Malaguti SPIDER MAX GT 500, Service Manual

Page 1: ...1 07 06 SPIDER MAX 500 EURO 3 EURO 3 ...

Page 2: ...raph S Section Sc Diagram T Table V Screw UNITS INDICATION The manual use measurements in mm SPARE PART CATALOGUE R SERVICE MANUAL CYCLE PARTS PRESENT MANUAL SERVICE MANUAL PIAGGIO S MOTOR DIAGNOSTICS MANUAL OF THE ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM DOCUMENTS CONCERNIG THE MODEL SPIDER MAX 500 A B C D E F MODIFIED PAGES Modified pages are indicated by the same number of the page in the pre...

Page 3: ... that may start a fire DANGER OF EXPLOSION Operations that may cause an explosion TOXIC FUMES It indicates danger of toxic fumes or respiratory inflammation MECHANICAL SERVICE STAFF Operations that must be carried out by a skilled mechanic ELECTRICAL SERVICE STAFF Operations that must be carried out by a skilled electrician or electronic technician NO Do not carry out this operation SYMMETRICAL OP...

Page 4: ... check A 8 2 Important tightening Front wheel E 43 Rear wheel E 80 Brake callipers E 45 Shock absorbers E 78 Exhaust E 77 Engine shaft E 81 Handlebar C 21 3 Liquid level check Battery F 88 Coolant B 16 Engine oil B 17 Transmission oil B 19 Brake liquid B 20 4 Adjustments Handlebar adjustment C 21 Shock absorbers C 22 Headlight beam D 25 NO SERVICE S P 5 Various checks Tyre pressure A 14 Starting A...

Page 5: ...uel tank 14 Helmet compartment 15 Luggage compartment 15 Coolant tank 16 Engine oil 17 B Transmission oil 19 Front and rear brake liquid 20 Lubricant table 20 Steering 21 C Handlebar adjustment 21 Rear shock absorber adjustment 22 Fairing components 23 Number plate assembly 24 Rear view mirrors 24 Central fairing 24 Windscreen 26 D Dashboard 26 Front fairing 27 Dashboard panel 30 Leg protector 30 ...

Page 6: ...callipers 45 Rear brake disc 49 Braking distributor 51 Braking system circuit 51 Braking system bleeding 54 Handlebar 55 Accelerator transmission cables 56 Fork 58 E Complete fork 59 Seat opening transmission cable 60 Luggage compartment opening transmission cable 62 Fuel tank 63 Fuel pump 65 Radiators including lines and expansion reservoir 66 Electrical fan radiator 68 Expansion reservoir coolan...

Page 7: ...E Rear arm 80 Rear wheel 81 Engine removal 81 Engine reassembly 82 Engine mount 82 Lighting system 84 Dashboard 85 Bulb change 85 Front headlights 85 Tail light S 86 Horn 86 Immobilizer ECU 86 Key switch 87 Side stand switch 87 F Electrical fan 88 Fuses 88 battery fitting 89 Spark plug 90 Coil 90 Voltage rectifier 91 Electronic injection ECU 91 ECU mount removal 92 Complete wiring 94 ...

Page 8: ...t hand cover of the engine B F 2 Any identification data changing is pursued by law Always indicate the vehicle identification data when ordering spare parts A ON DELIVERY When receiving the motorcycle follow the indications provided on the packaging and then dispose of the same in compliance with the Law in force VISUAL CHECK Visually inspect the assembly of all plastic components and inspect the...

Page 9: ...n variable spark advance and separate H T coil BRAKES Hydraulic system equipped with two front 2 discs Ø 270 mm and rear disc Ø 260 mm discs with braking distributor system Starting Left lever rear brake front brake vehicle right hand side Right lever front brake vehicle left hand side FRAME V Box type aluminium cast double housing halves coupled in the front and rear part to half frames in stainl...

