Malaguti RS 500 Service Manual

1 02/08

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.

2 02/08

NOTES FOR EASY CONSULTATION

ABBREVIATIONS

EDITING SYMBOLS:

• Symbols have been provided for quick and easy reference, identifying situations requiring utmost attention or providing practical suggestions or simple information.

• These symbols may appear next to a text (in which case they refer solely to the text itself), next to a figure (in which case they refer to the topic illustrated in the figure and

to the relative text), or at the top of the page (in which case they refer to all the topics dealt with in the page).

NOTE - The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations.

Cs 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

3 02/08

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

4 02/08

Before any servicing, make sure that the vehicle is perfectly stable. The front wheel should preferably be anchored to fixture, which is integral with the lift platform.

GENERAL WORK PROCEDURES

• The recommendations given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment

damage and idle times, and should therefore be strictly adhered to.

• Always listen with attention to the customer’ s opinion and complaints about the motor-bike operation, asking specific questions in order to 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”.

5 02/08

• 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.

6 02/08

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

7 02/08

DIMENSIONS

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

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

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

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

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

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

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

8 02/08

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°

9 02/08

MAINTENANCE TABLE

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

terrain.

Due to their simplicity, checks with no asterisk CAN also be carried out b y technicians not authorised by MALA GUTI, b ut under their direct responsibility.

Nr. : coupon

: check : clean : adjust : replace

10 02/08

LUBRICANT TABLE

NOTE - Use only recommended products.

LUBRICANTS

ENGINE OIL (4-STROKE TYPE) FORMULA EXCEL SAE 5W40

ENGINE TRANSMISSION OIL ZC 90

AIR FILTER LUBRICANT AIR FILTER OIL RADIATOR FLUID Q8 LONG-LIFE RED BRAKE CIRCUIT FLUID BRAKE FLUID DOT 4 FORK ROD OIL FORK OIL

11 02/08

FUEL TANK

To access the fuel tank, proceed as follows:

• Place the vehicle on the centre stand.

• Remove the ignition key from the ignition block.

• Open the door (A) in front of the seat, by acting on the lever (B).

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

• After refuelling, immediately remove any possible traces of fuel from the vehicle body, since fuel may deteriorate the vehicle’s outer surfaces.

Use UNLEADED PETROL.

F. 5

F. 7

COOLANT TANK

• 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

12 02/08

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

13 02/08

ENGINE OIL

• As far as four-stroke engines are concerned, engine oil is used to lubricate distribution components, base bearings and thermal unit. An insufficient amount of oil can seriously damage the engine.

• In all four-stroke engines, deterioration of the oil and a certain consumption are to be considered normal.

CHECK THE OIL LEVEL

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

1) Park the vehicle on flat ground and put it on its centre stand (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

14 02/08

every 6000 km or 12 months

CHANGE ENGINE OIL

• The engine must be emptied by letting the oil flow from the drainage cap (B) of the filter beside the transmission. To facilitate drainage, loosen the cap/dipstick (A F. 8/a).

• Unscrew the cartridge filter (C) and remove it. Fit a 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

15 02/08

Max Min

TRANSMISSION OIL

CHECK THE LEVEL

1) Place the vehicle on a level surface on its centre stand.

2) Unscrew the dipstick (A), clean it and refit it, wrenching it tightly.

3) Pull it out again and check that the oil level is between the MIN and MAX notches.

4) If the level is insufficient, top up until you almost reach the MAX notch.

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

Crankcase capacity approx.: 250 cm3

RENEW

• Carry out the operations described above at points 1-2, without refitting the dipstick; then put a container under the engine crankcase and unscrew the drainage screw (B), paying attention to the gasket.

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

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

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

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

every 6000 km or 12 months

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

F. 1 0

F. 1 1

16 02/08

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

17 02/08

BRAKING SYSTEM BLEEDING

INTEGRAL SYSTEM

Put the vehicle on firm and level ground.

• Remove the cover of the oil pump tank (left-hand side), releasing the two screws, so as to top up the liquid.

NOTE - The left brake lever allows the front right brake calliper and the rear brake calliper to be controlled interlockedly

at the same time.

To 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

18 02/08

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.

19 02/08

FORK

CHECK THE OIL LEVEL IN THE STANCHION

• In there case if the “limit switch” of the front fork or irregular noise, check the oil level inside the fork stems by removing the stems, as shown in the picture, and follow the instructions at page 63.

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

• Using a meter or the stick of a gauge, check the proper oil level, which should be at mm 123 from the upper edge of the leg.

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

F. 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.

20 02/08

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%

21 02/08

LOCATION OF THE MAIN ELECTRICAL ELEMENTS

F. 21

Battery Rollover sensor Ignition coil

Spark plugs Temperature sensor Relays and flasher

Fuel pump

7 4 5

22 02/08

F. 22

8 Immobilizer control unit 9 Lambda sensor

10 Fuel injector

11 Regulator

12 Diagnostic plug

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.

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.

+ 56 hidden pages

Malaguti RS 500 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual