Malaguti SPIDER MAX GT 500 User manual

Brand: Malaguti

Model: SPIDER MAX GT 500

Type: User manual

1 07/06

SPIDER MAX 500 - EURO 3

EURO 3

2 07/06

SPIDER MAX 500 - EURO 3

MANUAL SECTIONS

FOREWORD

• The present service manual concerns the main electrical, mechanical and necessary checks and the assembly of

single components before delivering the new motorcycle (the operation sequence is not compulsory)

• 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.

KNOW YOUR MOTORCYCLE

LUBRIFICANTS

MECHANICAL ADJUSTMENTS

BODYWORK (FAIRINGS)

MECHANICAL COMPONENTS

ELECTRICAL AND ELECTRONIC

COMPONENTS

ABBREVIATIONS USED IN THE

MANUAL

F Picture

Cs Torque wrench setting

Min. Minutes

P Page

Pr Paragraph

S Section

Sc Diagram

T Table

V Screw

UNITS INDICATION

• The manual use measurements in mm.

SPARE PART CATALOGUE

SERVICE MANUAL CYCLE PARTS

(PRESENT MANUAL)

SERVICE MANUAL PIAGGIO’S MOTOR

DIAGNOSTICS MANUAL OF THE ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM

DOCUMENTS CONCERNIG THE MODEL:

SPIDER MAX 500

MODIFIED PAGES

• Modified pages are indicated by the same number of the page in the previous edition, followed by an M and, the new

release date.

• It is possible that new pictures are inserted in the modified pages; if it is the case, the new picture (or pictures) will

have the same number of the previous picture/s followed by a letter of the alphabet.

• In case of number omission, the picture number will be displayed on a black ground (e.g.: F. 5 ).

ADDED PAGES

Added pages are indicated by the last number of their section followed by an A and the new release date.

I-E

USER AND SERVICE

MANUAL

3 07/06

SPIDER MAX 500 - EURO 3

IMPORTANT!

WARNING! - Used to indicate dangerous operation that can lead to the injury of service, workshop personnel

or people in general or damage to the facility, the motorcycle or equipment.

ENGINE OFF - Used for all the operations that must be carried out with engine off.

VOLTAGE OFF - Disconnect the battery negative pole before the operation.

DANGER OF FIRE - Operations that may start a fire.

DANGER OF EXPLOSION - Operations that may cause an explosion.

TOXIC FUMES - It indicates danger of toxic fumes or respiratory inflammation.

MECHANICAL SERVICE STAFF - Operations that must be carried out by a skilled mechanic.

ELECTRICAL SERVICE STAFF - Operations that must be carried out by a skilled electrician or electronic

technician.

NO! - Do not carry out this operation.

SYMMETRICAL OPERATIONS - Operations that must be carried out also on the other side of the unit or

component.

EMPTY THE CIRCUIT

PRE-DELIVERY OPERATIONS

ASSEMBLY OPERATIONS

DISASSEMBLY OPERATIONS

OPERATION SYMBOLS

4 07/06

SPIDER MAX 500 - EURO 3

• We suggest performing the following adjustments: adjust the handlebar, the shock absorbers and the tyre pressure,

according to the customer specifications, connect the battery. Deliver to the customer the Warranty and service

booklet and the User and service manual, duly stamped and signed, together with the motorcycle.

NO. SERVICE S P

1 On delivery

Visual check A 8

Identification data check A 8

2 Important tightening

Front wheel E 43

Rear wheel E 80

Brake callipers E 45

Shock absorbers E 78

Exhaust E 77

Engine shaft E 81

Handlebar C 21

3 (Liquid) level check

Battery F 88

Coolant B 16

Engine oil B 17

Transmission oil B 19

Brake liquid B20

4 Adjustments

Handlebar adjustment C 21

Shock absorbers C 22

Headlight beam D 25

NO. SERVICE SP

5 Various checks

Tyre pressure A 14

Starting A 12

Steering lock A 12

Accelerator E 56

Handlebar controls A 11

Brake levers A 11

Side stand A 12

Fuses F 87

6 Assembly

Mirrors D 24

Windscreen D 26

Number plate D 24

7 Road test

8 General cleaning

PRE-DELIVERY

5 07/06

SPIDER MAX 500 - EURO 3

S TOPICS P

Technical data 9

Dimensions 9

General specifications 9

Main component identification 10

Handlebar controls 11

Right control 11

Left control 11

A Key switch 12

Steering lock 12

Side stand 12

Dashboard 13

Tubeless tyres 14

Fuel tank 14

Helmet compartment 15

Luggage compartment 15

Coolant tank 16

Engine oil 17

B Transmission oil 19

Front and rear brake liquid 20

Lubricant table 20

Steering 21

C Handlebar adjustment 21

Rear shock absorber adjustment 22

Fairing components 23

Number plate assembly 24

Rear view mirrors 24

Central fairing 24

Windscreen 26

D Dashboard 26

Front fairing 27

Dashboard panel 30

Leg protector 30

Upper handlebar cover 32

Front and rear handlebar cover 33

INDEX

6 07/06

SPIDER MAX 500 - EURO 3

S TOPICS P

Driver seat 34

Passenger seat (including movable support) 35

Driver seat cushion 35

Grab handle 35

Helmet compartment 36

Rear fairing 37

Battery compartment 39

Airbox 41

Front mudguard 42

Lower fairing mudguard 42

Front wheel 43

(Front brakes) discs 43

Front wheel 44

Brake master cylinders 44

Brake callipers 45

(Rear brake) disc 49

Braking distributor 51

Braking system circuit 51

Braking system bleeding 54

Handlebar 55

Accelerator transmission cables 56

Fork 58

Complete fork 59

Seat opening transmission cable 60

Luggage compartment opening transmission cable 62

Fuel tank 63

Fuel pump 65

Radiators (including lines and expansion reservoir) 66

Electrical fan radiator 68

Expansion reservoir (coolant tank) 68

Thermal expansion valve 68

Coolant circuit 69

Hose routing (right-hand cooling circuit) 70

Hose routing (left-hand cooling circuit) 71

7 07/06

SPIDER MAX 500 - EURO 3

S TOPICS P

Cooling circuit bleeding 72

Subframe 73

Aluminium central frame 73

Frame dimension check 75

Exhaust 76

Lambda sensor 78

Rear shock absorbers 79

Rear arm 80

Rear wheel 81

Engine removal 81

Engine reassembly 82

Engine mount 82

Lighting system 84

Dashboard 85

Bulb change 85

Front headlights 85

Tail light S 86

Horn 86

Immobilizer ECU 86

Key switch 87

Side stand switch 87

Electrical fan 88

Fuses 88

battery fitting 89

Spark plug 90

Coil 90

Voltage rectifier 91

Electronic injection ECU 91

ECU mount removal 92

Complete wiring 94

8 07/06

SPIDER MAX 500 - EURO 3

F. 1

FRAME NO. – ENGINE NO. IDENTIFICATION DATA

• To access the vehicle identification number (VIN) (A - F. 1), lift the seat and remove the cover placed in front of the

helmet compartment.

• The engine identification data are written on the left-hand cover of the engine (B - F. 2).

Any identification data changing is pursued by law.

• Always indicate the vehicle identification data when ordering spare parts.

ON DELIVERY

• When receiving the motorcycle follow the indications provided on the packaging and then dispose of the same in

compliance with the Law in force.

VISUAL CHECK

• Visually inspect the assembly of all plastic components and inspect the motorcycle for marking and damage.

KNOW YOUR MOTORCYCLE

F. 2

9 07/06

SPIDER MAX 500 - EURO 3

TECHNICAL DATA

GENERAL SPECIFICATIONS

ENGINE

4-stroke single-cylinder with 4 valves - Type: PIAGGIO M341M

Refer to Piaggio Engine Service Manual.

SPARK PLUG

CHAMPION RG6YC - NGK CR7EKB

TRANSMISSION

Expansible–pulley automatic variator, V-belt, automatic dry centrifugal clutch, gear reduction unit and transmission

compartment with forced cooling circulation.

FUEL SUPPLY

Electronic injection with electrical fuel pump.

Fuel: unleaded petrol.

ELECTRONIC IGNITION

Inductive, high- performance, integrated into the ignition, variable spark advance and separate H.T. coil.

BRAKES

Hydraulic system equipped with two front (2 discs Ø 270 mm) and rear (disc Ø 260 mm) discs with braking

distributor system.