Page 10: ...ection indicator 27 Windscreen MAIN COMPONENT IDENTIFICATION 1 Left mirror 2 Coolant tank 3 Glove compartment 4 Battery 5 Battery compartment 6 Side stand 7 Throttle body 8 Air cleaner 9 Number plate bracket 10 Rear indicators 11 Parking and stop lights 12 Passenger grab handle 13 Fuel filler cap 14 Key switch 15 Dashboard 16 Right mirror A F 3 12 11 10 9 2 4 5 3 16 14 13 7 8 6 15 1 F 4 26 25 23 2...

Page 11: ...Emergency Stop engine cut out ON Engine ignition OFF Engine cut out B Light switch right off central position parking lights and dashboard left low beams C Electrical starter A F 6 F 5 LEFT CONTROL 1 Rear brake oil tank 2 Flash lever high beams passing 3 Rear front brake lever right hand 4 Counterweight 5 Horn button 6 Indicator switch 7 Light switch high beams low beams 5 4 A 1 2 B C 3 4 3 1 2 6 ...

Page 12: ...nt opening NOTE The vehicle is supplied with two keys F 7 F 8 STEERING LOCK ENGAGEMENT With the handlebar turned to the left or right insert the key and rotate counterclockwise F 8 Disengagement Rotate the key clockwise NOTE The motorcycle is equipped with a starter pedal SIDE STAND Check for proper side stand fitting and for spring 1 2 mounting Also check for proper microswitch A F 9 operation pr...

Page 13: ...Low beam indicator green 6 High beam indicator blue 7 Left direction indicator green 8 Right direction indicator green 9 Fuel level indicator The indicator goes on to indicate the fuel is low 10 Oil indicator red With the engine operating the indicator goes on when the engine oil pressure is too low 11 Immobilizer indicator red The led stops flashing after 20 days to prevent the battery from runni...

Page 14: ...the tank After the refuelling remove any fuel residue from the bodywork as soon as possible Use UNLEADED PETROL FUEL TANK litres TOTAL CAPACITY 14 RESERVE 3 TUBELESS TYRES PRESSURE CHECK Check and adjust tyre pressure with cold tyres A X 120 80 16 60S Y 150 70 16 68S Petrol is an extremely inflammable substance never stay near the fuel filler also during refuelling with lighted cigarettes or bare ...

Page 15: ...e the mobile phone battery Use the plug only with the engine operating and with headlights off The use of the plug reduces the duration of the battery charge and may reduce its lifetime Do not connect any appliance requiring a high power supply max power consumption 30W The plug can operate ALSO when the ignition key is on the OFF position Refit the cap after use to prevent debris from causing sho...

Page 16: ...he coolant with respect to the MIN and MAX marks peeping through the grid placed under the fairing in the front part of the vehicle Top up the coolant only with the products indicated in the present Manual or with a type of product having the same specifications Top up with water only in case of emergency and in any case replace all the system liquid with the indicated product type as soon as poss...

Page 17: ...e is in a vertical position a slight side inclination may give wrong results 2 Release the cap dipstick A dry it with a clean cloth and fit it back tightening it completely 3 Remove again the cap dipstick and check that the level is between the MAX and MIN marks if necessary top up oil with Q8 FORMULA EXCEL SAE 5W40 The MAX reference mark indicates around 1700cc of oil in the engine Should it be n...

Page 18: ...icated operation is carried out Spent oil contains pollutants refer to an Authorised Centre to dispose of it in compliance with the law in force REPLACE OIL every 6 000 Km or 12 months Empty the engine drain out the oil from the drain plug B of the mesh filter beside the transmission assembly Slacken the cap dipstick A to facilitate total oil drainage Release and remove the oil cartridge filter C ...

Page 19: ...r 1 000 Km and then every 24 000 Km Perform the operations described at points 1 2 without refitting the graduated dipstick then place a container beneath the engine crankcase and release the drain screw B taking care not to damage the gasket Let the oil drain into the container for a few minutes taking care to avoid burns Refit the drain plug and the gasket and top up with around 250 cc of new oi...

Page 20: ...etaining screws Use oil Q8 BRAKE FLUID DOT 4 Hydraulic oil is corrosive and may cause damage and injury Do not mix different oils Check for the perfect sealing of the gasket REPLACE every 2 years or 12000 km In the case of dirt debris or water in the oil replace it completely When the brake lever feels spongy there may be some air trapped in the circuit Bleed the circuit B LUBRICANT TABLE A MIN S ...

Page 21: ...ns of the appropriate wrench CHECK HANDLEBAR TIGHTENING Check for the proper tightening of the screws V4 HANDLEBAR ADJUSTMENT To adjust the handlebar proceed as follows Remove the handlebar upper cover Please refer P 32 F 37 Slacken moderately the screws V4 Adjust the handlebar position lifting or lowering it with both hands After finding the right adjustment tighten the screws V4 in a criss cross...

Page 22: ...rber wrench Four adjustments are possible 1 Position one driver only 2 Position two driver and luggage compartment 3 Position three driver and passenger 4 Position four driver passenger and luggage compartment F 3 Use the same adjustment for both shock absorbers an uneven adjustment may seriously compromise the vehicle stability Always use gloves to avoid abrasions during the adjustment operations...

Page 23: ...airing mudguard 6 Front handlebar cover 7 Rear handlebar cover 8 Central handlebar cover 9 Dashboard frame 10 Leg protector 11 Rear fairing 12 Number plate bracket 13 Tail light 14 Front headlight 15 Footpeg 16 Alukit chassis 17 Mobile rear fairing 18 Grab handle F 2 12 13 11 1 BODYWORK F 1 18 9 1 7 8 11 12 F 3 1 18 17 6 3 14 2 4 15 5 10 16 ...

Page 24: ...er plate holder 1 securing it to the slots A by means of screws or rivets Do not use adhesives both side adhesive tapes etc to secure the number plate F 4 REAR VIEW MIRRORS Lift the rubber part and release the front screw V Tilt the rear window to the front Lift the rubber part release the rear screw and remove the mirror F 5 F 6 F 7 CENTRAL FAIRING Release the screws V2 1 A A V V2 V 10 20 V2 1 5 ...

Page 25: ... force it Release the fairing from the front locking tab Extract the fairing with care remembering that it is anchored to the parking light wiring Extract the parking light bulb and remove the fairing completely ACCESSES After removing the central fairing it is possible to reach the dashboard connector A the braking distributor B the headlight beam adjusting knob and the horn not shown in the figu...

Page 26: ...PIDER MAX 500 EURO 3 D F 12 DASHBOARD Disconnect the dashboard connector A WINDSCREEN Release the screws V6 and remove the windscreen F 13 F 14 Release the screws V4 and extract the dashboard carefully V6 1 5 15 ...

Page 27: ...is made of two parts one on the right and the other on the left The following description refers to the complete fairing Release the screws V11 Release the central screw V V6 Release the screws V2 Lift slightly the air intake A and remove it F 17 F 18 V2 A V6 1 5 15 V11 1 5 15 V 5 20 V2 1 5 15 F 16 ...

Page 28: ... 500 EURO 3 D Release and remove the lower screw V1 and its washer Release the screws V2 and remove the passenger footpeg F 19 F 21 V1 V2 Remove the rubber mat F 20 Release the screws V8 F 22 V8 1 5 15 V2 40 15 V1 1 5 15 ...

Page 29: ...ectors A direction indicators Disconnect the connector B front headlight Remove the fairing F 23 F 24 ACCESSES Removing the two front half fairings the following components can be reached Left half fairing Coolant sump A Left radiator B Radiator fan C F 25 A B C A B Right half fairing Fuel pump D Immobilizer ECU E Right radiator E D F 26 ...

Page 30: ...rotating it counterclockwise Release the retaining screws V2 of the fusebox Remove the transparent cover Push forward the fusebox Release the screw V F 28 DASHBOARD PANEL Release the screws V2 Remove the dashboard panel A releasing it from the locking tabs F 27 V 5 20 V2 F 29 V V2 ...

Page 31: ...inside the luggage compartment Release the screws V3 F 30 V F 32 Release the screw underneath V1 F 31 Unlock the luggage compartment closing transmission cable from its seat A Open slightly the footpeg until the plastic locking tabs are released F 33 F 34 V3 V1 V1 5 20 ...

Page 32: ...peg if necessary release the screws V2 F 35 UPPER HANDLEBAR COVER Release the screws V2 and remove the upper handlebar cover A ACCESSES Removing the front handlebar cover allows reaching the terminals of the main wiring B and the four screws for handlebar adjustment B V2 A F 36 F 37 F 38 V2 V2 1 5 15 V2 1 5 15 ...

Page 33: ...lease the remaining four inside screws and remove the rear handlebar cover P F 39 B2 V2 FRONT AND REAR HANDLEBAR COVER Release the upper screws V2 P ACCESSES Removing the front handlebar cover allows to reach the two brake liquid pumps A and the two stop switches B F 42 B A B B2 1 5 15 V2 1 5 15 A A F 41 ...

Page 34: ...ng it form the locking tab B Remove the driver seat A ACCESSES Removing the driver seat allows reaching the following electronic components A Electronic injection ECU B Anti tilting device C Autodiagnostics plug D Flasher E F G H Relays Please refer Injection Manual M ECU ground A V2 B V2 5 20 A C F 45 F 46 G E F D H M C B A B ...

Page 35: ... handle and movable support In order to release the passenger seat B F 45 from the movable support first release the screws V6 F 47 F 48 F 49 CUSHION DRIVER SEAT In order to remove the cushion C F 45 Release the screws V2 F 49 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 V2 V5 V6 D V...

Page 36: ...ompartment inside coating F 51 F 52 F 53 Release the screws V2a Release the screws V2b Release the screws V4a Release the screws V4b Release and extract carefully the helmet compartment without removing it completely F 50 V2b V2b 5 15 V2a 5 15 V4b 1 5 15 V4a 10 20 V2b V2a V4a V4b V4a ...

Page 37: ... from the back of the helmet compartment REAR FAIRING Release the two screws V2 Release the screw V F 55 Lift the helmet compartment disconnect the connector A and release the cable from the clamp B Remove the helmet compartment completely F 56 F 54 V2 5 15 V 5 15 ...

Page 38: ...rear fairing allows reaching the following components Right hand side A Voltage rectifier B Coolant pump C Flywheel connector D Ground ends F 59 A C B Release the screws V4 F 58 F 57 Extract the entire fairing together with the tail lights V4 V4 V4 1 5 15 D ...

Page 39: ...t the dripproofing protection and the drain hose Remove the battery compartment cover F 60 F 61 F 62 Left side A Coil B Ground ends BATTERY COMPARTMENT Remove the seat S D P 34 Remove the fuel filler cap Release the screws V2 D V2 F 63 A B ...

Page 40: ...ting the battery cables and fusebox ACCESSES Removing the battery compartment allows reaching the starting relay and the corresponding 30 A fuse recharge protection F 64 F 66 F 65 NOTE Inside the battery compartment is located the general protection fuse A 30 A Release the battery cables Extract the battery S F P 89 A V V 10 20 ...

Page 41: ...1 07 06 SPIDER MAX 500 EURO 3 D 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 67 F 69 F 68 A V8 C C B ...

Page 42: ...ONT MUDGUARD Release the screws V2 Release the screws V and corresponding nuts A LOWER FAIRING MUDGUARD NOTE To remove the lower fairing mudguard first remo ve the front wheel S E P 43 and the front mudguard A V V2 V2 F 70 V2 3 5 10 V 3 5 10 ...

Page 43: ...ility of the motorcycle If necessary place an suitable support under the engine NOTE In order to remove the front wheel it is necessary to release the odometer sprocket transmission and the brake callipers F 2 FRONT BRAKE DISCS To separate the discs D from the front wheel release and remove the screws V6 and the washers E V2 30 20 A V V2 V2 B V1 V6 E F 3 Check the discs D for wear and replace if n...

Page 44: ...actuate the brake levers without the wheel as the pads would close Remove the front and rear handlebar cover S D P 33 Release and extract the coupling A Remove the tube B and the gaskets C Disconnect the Stop switch S 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 co...

Page 45: ...rews 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 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 V2 28 15 B F 7 A NE...

Page 46: ...F 9 F 12 F 11 F 13 B B B D A 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 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 E D 20 20 ...

Page 47: ... 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 11 Blow with a small compressed air flow to extract the two pistons from the calliper body ...

Page 48: ...coupling A and the gaskets B F 18 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 greasi...

Page 49: ...inding V6 B V6 C D V F 25 F 24 F 23 During the disc reassembly observe the rotation direction of the disc understandable from the orientation of the lightening holes as shown in pictures A D C D B C D B 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 Let a little ...

Page 50: ...emove the two pistons D Remove the two O Rings E 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 oi...

Page 51: ... the screws V2 Release the couplings B Remove the lines C and the gaskets D F 15 C B B F 30 BRAKING SYSTEM CIRCUIT NOTE The pictures shown hereafter highlight the hose routing of the liquid for the braking system and their anchorage seats on the frame which will have to be restored during the reassembly of the system NEW F 31 E D D D C C B 20 10 V2 10 20 F 29 V2 A ...

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Page 54: ...ation 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 avoid the contact between the brake liquid and the bodywork to avoid damages Moreover during the bleeding of the brake callipers avoid the contact between the liquid and the brake discs or the brake pads Failu...

Page 55: ... cables Remove the right and left brake master cylinders S E P 44 Release the transmissions from the accelerator control 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 V4 F 36 A C V4 B E V4 30 20 P M D D M P Tighten in a criss cross pattern ...

Page 56: ...R MAX 500 EURO 3 ACCELERATOR TRANSMISSION CABLES NOTE The pictures shown hereafter highlight the routing of the accelerator control cables which will have to be observed if the cables need replacing E F 37 F 38 F 39 ...

Page 57: ...57 07 06 SPIDER MAX 500 EURO 3 F 40 F 41 F 42 ...

Page 58: ...picture shown hereafter V2 20 15 Release the upper screw V2 Detach downwards the fork leg A rotating it in the two directions V 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 S E P 43 front mudguard S E P 42 brake callipers S E P 45 Release the screw V F 47 A V2 A ...

Page 59: ... remove the complete fork first remove front fairing S D P 27 front mudguard S D P 42 Front wheel optional S E P 43 brake callipers optional S E P 45 handlebar S E P 55 Release the nut D F 48 release the screws V2 F 48 and detach the unit T F 48 Release the ring nut E F 48 Detach the complete fork holding it to avoid its falling Take care not to let the upper F F 48 and lower G F 48 ball bearings ...

Page 60: ...SPIDER MAX 500 EURO 3 E F 52 F 51 F 53 SEAT OPENING TRANSMISSION CABLE NOTE The pictures shown hereafter highlight the routing of the transmission cables and their anchorage seats on the frame of the motorcycle ...

Page 61: ...61 07 06 SPIDER MAX 500 EURO 3 E F 55 F 54 ...

Page 62: ... E F 60 F 61 F 59 F 58 LUGGAGE COMPARTMENT OPENING TRANSMISSION CABLE NOTE The pictures shown hereafter highlight the proper position of the transmission cable for the opening of the luggage compartment after the possible reassembly ...

Page 63: ...le working and producing sparks such as welding grinding etc NOTE To access the fuel tank first remove the front fairing S D P 27 To drain the tank wait for the engine to cool down completely and use a manual pump Release the screws V4 To remove the tank proceed as follows Remove the battery and the whole compartment S D P 39 Remove the cap A Extract the dripproofing protection B and its tube C Re...

Page 64: ...base of the couplings The coupling 1 with the grey tube has to be fitted in the coupling 3 with grey ring nut The coupling 2 with the black tube has to be fitted in the coupling 4 with the black ring nut 2 1 1 2 4 3 F 68 B Disconnect the connector A of the fuel pump The fuel tank is blocked in its rear side by the two Silent Blocks B F 67 A ...

Page 65: ...he conditions of the gasket C and replace it if necessary Carefully clean the mesh filter D NOTE All of the information on the pump can be de ducted by reading the Manual Injection Disconnect the tube C After extracting the tank release the screw V F 64 69 releasing it from the support T F 64 69 Extract the tank sliding it from the front side of the frame downwards C C A C D B V T ...

Page 66: ...e spent liquid in a container suitable for its ecological disposal The coolant is potentially polluting therefore it should not be released in the environment In case the pump A has to be removed release the screws V6 Cut the clip E securing the electrical fan wiring Disconnect the connector of the electrical fan wiring C1 B1 V6 A B C F 75 Cut all the clips securing the lines composing the cooling...

Page 67: ...eassembling first fit the radiators on the upper silent blocks NOTE The radiators are fitted 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 Remove the left radiator including the electrical fan V2 10 20 V2 10 20 V 10 20 LEFT RADIATOR including the electrical fan F 79 V2 A V F 76 F 78 F 77 B B B V2 ...

Page 68: ... 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 B Thermal expansion valve on the engine To remove it release it from the clips of the rubber hoses and slide it from the support S V2 C V 10 20 ELECTRICAL FAN RADIATOR NOTE Please refer S F P 88 F 81 Release t...

Page 69: ...tor left 2 Circuit filler 3 Right radiator 4 Expansion reservoir 5 Thermal expansion valve for the second radiator adjustment 65 2 6 T coupling 7 Thermal expansion valve on the engine 82 2 8 Cylinder head 9 Centrifugal pump driven by the engine countershaft 10 Fan 107 103 F 85 ...

Page 70: ...and side cooling circuit NOTE The pictures shown hereafter highlight the routing of the tubes and hoses of the cooling circuit and their anchorage seats on the frame which will have to be restored during the reassembly of the different components E F 86 ...

Page 71: ...71 07 06 SPIDER MAX 500 EURO 3 E F 87 HOSE ROUTING left hand side cooling circuit ...

Page 72: ...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 which act as the ground screw Open the bleed nipple on the cylinder head and check ...

Page 73: ...rs Separate and extract the upper subframe 1 from the two side subframes SIDE SUBFRAMES F 93 Release and remove the lower screw M8 and its washer Release and remove the lower screw 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 ma...

Page 74: ...74 07 06 SPIDER MAX 500 EURO 3 V2b 60 15 V6 V2 B V2a 4 M10 M8 V3 V V2b A F 93 1 V4 2 3 V2 10 15 V 10 15 V2a 60 15 V6 25 15 V4 60 15 M10 55 15 M8 25 15 V3 25 15 V3 ...

Page 75: ...sed a distortion even light of the frame carry out a dimension check before any other restoration and set up The pictures hereafter show the check dimensions The dimension measured may have a 2 mm tolerance Otherwise replace completely the frame Do not distort the frame to restore the original dimensions E F 94 F 95 ...

Page 76: ...ool down and wear always and in any case suitable safety gloves F 97 EXHAUST Slacken the screw V of the clip securing the exhaust exhaust manifold Release and remove the screws V3 F 98 The upper screw V3 has a nut A F 99 Extract the exhaust and its heat protection and the clip securing it to the exhaust manifold V V3 V3 V3 A V3 25 15 ...

Page 77: ...NIFOLD Disconnect the Lambda sensor connector A Release the cable from the two hose clamps B Release the two nuts C Remove the exhaust manifold D Remove the gasket While reassembling always use a new gasket F 100 F 101 F 102 A B C D C 30 10 E ...

Page 78: ...l Slacken the Lambda sensor A from the exhaust manifold using a suitable locking system in order not to damage the manifold Reassembling Screw the Lambda sensor down with along cable and connector Tighten to the prescribed torque F 102 a F 102 b A A 45 15 ...

Page 79: ...shock absorbers are not to be completely removed simply release the shock absorbers by releasing the lower screws V2 F 103 To completely remove the shock absorbers release and remove the upper screws V2S as well V2I V2S D V2I D R D R R V2I R D R V2S F 103 b V2I 30 15 During both the removal and the reassembly of the rear shock absorbers remember that the lower and the upper screws have washers R a...

Page 80: ...the nuts B 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 During the removal and the reassembly of the rear arm make sure to place the two spacers between arm wheel and arm nut D SHOCK ABSORBER SUPPORTING PLATE Right if the shock absorber and the exhaust have already been released in order to remove the plate supporting the s...

