Malaguti SPIDER MAX RS 500 Service Manual
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Malaguti SPIDER MAX RS 500 Service Manual

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Summary of Contents for Malaguti SPIDER MAX RS 500

  • Page 2 FOREWORD • The present manual specifically addresses to specialised technical personnel (MALAGUTI authorised service centres and single motor mechanics) and contains all the service interventions indicated by the Manufacturer until the publishing of this document. • Some basic technical information has been intentionally omitted as it is considered to be common knowledge.
  • Page 3 NOTES FOR EASY CONSULTATION ABBREVIATIONS TECHNICAL DICTIONARY Torque wrench setting = (DC) Direct current (battery supply) ~ (AC) Alternating current (flywheel supply) Right : Ampere Unit of measurement of the electrical current Picture : Watt Unit of measurement of the electrical power (product of Volts and Amperes; A x V = W) Ω...
  • Page 4 SYMBOL LIST CAUTION! IDLING ENGINE Recommendations and SAFETY GLOVES DISASSEMBLY Switch on the engine, at precautions regarding rider These operations require OPERATIONS idling speed, to perfom safety and motor vehicle the use of safety gloves these interventions. integrity. WARNING! Situations entailing the risk of personal injury to ENGINE OFF IMPORTANT...
  • Page 5 GENERAL WORK PROCEDURES • The recommendations 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, and should therefore be strictly adhered to. • Always listen with attention to the customer’s opinion and complaints about the motor-bike operation, asking specific questions in order to have a complete understanding of all the symptoms and identify with good approximation the real causes of the trouble.
  • Page 6 • Before carrying out any operation, wait for all parts to cool down. • For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and co-ordinated beforehand. • Make sure that each component has been properly mounted before proceeding with assembling the next one. •...

  • Page 7: Table Of Contents

    CONTENTS 1 2 3 4 1 2 3 4 1 2 3 4 DESCRIPTION DESCRIPTION 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 SPECIFICATIONS RIGHT RADIATOR - LEFT RADIATOR 1 2 3 4 1 2 3 4 IDENTIFICATION DATA: FRAME N°...

  • Page 8: Specifications

    SPARK PLUGS SPECIFICATIONS Type ....................NGK CR7EKB TRANSMISSION Automatic speed variator with expandable pulleys, V-belt, automatic dry centrifuge clutch, reduction gear and transmission compartment with forced circulation cooling system. FUEL SYSTEM Electronic injection with electrical fuel pump. Fuel: unleaded petrol. ELECTRONIC IGNITION High efficiency, inductive type coupled with the injection system, variable advance and separate HV coil.

  • Page 9: Identification Data: Frame N° / Engine N° - Tyres 8 1 2 3

    IDENTIFICATION DATA: FRAME N° / ENGINE N° • To read the vehicle’s identification number (VIN) (A) lift the saddle and remove the cover located in front of the helmet compartment. • Engine identification data are located on the left-hand engine crankca- se (B).

  • Page 10: Maintenance Table

    NOTE - Maintenance operations should be performed more frequently if the vehicle is used in rainy weather, in dusty places or on rough : check terrain. : clean : adjust Due to their simplicity, checks with no asterisk CAN also be carried out by technicians not authorised by MALAGUTI, but under : replace their direct responsibility. 02/08...

  • Page 11: Lubricant Table

    LUBRICANT TABLE NOTE - Use only recommended products. LUBRICANTS ENGINE OIL (4-STROKE TYPE) FORMULA EXCEL SAE 5W40 ENGINE TRANSMISSION OIL ZC 90 AIR FILTER LUBRICANT AIR FILTER OIL RADIATOR FLUID Q8 LONG-LIFE RED BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4 FORK ROD OIL FORK OIL 02/08...
  • Page 12 FUEL TANK To access the fuel tank, proceed as follows: • Place the vehicle on the centre stand. • Remove the ignition key from the ignition block. • Open the door (A) in front of the seat, by acting on the lever (B).

  • Page 13: Bleeding, Cooling Circuit

    • Release and remove the BLEEDING, COOLING filler (B). CIRCUIT • Pour some coolant in the To bleed the air, with the main radiator (left). circuit completely drained • Slacken the coupling (A) from the coolant, proceed as and go on refilling the main follows: radiator until some liquid would drip off the tube (with...

  • Page 14: Engine Oil

    ENGINE OIL • As far as four-stroke engines are concerned, engine oil is used to lubricate distribution components, base bearings and thermal unit. An insufficient amount of oil can seriously damage the engine. • In all four-stroke engines, deterioration of the oil and a certain consumption are to be considered normal. every 3000 km or 6 months CHECK THE OIL LEVEL This check should be performed when the engine is cold, as described below:...

  • Page 15: Change Engine Oil 14 1 2 3

    every 6000 km or 12 months CHANGE ENGINE OIL • The engine must be emptied by letting the oil flow from the drainage cap (B) of the filter beside the transmission. To facilitate drainage, loosen the cap/dipstick (A F. 8/a). •...

  • Page 16: 2 3 4 Transmission Oil - Check The Level - Renew 15 1 2 3

    TRANSMISSION OIL CHECK THE LEVEL every 6000 km or 12 months 1) Place the vehicle on a level surface on its centre stand. 2) Unscrew the dipstick (A), clean it and refit it, wrenching it tightly. 3) Pull it out again and check that the oil level is between the MIN and MAX notches. 4) If the level is insufficient, top up until you almost reach the MAX notch.

  • Page 17: 2 3 4 Brake Oil - Check - Change 16 1 2 3

    BRAKE OIL every 30 days CHECK • The visual check should be made through the sight glass (S) of the tanks: front brake (A) and rear brake (B), when the vehicle is on level ground and perfectly upright. • The oil should be at 3 mm from the bottom edge of the sight glass. When topping up, never use more than one oil.

  • Page 18: Braking System Bleeding Integral System

    BRAKING SYSTEM BLEEDING INTEGRAL SYSTEM Put the vehicle on firm and level ground. • Remove the cover of the oil pump tank (left-hand side), releasing the two screws, so as to top up the liquid. NOTE - The left brake lever allows the front right brake calliper and the rear brake calliper to be controlled interlockedly at the same time.

  • Page 19: Checking Brake Pads And Discs Brake Pads

    CHECKING BRAKE PADS AND DISCS BRAKE PADS Check front and rear brake pads and discs for wear every 2,000 Km. • Visually check the thickness of the brake pads as shown in the picture. The minimum thickness of the brake pad lining should not be thinner than 2 mm.

  • Page 20: Fork - Check The Oil Level In The Stanchion

    FORK CHECK THE OIL LEVEL IN THE STANCHION • In there case if the “limit switch” of the front fork or irregular noise, check the oil level inside the fork stems by removing the stems, as shown in the picture, and follow the instructions at page 63.

  • Page 21: Rear Shock Absorber Adjustment - Steering 20 1 2 3

    REAR SHOCK ABSORBER ADJUSTMENT • The rear shock absorbers can be adjusted on the spring pre-load allowing to adapt the motorcycle behaviour according to the load, the type of ride and the road. • Use the supplied wrench on the ring nut placed in the shock absorber lower part; rotating it counterclockwise to increase the spring power.

  • Page 22: Location Of The Main Electrical Elements

    LOCATION OF THE MAIN ELECTRICAL ELEMENTS F. 21 Battery Spark plugs Fuel pump Rollover sensor Temperature sensor Ignition coil Relays and flasher 02/08...
  • Page 23 F. 22 Immobilizer control unit Regulator Lambda sensor Diagnostic plug Fuel injector 02/08...

  • Page 24: Instrument Board

    Injection This light comes on while the engine is running to indicate that the injection system is not functioning correctly; contact an Authorised MALAGUTI Service Centre. Avoid cleaning the instruments with pressurised cleaning systems in order to prevent any damage.

  • Page 25: Starting The Engine

    KEY SWITCH HANDLEBAR LOCK • This switch controls the ignition circuit and LOCKING the handlebar lock. Turn the handlebar all the way to the right or left, push the key in Ignition disabled (the key can be and turn it counter-clockwise (F. 8). removed).

