🏷️ Basic Information

Make:

Malaguti

Model:

Madison 180 / 200

Year:

2002

Product Type:

Service Repair Manual

👋 Introduction

Vehicle Segment:

Mid-size scooter, designed for urban commuting and light touring, blending practicality with a degree of performance.

Competitors:

Competed against other mid-size scooters from brands like Yamaha (Majesty series), Suzuki (Burgman series), Honda (Forza series), and Aprilia (Scarabeo series).

Design Philosophy:

Malaguti's Madison line was known for its Italian styling, comfortable ergonomics, and robust construction, aiming to offer a balance of performance and everyday usability.

📋 Manual Details

Systems Covered:

Engine mechanical, engine electrical, fuel system, ignition system, cooling system, lubrication system, exhaust system, transmission (CVT), clutch, brakes (front and rear disc), suspension (front telescopic fork, rear dual shock absorber), steering, wheels, tires, electrical system (lighting, starting, charging, ignition, instrumentation), chassis, bodywork, troubleshooting, maintenance schedules, wiring diagrams.

Estimated Pages:

Approx. 200-300 pages (typical for this era and model complexity)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (likely PDF, potentially scanned original)

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for disassembly, inspection, repair, and reassembly of the engine, including cylinder head, valves, pistons, connecting rods, crankshaft, camshaft, timing components, and engine block.

Fuel System:

Carburetor (or early injection for some variants) tuning, cleaning, and repair; fuel pump testing; fuel filter replacement; fuel line inspection.

Electrical System:

Comprehensive wiring diagrams, component testing procedures for battery, starter motor, alternator, ignition coil, CDI unit, lights, horn, and instrument cluster.

Routine Maintenance:

Oil changes, filter replacements (oil, air), spark plug replacement, coolant checks and replacement, chain adjustment, brake pad replacement, tire pressure checks, and general inspection points.

Troubleshooting:

Systematic diagnostic flowcharts and step-by-step guides to identify and resolve common and complex issues related to engine performance, electrical faults, and mechanical failures.

Rebuilding Procedures:

Detailed instructions for engine overhauls, carburetor rebuilding, transmission disassembly/reassembly, and brake caliper servicing.

Diagnostics:

Advanced diagnostic procedures, including symptom analysis, component testing with specifications, and troubleshooting guides for intermittent issues.

Repair Specifications:

Precise torque specifications for all fasteners, engine component clearances (piston-to-cylinder wall, valve lash), bearing tolerances, and assembly instructions.

Wiring Diagrams:

Detailed, schematic wiring diagrams illustrating the layout and connections of all electrical components, crucial for electrical system diagnosis and repair.

📊 Manual Specifications

Digital Format:

PDF (Searchable text is highly desirable for efficient information retrieval)

Quality:

High-resolution scans of original documents, ensuring clarity of text, diagrams, and images. Vector graphics for diagrams are ideal.

Binding:

N/A (for digital format)

Paper Quality:

N/A (for digital format, but original would be high-quality paper)

⚙️ Engine Specifications

Engine Type:

Four-stroke, single-cylinder, liquid-cooled

Engine Displacement 180:

Approximately 176cc

Engine Displacement 200:

Approximately 198cc

Bore X Stroke 180:

Approx. 65mm x 57mm (typical for this displacement class)

Bore X Stroke 200:

Approx. 67mm x 57mm (typical for this displacement class)

Compression Ratio:

Approx. 10.0:1 to 11.0:1

Horsepower Estimate:

Estimated 15-18 HP (for 180cc), 17-20 HP (for 200cc), varying slightly by specific tuning and market.

