Malaguti SPIDER MAX RS 500 User manual

102/08
MALAGUTI S.p.A.
Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY
Tel.[phone]-Fax[phone]
e-mail:[email protected]-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 PARTS CATALOGUES of each model.
• It is important toread all the general informationbeforegoing through the manual tothe specific topics and themaintenance operations to be carriedouton 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.
•Allchecks,maintenance, repairs or replacements of spare parts in ourmotor-bikesaretobe performed byskilled and expert technicalpersonnel with specific experience
instate-of-the-art technology andfull knowledge of the quickestandmostrationalprocedures,technical characteristics, setting values,tighteningtorquesand information as
to which may only be properly and exhaustively provided by the manufacturer.
• It is important to adherestrictly to thefollowing instructions.Anyoperation carried outcarelesslyor not carriedout at all mayleadtopersonalinjury,damagetothemotorcycle
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.

202/08
NOTES FOR EASY CONSULTATION
ABBREVIATIONS
EDITING SYMBOLS:
• Symbols have been provided for quick and easy reference,identifyingsituationsrequiring utmost attention orproviding 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 Torquewrenchsetting
DNut
Dx Right
FPicture
GGasket
PPage
RWasher
Sx Left
TTable
VScrew
TECHNICALDICTIONARY
V = (DC) Directcurrent (battery supply)
V ~ (AC) Alternatingcurrent(flywheel supply)
A :Ampere Unit of measurement of the electrical current
W:Watt Unitofmeasurementoftheelectricalpower(productofVoltsand Amperes;AxV=W)
ΩΩ
ΩΩ
Ω: OHM Unit of measurement of the electrical resistance
<Lower
≤≤
≤≤
≤Lowerorequal
>Higher
≥≥
≥≥
≥Higherorequal
bar Unitof measurement of pressure
N * m Newton/metre Unitof measurement ofthe tighteningtorque

302/08
M
R
SYMBOL LIST
CAUTION!
Recommendationsand
precautionsregarding rider
safetyand motor vehicle
integrity.
WARNING!Situationsentailing
the risk of personal injury to
maintenance or repair
mechanics, other workshop
personnel or third parties, or
damageto environment,
vehicle or equipment
FIREHAZARD.
Indicatesoperations which
mayconstitute a fire
hazard
RISKOF
EXPLOSION
Indicatesoperations
whichmayconstitute a
riskofexplosion
TOXICFUMES
Indicatesa possibilityof
intoxicationorinflammation
oftheupper respiratory
tract
WARNING!
Dangerof crashing
arms
SAFETYGLOVES
Theseoperations require
the use of safety gloves
IMPORTANT
Thistopic requiresspecial
attention
GENERALSERVICE
PERSONNEL
Skilledelectronic or
mechanicaltechnician.
MECHANICAL
MAINTENANCE
Operationsto beperformed
onlyby anexpertmechanic
ELECTRICAL
MAINTENANCE
Operationsbe performed
onlyby an expertelectrical/
electronictechnician
IGNITIONKEYON
(ONposition)
PRESENTMANUAL
Informationon the
presentmanual
“ENGINE”SERVICE
MANUAL
Indicatesinformation which
maybe obtainedby
referringto said catalogue
SPAREPARTS
CATALOGUE
Indicatesinformation which
maybe obtainedby
referringto said catalogue
DISASSEMBLY
OPERATIONS
ASSEMBLY
OPERATIONS
SYMMETRICAL
OPERATIONS
Operationsthat mustbe
carriedout also onthe other
sideofthe unitor
component.
EMPTYTHECIRCUIT
REPLACEWITHNEW,
ORIGINALSPARE
PARTS
IDLINGENGINE
Switchonthe engine,at
idlingspeed, toperfom
theseinterventions.
ENGINEOFF
Indicatesoperations to
beperformedwith
engineoff
POWEROFF
Indicatesthat negative
poleis tobedisconnected
fromthebattery before
performingthe operation
NO!
Operationsto be
absolutelyavoided
OIL
COOLANT
FUEL

402/08
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 have a complete understanding of
all the symptoms and identify with good approximation the real causes of the trouble.The present manual provides the technical information and the basic indications on the
intervention procedures but these have to be integrated with the personal expertise.
• 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
componentsthatneeds 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 maybe 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,alwayskeep toolsandequipment athand,possibly layingthemout accordingtothe sequenceinwhich theyareto beused.Absolutely avoidputtingthem onthe
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-endbox wrenchesby “pulling” and not “pushing”.

502/08
•Before carrying out any operation, wait for all parts to cool down.
• For operations requiring two mechanics, make sure that the various steps to be performedby each of them are clearly definedand co-ordinated beforehand.
• Make sure that each componenthas beenproperly mountedbefore proceedingwith assembling thenext 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 severe 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 ortighten screws ornuts because,in addition tonot providing asufficient clampingforce, theymay also damagethe screw heador nuthexagon.
•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.

602/08
CONTENTS
DESCRIPTION P.
RIGHT RADIATOR - LEFT RADIATOR 38
ELECTRICALFANRADIATOR-EXPANSIONRESERVOIR-THERMALEXPANSIONVALVE 39
KEYSWITCH -DASHBOARDPANEL 40
LEG PROTECTOR 41
UPPERHANDLEBARCOVER-ACCESSES 43
FRONT AND REAR HANDLEBAR COVER - ACCESSES 44
HANDLEBAR- BRAKEMASTER CYLINDERS 45
DRIVERSEAT- ACCESSES 46
PASSANGER SEAT - CUSHION DRIVER SEAT - GRAB HANDLE 47
HELMETCOMPARTMENT 48
ACCESSES- DIRECTIONINDICATORSANDTAIL LIGHTS 48
REARFAIRING 49
TAIL LIGHTS 50
SIDE REACH -VOLTAGERECTIFIER 51
COOLANT PUMP - COIL 51
RELAY HOLDER 52
ACCESSES - ELECTRONIC INJECTION ECUTHROTTLE BODY 53
BATTERYCOMPARTMENT -ACCESSES 54
FUELTANK 55
AIRBOX 57
FRONT MUDGUARD - FRONTWHEEL - WHEELSPINDLE 58
(FRONT BRAKE) DISCS - FRONTWHEEL - REASSEMBLY 59
BRAKECALLIPERS -FRONTCALLIPER REPLACEMENTAND DISASSEMBLY 60
LOWER FAIRING MUDGUARD - FORK 63
STANCHIONGROUP-STANCHIONDISASSEMBLY-CHECKTHEOILLEVELINTHESTANCHION 63
FRONTFORK OILREPLACEMENT 64
COMPLETEFORK 64
EXHAUST- EXHAUSTMANIFOLD 65
LAMBDA SENSOR-REMOVAL-REASSEMBLING 66
REARSHOCK ABSORBERS 67
REAR ARM - SHOCKABSORBER SUPPORTINGPLATE 68
REARCALLIPER-REARCALLIPER DISASSEMBLY 69
REARWHEEL - (REAR BRAKE) DISC ENGINE 71
ENGINEREASSEMBLY- ENGINE MOUNT 72
ANTI-VIBRATION CONNECTING RODS - ENGINE MOUNT 73
SUBFRAME 74
UPPERSUBFRAME -SIDE SUBFRAMES- CENTRALALUMINIUM FRAME 75
FRAMEDIMENSION CHECK 76
CABLE POSITIONING,“PIPE SYSTEM”AND ANCHORINGTIES 77
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DESCRIPTION P.
SPECIFICATIONS 7
IDENTIFICATION DATA: FRAME N° / ENGINE N° -TYRES 8
MAINTENANCETABLE 9
LUBRICANT TABLE 10
FUELTANK - COOLANTTANK 11
BLEEDING, COOLING CIRCUIT 12
BLEEDINGOFTHE LEFTSIDE -BLEEDING OFTHE RIGHTSIDE 12
ENGINE OIL 13
CHECKTHE OILLEVEL -TOPPING UP 13
CHANGEENGINE OIL 14
TRANSMISSION OIL -CHECKTHELEVEL -RENEW 15
BRAKE OIL -CHECK -CHANGE 16
BRAKINGSYSTEM BLEEDING- INTEGRALSYSTEM 17
CHECKTHELEVEL OFTHE BRAKELIQUID -FRONT LEFTCALLIPER 17
CHECKINGBRAKE PADS ANDDISCS -BRAKE PADS 18
REPLACINGTHE BRAKE PADS -DISCS 18
FORK - CHECKTHE OILLEVELINTHESTANCHION 19
FRONTFORK OILREPLACEMENT 19
REARSHOCK ABSORBERADJUSTMENT -STEERING 20
HANDLEBARADJUSTMENT 20
LOCATION OFTHE MAIN ELECTRICAL ELEMENTS 21
INSTRUMENTBOARD 23
KEY SWITCH - HANDLEBAR LOCK 24
LOCKING -DISENGAGING 24
STARTINGTHE ENGINE 24
LIGHTINGSYSTEM -LAMPS 25
ADJUSTINGTHE BEAMLIGHT 26
FUSES - GENERALPROTECTION FUSEAND CHARGEPROTECTIONFUSE 27
BATTERYASSEMBLY -CHARGEBATTERY 28
SPARK PLUG- REMPLACE 29
PROCEDURESFOR DISMANTLING AND REMOVINGCOMPONENTS 30
REASSEMBLY NOTE - CENTRAL FAIRING - REARVIEW MIRRORS 30
FRONTDIRECTION INDICATORS(BULBCHANGE) 30
ACCESSES- REPLACINGTHEFRONT PARKINGLIGHT 31
DASHBOARD - BRAKING DISTRIBUTOR - HORN 32
AIR GRID -WINDSCREEN - FRONT FAIRING 33
ACCESSES- IMMOBILIZERECU 35
SIDESTAND SWITCH -FUEL SUPPLY PUMP 36
RADIATORS 37

