Malaguti GT 500 Service 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 complaint s.

KNOW YOUR MOTORCYCLE

LUBRIFICANTS

MECHANICAL ADJUSTMENTS

BODYWORK (FAIRINGS)

MECHANICAL COMPONENTS

ELECTRICAL AND ELECTRONIC COMPONENTS

ABBREVIA TIONS 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 INDICA TION

• The manual use measurements in mm.

SP ARE P ART CA T ALOGUE

SERVICE MANUAL CYCLE P ARTS (PRESENT MANUAL)

SERVICE MANUAL PIAGGIO’S MOTOR

DIAGNOSTICS MANUAL OF THE ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM

DOCUMENTS CONCERNIG THE MODEL:

SPIDER MAX 500

A B

C D E

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

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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

ASSEMBL Y OPERATIONS

DISASSEMBL Y OPERATIONS

OPERATION SYMBOLS

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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

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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

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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

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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

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SPIDER MAX 500 - EURO 3

F. 1

FRAME NO. – ENGINE NO. IDENTIFICA TION DAT A

• 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

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SPIDER MAX 500 - EURO 3

TECHNICAL DA T A

GENERAL SPECIFICA TIONS

ENGINE

4-stroke single-cylinder with 4 valves - T ype: PIAGGIO M341M Refer to Piaggio Engine Service Manual.

SP ARK 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 SUPPL Y

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 st ainless 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

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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

14 13

7 8

F. 4

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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 S top, 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

B C

4 3

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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

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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

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SPIDER MAX 500 - EURO 3

FUEL T ANK

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 T ANK litres TOT AL CAP ACITY 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

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SPIDER MAX 500 - EURO 3

F. 13

F. 14

HELMET COMP ARTMENT

• 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 COMP ARTMENT

• 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

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SPIDER MAX 500 - EURO 3

COOLANT TANK (EXPANSION RESER VOIR)

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.

T op up the coolant only with the product s indicated in the present Manual, or with a type of product having the same specifications.

T op 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.

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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. W ait 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

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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 suggest s 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 pollut ants, 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, t aking care to lubricate the filter seal O-Rings with engine oil. As a cert ain 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 part s and can result in serious damage.

Spent oil contains pollut ants, 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 T ABLE

MIN

F. 8F. 7

MIN

(4T) ENGINE OIL

FORK ROD OIL

BRAKING CIRCUIT LUBRICANT

RADIA TOR LIQUID

AIRBOX LUBRICANT

ENGINE TRANSMISSION OIL

LUBRICANTS LUBRICANT TYPE

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SPIDER MAX 500 - EURO 3

STEERING

PLA Y 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.

CHECK HANDLEBAR TIGHTENING

• Check for the proper tightening of the screws (V4).

HANDLEBAR ADJUSTMENT

To adjust the handlebar, proceed as follows:

• Remove the handlebar upper cover (Please refer: P . 32 - F.37).

• Slacken moderately the screws (V4).

• Adjust the handlebar position, lifting or lowering it with both hands.

• After finding the right adjustment tighten the screws (V4), in a criss-cross pattern, until reaching the specified torque.

F. 1

MECHANICAL ADJUSTMENTS

F. 2

30 ± 20%

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SPIDER MAX 500 - EURO 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.

• In case of an exceeding friction, use force tube and the shock absorber wrench.

Four adjustments are possible:

1) Position one: driver only

2) Position two: driver and luggage compartment

3) Position three: driver and p assenger

4) Position four: driver , p assenger and luggage

compartment.

F. 3

Use the same adjustment for both shock absorbers; an uneven adjustment may seriously compromise the vehicle stability.

Always use gloves to avoid abrasions during the adjustment operations.

TIGHTENING CHECKS

• When performing pre-delivery operations and service checks for the proper tightening of the rear shock absorbers (upper (A) and lower (B) tightening have a different torque wrench setting).

