Malaguti SPIDER MAX RS 500 User manual

1 02/08

MALAGUTI S.p.A.

Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY

Tel. 051.62.24.811 - Fax 051.69.47.782

e-mail: inf[email protected] - http: // www.malaguti.com

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.

• Additional information is available in the SPARE PARTS CATALOGUES of each model.

• It is important to read all the general information before going through the manual to the specific topics and the maintenance operations to be carried out on the motor-bike in

order to make sure the topics, the technical and safety concepts are clearly understood and the manual can be used as a sure reference text.

• All checks, maintenance, repairs or replacements of spare parts in our motor-bikes are to be performed by skilled and expert technical personnel with specific experience

in state-of-the-art technology and full knowledge of the quickest and most rational procedures, technical characteristics, setting values, tightening torques and information as

to which may only be properly and exhaustively provided by the manufacturer.

• It is important to adhere strictly to the following instructions. Any operation carried out carelessly or not carried out at all may lead to personal injury, damage to the motorcycle

or simply to complaints.

MALAGUTI S.p.A. reserves the right to make any changes and modifications hereto it deems necessary without prior notice.

For further information and details, please contact MALAGUTI S.p.A. Servicing or Engineering Division.

2 02/08

NOTES FOR EASY CONSULTATION

ABBREVIATIONS

EDITING SYMBOLS:

• Symbols have been provided for quick and easy reference, 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.

Cs Torque wrench setting

D Nut

Dx Right

F Picture

G Gasket

P Page

R Washer

Sx Left

T Ta bl e

V Screw

TECHNICAL DICTIONARY

V = (DC) Direct current (battery supply)

V ~ (AC) Alternating current (flywheel supply)

A : Ampere Unit of measurement of the electrical current

W : Watt Unit of measurement of the electrical power (product of Volts and Amperes; A x V = W)

ΩΩ

Ω : OHM Unit of measurement of the electrical resistance

< Lower

≤≤

≤ Lower or equal

> Higher

≥≥

≥ Higher or equal

bar Unit of measurement of pressure

N * m Newton/metre Unit of measurement of the tightening torque

3 02/08

M

R

SYMBOL LIST

CAUTION!

Recommendations and

precautions regarding rider

safety and motor vehicle

integrity.

WARNING! Situations entailing

the risk of personal injury to

maintenance or repair

mechanics, other workshop

personnel or third parties, or

damage to environment,

vehicle or equipment

FIRE HAZARD.

Indicates operations which

may constitute a fire

hazard

RISK OF

EXPLOSION

Indicates operations

which may constitute a

risk of explosion

TOXIC FUMES

Indicates a possibility of

intoxication or inflammation

of the upper respiratory

tract

WARNING!

Danger of crashing

arms

SAFETY GLOVES

These operations require

the use of safety gloves

IMPORTANT

This topic requires special

attention

GENERAL SERVICE

PERSONNEL

Skilled electronic or

mechanical technician.

MECHANICAL

MAINTENANCE

Operations to be performed

only by an expert mechanic

ELECTRICAL

MAINTENANCE

Operations be performed

only by an expert electrical/

electronic technician

IGNITION KEY ON

(ON position)

PRESENT MANUAL

Information on the

present manual

“ENGINE” SERVICE

MANUAL

Indicates information which

may be obtained by

referring to said catalogue

SPARE PARTS

CATALOGUE

Indicates information which

may be obtained by

referring to said catalogue

DISASSEMBLY

OPERATIONS

ASSEMBLY

OPERATIONS

SYMMETRICAL

OPERATIONS

Operations that must be

carried out also on the other

side of the unit or

component.

EMPTY THE CIRCUIT

REPLACE WITH NEW,

ORIGINAL SPARE

PA RT S

IDLING ENGINE

Switch on the engine, at

idling speed, to perfom

these interventions.

ENGINE OFF

Indicates operations to

be performed with

engine off

POWER OFF

Indicates that negative

pole is to be disconnected

from the battery before

performing the operation

NO!

Operations to be

absolutely avoided

OIL

COOLANT

FUEL

4 02/08

Before any servicing, make sure that the vehicle is perfectly stable.

The front wheel should preferably be anchored to fixture, which is integral with the lift platform.

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. The present manual provides the technical information and the basic indications on the

intervention procedures but these have to be integrated with the personal expertise.

• We suggest planning the service interventions in order to avoid any waste of time or downtime. Try to reduce as much as possible the operations necessary to reach the

components that needs repairing.

• Prepare the components that are likely to be replaced and all the original spare parts you may need.

• Use only the original spare parts.

• Mark the components that may be mis-placed during re-assembly operations.

• Only use quality tools and equipment.

• Only use equipment conforming to EU Directives for lifting the vehicle.

• During operations, always keep tools and equipment at hand, possibly laying them out according to the sequence in which they are to be used. Absolutely avoid putting them on the

vehicle itself, out-of-sight or in poorly accessible places.

• Always keep the work area neat and clean.

• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progressive “pulls” using a “criss-cross” pattern.

• The torque settings specified in the manual refer to the “final torque”, which must be attained progressively by steps.

• Preferably use open-end box wrenches by “pulling” and not “pushing”.

5 02/08

• 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.

• Always replace gaskets, O-rings, circlips and split pins at every refitting.

• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.

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 floor of the workshop. Always use low flash point solvents to clean the vehicle components.

When welding, make sure that there are no flammable liquids in the vicinity.

Never suck from or blow into the fuel pipe.

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

Do not use fuses with a higher rated capacity than indicated: this may cause severe damages to the electrical system and burn a fire as a conse-quence of short circuit.

• Make sure that the vehicle is stable and not to have to take on awkward working positions.

• Never reuse old gaskets or circlips.

• Never use a screwdriver as a lever or chisel.

• Never use pincers 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 hexagon.

• Never tap the wrench with a hammer or other similar tool to loosen or tighten screws and nuts.

• Never attempt to increase the lever arm by fitting a tube into the wrench.

6 02/08

CONTENTS

DESCRIPTION P.

RIGHT RADIATOR - LEFT RADIATOR 38

ELECTRICAL FAN RADIATOR - EXPANSION RESERVOIR - THERMAL EXPANSION VALVE 39

KEY SWITCH - DASHBOARD PANEL 40

LEG PROTECTOR 41

UPPER HANDLEBAR COVER - ACCESSES 43

FRONT AND REAR HANDLEBAR COVER - ACCESSES 44

HANDLEBAR - BRAKE MASTER CYLINDERS 45

DRIVER SEAT - ACCESSES 46

PASSANGER SEAT - CUSHION DRIVER SEAT - GRAB HANDLE 47

HELMET COMPARTMENT 48

ACCESSES - DIRECTION INDICATORS AND TAIL LIGHTS 48

REAR FAIRING 49

TAIL LIGHTS 50

SIDE REACH - VOLTAGE RECTIFIER 51

COOLANT PUMP - COIL 51

RELAY HOLDER 52

ACCESSES - ELECTRONIC INJECTION ECU THROTTLE BODY 53

BATTERY COMPARTMENT - ACCESSES 54

FUEL TANK 55

AIRBOX 57

FRONT MUDGUARD - FRONT WHEEL - WHEEL SPINDLE 58

(FRONT BRAKE) DISCS - FRONT WHEEL - REASSEMBLY 59

BRAKE CALLIPERS - FRONT CALLIPER REPLACEMENT AND DISASSEMBLY 60

LOWER FAIRING MUDGUARD - FORK 63

STANCHION GROUP - STANCHION DISASSEMBLY - CHECK THE OIL LEVEL IN THE STANCHION 63

FRONT FORK OIL REPLACEMENT 64

COMPLETE FORK 64

EXHAUST - EXHAUST MANIFOLD 65

LAMBDA SENSOR - REMOVAL - REASSEMBLING 66

REAR SHOCK ABSORBERS 67

REAR ARM - SHOCK ABSORBER SUPPORTING PLATE 68

REAR CALLIPER - REAR CALLIPER DISASSEMBLY 69

REAR WHEEL - (REAR BRAKE) DISC ENGINE 71

ENGINE REASSEMBLY - ENGINE MOUNT 72

ANTI-VIBRATION CONNECTING RODS - ENGINE MOUNT 73

SUBFRAME 74

UPPER SUBFRAME - SIDE SUBFRAMES - CENTRAL ALUMINIUM FRAME 75

FRAME DIMENSION CHECK 76

CABLE POSITIONING, “PIPE SYSTEM” AND ANCHORING TIES 77

DESCRIPTION P.

SPECIFICATIONS 7

IDENTIFICATION DATA: FRAME N° / ENGINE N° - TYRES 8

MAINTENANCE TABLE 9

LUBRICANT TABLE 10

FUEL TANK - COOLANT TANK 11

BLEEDING, COOLING CIRCUIT 12

BLEEDING OF THE LEFT SIDE - BLEEDING OF THE RIGHT SIDE 12

ENGINE OIL 13

CHECK THE OIL LEVEL - TOPPING UP 13

CHANGE ENGINE OIL 14

TRANSMISSION OIL - CHECK THE LEVEL - RENEW 15

BRAKE OIL - CHECK - CHANGE 16

BRAKING SYSTEM BLEEDING - INTEGRAL SYSTEM 17

CHECK THE LEVEL OF THE BRAKE LIQUID - FRONT LEFT CALLIPER 17

CHECKING BRAKE PADS AND DISCS - BRAKE PADS 18

REPLACING THE BRAKE PADS - DISCS 18

FORK - CHECK THE OIL LEVEL IN THE STANCHION 19

FRONT FORK OIL REPLACEMENT 19

REAR SHOCK ABSORBER ADJUSTMENT - STEERING 20

HANDLEBAR ADJUSTMENT 20

LOCATION OF THE MAIN ELECTRICAL ELEMENTS 21

INSTRUMENT BOARD 23

KEY SWITCH - HANDLEBAR LOCK 24

LOCKING - DISENGAGING 24

STARTING THE ENGINE 24

LIGHTING SYSTEM - LAMPS 25

ADJUSTING THE BEAM LIGHT 26

FUSES - GENERAL PROTECTION FUSE AND CHARGE PROTECTION FUSE 27

BATTERY ASSEMBLY - CHARGE BATTERY 28

SPARK PLUG - REMPLACE 29

PROCEDURES FOR DISMANTLING AND REMOVING COMPONENTS 30

REASSEMBLY NOTE - CENTRAL FAIRING - REAR VIEW MIRRORS 30

FRONT DIRECTION INDICATORS (BULB CHANGE) 30

ACCESSES - REPLACING THE FRONT PARKING LIGHT 31

DASHBOARD - BRAKING DISTRIBUTOR - HORN 32

AIR GRID - WINDSCREEN - FRONT FAIRING 33

ACCESSES - IMMOBILIZER ECU 35

SIDE STAND SWITCH - FUEL SUPPLY PUMP 36

RADIATORS 37

7 02/08

DIMENSIONS

Wheel base (A) m .......................................................................................1,490

Max. length (B) m........................................................................................2,200

Max. width (C) m .........................................................................................0,930

Max. height (D) m........................................................................................1,470

Kerb weight kg ...............................................................................................230

Max. load with rider, passenger and luggage kg..............................................180

CAPACITY

Engine oil cm3 ........................................................................................... 1700*

Transmission oil cm3 ................................................................................... 250*

Fuel tank (total).............................................................................................. 14*

ENGINE: single-cylinder, four-valve

Valves type............................................................................. PIAGGIO M34CM

n° Cylinders ...................................................................................................... 1

Bore x stroke mm .................................................................................. Ø 94x71

Capacity cm3.................................................................................................493

Compression ratio ............................................................................... 10.5 ± 0.5

Cooling........................................................................................................ liquid

Starting system ............................................................................electric starter

Greasing system.................................................................................. wet sump

SPARK PLUGS

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.

BRAKES

The braking system is hydraulically operated and features double front disc (2

discs with a diam. of 270 mm) and rear disc (260 mm diam. disc) with braking

distribution system. The brakes are operated as follows:

Left lever: rear lever + front lever (right hand side of the vehicle)

Right lever: front brake (left hand side of the vehicle)

CHASSIS

“V-Box” type, composed of a double pressure die cast shell made of aluminium,

coupled, on the front and rear sides, to a steel pipe frame.

SUSPENSIONS

Front: hydraulically controlled fork with two Ø 41 mm rods.

Stroke: 120 mm

Rear: 2 hydraulic shock absorbers with adjustable preloading spring.

BATTERY

12V, 14Ah, maintenance-free.

TIRES

Front: 120/80 - 16 60 S

Rear: 150/70 - 16 68 S

*

Indicative Value

SPECIFICATIONS

F. 1

8 02/08

TYRES

Type: Tubeless (without inner tube)

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. Use only tyres with the relevant type approval.

Tyre inflation pressure must be adjusted while the tyre is at ambient

temperature.

150/70 - 16” - 68S

120/80 - 16” - 60S

2.3 2.3 2.3

(33.4) (33.4) (33.4)

2.3 2.3 2.3

(33.4) (33.4) (33.4)

B

F. 2

F. 3

A

• 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).

Any alteration to the vehicle identification data is pursued

by the Law.

Minimum tread depth is 2 mm.

• There are T.W.I. marks all around the tyre

sides. These correspond to tyre wear

indicators situated in the tyre’s tread; if

there is no difference between the

thickness of the tyre wear indicators and

the tread depth, the tyre must be replaced.

F. 4

X

Y

IDENTIFICATION DATA: FRAME N° / ENGINE N°

9 02/08

MAINTENANCE TABLE

NOTE - Maintenance operations should be performed more frequently if the vehicle is used in rainy weather, in dusty places or on rough

terrain.

Due to their simplicity, checks with no asterisk CAN also be carried out by technicians not authorised by MALAGUTI, but under

their direct responsibility.

Nr. : coupon

: check

: clean

: adjust

: replace

10 02/08

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

11 02/08

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).

• Insert the ignition key, remove the cap (B) and refuel the

tank.

• After refuelling, immediately remove any possible traces

of fuel from the vehicle body, since fuel may deteriorate

the vehicle’s outer surfaces.

Use UNLEADED PETROL.

F. 5

F. 7

COOLANT TANK

• To access the engine coolant tank, open the glove compartment (A) located at the

centre of the lower fairing and remove the plastic cover (B). Owing to the particular

position of the tank, the level of coolant, with respect to the minimum and maximum

level marks, can be checked through the grid under the upper fairing, on the front

side of the vehicle. Use the coolant prescribed in this manual - or one having

identical characteristics - for any topping up. Never unscrew the tank cap (T) when

the engine is warm, so as to avoid burnings. Do not top up with water, except in

emergency situations and in this case, have the entire contents of the tank replaced

by a suitable product as soon as possible.

A

*

Indicative Value

B

T

14*

3*

F. 6

A

B

C

FUEL TANK Litres

TOTAL TANK CAPACITY

RESERVE

12 02/08

BLEEDING, COOLING

CIRCUIT

To bleed the air, with the

circuit completely drained

from the coolant, proceed as

follows:

BLEEDING OF THE LEFT

SIDE

• Remove the cap on the

bleeding coupling (A).

• Fit a tube in the coupling

(A) of the bleed nipple on

the cylinder head.

• Refill the expansion reser-

voir with coolant, as descri-

bed: (P. 11).

• Release and remove the

filler (B).

• Pour some coolant in the

main radiator (left).

• Slacken the coupling (A)

and go on refilling the main

radiator until some liquid

would drip off the tube (with

regular flow).

• Now, close the bleed nipple

(coupling - A) and fill in up

to the rim of the main

radiator.

• Slacken the bleed screw (C),

until some liquid drips off with

regular flow.

• Close the screw and top up

the liquid.

• Open the bleed nipple on the

cylinder head and check the

tubes for liquid dripping,

showing that the bleeding

has been correctly carried

out.

• Close the coupling (A) back.

F. 7/a

F. 7/c

BLEEDING OF THE RIGHT

SIDE

•Slacken the bleed screw (D),

until some liquid drips off with

regular flow.

• Close the screw and top up the

liquid in the main radiator.

• With the help of an assistant,

slightly tilt the vehicle on the ri-

ght side and, keeping it in this

position, slightly slacken the

screw (D), to let any remaining

air out of the right radiator.

• Tighten the bleed screw (D),

F. 90/a

which act as the ground screw.

• Open the bleed nipple on the cylinder head and check the tubes for liquid dripping,

showing that the bleeding has been correctly carried out.

• Close the coupling (A), remove the tube and fit the cap.

• Check the main radiator is completely refilled with coolant; top up and refit the filler

(B), if necessary.

F. 7/d

F. 7/b

C

A

B

D

13 02/08

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.

CHECK THE OIL LEVEL

This check should be performed when the engine is cold, as described below:

1) Park the vehicle on flat ground and put it on its centre stand (even a slight inclination may alter results).

2) Unscrew the cap/dipstick (A), dry it with a clean cloth and refit it, wrenching it firmly in place.

3) Remove the cap/dipstick and make sure the level falls betwe en the MAX and MIN notches; if necessary, top up

with Q8 FORMULA EXCEL SAE 5W40 oil.

The MAX level notch corresponds to quantity of about 1700 cm3 of oil in the engine.

If you need to check the level when the engine is warm, remember that the level line will be lower. It is best to wait at least 10 minutes from stopping the

engine in order to have a correct reading.

The vehicle features a control system that activates the “LOW OIL PRESSURE” alarm signal of the digital instrument board in the event of trouble.

TOPPING UP

Before topping up, check the oil level and in no case allow the level to rise above the MAX notch.

• Topping up to level falling between the MIN and MAX marks means using about 400 cm3 of oil.

Never allow the level to rise above the MAX mark! This may seriously damage the engine, due to excessive internal pressure.

• Every 3000 km, it is recommended to have the engine oil checked.

ALARM MESSAGE (LOW OIL PRESSURE)

The digital instrument board features a control system displaying a “LOW OIL PRESSURE” message (B - § 3.11.6). The message appears when the vehicle is turned on to

signal that the check function is working. The message disappears automatically after a few seconds. It will only reappear during vehicle use if there is actually a low oil

pressure problem.

If the message appears when you are braking, when the engine is idling or when curving, stop the vehicle, check the oil level and top up if necessary.

Every 3,000 km, the message OIL is displayed on the digital instrument board. This warning light indicates that it is time to change the engine oil. This

warning light is displayed on the instrument board until the indicated operation is carried out.

Waste oil is toxic for the environment, therefore we suggest you contact an Authorised Service Centre for disposal according to the rules in force.

every 3000 km or 6 months

F. 8

A

14 02/08

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).

• Unscrew the cartridge filter (C) and remove it. Fit a new filter, and lubricate the O-rings with engine oil. Since a certain amount of oil remains in the circuit, fill through the cap

(A) using about 1500 cm3 of oil. Start the vehicle, let it run for a few minutes and turn it off: after 5 minutes, check the level and top up but never above the MAX mark.

F. 9

B

F. 9/a

C

The cartridge filter must be replaced every time the oil is changed. For topping up and replacement use Q8 FORMULA EXCEL SAE 5W40 oil.

Letting the engine run with an insufficient amount of lubricant or with the wrong types of lubricant causes wear to moving parts and can in the long run

cause serious damage.

Waste oil contains polluting substances. Have oil replaced by an Authorised Service Centre that will also dispose of waste oil in accordance to the law.

