Malaguti RS 500 Service Manual

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MALAGUTI S.p.A.

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

Tel. 051.62.24.811 - F ax 051.69.47.782

e-mail: info@malaguti.com - 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 P ARTS CAT ALOGUES 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 e xpert 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 pro vided by the manufacturer.

• It is important to adhere strictly to the following instructions. Any oper ation 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.

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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 T orque 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 ~ (A C) Alternating current (flywheel supply) A : Ampere Unit of measurement of the electrical current W : Watt Unit of measurement of the electrical power (product of V olts 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

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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

SP ARE PARTS CATALOGUE

Indicates information which may be obtained by referring to said catalogue

DISASSEMBL Y OPERATIONS

ASSEMBL Y 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 PARTS

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

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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 ha ve a complete understanding of

all the symptoms and identify with good approximation the real causes of the trouble. The present man ual provides the technical information and the basic indications on the intervention procedures but these have to be integrated with the personal e xpertise.

• 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”.

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• Before carrying out any operation, wait f or 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 se v ere 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.

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CONTENTS

DESCRIPTION P.

RIGHT RADIA T OR - LEFT RADIA T OR 38

ELECTRICAL FAN RADIA TOR - EXP ANSION RESER VOIR - THERMAL EXP ANSION VAL VE 39 KEY SWITCH - DASHBO ARD P ANEL 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 P ASSANGER SEA T - CUSHION DRIVER SEA T - GRAB HANDLE 47 HELMET COMP ARTMENT 48

ACCESSES - DIRECTION INDICA TORS AND T AIL LIGHTS 48

REAR FAIRING 49 TAIL LIGHTS 50 SIDE REACH - VOL T A GE RECTIFIER 51 COOLANT PUMP - COIL 51 RELA Y HOLDER 52 ACCESSES - ELECTRONIC INJECTION ECU THRO TTLE BODY 53 BA TTERY COMP AR TMENT - 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 DISASSEMBL Y 60 LOWER F AIRING MUDGU ARD - FORK 63

ST ANCHION GROUP - STANCHION DISASSEMBL Y - CHECK THE OIL LEVEL IN THE ST ANCHION 63 FRONT FORK OIL REPLACEMENT 64

COMPLETE FORK 64 EXHAUST - EXHA UST MANIFOLD 65 LAMBDA SENSOR - REMOV AL - REASSEMBLING 66 REAR SHOCK ABSORBERS 67 REAR ARM - SHOCK ABSORBER SUPPORTING PLA TE 68

REAR CALLIPER - REAR CALLIPER DISASSEMBL Y 69

REAR WHEEL - (REAR BRAKE) DISC ENGINE 71 ENGINE REASSEMBL Y - 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 D A T A: FRAME N° / ENGINE N° - TYRES 8 MAINTENANCE TABLE 9 LUBRICANT TABLE 10 FUEL TANK - COOLANT T ANK 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 - FR ONT LEFT CALLIPER 17

CHECKING BRAKE PADS AND DISCS - BRAKE P ADS 18 REPLACING THE BRAKE P ADS - DISCS 18 FORK - CHECK THE OIL LEVEL IN THE ST ANCHION 19

FRONT FORK OIL REPLACEMENT 19

REAR SHOCK ABSORBER ADJUSTMENT - STEERING 2 0 HANDLEBAR ADJUSTMENT 2 0 LOCATION OF THE MAIN ELECTRICAL ELEMENTS 21 INSTRUMENT BOARD 23 KEY SWITCH - HANDLEBAR LOCK 24

LOCKING - DISENGAGING 24

STAR TING THE ENGINE 24 LIGHTING SYSTEM - LAMPS 25

ADJUSTING THE BEAM LIGHT 26

FUSES - GENERAL PROTECTION FUSE AND CHARGE PROTECTION FUSE 27 BA TTERY ASSEMBLY - CHARGE BA TTERY 28 SP ARK PLUG - REMPLACE 29 PROCEDURES FOR DISMANTLING AND REMOVING COMPONENTS 30 REASSEMBL Y NOTE - CENTRAL F AIRING - REAR VIEW MIRRORS 30

FRONT DIRECTION INDICA TORS (BULB CHANGE) 30

ACCESSES - REPLACING THE FRONT PARKING LIGHT 31 DASHBOARD - BRAKING DISTRIB UTOR - HORN 32 AIR GRID - WINDSCREEN - FRONT F AIRING 33 ACCESSES - IMMOBILIZER ECU 35 SIDE STAND SWITCH - FUEL SUPPLY PUMP 36 RADIATORS 37

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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

CAP ACITY

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

T ransmission oil cm3 ................................................................................... 250*

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

ENGINE: single-cylinder , f our-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

SP ARK PLUGS

Type.............................................................................................. NGK CR7EKB

TRANSMISSION

Automatic speed variator with expandab le 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 brak es 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-Bo x” 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

Fr o n t: hydraulically controlled fork with two Ø 41 mm rods.

Stroke: 120 mm

Rear: 2 hydraulic shock absorbers with adjustable preloading spring.

BA TTER Y

12V , 14Ah, maintenance-free.

TIRES

Fr on t: 120/80 - 16 60 S Rear: 150/70 - 16 68 S

Indicative V alue

SPECIFICATIONS

F. 1

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TYRES

Type: T ubeless (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)

F. 2

F. 3

• 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 crankcase (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

IDENTIFICATION DATA: FRAME N° / ENGINE N°

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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 b y technicians not authorised by MALA GUTI, b ut under their direct responsibility.

Nr. : coupon

: check : clean : adjust : replace

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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

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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

• T o access the engine coolant tank, open the glov e compartment (A) located at the

centre of the lower fairing and remove the plastic co ver (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.

Indicative V alue

14*

F. 6

FUEL TANK Litres TOTAL TANK CAPACITY RESERVE

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BLEEDING, COOLING CIRCUIT

T o 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 described: (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 b leed 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 right 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

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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 (e v en a slight inclination ma y 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 le vel 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 lo wer . It is best to wait at least 10 minutes fr om stopping the engine in order to have a correct reading.

The vehicle features a control system that activates the “LO W OIL PRESSURE” alarm signal of the digital instrument boar d 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.

• T opping up to le v el falling betw een 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 (LO W 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 f e w 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 le vel 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 f or the environment, therefore we suggest you contact an A uthorised Service Centre for disposal according to the rules in for ce.

every 3000 km or 6 months

F. 8

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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 ne w 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 b ut never above the MAX mark.

F. 9

F . 9/a

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. Ha ve oil replaced by an Authorised Service Centre that will also dispose of waste oil in accordance to the la w.

F . 8/a

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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. 1 0

F. 1 1

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MIN

CHANGE

If the fluid features traces of dirt, debris or water, it m ust be replaced. A soft and spongy feeling in the brake le ver 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. 1 2

every 30 days

every 12.000 Km or 24 months

MIN

F. 1 3

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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 b leed the circuit of the integral system, fir st 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 le ver oper ating, slack en the bleed scre w 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, av oid the contact between the brake liquid and the bodywork, to avoid dama ges. 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

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

F. 1 4

12 ÷ 16

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CHECKING BRAKE PADS AND DISCS

BRAKE P ADS

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. 17

F. 1 5

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

to pages 60 and 61.

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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. 1 8

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.

• T urn ov er 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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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 counterc lockwise to increase the spring power.

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

Four adjustments are possible:

1) Driver only

2) Driver and luggage compartment

3) Driver and passenger

4) Driver, passenger and luggage compartment

F. 1 9

F. 2 0

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.

HANDLEBAR ADJUSTMENT

T o adjust the handlebar , proceed as follows:

• Remove the handlebar upper cover .

• 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.

30 ± 20%

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LOCATION OF THE MAIN ELECTRICAL ELEMENTS

F. 21

Battery Rollover sensor Ignition coil

Spark plugs Temperature sensor Relays and flasher

Fuel pump

7 4 5

Page 23

22 02/08

F. 22

8 Immobilizer control unit 9 Lambda sensor

10 Fuel injector

11 Regulator

12 Diagnostic plug

Page 24

23 02/08

F. 2 3

INSTRUMENT BOARD

1) Multifunction digital instrument board

2) Analogue instruments, Speedometer This indicates the current speed in km/h or mph.

3) Coolant temperature The warning light comes on to indicate that the coolant temperature is

too high.

4) Sidestand / engine stop This light comes on to indicate that the sidestand is down and that the

“Engine Stop” button is OFF.

5) Low beam

6) High beam

7) Left hand turn

8) Right hand turn

9) Fuel 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 immobiliz er function is still active.

12) Injection This light comes on while the engine is running to indicate that the injection system is not functioning correctly; contact an Authorised MALAGUTI Service Centre.

Avoid cleaning the instruments with pressurised c leaning systems in order to prevent any dama ge.

Page 25

24 02/08

KEY SWITCH

• This switch controls the ignition circuit and

the handlebar lock.

Ignition disabled (the key can be removed).

Ready to start’ position (the key cannot be emoved).

Handlebar lock activated (ignition is disabled. The ke y can be remov ed)

Helmet compartment opening position Glove compartment opening position

HANDLEBAR LOCK

LOCKING

Turn the handlebar all the way to the right or left, push the key in and turn it counter-clockwise (F. 8).

DISENGAGING

Turn the key clockwise.

NOTE - The motor-bike is not

equipped with kick starter.

F. 24

F. 25

NOTE - The vehicle is supplied with two keys. If you lose both ke ys, you will have to replace the entire key block and ‘Immobilizer’ system.

ST AR TING THE ENGINE

• The engine cannot be started if the sidestand is down or if the emergency stop button is turned OFF.

• Before pressing the ignition button, pull the front or rear brake le ver 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, then try again. Do not operate the ignition system for more than 10 seconds at each attempt.

CHECKING THE WARNING LIGHT OF THE ENGINE OIL PRESSURE SENSOR (AUT OMA TIC)

• When turning the ignition key inserted in the ignition block to position ( ), without starting the vehicle, the displa y should show the message LOW OIL PRESSURE f or

about 8 seconds, to signal that the engine oil pressure sensor is working; the LOW OIL PRESSURE message must disappear when the vehicle sets off. Should the message not appear on the display, check the engine oil level before starting the vehicle.

Page 26

25 02/08

F. 2 6

LIGHTING SYSTEM

LAMPS

Functions Specifications Replacing (page)

A (F ront) parking light 12V - 5W (W5W) 31 B Low beams/high 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 ne w, identical ones and test them before reassembling all the components previously removed.

Page 27

26 02/08

ADJUSTING THE BEAM LIGHT

• The adjusting knobs (A) of the two headlamp beam light are located inside the central shield,

as indicated in the picture. To adjust the beam light it is not necessary to remov e the central shield.

To c heck/adjust the beam, proceed as follows:

• Put the vehicle in running conditions at 10 metres from a wall.

• T urn 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 anticlockwise raises it.

Adjust the beam so that its bottom line projected on the wall is at about 78 cm from the floor .

F. 2 7

F. 2 8

Page 28

27 02/08

FUSES

• The electrical wiring includes eight fuses, protecting the main components from possible malfunctioning and are placed in the luggage compartment.

A - 15 A Lights B - 7.5 A Stop + Direction

indicators

C - 5 A ECU under the panel D - 5 A Relay E - 25 A Main fuse F - 10 A Coil - Pump fuel -

Injector

G - 7.5 A Electrical fan H - 3 A ECU supply support

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. 2 9

F. 3 0

• To replace one or more fuses, simply open the central door of the leg protector and extract the burnt out fuse, replacing it with one having the same specifications.

F. 3 1

Page 29

28 02/08

BATTERY ASSEMBLY

• The battery is placed in the central tunnel.

• To access the battery compartment, first remove the seat (P. 46).

• After suitably charging the battery, apply some adhesiv e tape, taking off the two protection films placed on the edges on the adhesive part (P).

• Extract from the battery compartment the wiring with the red cables (+) and the two black cables (-).

• Connect the wiring cable ends to the battery terminals.

Never invert the cables connection.

• Fit the battery inside the compartment.

• Place properly the wiring cables.

Before refitting the removed parts, we suggest to test the “control panel” in order to chec k the connections are properly fitted.

• Refit:

- Battery compartment cover

- Dripproofing protection (fuel) and drain hose.

- Fuel filler cap

- Seat

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

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 BA TTERY

To carry out this operation, we suggest to remove the battery from its compartment and disconnect the cables.

It is advisable to use gloves and protectiv e ey ew ear , when the battery must be remov ed from its housing; f or e xample, when it needs to be recharged.

• We recommend recharging with an amperage of 1/10 of the power of the charged battery.

• Refit the battery, taking care to connect the positive cable to the positive pole and the negative cables to the negative pole.

It is important to keep the battery always completely charged; therefore, in winter or when the v ehicle is not used, it should be recharged at least once a month.

Danger of explosion! Do not use open flames (lighters, matchsticks, etc.).

The battery contains highly toxic sulphuric acid. Av oid contact with the e y es , skin, and clothes. Keep the battery out of reach from children.

F. 3 2

Page 30

29 02/08

SPARK PLUG

REMPLACE

The spark plug is an essential component: NGK CR7EKB

Spark plugs with a heat degree different from the recommended one may seriously damage the engine.

• The SpiderMax engine features an ignition system with a doub le spark plug (C).

• For maintenance, remove the side partition (P), carefully remove the cap by turning it clockwise and anticlockwise alternatively . Now , unscrew the spark plug using the special wrench supplied with the vehicle.

Remove the spark plug when the engine is cold.

• Examine the spark plug conditions after a reasonably long drive (10-15 km) and after letting the engine cool down (at least 10-15 minutes), since the sediments and the colour of the insulator can provide useful information about the heat degree of the spark 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 “e xtremely light” mixture or the heat rating of the spark plug too low (spark plug

too “hot”).

Check and clean every 6.000 km.

• After disassembling the spark plug, carefully clean the electrodes and the insulating material, using a metal brush. Adjust the distance between the electrodes (operating only on the ground electrode), using a gauged shim: the distance should be

0.7 : 0.9 mm.

• Blow out energetically , to prev ent possible residues from entering the engine and refit it by tightening it by hand all the wa y in; then, tighten it to the prescribed torque.

F . 33/a

12 ÷ 14

F. 3 3

Page 31

30 02/08

• Release the screws lower

(V3).

• Carefully remove the central shield, paying special attention in order not to damage the locking teeth.

• Disconnect the connector (B) (parking light).

• Release the cable from the bracket (C) and remove the shield completely .