F. 4

30 ± 15%

45 ± 15%

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SPIDER MAX 500 - EURO 3

FAIRING COMPONENTS

NO. DESCRIPTION

1 Windscreen 2 Central fairing 3 Front fairing 4 Front mudguard 5 Lower fairing mudguard 6 Front handlebar cover 7 Rear handlebar cover 8 Central handlebar cover

9 Dashboard frame 10 Leg protector 11 Rear fairing 12 Number plate bracket 13 T ail light 14 Front headlight 15 Footpeg 16 Alukit chassis 17 Mobile rear fairing 18 Grab handle

F. 2

BODYWORK

F. 1

F. 3

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SPIDER MAX 500 - EURO 3

NUMBER PLATE ASSEMBLY

NOTE - The motorcycle is equipped with number plate bracket. The number plate is assembled at the dealer’s premises.

• Fit the number plate on the number plate holder (1), securing it to the slots (A) by means of screws or rivets.

Do not use adhesives, both-side adhesive tapes, etc... to secure the number plate.

F. 4

REAR VIEW MIRRORS

• Lift the rubber part and release the front screw (V).

• Tilt the rear window to the front.

• Lift the rubber part, release the rear screw and remove the mirror.

F. 5

F. 6

F. 7

CENTRAL F AIRING

Release the screws (V2).

10 ± 20%

1,5 ± 15%

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SPIDER MAX 500 - EURO 3

• Free the fairing from the front and the two side retainers (A).

T o facilit ate the sep aration of the locking tabs, remove the access covers to the front direction indicators, insert one hand and force it. Release the fairing from the front locking tab.

• Extract the fairing with care, remembering that it is anchored to the parking light wiring.

• Extract the parking light bulb and remove the fairing completely.

ACCESSES

• After removing the central fairing it is possible to reach the dashboard connector (A), the braking distributor (B), the headlight beam adjusting knob and the horn (not shown in the figure).

F. 8

F. 9

F. 10

F. 11

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SPIDER MAX 500 - EURO 3

F. 12

DASHBOARD

• Disconnect the dashboard connector (A).

WINDSCREEN

• Release the screws (V6) and remove the windscreen.

F. 13

F. 14

• Release the screws (V4) and extract the dashboard carefully .

1,5 ± 15%

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SPIDER MAX 500 - EURO 3

F. 15

• Release the screws (V6).

FAIRING FRONT

NOTE - The front fairing is made of two parts: one on the right and the other on the left. The following description refers to the complete fairing.

• Release the screws (V1 1).

• Release the central screw (V).

• Release the screws (V2).

• Lift slightly the air intake (A) and remove it.

F. 17

F. 18

1,5 ± 15%

V11

1,5 ± 15%

5 ± 20%

1,5 ± 15%

F. 16

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SPIDER MAX 500 - EURO 3

• Release and remove the lower screw (V1) and its washer.

Release the screws (V2) and remove the passenger footpeg.

F. 19

F. 21

• Remove the rubber mat.

F. 20

• Release the screws (V8).

F. 22

1,5 ± 15%

40 ± 15%

1,5 ± 15%

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SPIDER MAX 500 - EURO 3

• Release the half-fairing upper part from the mirror mount, opening it up carefully .

• Disconnect the two connectors (A) (direction indicators).

• Disconnect the connector (B) (front headlight).

• Remove the fairing.

F. 23

F. 24

ACCESSES

• Removing the two front half-fairings, the following components can be reached:

Left half-fairing:

• Coolant sump (A)

• Left radiator (B)

• Radiator fan (C).

F. 25

Right half-fairing:

• Fuel pump (D)

• Immobilizer ECU (E)

• Right radiator

F. 26

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SPIDER MAX 500 - EURO 3

LEG PROTECTOR

• Remove the key switch ring nut (A) rotating it counterclockwise.

• Release the retaining screws (V2) of the fusebox.

• Remove the transparent cover.

• Push forward the fusebox

• Release the screw (V).

F. 28

DASHBOARD P ANEL

• Release the screws (V2).

• Remove the dashboard panel (A), releasing it from the locking tabs.

F. 27

5 ± 20%

F. 29

+ 74 hidden pages

Malaguti GT 500 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual