Malaguti SPIDER MAX RS 500 Page 54 Service Manual Download

Page: 54 / 81

02/08

ACCESSES

A) Injection ECU

B) Injector

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.

ELECTRONIC
INJECTION ECU
THROTTLE BODY

• To remove the ECU see the Electric

System Diagnostics Manual
(Section“B”).

F. 116

• After disconnecting all

connectors, remove the relay
holder (1) on one side or
remove it completely.

F. 117

Summary of Contents for SPIDER MAX RS 500

Page 1: ......

Page 2: ...n 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 procedu...

Page 3: ...alt 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 Table V Screw TECHNICAL DICTIONARY V DC Direct current battery supply V AC Alternating current flywheel supply A Ampere Unit of measurement of...

Page 4: ...ECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technician IGNITIONKEYON ON position PRESENTMANUAL Information on the present manual ENGINE SERVICE MANUAL Indicates information which may be obtained by referring to said catalogue SPAREPARTS CATALOGUE Indicates information which may be...

Page 5: ...ce 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 a...

Page 6: ...ow 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...

Page 7: ...34 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 1234 DESCRIPTION P SPECIFICATIONS 7 IDENTIFICAT...

Page 8: ...ith 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 lev...

Page 9: ... 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 correspo...

Page 10: ...re 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 ...

Page 11: ...y 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 ...

Page 12: ...tment 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 unsc...

Page 13: ...e 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 OFTHE 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 ...

Page 14: ...oard 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 ...

Page 15: ...3 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 w...

Page 16: ...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 repe...

Page 17: ...f 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 ...

Page 18: ... 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 th...

Page 19: ...rake 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 17 F 15 F 16 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 ...

Page 20: ... necessary top up with oil Q8 FORK OIL F 18 V 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 envir...

Page 21: ...ent 3 Driver and passenger 4 Driver passenger and luggage compartment F 19 F 20 STEERING PLAY CHECK Place the motorcycle on the central stand Rotate the handlebar repeatedly in both directions to check that the ball bearings can slide smoothly In case of a light friction during rotation or exceeding smooth sliding adjust it by means of the appropriate wrench HANDLEBAR ADJUSTMENT To adjust the hand...

Page 22: ...21 02 08 LOCATION OF THE MAIN ELECTRICAL ELEMENTS F 21 Battery Rollover sensor Ignition coil Spark plugs Temperature sensor Relays and flasher Fuel pump 1 3 1 2 3 6 7 2 6 7 4 5 5 4 ...

Page 23: ...22 02 08 F 22 8 Immobilizer control unit 9 Lambda sensor 10 Fuel injector 11 Regulator 8 9 10 11 11 8 10 9 12 Diagnostic plug 12 12 ...

Page 24: ...uel level The warning light comes on to indicate that the reserve amount has been reached 10 Oil This light comes on while the engine is running to indicate that engine oil pressure is insufficient 11 Immobilizer After about 20 days the light stops flashing in order not to discharge the battery However the immobilizer function is still active 12 Injection This light comes on while the engine is ru...

Page 25: ...ency stop button is turned OFF Before pressing the ignition button pull the front or rear brake lever and keep it pulled to start the engine since this lever acts on a special ignition consent switch If the tank is empty do not operate the START button and do not turn the key ON as this would damage the injection system If the engine does not turn on release the ignition switch wait a few seconds ...

Page 26: ... beams 12V 35 35W HS1 35 C Front direction indicators 12V 21W PY21 30 D Number plate light 12V 5W W5W E Rear direction indicators 12V 16W W16W 48 F Rear parking lights 12V 5W R5W 50 G Rear parking and stop lights 12V 21 5W P21 5W 50 Always replace burnt bulbs by new identical ones and test them before reassembling all the components previously removed ...

Page 27: ... proceed as follows Put the vehicle in running conditions at 10 metres from a wall Turn on the low beam headlights and keep the vehicle balanced without a stand lean it against a wall for instance Turn the adjustment knobs of the two projectors A one at a time bearing in mind that turning clockwise lowers the beam and anti clockwise raises it Adjust the beam so that its bottom line projected on th...

Page 28: ...GENERAL PROTECTION FUSE NOTE Inside the battery compartment is located the general protection fuse A 30 A CHARGE PROTECTION FUSE Remove the battery holder to access the charge protection fuse 30 Amp Do not replace the fuses with ones having higher capacities since that may seriously damage the electrical system and set on fire the vehicle in case of short circuit F 29 F 30 To replace one or more f...

Page 29: ...st a battery with a drain hose While checking servicing repairing the vehicle absolutely avoid starting the engine with the electrical system connected even if only temporarily or for ignition to a battery having specifications different from those indicated by Malaguti CHARGE BATTERY To carry out this operation we suggest to remove the battery from its compartment and disconnect the cables It is ...

Page 30: ...rk plug carburetion lubrication and general conditions of the engine If the insulator is light brown around the central electrode it indicates good working order Black dry to touch sooty and tarnished deposits show that the functioning temperature is too low the heat rating of the spark plug is too high carburetion too rich or faulty ignition every 10 000 km Whitish insulating material shows an ex...

Page 31: ...he screw upper V PROCEDURES FOR DISMANTLING AND REMOVING COMPONENTS REASSEMBLY NOTE REAR VIEW MIRRORS Lift the rubber part A and release the fastening screws of the rear view mirror V Remove the rear view mirror complete V2 10 20 V3 1 5 15 V 1 5 15 F 34 F 35 F 36 F 37 FRONT DIRECTION INDICATORS BULB CHANGE The bulb holders of the front direction indicators are inte grated in the front headlights T...

Page 32: ...king light bulb is located inside the central shield Remove the bulb and replace by another of the same type Reconnect the connectors to test the new bulb before reassembling all components Remove the bulb holder F 38 F 40 F 41 REPLACINGTHE FRONT PARKING LIGHT Release the screws V5 Release the screws V2 Remove the cover A D C B A F 39 A V2 V5 ...

Page 33: ...5 BRAKING DISTRIBUTOR NOTE To access the braking distributor A remove the central fairing P 30 Drain completely the circuit Release the screws V2 V 10 20 Undo the connectors B Remove pipes C and gaskets D B 20 10 F 44 B V While reassembling take care not to invert the fitting of the Faston connectors Blue cable lower terminal Orange cable upper terminal V2 A C B D D C B C D ...

Page 34: ... the screws V3 and remove the windscreen FRONT FAIRING NOTE The front fairing is made of two parts one right and one left The following instructions apply to the whole fairing Release the screws V2 Release and remove the lower screw V1 and its washer F 47 V2 F 46 F 48 V3 V V1 V1 1 5 15 Release the screws V4 V4 1 5 15 V3 1 5 15 V2 1 5 15 Release the central upper screew V V 5 20 ...

Page 35: ...e the screws V2 and remove the passenger footpeg Remove the rubber mat V2 40 15 F 50 F 52 F 49 F 51 V2 Release the screws V8 Release the half fairing upper part from the mir ror mount opening it up carefully V8 1 5 15 ...

Page 36: ...adiator F Radiator fan F 55 E F D IMMOBILIZER ECU Disconnect the three connectors H Release the screws V2 Remove the Immobilizer ECU A V2 10 20 If the Immobilizer ECU is replaced store two or more ignition keys please refer DIAGNOSTICS MANUAL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM chapter Immobilizer Before refitting the different connectors make sure if the inside sealing rubbers yello...

Page 37: ...refit new clips placed and fixed as before F 57 F 56 V2 V2 A V2 5 20 B C F 58 FUEL SUPPLY PUMP Disconnect the connector C F 57 The procedure to remove the fuel supply pump A and its float B can be understood from the picture on the side Check the conditions of the gasket C and replace it if necessary Carefully clean the mesh filter D NOTE All of the information on the pump can be deducted by readi...

Page 38: ...e for its ecolo gical disposal The coolant is potentially polluting therefore it should not be released in the environment Disconnect the connector of the electrical fan wiring Release the bleed screws V on both the radiators releasing both ground cable ends M Cut all the clips securing the lines composing the cooling system circuit V M In case the pump A has to be removed release the screws V6 Cu...

Page 39: ...first fit the radiators on the upper silent blocks NOTE The radiators are fit ted on Silent blocks B first release them from the lower ones and then extract them from above Release and remove the screws V2 and their washers F 66 Remove the left radiator including the electrical fan LEFT RADIATOR including the electrical fan F 63 F 65 F 64 V 10 20 V2 10 20 V2 10 20 B B A V V2 B V2 ...

Page 40: ...cludes two thermal expansion valves A Thermal expansion valve for the right radiator adjustment To remove it release it from the clips F and slide it from the support S ELECTRICAL FAN RADIATOR Release the screw V and remove the expansion reservoir V2 10 20 V 10 20 V2 C F 68 V A S F F 70 B Thermal expansion valve on the engine To remove it release it from the clips of the rubber hoses and slide it ...

Page 41: ...are not to damage the cables during the operation Squeezing or cuts of some of the fibres of the cables imply their complete replacement Disconnect the two way con nector connected to the Im mobilizer DASHBOARD PANEL Release the screws V2 Remove the dashboard panel A releasing it from the locking tabs F 73 V2 V2 B A V2 C D V2 If the key switch is replaced or all of the stored keys are lost replace...

Page 42: ...nut A rotating it counter clockwise Release the retaining screws V2 of the fusebox Remove the transparent cover Push forward the fusebox Release the screw V Release the three screws V inside the luggage compartment Release the screw underne ath V1 V1 5 20 V 5 20 V V1 V V2 ...

Page 43: ...81 Release the screws V3 Unlock the luggage com partment closing transmis sion cable from its seat A Open slightly the footpeg until the plastic locking tabs are released Extract the leg protector assembly together with the footpegs V3 ...

Page 44: ...screws V2 ACCESSES after removing the upper handlebar cover B Main wiring end V4 Handlebar inclination adjusting screws V2 1 5 15 V2 1 5 15 F 84 F 82 F 83 UPPER HANDLEBAR COVER Release the screws V2 and remove the upper handlebar cover A F 85 V2 V2 A B V4 ...

Page 45: ...ase the remaining four inside screws and remove the rear handlebar cover P FRONT AND REAR HANDLEBAR COVER Release the upper screws V2 ACCESSES Removing the front handlebar cover allows to reach the two brake liquid pumps A and the two stop switches B V2 V2 1 5 15 B2 1 5 15 F 87 P B2 A B A B A ...

Page 46: ...F 91 Release and extract the coupling A Remove the tube B and the gaskets C Disconnect the Stop switch S NOTE Repeat the same procedure for both brake pumps S B A C 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 t...

Page 47: ...t allows reaching the following electronic components A Relay black Starter B Relay yellow Electric fan C Relay red Injection system D Tilt sensor connector E Tilt sensor F Flasher B NOTE In order to access the tilt sensor E it is necessary to remove the rubber protec tion G When reassembling the sensor make sure that the cable H is facing downwards F 96 G A B F 95 E F C D H ...

Page 48: ...gether with the grab handle and movable support In order to release the passenger seat F 49 from the movable support first release the screws V6 CUSHION DRIVER SEAT Release the screws V2 Slackening the screws V2 allows adjusting the cushion travel according to the user s requirements GRAB HANDLE Release the screws V5 and remove the grab handle D D C V2 V5 30 15 V2 10 20 V6 10 20 V5 V2 V5 V6 F 99 ...

Page 49: ...V2a V2a F 103 DIRECTION INDICATORS AND TAIL LIGHTS BULB CHANGE Lift the seat Removing the inserted side covers A allows reaching the rear direction indicator bulbs Removing the inserted rear covers B allows reaching the tail light bulbs V2 5 15 V4 10 20 V2a 5 15 Release and extract care fully the helmet compart ment without removing it completely V2a Release the screws V2 Release the screws V4 V2 ...

Page 50: ...FAIRING Release the two screws V2 Release the screw V F 104 Lift the helmet compartment disconnect the connector A and release the cable from the clamp B Remove the helmet compart ment completely F 105 V 5 15 V2 5 15 ...

Page 51: ...nd the rear fairing Disconnect the wiring Release the screws V3 Remove the cable clamps A Remove the headlight concerned While reassembling refit the cable clamps as before The tail lights glass cannot be replaced If it is broken replace the whole headlight A V3 V4 1 5 15 Keep the rear fairing components far from heat sources in a clean place where they cannot be accidentally damaged V4 V4 ...

Page 52: ...ends F 110 Left side A Coil B Ground ends F 111 C B A B C V4 VOLTAGE REGULATOR Release the screws V2 Remove the wiring cable ends from the right screw Remove the voltage rectifier A Disconnect the flywheel connector C and the connector F located underneath the wiring protection sheaths COIL Disconnect the connector C Release the screws V4 Remove the coil A COOLANT PUMP See Service Manual Section C...

Page 53: ...two front screws V2 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 F 114 V1 V2 C F 115 C ...

Page 54: ...s can be deducted by reading the DIA GNOSTICS MANUAL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM ELECTRONIC INJECTION ECU THROTTLE BODY To remove the ECU see the Electric System Diagnostics Manual Section B F 116 B C 1 A After disconnecting all connectors remove the relay holder 1 on one side or remove it completely F 117 ...

Page 55: ...bottom of the battery compartment and remove the compartment extracting the battery cables and fusebox ACCESSES Removing the battery compartment allows reaching the starting relay and the corresponding 30 A fuse recharge protection F 118 F 121 F 120 NOTE Inside the battery com partment is located the general protection fuse F 30 A Release the battery cables Extract the battery F 119 V 10 20 F B A ...

Page 56: ...he front fairing P 33 Fuel fumes are highly toxic and therefore harmful to your health Ventilate the room before proceeding and if necessary wear a protection mask Do not remove the tank unless the latter has been previously emptied Do not smoke nor use bare flames Do not carry out any the operation while working and producing sparks such as welding grinding etc Remove the connector 1 from the fue...

Page 57: ...e the screw V releasing it from the support T Extract the tank sliding it from the front side of the frame downwards Disconnect the connector A of the fuel pump The fuel tank is blocked in its rear side by the two Silent Blocks B A T V C F 126 F 128 F 127 F 129 C B ...

Page 58: ...57 02 08 AIRBOX Release the screws V8 and remove the cover A Release the hose B from the throttle body Extract the airbox Release the gas recovery hose C F 130 F 131 F 132 A V8 C C B ...

Page 59: ...t stability of the motorcycle If ne cessary place one sui table support under the engine FRONT MUDGUARD Release the screws Va Release the screws Vb and corresponding nuts A F 133 Vb 3 5 10 Va 3 5 10 F 134 F 135 F 136 Do not actuate the brake levers without the wheel as the pads would close Release the screws V2 and release the entire callipers Release the screw V and extract the odometer sprocket ...

Page 60: ...ecified torque FRONT BRAKE DISCS To separate the discs D from the front wheel release and remove the screws V6 and the washers E 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 When reassembling the right and left brake discs observe disc rotation direction which can be determined by the position of the slots ...

Page 61: ...nd the gaskets B Do not use the brake lever after removing the callipers the piston may jump off causing brake liquid leaks The liquid is corrosive and may cause serious personal damage After removing the callipers from their housing place a container underneath in order to let the liquid drain from the hydraulic system and dispose of it in compliance to the law in force V2 30 20 FRONT CALLIPER DI...

Page 62: ...ove and replace the pads without removing the brake callipers from the vehicle Release the nut D F 146 Remove the floating sup port S from the calliper body including the two slide pins During reassembly lubricate the slide pins must rubber gasket grease D 20 20 F 147 F 146 F 148 F 149 D S B B ...

Page 63: ...system always check that The brake liquid tubes are not damaged squeezed or twisted The brake discs and pads are not soiled with oil or grease All the screws and couplings are properly tightened There are no leaks from the couplings Remove the dust seal A and the seal ring B from both the pistons During this operation take care not to damage the dust seal and seal ring housing Make sure there are ...

Page 64: ...e screw V NOTE The disassembly of the stanchion can be deducted from the picture shown hereafter CHECKTHE OIL LEVEL IN THE STANCHION If there is the limit switch of the front fork or irregular noise check the oil level inside the legs of the fork proceeding as follows Release the upper cap A Remove the O Ring B Carefully remove the spring C and let it drip off completely the oil in which it was pr...

Page 65: ...oil Q8 FORK OIL Before refitting the front fork clean all the components eliminating any sign of grease Check the conditions of the components and replace them if necessary Grease the ball bearings and their seats and reassemble the front fork Quantity per leg 385 cc F 160 D T V2 E F G Sfere superiori C n Ø Sfere inferiori D n Ø Upper ball bearings F n 18 Ø 1 4 Lower ball bearings G n 18 Ø 1 4 D 1...

Page 66: ...n any case suitable safety gloves Vb Release the clamp F and remove the exhaust pipe Slacken the screw V of the clip securing the exhaust exhaust manifold Va Vb 14 15 F 161 F 162 F 163 F 164 Va V Vb B Release the Lambda sensor cable from the clamp B V3 A Va 25 15 F EXHAUST MANIFOLD Undo the screws V3 of the heat guard A Remove the grid ...

Page 67: ...e gasket F 165 While reassembling always use a new gasket F 166 C 30 10 C D LAMBDA SENSOR Removal Slacken the Lambda sensor A from the exhaust manifold using a suitable locking system in order not to damage the manifold F 168 F 167 A Reassembling Screw the Lambda sensor down with along cable and connector Tighten to the prescribed torque A 45 15 ...

Page 68: ...stem ensuring the vehicle perfect stability even without shock absorbers F 169 V2I V2S F 171 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 V2I V2S V2I V2S V2S R D D D D R R R R V2I V2I 30 15 V2S 45 15 V2I ...

Page 69: ...ve Anti vibration O Ring 1 Spilt pin 2 Cover 3 Release the underlying nut D Remove the shim S and release the arm A F 175 B2 33 41 D 100 15 When removing and reassembling the upper arm make sure the spacer E orientation is correct SHOCK ABSORBER SUPPORTING PLATE Right plate Release the right shock absorber P 67 V2 Remove the plate P F 172 F 175 F 176 E F 173 F 174 1 2 3 S D 1 2 3 B2 P A V2 30 10 V...

Page 70: ...After removing the callipers from their housing place a container underneath to let the hydraulic system liquid drain and dispose of it in compliance with the law in force V2 V2a A V F 177 Let a little compressed air in so as to let the two pistons out of their seats in the two housing halves composing the calliper C D REAR CALLIPER DISASSEMBLY Remove the retaining ring A of the spindle securing t...

Page 71: ...the dust seals lubricating with brake liquid Remove the dust seal A and the seal ring B in both the housing halves taking care not to damage their seats Check that the pistons and their seats are in perfect conditions At the end of each operation on the braking SYSTEM always check that The brake liquid lines are not damaged squeezed or twisted The disc and the brake pads are not soiled with oil or...

Page 72: ...ve the washers and the nut Once the shock absorber has been released move it upwards and hold it so that it will not impede the subse quent operations F 183 V REAR BRAKE DISC During the check and the service on the rear brake calliper check the disc conditions C If the disc is too worn out service limit 3 5 mm replace it releasing and removing the screws V6 including their washers D In case of irr...

Page 73: ...ngine using safety gloves and an assistant Support suitably the engine with systems ensuring both the top safety for the operators during the removal as well as the perfect stability of the vehicle before during and after the operation Bear in mind that only the left shock absorber will be kept active once the engine will be removed Place the coolant manifolds so that they will not impede the engi...

Page 74: ...ove the screw V and the washer G Remove the anti vibration connecting rods H ENGINE MOUNT Place the mount A inside the frame Fit the shaft E Fit the threaded bushing C including the lock nut D to the frame taking care to observe the prescribed torque Fit the lock nut D tightening it completely to the frame Fit the self locking nut B tightening it to the prescribed torque If the bushing C was tight...

Page 75: ...ponents described up to this paragraph Cut all the clips from the subframe and release the different wirings Disconnect the connectors of the electrical componen ts to be removed Disconnect the connector A from the switch placed on the side stand Remove the immobilizer ECU B P 35 Release the screw V and release the lines of the brake oil D E Remove the braking distributor F P 32 F 194 F 195 A B V ...

Page 76: ...removed together with its side stand CENTRAL ALUMINIUM FRAME NOTE The aluminium frame 4 is made up of the two symmetrical parts Release on both sides the screws V4 securing the aluminium frame to the rear frame Release the central screws V2a and remove the spacer between the two half fra mes Release the lower screws V2b and remove the spacer A Release and remove the upper screws V6 with their wash...

Page 77: ...stortion 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 2 mm tolerance Otherwise replace completely the frame Do not distort the frame to restore the original dimensions F 197 ...

Page 78: ...77 02 08 CABLE POSITIONING PIPE SYSTEM AND ANCHORING TIES F 198 F 199 ...

Page 79: ...78 02 08 F 200 ...

Page 80: ...79 02 08 F 201 ...

Page 81: ...80 02 08 F 202 ...

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Malaguti SPIDER MAX RS 500, Service Manual

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