CENTRAL FAIRING

• Release the 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.

10 ± 20%

1,5 ± 15%

F. 3 4

F. 3 5

F. 3 6 F. 3 7

FRONT DIRECTION INDICA T ORS (BULB CHANGE)

• The bulb holders of the front direction indicators are integrated in the front headlights.

• To access the bulbs of the front direction indicators, remove the inserted side covers (A).

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31 02/08

ACCESSES

(after removng the central shield)

A) Control panel B) Antilock

bracking system

C) Beam light

adjusting knobs

D) Horn

NOTE - The parking 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. 3 8

F. 4 0 F. 4 1

REPLACING THE FRONT PARKING LIGHT

• Release the screws (V5).

• Release the screws (V2).

• Remove the cover (A).

F. 3 9

Page 33

32 02/08

F. 42

DASHBOARD

• Undo the screws (V4) and remove the control

panel carefully .

HORN

• Disconnect the two clamps (B).

• Release the screw (V) and remove the horn.

F. 43

10 ± 20%

1,5 ± 15%

BRAKING DISTRIBUTOR

NOTE - To access the braking distributor (A),

remove the central fairing (P. 30).

Drain completely the circuit.

• Release the screws (V2).

10 ± 20%

• Undo the connectors (B).

• Remove pipes (C) and gaskets (D).

20 ± 10%

F. 4 4

While reassembling, take care not to in vert the fitting of the Faston connectors. Blue cable (+)lower terminal - Orange cable (-) upper terminal.

D D

Page 34

33 02/08

AIR GRID

• After removing the cover of the front parking light bulb, you can remove the air grid in order to clean it.

F. 4 5

WINDSCREEN

• Remove the central fairing (p. 30).

• Release 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

F. 4 6

F. 4 8

1,5 ± 15%

• Release the screws (V4).

1,5 ± 15%

• Release the central upper screew (V).

5 ± 20%

Page 35

34 02/08

• Release the screws (V2) and remove the passenger

footpeg.

• Remove the rubber mat.

40 ± 15%

F. 5 0

F. 5 2

F. 4 9

F. 5 1

• Release the screws (V8).

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

1,5 ± 15%

Page 36

35 02/08

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

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

• Remove the fairing.

ACCESSES

(after removing the two front half-fairings)

Right half-fairing:

A) Immobilizer ECU B) Side stand switch

connector

C) Fuel pump

- Right radiator

- Key switch

F. 5 3

F. 54

Left half-fairing:

D) Expansion reservoir E) Left radiator F) Radiator fan

F. 5 5

IMMOBILIZER ECU

• Disconnect the three connectors (H).

• Release the screws (V2).

• Remove the Immobilizer ECU (A).

10 ± 20%

If the Immobilizer ECU is replaced, store two or more ignition keys. (please refer: DIA GNOSTICS MANUAL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM, chapter “Immobilizer”).

Before refitting the different connectors, make sure if the inside sealing rubbers (yellow) are worn out, and if the external ones are in the right place. If these checks are not observed, in case of rain, the dashboard may indicate improper warnings.

Page 37

36 02/08

SIDE STAND SWITCH

• Release the screws (V2).

• Remove the switch (A).

• Open the front fairing.

• Disconnect the connector (B) and detach the whole wiring (if necessary), after releasing its clips.

NOTE - While assembling a

new complete wiring, refit new clips, placed and fixed as before.

F. 5 7

F. 5 6

5 ± 20%

F. 5 8

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 inf ormation

on the pump can be deducted by reading the Manual “Injection”.

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37 02/08

F. 6 2

F. 5 9

F. 6 0

F. 6 1

RADIATORS (including lines and expansion reservoir)

• Wait for the engine to cool down completely .

• Put a suitable container under the coolant pump (A).

• Remove the clip (B).

• Detach the tube (C) and fit it in the container.

• Remove the cap (D - F. 60) from the expansion reservoir.

• In case radiators have to be removed together with lines, slacken the clip (B1) and detach the tube (C1).

• Let the liquid completely drain into the container. Pour the spent liquid in a container suitable for its ecological 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.

In case the pump (A) has to be removed, release the screws (V6).

• Cut the clip (E) securing the electrical fan wiring.

After refitting any of the components of the cooling system, fix the lines with new clips, in the same position as before, and fix the ground cable end (M - F . 62) again, both to the right radiator as well as to the left radiator .

V6 CBA

Page 39

38 02/08

• Release and remove the screws (V2) and their washers.

• Remove the right radiator.

RIGHT RADIATOR

• Release the lower securing screw (V) of the right radiator (A).

• While reassembling, 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. 6 6

• Remove the left radiator , including the electrical fan.

LEFT RADIATOR (including the electrical fan)

F. 6 3

F. 6 5

F. 64

10 ± 20%

Page 40

39 02/08

F. 6 7

F. 6 9

EXPANSION RESERVOIR

Drain the coolant from the circuit, as previously described.

• Disconnect the tube (C) from the expansion reservoir.

• Release the screws (V2).

THERMAL EXPANSION VALVE

NOTE - The cooling system

includes 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.

10 ± 20%

F. 6 8

F. 70

B - Thermal expansion valve on the engine

• T o remove it, release it from the clips of the rubber hoses and slide it from the support (S).

S B

Page 41

40 02/08

F. 7 1

KEY SWITCH

• Disconnect the seat opening transmission cable (A).

• Disconnect the helmet compartment opening transmission cable (B).

• The key switch (C) is fitted by two nuts (D) and two “antitampering” screws (V2), that can be accessed from the lower part of the switch body .

To disassemb le the key switch, use the special insert: “T orks t 30” for special screws.

cod. 08606600

F. 7 2

Take care 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 connector connected to the Immobilizer.

DASHBOARD PANEL

• Release the screws (V2).

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

F. 7 3

If the key switch is replaced, or all of the stored keys are lost, replace the

Immobilizer ECU as well, and store new keys. To store a third key, use the “Master key” (cod. 09007000) (please ref er: DIAGNOSTICS MANU AL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM).

Page 42

41 02/08

F. 7 4 F. 7 5

F. 7 6 F. 7 7

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).

• Release the three screws (V) inside the luggage compartment.

• Release the screw underneath (V1).

5 ± 20%

Page 43

42 02/08

F. 7 8 F. 7 9

F. 8 0

5 ± 20%

F. 8 1

• Release the screws (V3). • Unlock the luggage compartment closing transmission 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.

Page 44

43 02/08

• Remove the footpeg if necessary, release the screws (V2).

ACCESSES

(after removing the upper handlebar cover)

B) Main wiring end

V4) Handlebar inclination

adjusting screws.

1,5 ± 15%

F. 8 4

F. 8 2 F. 8 3

UPPER HANDLEBAR COVER

• Release the screws (V2) and remove the upper handlebar cover (A).

F. 8 5

Page 45

44 02/08

F. 8 6

F. 8 8

• Release the outside screws (B2) and remove the front handlebar cover (A).

• Release 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).

1,5 ± 15%

F. 8 7

Page 46

45 02/08

BRAKE MASTER CYLINDERS

Empty the hydraulic system and dispose of the liquid in compliance with the law in force.

Ensure that there are no leaks or splashes of brake liquid, as it is corrosive and may cause personal injury or damage the motorcycle painted parts.

• Release the screws (V2) and

remove the clamp (D).

• Remove the pump unit (E).

• In order to reassemble the unit lock (by means of a long T-wrench) the lower screw, without tightening it, and then the upper screw; finally tighten both of them to the specified torque.

NOTE- After reassembling the hydraulic pump, always refill the system with new

liquid.

28 ± 15%

20 ± 10%

F. 9 1

• 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.

HANDLEBAR

To remo ve the handlebar:

• Remove the handlebar cover: upper, front and rear (P. 4 4).

• Cut the clips securing wiring, tubes, and cables.

• Remove the (right and left) brake master cylinders.

• Release the transmissions from the accelerator con-

trol (B).

• Release the two counterweights (P).

• Detach the two twistgrips (M).

• Release the two switches (D).

• Release the screws (V4).

• Remove the plate securing the handlebar (A).

• Remove the handlebar (C).

Tighten in a criss-cross pattern.

30 ± 20%

After assembling the (front/rear) brake master cylinder, fit the tube (B) between two new gaskets (C) And tighten the coupling A to the specified torque.

F. 9 2

D C

F. 8 9

F. 9 0

Page 47

46 02/08

F. 9 3

F. 9 4

DRIVER SEAT

• Release the screws (V2) on the rear part.

• Remove the driver seat (A), releasing it form the locking tab (B).

5 ± 20%

V2 A

ACCESSES

• Removing the driver seat, 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

NOTE - In order to access the

tilt sensor (E) it is necessary to remove the rubber protection (G).

When reassembling the sensor, make sure that the cable (H) is facing downwards.

F. 9 6

F. 9 5

Page 48

47 02/08

F. 97

F. 9 8

PASSANGER SEAT (including movable support)

• Remove the Benzing ring (C)

and release the passenger seat shock absorbers.

• Release the screws (V2) from the front supports.

• Remove the seat together 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).

30 ± 15%

10 ± 20%

F. 9 9

Page 49

48 02/08

F. 100

F. 1 01

F. 102

F. x x

• Disconnect the 12V plug cable from the back of the helmet compartment.

HELMET COMPARTMENT

• Extract (without any tool) the compartment inside coating.

• Release the screws (V).

• Release the screws (V2a).

V2a

F. 1 03

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.

5 ± 15%

10 ± 20%

V2a

5 ± 15%

• Release and extract carefully the helmet compartment without removing it completely.

V2a

• Release the screws (V2).

• Release the screws (V4).

1,5 ± 15%

Page 50

49 02/08

REAR 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 compartment completely .

F. 105

5 ± 15%

Page 51

50 02/08

F. 106

F. 1 07

F. 108 F. 109

• Release the screws (V4). • Extract the entire fairing to-

gether with the tail lights.

TAIL LIGHTS

• Tail lights can be accessed by removing the helmet compartment and 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.

1,5 ± 15%

• Keep the rear fairing components far from heat sources, in a clean place where they cannot be accidentally damaged.

V4V4

Page 52

51 02/08

SIDE REACH (after removing the rear fairing)

• Removing the rear fairing

allows reaching the following components:

Right-hand side

A) Voltage regulator B) Coolant pump C) (T ree-phase) stator

connector

D) Ground ends

F. 110

Left side

A) Coil B) Ground ends

F. 1 11

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”).

DA V2

Page 53

52 02/08

• Disconnect the connector of the anti-tilting device.

F. 112

• Release the rear screw (V1).

F. 1 13

• Release the two front screws (V2).

RELAY HOLDER

• Extract the starting relay (C), including the 30A fuse (battery recharge protection).

If the starting relay is replaced, take special care to the assembly of the red and blue cable (Please refer: DIAGNOSTICS MANU AL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM).

F. 114

F. 1 15

Page 54

53 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 DIAGNOSTICS MANUAL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM.

ELECTRONIC INJECTION ECU THROTTLE BODY

• T o remo v e 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. 1 17

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54 02/08

BATTERY COMPARTMENT

• Remove the fuel filler cap (A).

• Release the screws (V2).

• Extract the dripproofing protection (B) and the drain hose.

• Remove the battery compartment cover.

• Release the screw (V) at the 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. 1 19

10 ± 20%

A V2

Page 56

55 02/08

F. 1 25F. 124

• Release the screws (V4).

To remo ve the tank,

proceed as follows:

• Remove the battery and the whole compartment (P. 54).

• Remove the cap (A).

• Extract the dripproofing protection (B) and its tube (C).

• Refit the original cap on the fuel filler, to prev ent dirt from entering the fuel tank, during the frame removal operations.

FUEL TANK

NOTE - To access the fuel tank, first remove the front fairing (P. 33).

Fuel fumes are highly toxic, and therefore harmful to your health. V entilate

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 fuel pump, pressing by two fingers at the base of the connector.

F. 1 23

F. 122

T V4

To drain the tank, w ait

for the engine to cool down completely and use a manual pump.

10 ± 20%

Page 57

56 02/08

• Disconnect the tube (C).

• After extracting the tank, release 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).

F. 126

F. 128

F. 1 27

F. 129

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. 1 31

F. 132

Page 59

58 02/08

WHEEL SPINDLE

• Slacken the screw (V1) from the wheel spindle clamp.

• Release the wheel spindle (B) and extract it, taking care not to damage spacer (C) and the spacer (B1).

FRONT WHEEL

REMOVAL

Before removing the front wheel, check for the perfect stability of the motorcycle. If necessary, place one suitable support under the engine.

FRONT MUDGUARD

• Release the screws (Va)

• Release the screws (Vb) and corresponding

nuts (A).

F. 133

3,5 ± 10%

F. 1 34

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 (A).

30 ± 20%

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59 02/08

FRONT WHEEL

REASSEMBLY

When reassembling the wheel, observe rotation direction, which can be determined by the position of the spokes of the rim (see previous pictures).

T o reassemble the wheel, proceed as f ollows:

• Insert the wheel in the fork (in the proper direction).

• Insert the wheel spindle (B) and the spacer (B1).

• Insert the spacer (C).

Do not exchange the spacer (B1) with the spacer (C).

Tighten the spindle (B) to the specified torque.

(FRONT BRAKE) DISCS

• T o 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.

45 ± 15%

11 ± 10 %

F. 137

• Tighten the screw (V1) of the wheel spindle clamp.

F. 141

• Refit the odometer sprocket (pick-up) (A) and secure it by means of the screw (V).

10 ± 15%

20 ± 15%

F. 138

F. 140

F. 139

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60 02/08

BRAKE CALLIPERS

An abnormal resistance or an excessive travel of the brake levers may indicate the braking system malfunctioning.

• Open up the clamp (F).

• Undo the screws (V2) in order to release the fork clipper.

FRONT CALLIPER REPLACEMENT

NOTE - The front callipers

have the same technical specifications but are one right and one left.

• After removing the front brake callipers, release the screw/coupling (V) and extract the swinging coupling (A) and 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.

30 ± 20%

FRONT CALLIPER DISASSEMBLY

In order to extract the pads:

• Release and remove the screw (V).

• Shift downward the stop plate (A), in order to release the pins (B) and extract them from the other side of the calliper unit.

20 ± 10%

F. 142

F. 144 F. 145

F. 1 43

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61 02/08

• Remove the stop plate. • Extract the pins (B).

• Extract the pads.

NOTE - It is possible to

remove and replace the pads without removing the brake callipers from the vehicle.

• Release the nut (D - F. 146).

• Remove the floating support (S) from the calliper body , including the two slide pins.

During reassembly , lubricate the slide pins must rubber gasket grease.

20 ± 20%

F. 1 47

F. 146

F. 148

F. 1 49

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62 02/08

• Check the dust seals (P - P1) for wear. In case of signs of (even light) wear or damage, replace them.

• Open by means of a screwdriver (or any other similar tool), the bracket (B) fins (A). Remember to wear safety gloves.

• Release the screws (V2).

• Remove the plate (C).

After refitting the plate (C) and the bracket and tightening the screws (V2) to the specified torque, lean the fins (A) as before (Please refer: F. 144).

• Blow with a small compressed air flow to extract the two pistons from the calliper body .

An excessive pressure may cause the two pistons (E) to jump off violently .

After servicing the braking 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 no signs of scoring on the pistons and their housing.

• Clean carefully and wash only with alcohol.

Always use new dust seals and seal rings. Refit the pistons, the seal rings (B) and the dust seals (A), greasing with brake liquid.

Complete the check, clean, replace and refit all the components repeating the disassembly operations in the reverse order .

F. 1 53F. 152

F. 150

F. 1 51

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63 02/08

30 ± 25%

FORK

STANCHION GR OUP

Make sure that the motorcycle is really stable; in case, put a suitable support under the engine. The front wheel will ha ve to protrude over the runawa y edge of the lift.

ST ANCHION DISASSEMBL Y

Lock the stanchion group in a suitable vice, carefully protecting the slider side with soft jaws, as to avoid squeezing or scoring.

• Release the upper screw (V2).

• Detach downwards the fork leg (A), rotating it in the two directions.

NOTE - To remove one or both of the legs

of the front fork, completed with stanchion, first remove:

• front fairing

• (front/rear) handlebar cover

• (right-hand side) odometer sprocket

• Front wheel

• brake callipers

• front mudguard

• Release the screw (V).

NOTE - The disassemb ly of the

stanchion can be deducted from the picture shown hereafter.

CHECK THE OIL LEVEL IN THE ST ANCHION

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 previously plunged.

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

F. 156

F. 154

LOWER FAIRING MUDGUARD

NOTE - T o remove the lo wer

fairing mudguard, first remove the front wheel and the front mudguard.

F. 155

20 ± 15%

F. 157

The stanchion group contains oil. Therefore, do not turn it over or tilt it while it is removed or its internal components are disassembled.

The hydraulic oil is corrosive and may cause serious personal damages.

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64 02/08

COMPLETE FORK

Place a suitable support under the engine. The front wheel will have to pr otrude over the runa way edge of the lift , so that the fork can be removed, together with the wheel, if necessary (in order to remove the front fork, the front wheel does

not have to be removed). NOTE - To remove the complete fork, first remov e:

• front fairing (P. 33)

• front mudguard (P. 58)

• Front wheel (optional) (P. 58)

• brake callipers (optional) (P. 60)

• handlebar (P. 46).

•

Release the nut (D), release the screws (V2) and detach the unit (T).

•

Release the ring nut (E).

•

Detach the complete fork, holding it to avoid its falling.

•

T ak e care not to let the upper (F) and lower (G) ball bearings f all off.

30 ± 15%

• 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

• 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

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”

18 ÷ 20

F. 158

F. 159

53 ± 15%

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.

• T urn ov er 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.

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EXHAUST

Before operating on the exhaust and on the exhaust manifold, wait for the components to cool down and wear, always and in 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.

14 ÷ 15

F. 161

F. 1 62

F. 163 F. 164

• Release the Lambda sensor cable from the clamp (B).

25 ± 15%

EXHAUST MANIFOLD

• Undo the screws (V3) of the heat guard (A).

• Remove the grid.

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66 02/08

• First remove the relay holder (P. 52).

• Disconnect the Lambda sensor connector.

• Release the two nuts (C).

• Remove the exhaust manifold (D).

• Remove the gasket.

F. 165

While reassembling, always use a new gasket.

F. 1 66

30 ± 10%

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. 168F. 167

Reassembling

• Screw the Lambda sensor down with along cable and connector.

• Tighten to the prescribed torque.

45 ± 15%

Page 68

67 02/08

REAR SHOCK ABSORBERS

Before carrying out any operation in the rear shock absorbers, prepare a system 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

V2I

30 ± 15%

V2S

45 ± 15%

V2I

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68 02/08

Remove:

• Exhaust pipe (P . 65)

• Right shock absorber (P . 67)

• Right abosorber upper plate (P - F. 176).

•B2

REAR ARM

Before removing the rear arm (A), check that the vehicle is in perfectly stable conditions.

Remove:

• 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).

33 ÷ 41

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

F. 173

F. 1 74

30 ± 10%

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69 02/08

Left plate

• Release the left shock absorber (P. 67).

• V2.

• Remove the plate (P).