  • Page 26: Lighting System - Lamps 25 1 2 3

    LIGHTING SYSTEM F. 26 LAMPS Functions Specifications Replacing (page) (Front) parking light 12V - 5W (W5W) Low beams/high beams 12V - 35/35W (HS1) Always replace burnt bulbs by new, identical ones Front direction indicators 12V - 21W (PY21) and test them before reassembling all the Number plate light 12V - 5W (W5W) components previously removed.

  • Page 27: Adjusting The Beam Light 26 1 2 3

    ADJUSTING THE BEAM LIGHT • The adjusting knobs (A) of the two headlamp beam light are located inside the central shield, as indicated in the picture. To adjust the beam light it is not necessary to remove the central shield. F.

  • Page 28: Fuses

    GENERAL PROTECTION FUSE FUSES • The electrical wiring includes eight fuses, NOTE - Inside the battery compartment, protecting the main components from is located the general protection possible malfunctioning and are placed fuse (A) (30 A). in the luggage compartment. A - 15 A Lights B - 7.5 A...

  • Page 29: Battery Assembly - Charge Battery 28 1 2 3

    - Fuel filler cap - Seat The original battery, supplied by “Malaguti”, is a hermetic type (12V - 14A). If replaced, install a battery having the same specifications. In fact, the battery compartment cannot host a battery with a drain hose.

  • Page 30: Spark Plug - Remplace 29 1 2 3

    SPARK PLUG every 10.000 km REMPLACE The spark plug is an essential component: NGK CR7EKB Spark plugs with a heat degree different from the recommended one may seriously damage the engine. • The SpiderMax engine features an ignition system with a double spark plug (C).

  • Page 31: Front Direction Indicators (Bulb Change) 30 1 2 3

    PROCEDURES FOR DISMANTLING AND CENTRAL FAIRING REMOVING COMPONENTS • Release the screw upper (V) REASSEMBLY NOTE 1,5 ± 15% REAR VIEW MIRRORS • Lift the rubber part (A) and FRONT DIRECTION release the fastening screws INDICATORS of the rear view mirror (V). (BULB CHANGE) •...

  • Page 32: Accesses - Replacing The Front Parking Light 31 1 2 3

    REPLACING THE FRONT PARKING LIGHT ACCESSES • Release the screws (V5). (after removng the • Release the screws (V2). central shield) • Remove the cover (A). A) Control panel B) Antilock bracking system C) Beam light adjusting knobs D) Horn NOTE - The parking light bulb F.
  • Page 33 DASHBOARD • Undo the screws (V4) and remove the control 1,5 ± 15% panel carefully. F. 42 BRAKING DISTRIBUTOR • Undo the connectors (B). • Remove pipes (C) and NOTE - To access the braking distributor (A), gaskets (D). remove the central fairing (P. 30). Drain completely the circuit.
  • Page 34 AIR GRID WINDSCREEN • After removing the cover of • Remove the central fairing the front parking light bulb, (p. 30). you can remove the air grid • Release the screws(V3) in order to clean it. and remove the windscreen. 1,5 ±...
  • Page 35 • Remove the rubber mat. • Release the screws (V2) and remove the passenger footpeg. 40 ± 15% F. 49 F. 50 • Release the screws • Release the half-fairing upper part from the mir- (V8). ror mount, opening it up carefully.
  • Page 36 • Disconnect the two con- ACCESSES nectors (A) (direction (after removing the two indicators). front half-fairings) • Disconnect the connector Right half-fairing: (B) (front headlight). • Remove the fairing. A) Immobilizer ECU B) Side stand switch connector C) Fuel pump - Right radiator - Key switch F.
  • Page 37 • Open the front fairing. SIDE STAND • Disconnect the connector (B) SWITCH and detach the whole wiring (if necessary), after releasing • Release the screws (V2). its clips. • Remove the switch (A). NOTE - While assembling a new complete wiring, 5 ±...

