Malaguti SPIDER MAX GT 500 User manual

107/06
SPIDER MAX 500 - EURO 3
EURO 3

207/06
SPIDER MAX 500 - EURO 3
MANUAL SECTIONS
FOREWORD
• The present service manual concerns the main electrical, mechanical and necessary checks and the assembly of
single components before delivering the new motorcycle (the operation sequence is not compulsory)
• It is important to adhere strictly to the following instructions.Any operation carried out carelessly or not carried out at
all may lead to personal injury, damage to the motorcycle or simply to complaints.
KNOWYOURMOTORCYCLE
LUBRIFICANTS
MECHANICAL ADJUSTMENTS
BODYWORK (FAIRINGS)
MECHANICAL COMPONENTS
ELECTRICAL AND ELECTRONIC
COMPONENTS
ABBREVIATIONS USED IN THE
MANUAL
FPicture
Cs Torque wrench setting
Min. Minutes
PPage
Pr Paragraph
SSection
Sc Diagram
TTable
VScrew
UNITS INDICATION
• The manual use measurements in mm.
SPARE PART CATALOGUE
R
SERVICE MANUALCYCLE PARTS
(PRESENT MANUAL)
SERVICE MANUALPIAGGIO’S MOTOR
DIAGNOSTICS MANUAL OF THE ELECTRICAL SYSTEMAND 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 previous edition, followed by an M and, the new
release date.
• It is possible that new pictures are inserted in the modified pages; if it is the case, the new picture (or pictures) will
have the same number of the previous picture/s followed by a letter of the alphabet.
• In case of number omission, the picture number will be displayed on a black ground (e.g.: F. 5 ).
ADDED PAGES
Added pages are indicated by the last number of their section followed by an A and the new release date.
I-E
UM USER AND SERVICE
MANUAL

307/06
SPIDER MAX 500 - EURO 3
IMPORTANT!
WARNING! - Used to indicate dangerous operation that can lead to the injury of service, workshop personnel
or people in general or damage to the facility, the motorcycle or equipment.
ENGINE OFF - Used for all the operations that must be carried out with engine off.
VOLTAGE OFF - Disconnect the battery negative pole before the operation.
DANGER OF FIRE - Operations that may start a fire.
DANGER OF EXPLOSION - Operations that may cause an explosion.
TOXIC FUMES - It indicates danger of toxic fumes or respiratory inflammation.
MECHANICAL SERVICE STAFF - Operations that must be carried out by a skilled mechanic.
ELECTRICAL SERVICE STAFF - Operations that must be carried out by a skilled electrician or electronic
technician.
NO! - Do not carry out this operation.
SYMMETRICAL OPERATIONS - Operations that must be carried out also on the other side of the unit or
component.
EMPTY THE CIRCUIT
PRE-DELIVERY OPERATIONS
ASSEMBLY OPERATIONS
DISASSEMBLY OPERATIONS
OPERATION SYMBOLS

407/06
SPIDER MAX 500 - EURO 3
• Wesuggestperformingthefollowingadjustments:adjust the handlebar,theshockabsorbers and the tyrepressure,
according to the customer specifications, connect the battery. Deliver to the customer the Warranty and service
booklet and the User and service manual, duly stamped and signed, together with the motorcycle.
NO. SERVICE S P
1On delivery
Visual check A 8
Identification data check A 8
2Important tightening
Front wheel E 43
Rear wheel E 80
Brake callipers E 45
Shock absorbers E 78
Exhaust E 77
Engine shaft E 81
Handlebar C 21
3 (Liquid) level check
Battery F 88
Coolant B 16
Engine oil B 17
Transmission oil B 19
Brake liquid B20
4 Adjustments
Handlebar adjustment C 21
Shock absorbers C 22
Headlight beam D 25
NO. SERVICE SP
5 Various checks
Tyre pressure A 14
Starting A 12
Steering lock A 12
Accelerator E 56
Handlebar controls A 11
Brake levers A 11
Side stand A 12
Fuses F 87
6Assembly
Mirrors D 24
Windscreen D 26
Number plate D 24
7Road test
8General cleaning
PRE-DELIVERY

507/06
SPIDER MAX 500 - EURO 3
S TOPICS P
Technical data 9
Dimensions 9
General specifications 9
Main component identification 10
Handlebar controls 11
Right control 11
Left control 11
AKey switch 12
Steering lock 12
Side stand 12
Dashboard 13
Tubeless tyres 14
Fuel tank 14
Helmet compartment 15
Luggage compartment 15
Coolant tank 16
Engine oil 17
BTransmission oil 19
Front and rear brake liquid 20
Lubricant table 20
Steering 21
CHandlebar adjustment 21
Rear shock absorber adjustment 22
Fairing components 23
Number plate assembly 24
Rear view mirrors 24
Central fairing 24
Windscreen 26
DDashboard 26
Front fairing 27
Dashboard panel 30
Leg protector 30
Upper handlebar cover 32
Front and rear handlebar cover 33
INDEX

607/06
SPIDER MAX 500 - EURO 3
S TOPICS P
Driver seat 34
Passenger seat (including movable support) 35
Driver seat cushion 35
Grab handle 35
Helmet compartment 36
DRear fairing 37
Battery compartment 39
Airbox 41
Front mudguard 42
Lower fairing mudguard 42
Front wheel 43
(Front brakes) discs 43
Front wheel 44
Brake master cylinders 44
Brake callipers 45
(Rear brake) disc 49
Braking distributor 51
Braking system circuit 51
Braking system bleeding 54
Handlebar 55
Accelerator transmission cables 56
Fork 58
EComplete fork 59
Seat opening transmission cable 60
Luggage compartment opening transmission cable 62
Fuel tank 63
Fuel pump 65
Radiators (including lines and expansion reservoir) 66
Electrical fan radiator 68
Expansion reservoir (coolant tank) 68
Thermal expansion valve 68
Coolant circuit 69
Hose routing (right-hand cooling circuit) 70
Hose routing (left-hand cooling circuit) 71

707/06
SPIDER MAX 500 - EURO 3
S TOPICS P
Cooling circuit bleeding 72
Subframe 73
Aluminium central frame 73
Frame dimension check 75
Exhaust 76
Lambda sensor 78
Rear shock absorbers 79
ERear 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
FElectrical 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

807/06
SPIDER MAX 500 - EURO 3 A
F. 1
FRAME NO. – ENGINE NO. IDENTIFICATION DATA
• To access the vehicle identification number (VIN) (A - F. 1), lift the seat and remove the cover placed in front of the
helmet compartment.
• The engine identification data are written on the left-hand cover of the engine (B - F. 2).
Any identification data changing is pursued by law.
• Always indicate the vehicle identification data when ordering spare parts.
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 motorcycle for marking and damage.
KNOWYOUR MOTORCYCLE
F. 2
B

907/06
SPIDER MAX 500 - EURO 3 A
TECHNICALDATA
GENERAL SPECIFICATIONS
ENGINE
4-stroke single-cylinder with 4 valves - Type: PIAGGIO M341M
Refer to Piaggio Engine Service Manual.
SPARK PLUG
CHAMPION RG6YC - NGK CR7EKB
TRANSMISSION
Expansible–pulley automatic variator, V-belt, automatic dry centrifugal clutch, gear reduction unit and transmission
compartment with forced cooling circulation.
FUEL SUPPLY
Electronic injection with electrical fuel pump.
Fuel: unleaded petrol.
ELECTRONIC IGNITION
Inductive, high- performance, integrated into the ignition, variable spark advance and separate H.T. coil.
BRAKES
Hydraulic system equipped with two front (2 discs Ø 270 mm) and rear (disc Ø 260 mm) discs with braking
distributor system.
Starting:
Left lever: rear brake + front brake (vehicle right-hand side)
Right lever: front brake (vehicle left-hand side)
FRAME
V-Box type, aluminium cast double housing halves, coupled in the front and rear part to half-frames in stainless
steel tubes.
SUSPENSIONS
Front: telehydraulic fork, with two 41-mm legs;
Travel: 120mm.;
Rear: 2 hydraulic shock absorbers with adjustable spring pre-load;
Travel:75 mm.
BATTERY
Type:12V,14Ah.
TYRES
Front: 120/80 - 16 60 S
Rear: 150/70 - 16 68 S
DIMENSIONS
Pitch (A) 1.490 mm
Length (B) 2.255 mm
Width (C) 930 mm
Max. height (D) 1.470 mm
Weight 230 Kg
A
B
C
D

10 07/06
SPIDER MAX 500 - EURO 3
17) Double seat
18) Helmet compartment
19) Exhaust
20) Anti-theft hook
21) Central stand
22) Right direction indicator
23) Front right headlight
24) Front left headlight
25) Parkinglight
26) Left direction indicator
27) Windscreen
MAIN COMPONENT
IDENTIFICATION
1) Left mirror
2) Coolant tank
3) Glove compartment
4) Battery
5) Battery compartment
6) Side stand
7) Throttlebody
8) Air cleaner
9) Number plate bracket
10) Rear indicators
11) Parking and stop lights
12) Passengergrab handle
13) Fuel filler cap
14) Keyswitch
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
22
24
27
17
18
20
21
19

11 07/06
SPIDER MAX 500 - EURO 3
HANDLEBAR CONTROLS
RIGHT CONTROL
1) Counterweight
2) Throttle
3) Frontbrake lever (left-hand)
4) MODE button: to select the digital dashboard
functions
5) Front brake oil tank
A) Emergency Stop, engine cut-out.
ON - Engine ignition
OFF - Engine cut-out
B) Lightswitch:
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) Indicatorswitch
7) Lightswitch:
high beams
low beams
5
4
A
1
2
B
C
3
4
3
1
2
6
5
7

12 07/06
SPIDER MAX 500 - EURO 3 A
KEY SWITCH
• This switch controls the ignition circuit and the steering
lockdevice.
a) Locked ignition(key can be removed)
b) Ignition ready position (key cannot be
removed)
c) Steering lock engagement (locked ignition;
key can be removed)
d) Helmet compartment opening
e) luggage compartment opening
NOTE - The vehicle is supplied with two keys. F. 7
F. 8
STEERING LOCK
ENGAGEMENT
With the handlebar turned to the left or right, insert the
key and rotate counterclockwise
(F. 8).
Disengagement
Rotate the key clockwise.
NOTE - The motorcycle is equipped with a starter pedal.
SIDE STAND
Check for proper side stand fitting and for spring (1 - 2)
mounting.
Also check for proper microswitch (A- F. 9) operation
preventing engine starting when the side stand is not
foldedup.
Never remove or alter this safety device.
A2 1
F. 9

13 07/06
SPIDER MAX 500 - EURO 3 A
DASHBOARD
1) Multifunction digital dashboard
(Refer to the User Manual for function set up).
2) Analogic speedometer
indicates the current driving speed in km/h and miles (mph).
3) Coolant temperature indicator
The indicator goes on when the coolant temperature is too high.
4) Side stand/engine stop indicator (red)
The indicator goes on when the side stand is down or the Engine Stop button is on the OFF position.
5) Low beam indicator (green)
6) High beam indicator (blue)
7) Left direction indicator (green)
8) Right direction indicator (green)
9) Fuel level indicator
The indicator goes on to indicate the fuel is low.
10) Oil indicator (red)
With the engine operating, the indicator goes on when the engine oil pressure is too low.
11) Immobilizer indicator (red)
The led stops flashing after 20 days to prevent the battery from running down but the immobilizer
function is enabled
12) Injection Indicator (orange)
The indicator goes on to indicate injection system fault.
Do not use pressure to clean the instruments in order to avoid any damage.
F. 10 12
11
8
3 1
7
6
10924 5

14 07/06
SPIDER MAX 500 - EURO 3
FUELTANK
To reach the fuel tank, proceed as follows:
• place the motorcycle on the central stand.
• Extract the ignition key from the switch.
• Open the hatch (A) by acting on the lever (B).
• Insert the ignition key, release the cap (B) and refill the
tank.
• After the refuelling, remove any fuel residue from the
bodywork as soon as possible.
Use UNLEADED PETROL.
FUELTANK litres
TOTALCAPACITY 14
RESERVE 3
TUBELESS TYRES
PRESSURE CHECK
Check and adjust tyre pressure with “cold tyres”.
A
X120/80 - 16” 60S
Y150/70 - 16” 68S
Petrol is an extremely inflammable substance: never stay near the fuel filler, also during refuelling,
with lighted cigarettes or bare flames (e.g. matches). Danger of fire.
F.12/a
X
YF. 11
A C
F. 12
A
B

15 07/06
SPIDER MAX 500 - EURO 3
F. 13
F. 14
HELMET COMPARTMENT
• Placed under the passenger seat. Place the motorcycle
onthe stand,press and rotatetheignition key clockwise:
this operation releases the seat lock.
• In the helmet compartment a light goes on and off when
openingand closingthe compartment.Thelightoperates
only if the ignition key is on the ON position.
A
A
• The helmet compartment is equipped with a 12V plug
(A)that maybeused,forinstance,to rechargethemobile
phonebattery.Use theplugonlywith theengineoperating
and with headlights off. The use of the plug reduces the
durationofthe batterycharge andmay reduceitslifetime.
Do not connect any appliance requiring a high power
supply (max power consumption: 30W). The plug can
operate ALSO when the ignition key is on the OFF
position.
• Refit the cap after use to prevent debris from causing
short circuits.
LUGGAGE COMPARTMENT
• Equipped with a lock (A) that can be opened by means of the ignition key: press and rotate the key counterclockwise.
• The electrical system fuses (B) are fitted inside the compartment (Please refer: S/F - P. 88 of the present Manual).
F. 15
A
P
B

16 07/06
SPIDER MAX 500 - EURO 3
COOLANT TANK (EXPANSION RESERVOIR)
To access the coolant tank, containing the engine cooling liquid, open the luggage compartment
(A) and remove the plastic cover (B).
LEVEL CHECK
• At thispoint, thanks tothe tank position, itis possible tocheck the levelof the coolant withrespect to theMIN 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 possible.
B
LUBRIFICANTS
F. 1 B A
T
F.1/a
T
• Remove the plug (T) in order to pour the coolant.

17 07/06
SPIDER MAX 500 - EURO 3 B
ENGINE OIL
• In 4T engines, the engine oil is used to lubricate the timing components, crankcase stand and the thermal unit. Alow
oil quantity may cause damage to the engine.
• In all 4Tengines, oil characteristics and oil consumption may change over time.
CHECK LEVEL every 3000 km or 6 months
Perform this operation with “cold engine”, proceeding as follows:
1) Place the vehicle on the central stand and on level ground (a moderate side inclination may give wrong results).
NOTE -When checking oillevel, make surethat the motorcycleis in avertical position; aslight side inclinationmay give
wrong results.
2) Release the cap/dipstick (A), dry it with a clean cloth and fit it back, tightening it completely .
3) Remove again the cap/dipstick and check that the level is between the MAX and MIN marks; if necessary top up oil
with Q8 FORMULA EXCEL SAE 5W40.
The MAX reference mark indicates around 1700cc of oil in the engine.
Should it be necessary to check oil level with “hot engine”, the level line will be lower. Wait at least 10
minutes after stopping the engine, in order to let the engine cool down to get the right oil level.
The vehicle is equipped with a check system that, in case of malfunctioning, turns on an alarm
warning message “LOW OIL PRESSURE” on the digital dashboard.
F. 2
Max
Min
A

18 07/06
SPIDER MAX 500 - EURO 3
OIL TOPPING UP
Always check oil level before topping it up and never exceed the MAX mark.
Topping up oil between MIN and MAX marks indicates a quantity of oil around. 400 cc.
Never exceed the MAX mark! An excessive inner pressure may damage the engine.
Check and top up engine oil level every 3000 km.
ALARM WARNING MESSAGE (LOW OIL PRESSURE)
When starting the vehicle, the digital dashboard check system displays the “LOW OIL
PRESSURE” warning message to indicate that the check is enabled. The message automatically disappears
after a few seconds and stays on only in case oil pressure problems occurs during the vehicle operation.
If the message goes on while braking, at idling speed or on bends, check oil level and top it up, if
necessary.
Every 3000 Km, the word OIL is displayed on the digital dashboard: it suggests to check or replace the
engine oil. The warning message will stay on the dashboard until the indicated operation is carried
out.
Spent oil contains 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). Fit a new oil filter, taking care to lubricate the filter seal O-Rings with
engine oil.As a certain quantity of oil remains in the circuit, top up with around 1500 cc. of oil from the cap (A). Start
the vehicle, and let it idle for a few minutes before stopping it: after around 5 minutes, check oil level and top up, if
necessary, without exceeding the MAX mark.
Replace the cartridge filter at every oil change. Use Q8 FORMULA EXCEL SAE 5W40 oil for topping ups and
change.
Operating the engine with an insufficient lubrication or with wrong lubricants increase the wear of
moving parts and can result in serious damage.
Spent oil contains pollutants, refer to an Authorised Centre to dispose of it in compliance with the law
in force.
F. 3 F. 4
B
B
C

19 07/06
SPIDER MAX 500 - EURO 3 B
TRANSMISSION OIL
CHECK LEVEL every 6.000 Km or 12 months
1) Place the vehicle on a level surface, on the central stand.
2) Release the dipstick (A), clean it, then fit it back tightening it completely.
3) Extract it again and check that the oil level is between the MAX and MIN marks.
4) If the oil level is low, top it up to the MAX mark.
5) Refill the case with oil: Q8 ZC 90
Case capacity: around 250 cc.
REPLACE first time after 1.000 Km and then every 24.000 Km
Perform the operations described at points: 1 - 2 without refitting the graduated dipstick, then place a container
beneath the engine crankcase and release the drain screw (B), taking care not to damage the gasket
Let the oil drain into the container for a few minutes (taking care to avoid burns).
Refit the drain plug and the gasket and top up with around 250 cc of new oil (Q8 ZC 90) then fit the oil plug with the
dipstick (A).
At this point, repeat the check operations indicated at point 3-4-5. Replace the drain screw gasket if necessary.
Check for oil leaks in the areas near the drain plug, rear wheel.
F. 5 F. 6
Max
Min
A
B

20 07/06
SPIDER MAX 500 - EURO 3
FRONT AND REAR BRAKE LIQUID
CHECK every 30 days
• Use the tank indicator (S) for the (visual) check: front brake (A) and rear brake (B), with the motorcycle on a level
ground and vertical position.
• The level is correct when the oil is 3 mm above the indicator lower side.
• To top up oil remove the caps (A-B), after unscrewing the two retaining screws. Use oil: Q8 BRAKE FLUID DOT 4.
Hydraulic oil is corrosive and may cause damage and injury. Do not mix different oils.
Check for the perfect sealing of the gasket.
REPLACE every 2 years or 12000 km
• In the case of dirt, debris or water in the oil, replace it completely.
• When the brake lever feels spongy there may be some air trapped in the circuit. Bleed the circuit.
B
LUBRICANT TABLE
A
MIN S
F. 8F. 7
MIN S
B
(4T) ENGINE OIL
FORK ROD OIL
BRAKING CIRCUIT LUBRICANT
RADIATORLIQUID
AIRBOXLUBRICANT
ENGINE TRANSMISSION OIL
LUBRICANTS LUBRICANT TYPE