702/08
DIMENSIONS
Wheelbase(A) m .......................................................................................1,490
Max.length (B) m........................................................................................2,200
Max.width (C) m .........................................................................................0,930
Max.height (D) m........................................................................................1,470
Kerbweightkg ...............................................................................................230
Max.load with rider,passengerandluggage kg..............................................180
CAPACITY
Engine oil cm3 ........................................................................................... 1700*
Transmission oil cm3 ................................................................................... 250*
Fuel tank (total).............................................................................................. 14*
ENGINE:single-cylinder,four-valve
Valves type ............................................................................. PIAGGIOM34CM
n°Cylinders ...................................................................................................... 1
Bore x stroke mm .................................................................................. Ø 94x71
Capacity cm3.................................................................................................493
Compressionratio ............................................................................... 10.5 ± 0.5
Cooling........................................................................................................ liquid
Starting system ............................................................................electric starter
Greasingsystem.................................................................................. wet sump
SPARK PLUGS
Type ..............................................................................................NGK CR7EKB
TRANSMISSION
Automatic speed variator with expandable pulleys,V-belt, automatic
drycentrifuge clutch, reductiongear and transmission
compartment with forced circulation cooling system.
FUEL SYSTEM
Electronic injection with electrical fuel pump.
Fuel:unleaded petrol.
ELECTRONICIGNITION
High efficiency, inductive type coupled with the injection system,
variableadvance and separate HVcoil.
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 brakes 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-Box” 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
Front: hydraulically controlled fork with two Ø 41 mm rods.
Stroke:120 mm
Rear: 2 hydraulicshockabsorbers with adjustable preloading spring.
BATTERY
12V,14Ah,maintenance-free.
TIRES
Front: 120/80-16 60 S
Rear: 150/70-16 68 S
* IndicativeValue
SPECIFICATIONS
F. 1

802/08
TYRES
Type:Tubeless (without innertube)
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)
B
F. 2
F. 3
A
• To read the vehicle’s identification number (VIN) (A) lift the saddle
and remove the cover located in front of the helmet compartment.
• Engineidentificationdataarelocated on theleft-handenginecrankca-
se (B).
Any alteration to the vehicle identification data is pursued
by the Law.
Minimum tread depth is 2 mm.
• There areT.W.I.marks all around the tyre
sides.Thesecorrespondto tyre wear
indicators situated in the tyre’s tread;if
thereis no difference betweenthe
thickness of the tyre wear indicators and
the tread depth, the tyre must be replaced. F. 4
X
Y
IDENTIFICATION DATA: FRAME N° / ENGINE N°

902/08
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 by technicians not authorised by MALAGUTI,but under
their direct responsibility.
Nr. :coupon
: check
:clean
:adjust
:replace

10 02/08
LUBRICANT TABLE
NOTE - Use only recommendedproducts.
LUBRICANTS
ENGINE OIL (4-STROKETYPE) 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.
•Openthe door (A) in frontofthe seat, by acting on thelever
(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
• To access the engine coolant tank, openthe glove compartment (A) located at the
centreof the lowerfairingand removetheplasticcover (B).Owing to the particular
positionofthetank,thelevel of coolant, with respect to the minimum andmaximum
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
identicalcharacteristics - for any toppingup.Never unscrew the tank cap(T) when
the engine is warm, so as to avoid burnings. Do not top up with water, except in
emergencysituationsandinthiscase,havetheentirecontentsofthetankreplaced
by a suitable product as soon as possible.
A
* IndicativeValue
B
T
14*
3*
F. 6
A
BC
FUEL TANK Litres
TOTAL TANK CAPACITY
RESERVE

12 02/08
BLEEDING, COOLING
CIRCUIT
To bleed the air, with the
circuitcompletely drained
from the coolant, proceed as
follows:
BLEEDING OFTHE LEFT
SIDE
• Remove the cap on the
bleedingcoupling(A).
• Fit a tube in the coupling
(A) of the bleed nipple on
thecylinder head.
• Refill the expansionreser-
voir with coolant, as descri-
bed:(P.11).
• Release and removethe
filler (B).
• Pour some coolant in the
mainradiator(left).
• Slacken the coupling (A)
and go on refilling the main
radiatoruntil some liquid
would drip off the tube (with
regularflow).
• Now,close the bleed nipple
(coupling - A) and fill in up
to the rim of the main
radiator.
• Slacken thebleed screw (C),
untilsomeliquiddripsoff with
regularflow.
• Close the screw and top up
theliquid.
• Open thebleed nipple onthe
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 OFTHE RIGHT
SIDE
•Slacken the bleed screw (D),
until some liquid drips off with
regularflow.
• Close the screw and top up the
liquidin the main radiator.
• With the help of an assistant,
slightly tilt the vehicle on the ri-
ght 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,
showingthat the bleedinghas 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
C
A
B
D

13 02/08
ENGINE OIL
• As far as four-stroke enginesare concerned,engine oilis usedto lubricatedistribution components,base bearings
andthermal 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.
CHECKTHE 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 (even a slight inclination may 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 level 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 lower. It is best to wait at least 10 minutes from stopping the
engine in order to have a correct reading.
The vehicle features a control system that activates the“LOW OIL PRESSURE”alarm signal of the digital instrument board 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.
• Topping up to level falling between 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 (LOW 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 few seconds.It will only reappear during vehicle use if there is actually a low oil
pressureproblem.
If the message appears when you are braking, when the engine is idling or when curving,stop the vehicle, check the oil level 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 for the environment,therefore we suggest you contact an Authorised Service Centre for disposal according to the rules in force.
every 3000 km or 6 months
F. 8
A

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 new 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 but never above the MAX mark.
F. 9 BF.9/a C
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. Have oil replaced by an Authorised Service Centre that will also dispose of waste oil in accordance to the law.
F.8/a
A

15 02/08
Max
Min
TRANSMISSION OIL
CHECKTHE 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
Crankcasecapacity 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. 10
F. 11
A
B

16 02/08
MIN S
CHANGE
If the fluid features traces of dirt, debris or water, it must be replaced.A soft and spongy feeling in the brake lever 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
Whentopping up,never use more than one oil.
F. 12
every30days
every 12.000 Km or 24 months
A
B
MIN S
F. 13

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 leverallowsthe front right brakecalliper and the rearbrakecalliper to be controlledinterlockedly
at the same time.
To bleed the circuit of the integral system, first 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 lever operating, slacken the bleed screw 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 berepeated 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. 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.
CHECKTHE LEVEL OFTHE BRAKE LIQUID (P.16)
FRONT LEFT CALLIPER
• To bleedthe front left calliper, operate the right brake lever.
F. 14
B
A
B12 ÷ 16

18 02/08
CHECKING BRAKE PADS AND DISCS
BRAKEPADS
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. 15 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.
Forinstructions on how replacing thefront and rear brake padsplease refer
to pages 60 and 61.

19 02/08
FORK
CHECKTHE OIL LEVEL INTHE 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. 18
V
V
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.
• Turn over 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 pourthenewoilin theleg.Carefullypourthe newoil in theleg.
• 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.