Page 81: ... absorber has been released move it upwards and hold it so that it will not impede the subsequent operations Remove the rear arm as described in the previous page Extract the rear wheel ENGINE REMOVAL NOTE To remove the engine from the frame first remove rear fairing S D P 37 exhaust S E P 76 rear arm S E P 80 rear brake calliper S E P 48 Drain completely the coolant circuit Disconnect all the wir...

Page 82: ... Extract carefully the engine using safety gloves and an assistant F 113 F 112 E P D Place the coolant manifolds so that they will not impede the engine removal taking care not to bend nor damage them F 114 F 115 B C A D B C ENGINE REASSEMBLY Lubricate the spacers B C and the shaft P F 112 with bearing grease Align the engine to the engine shaft P Fit the engine shaft P Fit the nut D up to get to ...

Page 83: ... V and the washer G Remove the anti vibration connecting rods H V 65 15 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 F 118 E V E H V G H F D C B X Y...

Page 84: ...Low beams high beams 12V 35 35W HS1 C Front direction indicators 12V 21W PY21 D Number plate light 12V 5W W5W E Rear direction indicators 12V 16W W16W F Rear parking lights 12V 5W R5W G Rear parking and stop lights 12V 21 5W P21 5W ELECTRICAL AND ELECTRONIC COMPONENTS F C B C B E D G F G F E A ...

Page 85: ...e seat Removing the inserted side covers B allows reaching the rear direction indicator bulbs Removing the inserted rear covers C allows reaching the tail light bulbs FRONT HEADLIGHTS ACCESS To access the front headlight bulbs remove the central fairing S D P 24 While fitting the new bulb having the same specifications as the burnt out one take care not to touch the glass with fingers FRONT HEADLI...

Page 86: ...and the rear fairing S D P 37 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 V 10 20 V2 10 20 If the Immobilizer ECU is replaced store two or more ignition keys please refer DIAGNOSTICS MANUAL of the ELECTRICA...

Page 87: ... two nuts D and two anti tampering screws V2 that can be accessed from the lower part of the switch body To disassemble the key switch use the special insert Torks t 30 for special screws 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 refer DIAGNOSTICS MANUAL of the ...

Page 88: ...urnt out fuse replacing it with one having the same specifications The vehicle has a further general protection fuse 30 A placed inside the battery compartment 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 ELECTRICAL FAN Remove the fairing S D P 24 Remove the leg protector S D P...

Page 89: ...ttery compartment cannot host a battery with a drain hose 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 F 19 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 specifi...

Page 90: ... 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 bru sh Adjust the distance between the electrodes opera ting only on the ground electrode using a gauged shim the distance should be 0 7 0 8 mm Blow out energetically to prevent possible residues from en...

Page 91: ... if necessary F 27 F 26 F 25 C D B V4 A A V2 A1 ELECTRONIC INJECTION ECU NOTE To access the ECU first remove the driver seat S D P 34 Remove the anti vibration element A NOTE While reassembling the different components pre viously removed always refit the element A Release the screws V4 Remove the ground cable end B on the ECU C do not forget to refit it during the reassembly of the ECU Extract th...

Page 92: ...battery recharge protection If the starting relay is replaced take special care to the assembly of the red and blue cable Please refer DIAGNOSTICS MANUAL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM F 29 C C Extract the relays 1 2 3 4 F 26 and remove their supports releasing their screws Release the rear screw V1 placed under the red relay support F 30 Release the two front screws V2 V2 F 31 ...

Page 93: ...f the information concerning these components can be deducted by reading the DIAGNOSTICS MANUAL of the ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM F 34 Disconnect the connector of the anti tilting device F 32 B C D E Remove the ECU mount and the relay If the anti tilting device 5 is to be removed take care to refit it in its original position and not upside down 5 F 33 A ...

Page 94: ...uti who is not liable in any way for any damage caused by the non observance of this concept which is a normal and rational way of operating All the cut or removed clips have to be replaced and applied in their original position The colours of the wirings in the pictures shown hereafter have no connection with the actual colours of the different cables but they have been chosen for an easier and f...

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