Torque Estimate:

Estimated 14-17 Nm (for 180cc), 16-19 Nm (for 200cc)

Fuel Delivery:

Carburetor (likely Mikuni or Keihin, specific model would be in the manual)

Carburetor Size:

Likely 28-32mm diameter

Cooling Type:

Liquid-cooled with a radiator and fan

Oil Capacity:

Approx. 1.0 - 1.2 liters (including filter if applicable)

🔧 Transmission

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Optional Transmission:

N/A (CVT is standard for this model)

Drive Type:

Belt drive to rear wheel

Clutch Type:

Automatic centrifugal clutch

📐 Dimensions

Length:

Approx. 2100-2200 mm

Width:

Approx. 750-800 mm

Height:

Approx. 1400-1450 mm (seat height would be around 780-800 mm)

Wheelbase:

Approx. 1450-1500 mm

Ground Clearance:

Approx. 100-120 mm

Dry Weight:

Approx. 150-160 kg

Fuel Tank Capacity:

Approx. 10-12 liters

Gross Vehicle Weight Rating:

Approx. 300-320 kg

🛡️ Safety Features

Crash Test Ratings:

N/A (Scooters of this era were not typically subjected to comprehensive automotive crash testing standards.)

Braking System Front:

Hydraulic disc brake (single or dual disc depending on variant/market)

Braking System Rear:

Hydraulic disc brake

Suspension Front:

Telescopic fork, hydraulic damping

Suspension Rear:

Twin shock absorbers, adjustable preload

Wheel Type Front:

13-inch alloy wheel

Wheel Type Rear:

13-inch alloy wheel

Tire Size Front:

120/70-13

Tire Size Rear:

140/60-13 or 130/70-13

Lighting System:

Halogen headlight, LED or incandescent tail/brake lights, turn signals.

💡 Technology Features

Instrument Panel:

Analog speedometer and tachometer, fuel gauge, coolant temperature gauge, odometer, trip meter, various warning lights (oil, battery, turn signals, high beam).

Lighting Technology:

Reflector-based halogen headlamp for good illumination. LED technology may be present in some newer iterations or aftermarket upgrades.

ABS:

ABS was typically an optional feature or not widely available on models of this specific year, but the manual would detail its operation if equipped.

Connectivity Features:

N/A (No advanced connectivity features expected for this era of scooter.)

🔧 Maintenance

Oil Change Interval:

Every 3,000 - 5,000 km or annually, whichever comes first (refer to manual for exact specification).

Spark Plug Replacement:

Every 6,000 - 10,000 km

Air Filter Cleaning Replacement:

Every 3,000 - 5,000 km (cleaning), 10,000 - 15,000 km (replacement)

Transmission Oil Change:

CVT drive unit typically does not require regular oil changes, but roller weights and clutch springs inspection/replacement at recommended intervals (e.g., 10,000 - 20,000 km).

Engine Oil Type:

Synthetic or semi-synthetic motorcycle engine oil, API SG/SH/SJ or higher, SAE 10W-40 or 10W-50 (check manual for precise viscosity and specification).

Coolant Type:

Ethylene glycol-based antifreeze mixture, typically a 50/50 mix with distilled water. (Specific type and color may vary, consult manual).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Gear Oil Type:

Refer to manual for final drive/gearbox oil specification (typically SAE 80W-90 or similar gear oil).

Common Wear Items:

CVT belt wear, brake pad wear, suspension wear, electrical connections can be susceptible to corrosion in damp climates.

Potential Failures:

Water pump seal leaks, stator/regulator issues (though less common than in some other brands), carburetor jetting issues due to fuel quality variations.

Electrical Quirks:

Corrosion on handlebar switches, battery terminal oxidation, and occasional headlight bulb failures are common on older scooters exposed to elements.

Cooling System Maintenance:

Regular flushing and replacement of coolant is vital to prevent overheating and corrosion in the radiator and engine passages.

📚 Vehicle History

Manufacturer Origin:

Malaguti is an Italian manufacturer, known for its motorcycles and scooters since its founding in 1930.

Madison Line:

The Madison line was Malaguti's premium scooter offering, competing in the growing maxi-scooter market of the late 1990s and early 2000s.

Engine Variants:

Introduced with 125cc and 180cc engines, with the 200cc variant being a later or alternative option depending on market regulations and consumer demand.

Production Period:

The Madison 180/200 was produced in the early to mid-2000s, with the 2002 model year being a key variant.

🏆 Awards & Recognition

Awards And Accolades:

Specific awards are not widely documented for this model, but its European market reception would have been influenced by contemporary scooter reviews and owner satisfaction.