  • Page 38: Radiators

    • Let the liquid comple- RADIATORS tely drain into the con- (including lines tainer. Pour the spent and expansion liquid in a container reservoir) suitable for its ecolo- gical disposal. • Wait for the engine to cool down completely. The coolant is •...
  • Page 39 • Release and remove the RIGHT RADIATOR screws (V2) and their • Release the lower securing washers. screw (V) of the right radia- tor (A). 10 ± 20% 10 ± 20% • Remove the right radiator. F. 63 F. 64 NOTE - The radiators are fit- LEFT RADIATOR (including ted on Silent blocks...
  • Page 40 • Release the screw (V) and ELECTRICAL FAN remove the expansion RADIATOR reservoir. EXPANSION 10 ± 20% RESERVOIR Drain the coolant from the circuit, as previously described. • Disconnect the tube (C) from the expansion reservoir. • Release the screws (V2). F.
  • Page 41 • The key switch (C) is fitted by two nuts (D) and two “anti- SWITCH tampering” screws (V2), that can be accessed from the • Disconnect the seat opening lower part of the switch body. transmission cable (A). • Disconnect the helmet com- To disassemble the partment opening transmis- key switch, use the...

  • Page 42: Leg Protector

    • Release the retaining screws (V2) of the fusebox. PROTECTOR • Remove the transparent • Remove the key switch ring cover. nut (A) rotating it counter- • Push forward the fusebox clockwise. • Release the screw (V). 5 ± 20% F.
  • Page 43 • Release the screws (V3). • Unlock the luggage com- partment closing transmis- sion cable from its seat (A). 5 ± 20% F. 78 F. 79 • Open slightly the footpeg • Extract the leg protector until the plastic locking tabs assembly, together with the are released.

  • Page 44: Upper Handlebar Cover - Accesses

    • Remove the footpeg if UPPER HANDLEBAR necessary, release the COVER screws (V2). • Release the screws (V2) and remove the upper handlebar cover (A). 1,5 ± 15% 1,5 ± 15% F. 82 F. 83 ACCESSES (after removing the upper handlebar cover) B) Main wiring end V4) Handlebar inclination...

  • Page 45: Front And Rear Handlebar Cover - Accesses

    • Release the outside screws FRONT AND REAR (B2) and remove the front HANDLEBAR handlebar cover (A). COVER • Release the remaining four inside screws and remove • Release the upper screws the rear handlebar cover (V2). (P). 1,5 ± 15% 1,5 ±...
  • Page 46 HANDLEBAR To remove the handlebar: • Remove the handlebar cover: upper, front and rear (P. 44). • Cut the clips securing wiring, tubes, and cables. • Remove the (right and left) brake master cylinders. • Release the transmissions from the accelerator con- trol (B).

  • Page 47: Driver Seat - Accesses

    • Remove the driver seat (A), DRIVER releasing it form the locking SEAT tab (B). • Release the screws (V2) on the rear part. 5 ± 20% F. 94 F. 93 ACCESSES NOTE - In order to access the tilt sensor (E) it is necessary •...
  • Page 48 PASSANGER • Release the screws (V2) SEAT from the front supports. (including movable support) 10 ± 20% • Remove the seat together • Remove the Benzing ring (C) with the grab handle and and release the passenger movable support. seat shock absorbers. •...

  • Page 49: Helmet Compartment

    DIRECTION INDICATORS AND TAIL LIGHTS (BULB CHANGE) HELMET • Lift the seat. COMPARTMENT • Removing the inserted side covers (A), allows reaching the rear direction indicator • Extract (without any tool) the bulbs. compartment inside coating. • Removing the inserted rear covers (B), allows reaching the tail light bulbs. •...

  • Page 50: Rear Fairing

    • Lift the helmet compartment, disconnect the connector (A) and release the cable from the clamp (B). • Remove the helmet compart- ment completely. F. 104 REAR FAIRING • Release the two screws (V2). 5 ± 15% • Release the screw (V). 5 ±...

  • Page 51: Tail Lights

    • Release the screws (V4). • Extract the entire fairing to- gether with the tail lights. 1,5 ± 15% F. 106 TAIL LIGHTS • Keep the rear fairing • Tail lights can be accessed by components far from heat removing the helmet compart- sources, in a clean place ment and the rear fairing.

  • Page 52: Coolant Pump - Coil

    Left side SIDE REACH (after Coil removing the rear Ground ends fairing) • Removing the rear fairing allows reaching the following components: Right-hand side Voltage regulator Coolant pump (Tree-phase) stator connector Ground ends F. 110 F. 111 VOLTAGE REGULATOR COOLANT PUMP COIL •...

  • Page 53: Relay Holder

    • Release the two front screws (V2). RELAY HOLDER • Extract the starting relay (C), including the 30A fuse (battery recharge protection). If the starting relay is replaced, take special care to the assembly of the red and blue cable (Please refer: DIAGNOSTICS MANUAL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM).
  • Page 54 • After disconnecting ACCESSES connectors, remove the relay A) Injection ECU holder (1) on one side or B) Injector remove it completely. C) Motor temperature sensor NOTE - All of the information concerning these com- ponents can be deducted by reading the DIA- GNOSTICS MANUAL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM.

  • Page 55: Battery Compartment - Accesses

    NOTE - Inside the battery com- BATTERY partment, is located COMPARTMENT the general protection • Remove the fuel filler cap fuse (F) (30 A). (A). • Release the battery cables. • Release the screws (V2). • Extract the battery. • Extract the dripproofing protection (B) and the drain hose.

  • Page 56: Fuel Tank

    To remove the tank, FUEL TANK proceed as follows: NOTE - To access the fuel tank, first remove the front fairing (P. 33). • Remove the battery and the whole compartment (P. 54). Fuel fumes are highly toxic, and therefore harmful to your health. Ventilate •...
  • Page 57 • Disconnect the connector (A) • The fuel tank is blocked, in of the fuel pump. its rear side, by the two Silent Blocks (B). F. 126 F. 127 • Extract the tank, sliding it • Disconnect the tube (C). from the front side of the •...

  • Page 58: Airbox

    • Release the gas recovery AIRBOX hose (C). • Release the screws (V8) and remove the cover (A). F. 130 F. 131 • Release the hose (B) from the throttle body. • Extract the airbox. F. 132 02/08...
  • Page 59 FRONT FRONT WHEEL MUDGUARD REMOVAL • Release the screws Before removing the (Va) front wheel, check for the perfect stability of • Release the screws the motorcycle. If ne- (Vb) and corresponding cessary, place one sui- nuts (A). table support under the engine.
  • Page 60 (FRONT BRAKE) DISCS • To separate the discs (D) from the front wheel, release and remove the screws (V6) and the washers (E). 11 ± 10 % F. 138 Check the discs (D) for wear and replace if necessary (service limit 4.5 mm). In case of abnormal wear or signs of scoring, carry out grinding.
  • Page 61 FRONT CALLIPER BRAKE REPLACEMENT CALLIPERS NOTE - The front callipers An abnormal resistance have the same technical or an excessive travel specifications but are one of the brake levers may right and one left. indicate the braking system malfunctioning. • After removing the front brake callipers, release •...
  • Page 62 • Remove the stop plate. • Extract the pins (B). 20 ± 20% F. 146 F. 147 • Extract the pads. • Release the nut (D - F. 146). • Remove the floating sup- NOTE - It is possible to port (S) from the calliper remove and replace body, including the two...
  • Page 63 • Check the dust seals (P - P1) • Blow with a small compres- for wear. In case of signs of sed air flow to extract the (even light) wear or damage, two pistons from the replace them. calliper body. •...

  • Page 64: Lower Fairing Mudguard - Fork

    LOWER FAIRING FORK MUDGUARD STANCHION GROUP NOTE - To remove the lower Make sure that the motorcycle is really stable; in case, put a suitable support fairing mudguard, first under the engine. The front wheel will have to protrude over the runaway remove the front edge of the lift.