F. 179

F. 178

30 ± 10%

V2a

30 ± 20%

20 ± 10%

REAR CALLIPER

• Release the screws (V2a).

• Extract the calliper unit (A), including the brake liquid feed tubes.

• Release the coupling screw (V) and extract the coupling (A) and the gaskets.

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.

V2a

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.

REAR CALLIPER DISASSEMBLY

• Remove the retaining ring (A) of the spindle securing the brake pads (B).

• Detach the spindle securing the brake pads (B).

• Extract the clip (C) and the two brake pads (D).

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F. 180

• Release and remove the screws (V2).

• Separate the two housing halves, taking care not to let the two pistons fall.

• Remove the two pistons (D).

• Remove the two O-Rings (E).

F. 181

20 ± 20%

F. 182

Always fit new seal rings and dust seals. Refit the pistons, the O-Rings, the seal rings and 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 grease.

• All the screws and couplings are properly tightened.

• There are no leaks from the couplings.

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F. 185

ENGINE

NOTE - To remove the

engine from the

frame, first remove rear fairing (P . 49), exhaust (P. 65), rear arm (P . 68), rear brake calliper (P. 69).

• Drain completely the

coolant circuit.

• Disconnect all the wirings

connected to the engine.

• Release the screws (V2)

(double ground screws on the starter motor).

F. 186

Do not cut nor damage the transmission cables of the accelerator control, since they are not to be replaced during the reassembly of the engine.

REAR WHEEL

NOTE - To extr act the rear

wheel, first remove

the brake calliper,

and the exhaust.

• Release and remove the

screw (V) securing the right shock absorber, on the rear arm.

• Remove 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 subsequent operations.

F. 183

(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 irregular wear or scoring, carry out the grinding.

• Disconnect the accelerator transmission cables (A).

• Disconnect the manifold linked to the connector (B) from the thermal expansion valve.

11 ± 10%

V6C

F. 1 84

During the disc reassembly , observe the rotation direction of the disc, understandable from the orientation of the lightening holes (as shown in pictures).

• Remove the rear arm, as described in the previous page 68.

• Extract the rear wheel.

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72 02/08

• Slacken the clips (A) and release the coolant manifolds from the pump.

F. 187

65 ± 15%

F. 190

ENGINE MOUNT

T o remov e the engine mount (A) (after removing the engine), proceed as follows:

• Release the self-locking nut

(B).

• Slacken the lock nut (D).

• Release the threaded

bushing (C).

While reassembling, do not exchange spacer (B) with spacer (C).

F. 189

F. 1 88

• Release the nut (D) of the engine shaft.

• Detach the engine shaft (P).

• Extract carefully the engine, 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 engine removal, taking care not to bend nor damage them.

ENGINE REASSEMBLY

• Lubricate the spacers (B - C) and the shaft (P - F . 187) with bearing grease

• Align the engine to the engine shaft (P).

• Fit the engine shaft (P).

• Fit the nut (D) up to get to the prescribed torque.

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73 02/08

35 ± 15%

F. 191

F. 1 92

10 ± 15%

65 ± 15%

• Detach the (upper) mount shaft (E).

• Remove the engine mount and the spacers.

While reassembling, take care not to interfere and exchange the spacers, which will have to be lubricated with bearing grease.

ANTI-VIBRATION CONNECTING RODS

• After removing the engine and its mount, release the nut (F - F. 193).

• Remove 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 tightened too much, it may cause annoying vibrations to the vehicle and irreparable damages to the bearing (U).

F. 193

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74 02/08

SUBFRAME

NOTE - The subframe is

made up of three parts:

1 - Upper subframe 2 - Right-hand side subframe 3 - Left-hand side subframe

• T o remov e the subframe from the central aluminium frame, first remove all the components described up to this paragraph.

• Cut all the clips from the subframe and release the different wirings.

• Disconnect the connectors of the electrical components 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

10 ± 20%

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75 02/08

UPPER SUBFRAME

• Release and remove the two screws (V) and their washers.

• Release and remove the screws (V2) and their washers.

• Separate and extract the upper subframe (1) from the two side subframes.

SIDE SUBFRAMES

• Release and remove the lower screw (M8) and its w asher.

• Release and remove the lower scre w (M10) and its washer.

• Release and remove the screws (V3) and their washers.

• Remove the side subframes.

NOTE - The left subframe can be 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-frames.

• Release the lower screws (V2b) and remove the spacer (A).

• Release and remove the upper screws (V6) with their washers and nuts. Moreover these screws secure the headstock (B).

• Separate the two aluminium “half-frames“.

F. 196

V2a

V2b

M10M8

10 ± 15%

V2a

60 ± 15%

V2b

60 ± 15%

25 ± 15%

60 ± 15%

25 ± 15%

M10

55 ± 15%

Page 77

76 02/08

FRAME DIMENSION CHECK

• If the motorcycle has had an accident, which “appear” to ha ve caused a distortion, even light of the frame, carry out a dimension check, bef ore any other “restor ation 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