Starting:

Left lever: rear brake + front brake (vehicle right-hand side)

Right lever: front brake (vehicle left-hand side)

FRAME

V-Box type, aluminium cast double housing halves, coupled in the front and rear part to half-frames in stainless

steel tubes.

SUSPENSIONS

Front: telehydraulic fork, with two 41-mm legs;

Travel: 120 mm.;

Rear: 2 hydraulic shock absorbers with adjustable spring pre-load;

Travel: 75 mm.

BATTERY

Type: 12V, 14Ah.

TYRES

Front: 120/80 - 16 60 S

Rear: 150/70 - 16 68 S

DIMENSIONS

Pitch (A) 1.490 mm

Length (B) 2.255 mm

Width (C) 930 mm

Max. height (D) 1.470 mm

Weight 230 Kg

10 07/06

SPIDER MAX 500 - EURO 3

17) Double seat

18) Helmet compartment

19) Exhaust

20) Anti-theft hook

21) Central stand

22) Right direction indicator

23) Front right headlight

24) Front left headlight

25) Parking light

26) Left direction indicator

27) Windscreen

MAIN COMPONENT

IDENTIFICATION

1) Left mirror

2) Coolant tank

3) Glove compartment

4) Battery

5) Battery compartment

6) Side stand

7) Throttle body

8) Air cleaner

9) Number plate bracket

10) Rear indicators

11) Parking and stop lights

12) Passenger grab handle

13) Fuel filler cap

14) Key switch

15) Dashboard

16) Right mirror

F. 3

7 8

F. 4

11 07/06

SPIDER MAX 500 - EURO 3

HANDLEBAR CONTROLS

RIGHT CONTROL

1) Counterweight

2) Throttle

3) Front brake lever (left-hand)

4) MODE button: to select the digital dashboard

functions

5) Front brake oil tank

A) Emergency Stop, engine cut-out.

ON - Engine ignition

OFF - Engine cut-out

B) Light switch:

right = off

central position = parking lights and

dashboard

left = low beams.

C) Electrical starter.

F. 6

F. 5

LEFT CONTROL

1) Rear brake oil tank

2) “Flash” lever high beams (passing)

3) Rear/front brake lever (right-hand)

4) Counterweight

5) Horn button

6) Indicator switch

7) Light switch:

high beams

low beams

12 07/06

SPIDER MAX 500 - EURO 3

KEY SWITCH

• This switch controls the ignition circuit and the steering

lock device.

a) Locked ignition(key can be removed)

b) Ignition ready position (key cannot be

removed)

c) Steering lock engagement (locked ignition;

key can be removed)

d) Helmet compartment opening

e) luggage compartment opening

NOTE - The vehicle is supplied with two keys.

F. 7

F. 8

STEERING LOCK

ENGAGEMENT

With the handlebar turned to the left or right, insert the

key and rotate counterclockwise

(F. 8).

Disengagement

Rotate the key clockwise.

NOTE - The motorcycle is equipped with a starter pedal.

SIDE STAND

Check for proper side stand fitting and for spring (1 - 2)

mounting.

Also check for proper microswitch (A - F. 9) operation

preventing engine starting when the side stand is not

folded up.

Never remove or alter this safety device.

A2 1

F. 9

13 07/06

SPIDER MAX 500 - EURO 3

DASHBOARD

1) Multifunction digital dashboard

(Refer to the User Manual for function set up).

2) Analogic speedometer

indicates the current driving speed in km/h and miles (mph).

3) Coolant temperature indicator

The indicator goes on when the coolant temperature is too high.

4) Side stand/engine stop indicator (red)

The indicator goes on when the side stand is down or the Engine Stop button is on the OFF position.

5) Low beam indicator (green)

6) High beam indicator (blue)

7) Left direction indicator (green)

8) Right direction indicator (green)

9) Fuel level indicator

The indicator goes on to indicate the fuel is low.

10) Oil indicator (red)

With the engine operating, the indicator goes on when the engine oil pressure is too low.

11) Immobilizer indicator (red)

The led stops flashing after 20 days to prevent the battery from running down but the immobilizer

function is enabled

12) Injection Indicator (orange)

The indicator goes on to indicate injection system fault.

Do not use pressure to clean the instruments in order to avoid any damage.

F. 10

3 1

10924 5

14 07/06

SPIDER MAX 500 - EURO 3

FUEL TANK

To reach the fuel tank, proceed as follows:

• place the motorcycle on the central stand.

• Extract the ignition key from the switch.

• Open the hatch (A) by acting on the lever (B).

• Insert the ignition key, release the cap (B) and refill the

tank.

• After the refuelling, remove any fuel residue from the

bodywork as soon as possible.

Use UNLEADED PETROL.

FUEL TANK litres

TOTAL CAPACITY 14

RESERVE 3

TUBELESS TYRES

PRESSURE CHECK

Check and adjust tyre pressure with “cold tyres”.

X 120/80 - 16” 60S

Y 150/70 - 16” 68S

Petrol is an extremely inflammable substance: never stay near the fuel filler, also during refuelling,

with lighted cigarettes or bare flames (e.g. matches). Danger of fire.

F. 12/a

YF. 11

A C

F. 12

15 07/06

SPIDER MAX 500 - EURO 3

F. 13

F. 14

HELMET COMPARTMENT

• Placed under the passenger seat. Place the motorcycle

on the stand, press and rotate the ignition key clockwise:

this operation releases the seat lock.

• In the helmet compartment a light goes on and off when

opening and closing the compartment. The light operates

only if the ignition key is on the ON position.

• The helmet compartment is equipped with a 12V plug

(A) that may be used, for instance, to recharge the mobile

phone battery. Use the plug only with the engine operating

and with headlights off. The use of the plug reduces the

duration of the battery charge and may reduce its lifetime.

Do not connect any appliance requiring a high power

supply (max power consumption: 30W). The plug can

operate ALSO when the ignition key is on the OFF

position.

• Refit the cap after use to prevent debris from causing

short circuits.

LUGGAGE COMPARTMENT

• Equipped with a lock (A) that can be opened by means of the ignition key: press and rotate the key counterclockwise.

• The electrical system fuses (B) are fitted inside the compartment (Please refer: S/F - P. 88 of the present Manual).

F. 15

16 07/06

SPIDER MAX 500 - EURO 3

COOLANT TANK (EXPANSION RESERVOIR)

To access the coolant tank, containing the engine cooling liquid, open the luggage compartment

(A) and remove the plastic cover (B).

LEVEL CHECK

• At this point, thanks to the tank position, it is possible to check the level of the coolant with respect to the MIN and MAX

marks peeping through the grid placed under the fairing in the front part of the vehicle.

Top up the coolant only with the products indicated in the present Manual, or with a type of product

having the same specifications.

Top up with water only in case of emergency and in any case replace all the system liquid with the

indicated product type as soon as possible.

LUBRIFICANTS

F. 1

B A

F. 1/a

• Remove the plug (T) in order to pour the coolant.

17 07/06

SPIDER MAX 500 - EURO 3

ENGINE OIL

• In 4T engines, the engine oil is used to lubricate the timing components, crankcase stand and the thermal unit. A low

oil quantity may cause damage to the engine.

• In all 4T engines, oil characteristics and oil consumption may change over time.

CHECK LEVEL every 3000 km or 6 months

Perform this operation with “cold engine”, proceeding as follows:

1) Place the vehicle on the central stand and on level ground (a moderate side inclination may give wrong results).

NOTE - When checking oil level, make sure that the motorcycle is in a vertical position; a slight side inclination may give

wrong results.

2) Release the cap/dipstick ( A), dry it with a clean cloth and fit it back, tightening it completely .

3) Remove again the cap/dipstick and check that the level is between the MAX and MIN marks; if necessary top up oil

with Q8 FORMULA EXCEL SAE 5W40.

The MAX reference mark indicates around 1700cc of oil in the engine.

Should it be necessary to check oil level with “hot engine”, the level line will be lower. Wait at least 10

minutes after stopping the engine, in order to let the engine cool down to get the right oil level.

The vehicle is equipped with a check system that, in case of malfunctioning, turns on an alarm

warning message “LOW OIL PRESSURE” on the digital dashboard.

F. 2

Max

Min

18 07/06

SPIDER MAX 500 - EURO 3

OIL TOPPING UP

Always check oil level before topping it up and never exceed the MAX mark.

Topping up oil between MIN and MAX marks indicates a quantity of oil around. 400 cc.

Never exceed the MAX mark! An excessive inner pressure may damage the engine.

Check and top up engine oil level every 3000 km.

ALARM WARNING MESSAGE (LOW OIL PRESSURE)

When starting the vehicle, the digital dashboard check system displays the “LOW OIL

PRESSURE” warning message to indicate that the check is enabled. The message automatically disappears

after a few seconds and stays on only in case oil pressure problems occurs during the vehicle operation.

If the message goes on while braking, at idling speed or on bends, check oil level and top it up, if

necessary.

Every 3000 Km, the word OIL is displayed on the digital dashboard: it suggests to check or replace the

engine oil. The warning message will stay on the dashboard until the indicated operation is carried

out.

Spent oil contains pollutants, refer to an Authorised Centre to dispose of it in compliance with the law

in force.

REPLACE OIL every 6.000 Km or 12 months

Empty the engine, drain out the oil from the drain plug (B) of the mesh filter beside the transmission assembly.

Slacken the cap/dipstick (A) to facilitate total oil drainage.

Release and remove the oil cartridge filter (C). Fit a new oil filter, taking care to lubricate the filter seal O-Rings with

engine oil. As a certain quantity of oil remains in the circuit, top up with around 1500 cc. of oil from the cap (A). Start

the vehicle, and let it idle for a few minutes before stopping it: after around 5 minutes, check oil level and top up, if

necessary, without exceeding the MAX mark.

Replace the cartridge filter at every oil change. Use Q8 FORMULA EXCEL SAE 5W40 oil for topping ups and

change.

Operating the engine with an insufficient lubrication or with wrong lubricants increase the wear of

moving parts and can result in serious damage.

Spent oil contains pollutants, refer to an Authorised Centre to dispose of it in compliance with the law

in force.

F. 3 F. 4

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SPIDER MAX 500 - EURO 3

TRANSMISSION OIL

CHECK LEVEL every 6.000 Km or 12 months

1) Place the vehicle on a level surface, on the central stand.

2) Release the dipstick (A), clean it, then fit it back tightening it completely.

3) Extract it again and check that the oil level is between the MAX and MIN marks.

4) If the oil level is low, top it up to the MAX mark.

5) Refill the case with oil: Q8 ZC 90

Case capacity: around 250 cc.

REPLACE first time after 1.000 Km and then every 24.000 Km

Perform the operations described at points: 1 - 2 without refitting the graduated dipstick, then place a container

beneath the engine crankcase and release the drain screw (B), taking care not to damage the gasket

Let the oil drain into the container for a few minutes (taking care to avoid burns).

Refit the drain plug and the gasket and top up with around 250 cc of new oil (Q8 ZC 90) then fit the oil plug with the

dipstick (A).

At this point, repeat the check operations indicated at point 3-4-5. Replace the drain screw gasket if necessary.

Check for oil leaks in the areas near the drain plug, rear wheel.

F. 5 F. 6

Max

Min

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SPIDER MAX 500 - EURO 3

FRONT AND REAR BRAKE LIQUID

CHECK every 30 days

• Use the tank indicator (S) for the (visual) check: front brake (A) and rear brake (B), with the motorcycle on a level

ground and vertical position.

• The level is correct when the oil is 3 mm above the indicator lower side.

• To top up oil remove the caps (A-B), after unscrewing the two retaining screws. Use oil: Q8 BRAKE FLUID DOT 4.

Hydraulic oil is corrosive and may cause damage and injury. Do not mix different oils.

Check for the perfect sealing of the gasket.

REPLACE every 2 years or 12000 km

• In the case of dirt, debris or water in the oil, replace it completely.

• When the brake lever feels spongy there may be some air trapped in the circuit. Bleed the circuit.

LUBRICANT TABLE

MIN

F. 8F. 7

MIN

(4T) ENGINE OIL

FORK ROD OIL

BRAKING CIRCUIT LUBRICANT

RADIATOR LIQUID

AIRBOX LUBRICANT

ENGINE TRANSMISSION OIL

LUBRICANTS LUBRICANT TYPE

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Malaguti SPIDER MAX GT 500 User manual

Malaguti SPIDER MAX GT 500 User manual

Malaguti SPIDER MAX GT 500 User manual

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