup-

port and disconnect it.
Note that connector (A) must always be se-

cured to its support to ensure correct ope-
ration of the Lambda probe.
• Cut clamp (B), unscrew nuts (D2) then extract mani-

fold (C) including Lambda probe. 06039339_1
D2 30 ± 10%
D D2
• If necessary, unscrew Lambda probe (D) from mani-

fold. C
D 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).
06039488
44 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
REAR SHOCK ABSORBERS
Before disassembly, support the frame at the

• First undo lower screw (Vi); then upper screw (Vs).
Vs
Vi/s 45 ± 15%
• Remove shock-absorber (A).
Vi
06039332_1
REAR BRAKE CALIPER

• Undo brake fluid line screw (V) and detach brake line V A
from caliper.
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
After having removed the hydraulic tran- B C

smission and the caliper from its seat, pla-
ce a recipient under it to collect the brake
fluid. Dispose of used brake fluid in com-
pliance with statutory legislation.
06039346_1
45 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
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 05053576
3.5 mm, it must be renewed.
Minimum thickness of the pads is 2 mm.
Note For overhauling the caliper, see the specific

Chapter.
06039489
REAR WHEEL
A B C D E
• (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 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 C
towards the wheel bearing, as shown in the
photo.
06039344_1
06039496
46 05/06
MADISON 3
250 ie
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 si-
milar to the spacer IN FRONT of the arm;
the spacer must be refitted with the smal-
lest 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 re-
moved snap ring (L). H
06039498
• Remove rear wheel (M).

M
06039358_1
47 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
Before reassembling, grease shaft (N) abundan-

tly, especially on the splines.
06039362_1
REAR DISC
V5
• (Remove rear brake caliper).
• (Remove right-hand shock absorber).
• (Remove rear wheel).
The thickness of the rear brake disc must

NEVER be less than 3.5 mm; otherwise,
RENEW THE DISC.
06039360_1
V5
V5 11 ± 10%
When reassembling, use new screws and

apply a high strength thread locker.
48 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
FILTER BOX
• (Remove rider seat). V9c
• (Remove pillion grab handle). Vb
• (Remove rear fairing).
• Undo screws (V3a), screw (Vb) and screws (V9c); now V3a
remove cover (A) from airbox.
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).

06039373_1
• Loosen screw of clamp (D).
B C
• Undo screws (V3d).

• Remove airbox (E) from vehicle, prising gently in con-
nection point with throttle body.
E
V3d
49 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
The sequence for disassembling the filter box compo-

nents is shown in the figure.
06039495
ENGINE
• (Remove fairing). V
• (Remove exhaust manifold).
• (Remove shock absorbers). A
• (Remove filter box).
Before disassembly, support the frame at

the centre to prevent the scooter from fal-
ling.
• 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
50 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
• Disconnect wires (C) from starter motor.
06039382_1
• Undo screw (Vb), disengage hose (D) and underlying

wiring. E F
• Disconnect injection control unit connector (E).
• Disconnect hoses (D) and (F), injector connector (G), G
engine temperature thermistor connector (H). Vb
• Disconnect connector of oil pressure switch (I).
51 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
• 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 radia-
tor”).
M
06039358_1
• Disconnect coolant return hose (N).
Before disconnecting hose (N), empty the

cooling system (see “Removing the radia- N
tor”).
52 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
• Temporarily fit rear wheel on its spindle and lock tem-
porarily with its nut.
This operation will facilitate removal of en-

gine from scooter.
• Undo the nut (D).
D 68 ± 10%
• Unhook spring (M).

• Remove pin (P) and extract engine towards rear of
vehicle.
M
53 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
SIDE STAND
• Detach springs (A) and undo screw (V).
V 20 ± 15%
06039228_1
SIDE STAND SWITCH

V2
V2 5 ± 20%
06039228_1
• Disconnect connector (A) under the footboard on the

right-hand side of the scooter.
06039286_1
54 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
FUEL TANK
• (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 emp-

tying the tank, wait for the engine to cool
down. Use a manual pump.
A
B
• Remove fuel tank cap, remove gasket (A), discon-
necting it from the drip hose, then refit the cap.
Screw the fuel tank cap back on immedia-

tely after removing the gasket.
• Disconnect fuel pump hoses (B) and fuel pump con-

nector (C). C
06039393_1
• Undo screws (V4) and remove tank (D).
There is a bushing (D) under each screw

(V4).
• The tank support must rest on a rubber Silent Block D

(F); ensure the rubber mount does not fall.
V4
V4
E
06039316_1
06039497
55 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
FUEL LEVEL SENSOR

06039400_1

• (Remove helmet compartment). B V4
• Detach connector (A) and undo screws (V4).
During this procedure do not use heat and

keep sparks and naked flames well clear of
the scooter. If the tank remains without the A
fuel level sensor fitted for a prolonged pe- V4
riod, plug the hole to prevent the accumula-
tion of petrol vapour in the workshop.
• Remove sensor (B).
HANDLEBAR
B
D
• (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 50 ± 20%
06039315_1
56 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
SUB-FAIRING
• Loosen all screws (V4) and remove one for each brac-
ket (A); then turn latter until to align them with ope-
ning in sub-fairing (B).
V4
V4
06039402_1
• Undo screw (V) and remove sub-fairing (B) passing

slider stanchion tubes through relative opening.
06039404_1
57 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
FRONT FORK
06039315_1
• (Remove front fairing).

• (Remove handlebar).
• (Remove mudguard).
• (Remove front brake caliper).
• (Remove speedometer sensor).
Before disassembly, support the frame at A

the centre to prevent the scooter from fal-
ling. 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.
Support the fork to prevent them falling. A
• Pay attention because balls (C) may fall from their B

races.
• Clean away any grease, including the grease in the
ball races. Check for wear and renew if necessary. C
• Grease and refit.
Upper race: 22 balls (Ø 3/16")

Lower race: 19 balls (Ø 1/4")
06039490
58 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
FRONT DAMPER
RIGHT
• (Remove wheel).
• (Remove sub-fairing).
LEFT
• (Remove wheel).
• (Remove brake caliper).
• (Remove odometer pick-up).
Before disassembly, support the frame at the 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
06039408_1
59 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
CHECKING THE OIL LEVEL IN THE DAMPER
If the front suspension bottoms out or makes anomalous A

noises, check the oil level in the dampers as follows:
C B
• Remove upper cover (A);
• Remove circlip (B), using a screwdriver to press D
downwards on cap (C) complete with O-ring (D);
• Carefully remove spring (E) and allow the oil in which F
it was immersed to drip off;
• Bring the damper (F) to its bottom travel limit while E
keeping it in a perfectly vertical position.
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
MADISON 3
250 ie
DISASSEMBLY 4 A
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 resi-
dual oil.
Hydraulic fluid is corrosive and can cause

serious personal injury.
06039492
Spent oil must be disposed of in complian-
ce with local legislation.
V
• Refit drain screw (V).
NOTE When reassembling renew copper washer

under screw (V). Quantity of oil for damper: 178 ± 4 cc
V 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
MADISON 3
A 4 DISASSEMBLY
250 ie
RADIATOR
• (Remove lower fairing and footboard).
DANGER OF BURNS!
Before proceeding, make sure that the coo-
lant temperature is lower than 50 °C.
• Open expansion vessel cap (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.
06039415_1
62 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
• 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 discon-

nect fan connector.
06039493
• Undo screws (V2b) and remove the radiator (E).
V2b
V2b
06039415_1
63 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
When reassembling remember to insert

06039090_1
ground cable (D) under right-hand screw
(V2b).
V2b
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 A

have made with pen or thread may be da-
maged.
• 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 ble-
ed screw.
06039380_1
64 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
HORN
06039412_1

• 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.
BRAKE CALIPERS OVERHAUL
OVERHAUL OF REAR CALIPER B
• Remove retaining ring (A) of brake pad pin (B).
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
MADISON 3
A 4 DISASSEMBLY
250 ie
• Apply a low pressure jet of compressed air to the oi-

lway (E) in which the brake fluid union was fitted in
E
order to cause the two plungers to be ejected from V2
their seats in the two halves of the caliper; now undo
and remove screws (V2). V2
V2 20 ± 20%
06039503
• Separate the two caliper halves, ensuring that the two

plungers (F) and gaskets (G) do not fall.
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 undama-
ged.
• Clean the parts thoroughly and flush with exclusively H L
alcohol.
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, cru- 06039505
shed, 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 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
OVERHAUL OF FRONT CALIPER
• Unscrew pins (V2) from their seats (C) and remove

pads (D).
C
V2 20 ± 20%
V2
NOTE The brake pads can be removed and chan-

ged without having to disassemble the brake
calipers from the scooter.
AGF00019
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 exces-

sively violent ejection of the two plungers
(A).
A
AGF00020
67 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
• Remove wiper seal ring (B) and oil seal ring (C) rela-
tive to both plunger cylinders.
During this procedure take care not to da- B C

mage the wiper seal and oil seal grooves. B C
• 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), lubri-
cating with brake fluid. AGF00021
After terminating the inspection, cleaning and replace-

ment 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, cru-
shed, 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 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
BRAKE MASTER CYLINDERS
Empty the hydraulic circuit and drain the fluid into a con-
tainer so that it may be disposed of in compliance with
statutory environmental and waste disposal legislation. C
Beware of possible spills and splashes of A

brake fluid. Brake fluid is highly corrosive
and can cause personal injury and damage
painted parts of the scooter.
• Remove upper handlebar cover.

• Unscrew and remove union (A).
• Remove brake fluid line (B) and gaskets (C). B S
• Disconnect brake light switch (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 V2
(using a long “T” handle wrench) without tightening it
and then start the upper screw, then tighten both E
screws to the prescribed torque.
D
After assembling the brake master cylinders C
(front/rear), fit brake line banjo union (B),
interposing two new gaskets (C) and tighten
the union screw (A) to the prescribed tor-
que.
B
A
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
MADISON 3
A 4 DISASSEMBLY
250 ie
BLEEDING THE BRAKE SYSTEM
REAR BRAKE CALIPER A
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. B C
• Keeping the lever pulled, loosen the bleed screw to
allow any air in the circuit to escape. Now tighten ble-
ed screw (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 sco-
oter bodywork (risk of damage). In addition,
while bleeding the brake calipers avoid con-
tamination of brake discs or pads with brake
fluid. Failure to comply with this prescrip-
tion will have a negative effect on the effi-
ciency of the brake system.
If the escaping brake fluid continues to con-
tain 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 B C
the possible ingress of air.
When performing the bleed operation brake
fluid may leak from the bleed screw and con-
taminate the caliper or the disc: in this case,
dry the caliper thoroughly and degrease the
disc.
FRONT BRAKE CALIPER

06039095_1
• To bleed the front caliper, follow the procedure outli-

ned above, but using the right brake lever.
70 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
SECURING CLAMPS
06039315_1
The following description contains a list of the main se-

curing clamps on the vehicle, together with an indication
of the component they fasten (in some cable harnesses 1
the position of the clamp is shown by means of coloured
adhesive tape).
1. Handlebar wiring harnesses

- RH switch 2
- Lh switch
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
5 4
06039316_1
71 05/06
MADISON 3
A 4 DISASSEMBLY
250 ie
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
1 2
06039288_1
5. Frame right-hand side wiring fixing
2
06039285_1
72 05/06
MADISON 3
250 ie
DISASSEMBLY 4 A
1. Lambda sensor wiring 06039339_1
2. Coil cable
1
Sidestand switch wiring
3. Bank angle sensor wiring

06039320_1
73 05/06

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FRAME AND RUNNING GEAR

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INTRODUCTION. .................................................... 5 FRONT BRAKE DISC . ........................................... 25

NOTES FOR EASY CONSULTATION

CONFIGURATION OF THE PAGES

Never use open flames for any reason.

Never suck from or blow into the fuel pipe.

Never leave the engine running in closed or poorly ventilated areas.

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

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

NO! - Operations to be absolutely avoided.

FITTING AND ASSEMBLY OPERATIONS

REMOVAL AND DISASSEMBLY OPERATIONS

DIMENSIONS FUEL SYSTEM

ENGINE: 4-VALVE SINGLE-CYLINDER PIAGGIO FRAME

Control dimension (A) must be 1220 mm with a tolerance of ± 2 mm.

RIGHT-HAND MIRROR is fitted by screwing

CENTRAL FAIRING 06039029_1

• Disengage central fairing (B) and remove it from sco- 06039041_1

CHANGING THE FRONT TURN INDICATOR 06039029_1

• Turn bulb-holder ringnut (B) counter-clockwise and 06039032_1

• (Remove central fairing).

• Undo screws (V6). A

UPPER HANDLEBAR COVER 06039048_1

• (Remove rear-view mirrors).

• Undo screws (V2a) and (V2b). A

• Handlebar screw (A);

• (Remove rear-view mirrors).

• Unscrew union (B).

Use compressed air to reduce friction when A

At time of reassembly shorter screw (V2)

LEFT-HAND CONTROL 06039386

• (Remove rear-view mirrors). V2 V

• Disconnect switch connector.

Use compressed air to reduce friction when

At time of reassembly shorter screw (V2)

AMBIENT TEMPERATURE SENSOR 06039060_1

• (Remove rear-view mirrors).

• Detach the connector (A).

• Remove sensor (B) from lower handlebar cover (C). 06039021_1

The sensor must be mounted EXTERNAL-

• (Remove rear-view mirrors). V2

• Undo screws (V2).

• Undo screw (V). 06039061_1

• Remove lower handlebar cover.

To remove handlebar cover completely, di-

SUB PANEL 06039082_1

• Remove footboards (A).

• Undo screw (V). 06039085_1

• Undo screws (V4a) and (V4b). 06039086_1

• Remove sub-panel (B). V4b

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

Removing the sub panel provides access to the following

• Ignition coil (A).

• Radiator drain plug (C). 06039090_1

• Side stand switch (D). 06039227_1

SPEEDOMETER SENSOR 06039095_2

• Undo screw (V) ensuring the spacer does not fall. V

When refitting, use a feeler gauge, to check

• Remove the sensor complete with the transmission.

FRONT BRAKE CALIPER 06039095_2

• Undo the screw of the hydraulic transmission (V) and

When reassembling, replace the gaskets of