  • Page 65: Front Fork Oil Replacement

    • Using a meter or the stick of a gauge, FRONT FORK OIL REPLACEMENT check the proper oil level, which should • Place a suitable container under the stanchion and remove be at mm 123 from the upper edge of the screw (V).

  • Page 66: Exhaust/Exhaust Manifold

    • Slacken the screw (V) of EXHAUST the clip securing the Before operating on exhaust/exhaust manifold. the exhaust and on • Va. the exhaust manifold, wait for the components to cool down and wear, 25 ± 15% always and in any case, suitable safety gloves.
  • Page 67 • First remove the relay • Release the two nuts (C). holder (P. 52). • Remove the exhaust • Disconnect the Lambda manifold (D). sensor connector. • Remove the gasket. 30 ± 10% While reassembling, always use a new gasket. F.

  • Page 68: Rear Shock Absorbers

    • V2 REAR SHOCK • V2 ABSORBERS Before carrying out any operation in the rear 30 ± 15% shock absorbers, prepare a system ensuring the vehicle 45 ± 15% perfect stability even without shock absorbers. F. 169 F. 170 During both the removal and the reassembly of the rear shock absorbers, remember that the lower and the upper screws have washers (R) and nuts (D).
  • Page 69 Remove: REAR ARM • Anti-vibration O -Ring (1) Before removing the rear arm (A), check that the vehicle is in perfectly • Spilt pin (2) stable conditions. • Cover (3) Remove: • Release the underlying nut (D). • Exhaust pipe (P. 65) •...
  • Page 70 Left plate REAR CALLIPER • Release the left shock • Release the screws (V2a). absorber (P. 67). • Extract the calliper unit (A), including the brake liquid • V2. feed tubes. 30 ± 10% 30 ± 20% • Remove the plate (P). •...
  • Page 71 • Release and remove the • Remove the two pistons (D). screws (V2). • Remove the two O-Rings (E). • Separate the two housing halves, taking care not to let the two pistons fall. 20 ± 20% F. 180 F. 181 •...
  • Page 72 (REAR BRAKE) DISC REAR WHEEL During the check and the NOTE - To extract the rear service on the rear brake wheel, first remove calliper, check the disc the brake calliper, conditions (C). If the disc is and the exhaust. too worn out, (service limit 3.5 mm), replace it, •...
  • Page 73 • Slacken the clips (A) and Support suitably the engine with systems release the coolant ma- ensuring both the nifolds from the pump. top safety for the operators during the Place the coolant removal, as well as manifolds so that the perfect stability they will not of the vehicle, before,...
  • Page 74 • Detach the (upper) ANTI-VIBRATION mount shaft (E). CONNECTING RODS • Remove the engine mount and the spacers. • After removing the engine and its While mount, release the reassembling, nut (F - F. 193). take care not to interfere and •...

  • Page 75: Subframe

    • Release the screw (V) and release the lines of the SUBFRAME 10 ± 20% brake oil (D - E). NOTE - The subframe is • Remove the braking distributor (F) ( P. 32). made up of three parts: 1 - Upper subframe 2 - Right-hand side subframe 3 - Left-hand side subframe •...
  • Page 76 UPPER SUBFRAME • Release and remove the two screws (V) and their washers. • Release and remove the screws (V2) and their washers. • Separate and extract the upper subframe (1) from the two side subframes. SIDE SUBFRAMES • Release and remove the lower screw (M8) and its washer. •...

  • Page 77: Frame Dimension Check

    FRAME DIMENSION CHECK • If the motorcycle has had an accident, which “appear” to have caused a distortion, even light of the frame, carry out a dimension check, before any other “restoration and set up”. • The pictures hereafter show the check dimensions. The dimension measured may have a ±...

  • Page 78: Cable Positioning, "Pipe System" And Anchoring Ties

    CABLE POSITIONING, “PIPE SYSTEM” AND ANCHORING TIES F. 198 F. 199 02/08...
  • Page 79 F. 200 02/08...
  • Page 80 F. 201 02/08...
  • Page 81 F. 202 02/08...

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