F. 8/a

A

15 02/08

Max

Min

TRANSMISSION OIL

CHECK THE LEVEL

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.

5) Fill the crankcase with this type of oil: Q8 ZC 90

Crankcase capacity approx.: 250 cm3

RENEW

• Carry out the operations described above at points 1-2, without refitting the dipstick; then put a container under the

engine crankcase and unscrew the drainage screw (B), paying attention to the gasket.

• Let oil flow into the container (pay attention to avoid scorching).

• Refit the drain plug with gasket and fill with approximately 250 cm3 of new oil (Q8 ZC 90), then refit the cap and

dipstick (A).

• Now repeat checks 3-4-5. If the drainage screw gasket is damaged, replace it.

Regularly check for oil leakages near the drain plug at the rear wheel.

every 6000 km or 12 months

after the first 1,000 km and every 24,000 km

F. 10

F. 11

A

B

16 02/08

MIN

S

CHANGE

If the fluid features traces of dirt, debris or water, it must be replaced. A soft and spongy feeling in the brake lever can indicate the presence of air in the

circuit.

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.

BRAKE OIL

When topping up, never use more than one oil.

F. 12

every 30 days

every 12.000 Km or 24 months

A

B

MIN

S

F. 13

17 02/08

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.

To bleed the circuit of the integral system, first bleed the rear brake calliper.

• Fill in the left brake liquid tank up to the maximum level.

• Remove the rubber cap (A) from the bleed screw (B) and fit the rubber hose to collect the brake liquid.

• Operating the left brake lever, charge and pressurise.

• Keeping the left brake lever operating, slacken the bleed screw to let the air out. Then, tighten the bleed screw (B).

• Repeat the operation until only brake liquid is let out of rubber hose.

• These operations should be repeated for the front right calliper.

• Restore the level of the brake liquid in the sump.

During the bleeding, avoid the contact between the brake liquid and the bodywork, to avoid damages. Moreover, during the bleeding of the brake callipers,

avoid the contact between the liquid and the brake discs or the brake pads. Failure to observe this rule may affect the functions and the efficiency of the

braking system. If, during the bleeding, more air would come out, check all of the couplings: if they do not show any malfunctioning, look for the entrance

of the air in the different seals of the pump and in the pistons of the calliper.

During this operation, oil may leak from the bleed screw on the calliper and on the disc: if so, carefully dry the calliper and degrease the disc.

CHECK THE LEVEL OF THE BRAKE LIQUID (P. 16)

FRONT LEFT CALLIPER

• To bleed the front left calliper, operate the right brake lever.

F. 14

B

A

B

12 ÷ 16

18 02/08

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.

• Replace the brake pads in case their thickness is below

the allowed limit or they are damaged.

REPLACING THE BRAKE PADS

F. 1 7

F. 15

F. 1 6

DISCS

Check the discs for wear and replace if necessary (service limit 4.5 mm).

In case of abnormal wear or signs of scoring, carry out grinding.

For instructions on how replacing the front and rear brake pads please refer

to pages 60 and 61.

19 02/08

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.

• Bring to the limit (downwards) the leg, keeping it in perfect vertical position.

• Using a meter or the stick of a gauge, check the proper oil level, which should be at

mm 123 from the upper edge of the leg.

• If necessary, top up with oil: Q8 FORK OIL

F. 18

V

FRONT FORK OIL REPLACEMENT

• Place a suitable container under the stanchion and remove the screw (V).

• Allow as much oil as possible to drain out.

• Disassemble the stanchions, as previously described.

• Turn over the stanchion, to let the remaining oil drain out.

The hydraulic oil is corrosive and may cause personal damages.

Do not dispose of spent oil in the environment.

• Refit the drain screw (V).

• Carefully pour the new oil in the leg.Carefully pour the new oil in the leg.

• Check the oil level, as previously described.

• Refit the components of the legs and the legs themselves on the motorcycle.

Quantity per leg 385 cc.

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Malaguti SPIDER MAX RS 500 User manual

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