SPIDER MAX 500 - EURO 3

EURO 3
1 07/06
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 SPIDER MAX 500 - EURO 3
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.

DOCUMENTS CONCERNIG THE MODEL:

SPIDER MAX 500

SERVICE MANUAL CYCLE PARTS USER AND SERVICE

(PRESENT MANUAL) UM MANUAL

SERVICE MANUAL PIAGGIO’S MOTOR

I-E DIAGNOSTICS MANUAL OF THE ELECTRICAL SYSTEM AND EMS INJECTION SYSTEM

R SPARE PART CATALOGUE

MANUAL SECTIONS ABBREVIATIONS USED IN THE

MANUAL

A KNOW YOUR MOTORCYCLE F Picture

Cs Torque wrench setting
Min. Minutes
B LUBRIFICANTS
P Page
Pr Paragraph
C MECHANICAL ADJUSTMENTS S Section
Sc Diagram
T Table
D BODYWORK (FAIRINGS)
V Screw

E MECHANICAL COMPONENTS UNITS INDICATION

• The manual use measurements in mm.
ELECTRICAL AND ELECTRONIC
F COMPONENTS

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.

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 SPIDER MAX 500 - EURO 3

OPERATION SYMBOLS

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

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 SPIDER MAX 500 - EURO 3

PRE-DELIVERY

NO. SERVICE S P NO. SERVICE S P

1 On delivery 5 Various checks

Visual check A 8 Tyre pressure A 14

Identification data check A 8 Starting A 12

2 Important tightening Steering lock A 12

Front wheel E 43 Accelerator E 56

Rear wheel E 80 Handlebar controls A 11

Brake callipers E 45 Brake levers A 11

Shock absorbers E 78 Side stand A 12

Exhaust E 77 Fuses F 87

Engine shaft E 81 6 Assembly

Handlebar C 21 Mirrors D 24

3 (Liquid) level check Windscreen D 26

Battery F 88 Number plate D 24

Coolant B 16 7 Road test

Engine oil B 17 8 General cleaning

Transmission oil B 19

Brake liquid B 20

4 Adjustments

Handlebar adjustment C 21

Shock absorbers C 22

Headlight beam D 25

• We suggest performing the following adjustments: adjust the handlebar, the shock absorbers and the tyre pressure,
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.

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 SPIDER MAX 500 - EURO 3

INDEX

S TOPICS P
Technical data 9

Dimensions 9

General specifications 9

Main component identification 10

Handlebar controls 11

Right control 11

Left control 11

A Key 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

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

Upper handlebar cover 32

Front and rear handlebar cover 33

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 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
D Rear 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
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 (coolant tank) 68

Thermal expansion valve 68

Coolant circuit 69

Hose routing (right-hand cooling circuit) 70

Hose routing (left-hand cooling circuit) 71

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 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

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

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 SPIDER MAX 500 - EURO 3 KNOW YOUR MOTORCYCLE 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.

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.

F. 1 F. 2

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 SPIDER MAX 500 - EURO 3 A
TECHNICAL DATA
C
DIMENSIONS
Pitch (A) 1.490 mm
Length (B) 2.255 mm
Width (C) 930 mm
Max. height (D) 1.470 mm D
Weight 230 Kg

A
B

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: 120 mm.;
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

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 SPIDER MAX 500 - EURO 3 A
MAIN COMPONENT
16
IDENTIFICATION
1) Left mirror
2) Coolant tank 15
3) Glove compartment
4) Battery 1
12
5) Battery compartment 14
6) Side stand
7) Throttle body 13
8) Air cleaner
9) Number plate bracket
2
10) Rear indicators 11
11) Parking and stop lights
3
12) Passenger grab handle 10
13) Fuel filler cap
14) Key switch 4
15) Dashboard
16) Right mirror 5

6 9

7 8
F. 3

17) Double seat

18) Helmet compartment
27 19) Exhaust
20) Anti-theft hook
17 21) Central stand
26
18 22) Right direction indicator
23) Front right headlight
24) Front left headlight
25 25) Parking light
26) Left direction indicator
27) Windscreen
24

23

22
19

20

21

F. 4

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 SPIDER MAX 500 - EURO 3 A
HANDLEBAR CONTROLS
RIGHT CONTROL
1) Counterweight
5
2) Throttle
3) Front brake lever (left-hand)
4) MODE button: to select the digital dashboard 1
functions
5) Front brake oil tank 2 4

A) Emergency Stop, engine cut-out.

3
ON - Engine ignition
OFF - Engine cut-out

B) Light switch:
A
right = off
central position = parking lights and
dashboard
left = low beams. B

C
C) Electrical starter.

F. 5

LEFT CONTROL
1) Rear brake oil tank
1
2) “Flash” lever high beams (passing)
3) Rear/front brake lever (right-hand)
4) Counterweight
2 5) Horn button
4
6) Indicator switch
3 7) Light switch:
high beams
low beams

F. 6

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 SPIDER MAX 500 - EURO 3 A
KEY SWITCH
• This switch controls the ignition circuit and the steering
lock device.

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

F. 7
NOTE - The vehicle is supplied with two keys.

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.

F. 8

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
folded up.

Never remove or alter this safety device.

F. 9 2 1 A

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 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.

4 5 2 9 10

7
8

6 11

3 1 12
F. 10

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 SPIDER MAX 500 - EURO 3 A
TUBELESS TYRES
X 120/80 - 16” 60S
Y 150/70 - 16” 68S

PRESSURE CHECK

Check and adjust tyre pressure with “cold tyres”.

F. 11 Y X

FUEL TANK
To reach the fuel tank, proceed as follows:
• place the motorcycle on the central stand.
B
• 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.
A
Use UNLEADED PETROL.

F. 12
FUEL TANK litres
TOTAL CAPACITY 14
RESERVE 3

A C

F. 12/a

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.

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 SPIDER MAX 500 - EURO 3 A
HELMET COMPARTMENT
• Placed under the passenger seat. Place the motorcycle
on the stand, press and rotate the ignition key clockwise:
this operation releases the seat lock.
• In the helmet compartment a light goes on and off when
opening and closing the compartment. The light operates
only if the ignition key is on the ON position.

F. 13

• The helmet compartment is equipped with a 12V plug

(A) that may be used, for instance, to recharge 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. A
• Refit the cap after use to prevent debris from causing
short circuits.
F. 14

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

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 SPIDER MAX 500 - EURO 3 LUBRIFICANTS B
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 this point, thanks to the tank position, it is possible to check the level of the 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.

• Remove the plug (T) in order to pour the coolant.

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.

T
B A
F. 1

F. 1/a

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 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. A low
oil quantity may cause damage to the engine.
• In all 4T engines, 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 oil level, make sure that the motorcycle 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 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.

Max

Min

A
F. 2

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 SPIDER MAX 500 - EURO 3 B
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.

B
C
F. 3 F. 4

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 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.

Max
Min B

A
F. 5 F. 6

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 SPIDER MAX 500 - EURO 3 B
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.

MIN
S
MIN
S

A
B

F. 7 F. 8

LUBRICANT TABLE

LUBRICANTS LUBRICANT TYPE

(4T) ENGINE OIL
ENGINE TRANSMISSION OIL
AIRBOX LUBRICANT
RADIATOR LIQUID
BRAKING CIRCUIT LUBRICANT
FORK ROD OIL

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 MECHANICAL
SPIDER MAX 500 - EURO 3
ADJUSTMENTS C
STEERING

PLAY 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.

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 pattern, until reaching the specified torque.

V4 30 ± 20%

V4

F. 1 F. 2

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 SPIDER MAX 500 - EURO 3 C
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 counterclockwise
to increase the spring power.
• In case of an exceeding friction, use force tube and the
shock absorber 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.

TIGHTENING CHECKS

• When performing pre-delivery operations and service checks for the proper tightening of the rear shock absorbers
(upper (A) and lower (B) tightening have a different torque wrench setting).

A
A 45 ± 15% B

B 30 ± 15%

F. 4

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 SPIDER MAX 500 - EURO 3 BODYWORK D
FAIRING COMPONENTS

NO. DESCRIPTION 1
1 Windscreen 9 8
2 Central fairing
3 Front fairing 7
4 Front mudguard
18
5 Lower fairing mudguard
6 Front handlebar cover
7 Rear handlebar cover
8 Central handlebar cover
9 Dashboard frame
10
10 Leg protector
11 Rear fairing
12 Number plate bracket
13 Tail light 16
14 Front headlight
15 Footpeg 12
16 Alukit chassis
17 Mobile rear fairing 11
18 Grab handle F. 1

1 6
1
18
17
13
3

11
14

15

12

F. 2 F. 3

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 SPIDER MAX 500 - EURO 3 D
NUMBER PLATE ASSEMBLY

NOTE - The motorcycle is equipped with number plate

bracket. The number plate is assembled at the dealer’s
premises.

• Fit the number plate on the number 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.

A A
F. 4

REAR VIEW MIRRORS

• Lift the rubber part and release the front screw (V).

V 10 ± 20%

• Tilt the rear window to the front.

V
• Lift the rubber part, release the rear screw and remove
the mirror. F. 5

F. 6

CENTRAL FAIRING
V2
Release the screws (V2).

V2 1,5 ± 15%

F. 7

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 SPIDER MAX 500 - EURO 3 D
• Free the fairing from the front and the two side retainers
(A).
To facilitate the separation of the locking tabs,
remove the access covers to the front
direction indicators, insert one hand and force
it.
Release the fairing from the front locking tab.

F. 8

• Extract the fairing with care, remembering that it is

anchored to the parking light wiring.

F. 9

• 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 figure). F. 10

F. 11

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 SPIDER MAX 500 - EURO 3 D
WINDSCREEN

• Release the screws (V6) and remove the windscreen.

V6

F. 12

DASHBOARD

• Disconnect the dashboard connector (A).

F. 13

• Release the screws

(V4) and extract the
dashboard carefully.
1,5 ± 15%

F. 14

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 SPIDER MAX 500 - EURO 3 D
FAIRING FRONT V6

NOTE - The front fairing 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 (V6).

V6 1,5 ± 15%

F. 15

• Release the screws (V11).

• Release the central screw (V).

V11 1,5 ± 15%

V 5 ± 20%

F. 16

• Release the screws (V2).

V2

V2 1,5 ± 15%

F. 17

• Lift slightly the air intake (A) and remove it.

A

F. 18

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 SPIDER MAX 500 - EURO 3 D
• Release and remove the lower screw (V1) and its
washer.

V1 1,5 ± 15%

V1

F. 19

• Remove the rubber mat.

F. 20

Release the screws (V2) and remove the

passenger footpeg. V2

V2 40 ± 15%

F. 21

• Release the screws (V8).

V8 1,5 ± 15%

F. 22

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 SPIDER MAX 500 - EURO 3 D
• Release the half-fairing upper part from the
mirror mount, opening it up carefully.

F. 23

• Disconnect the two connectors (A) (direction

indicators).
• Disconnect the connector (B) (front headlight).
• Remove the fairing.
ACCESSES
A
• Removing the two front half-fairings, the following B
components can be reached:

Left half-fairing:

• Coolant sump (A) F. 24

• Left radiator (B)
• Radiator fan (C).

A
F. 25
E

Right half-fairing:
D
• Fuel pump (D)

• Immobilizer ECU (E)

• Right radiator

F. 26

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 SPIDER MAX 500 - EURO 3 D
DASHBOARD PANEL

• Release the screws (V2).

• Remove the dashboard panel (A), releasing it from the V2
locking tabs.

F. 27

LEG PROTECTOR

• Remove the key switch ring nut (A) rotating it

counterclockwise.

F. 28

• Release the retaining screws (V2) of the fusebox.

• Remove the transparent cover.
• Push forward the fusebox
• Release the screw (V).

V 5 ± 20%

V2

F. 29

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 SPIDER MAX 500 - EURO 3 D
• Release the three screws (V) inside the luggage
compartment.

F. 30

• Release the screw underneath (V1).

V1 5 ± 20%

V1
F. 31
• Release the screws (V3).
V3

V3 5 ± 20%

F. 32
• Unlock the luggage compartment closing transmission
cable from its seat (A).

F. 33
• Open slightly the footpeg until the plastic locking tabs
are released.

F. 34

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 SPIDER MAX 500 - EURO 3 D
• Extract the leg protector assembly, together with the
footpegs.

F. 35

• Remove the footpeg if necessary, release the

screws (V2).

V2

V2 1,5 ± 15%

F. 36

UPPER HANDLEBAR COVER V2

• Release the screws (V2) and remove the upper

handlebar cover (A).

V2 1,5 ± 15%
A

F. 37

ACCESSES
B
• Removing the front handlebar cover allows reaching
the terminals of the main wiring (B) and the four
screws for handlebar adjustment.

F. 38

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 SPIDER MAX 500 - EURO 3 D
FRONT AND REAR HANDLEBAR
COVER
V2
• Release the upper screws (V2).

V2 1,5 ± 15%

F. 39

• Release the outside screws (B2) and remove the front

handlebar cover (A). A
• Release the remaining four inside screws and remove
the rear handlebar cover (P).

B2 1,5 ± 15%

P
B2
F. 41

ACCESSES
A A
• Removing the front handlebar cover allows to reach the
two brake liquid pumps (A) and the two stop switches
(B).

B
B
F. 42

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 SPIDER MAX 500 - EURO 3 D
DRIVER SEAT

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

V2 A
V2 5 ± 20%

F. 43

• Remove the driver seat (A), releasing it form the

locking tab (B).

F. 44

C B

A
• Remove the driver seat (A).

F. 45

ACCESSES
D G

• Removing the driver seat, allows reaching the

following electronic components: H

A) Electronic injection ECU

B) Anti-tilting device
A
C) Autodiagnostics plug
D) Flasher M
E - F - G - H) Relays (Please refer: “Injection”
Manual)
C F
M) ECU ground
B
E
F. 46

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 SPIDER MAX 500 - EURO 3 D
PASSANGER SEAT
(including movable support) C

• Remove the Benzing ring (C) and release

the passenger seat shock absorbers.

F. 47

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

V2 10 ± 20%
V2

• Remove the seat together with the grab handle and

movable support.

• In order to release the passenger seat (B - F. 45) from

the movable support, first release the screws (V6). F. 48

V6 10 ± 20%

V5
V5

CUSHION DRIVER SEAT

• In order to remove the cushion (C - F. 45)

• Release the screws (V2 - F. 49).

Slackening the screws (V2) allows adjusting V6

the cushion travel according to the user’s
requirements.

GRAB HANDLE V2

• Release the screws (V5) and remove the grab handle

(D).

V5 30 ± 15%
F. 49

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 SPIDER MAX 500 - EURO 3 D
HELMET COMPARTMENT

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

F. 50

• Release the screws (V2a).

V2b
• Release the screws (V2b).
• Release the screws (V4a).
• Release the screws (V4b).

V2a 5 ± 15%

V2b 5 ± 15% V2b

F. 51

V4a 10 ± 20%

V4b 1,5 ± 15%

V4a

V2a

V4a
V4b

F. 52

• Release and extract carefully the helmet compartment

without removing it completely.

F. 53

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 SPIDER MAX 500 - EURO 3 D
• Disconnect the 12V plug cable from the back of the helmet
compartment.

F. 54

• Lift the helmet compartment,

disconnect the connector (A) and
release the cable from the clamp
(B).
• Remove the helmet compartment
completely.

F. 55

REAR FAIRING
• Release the two screws (V2).

V2 5 ± 15%

• Release the screw (V).

V 5 ± 15%

F. 56

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 SPIDER MAX 500 - EURO 3 D
• Release the screws (V4).

V4 1,5 ± 15%

V4 V4
F. 57

• Extract the entire fairing together with the tail lights.

F. 58

ACCESSES
A
D
C
• Removing the rear fairing allows
reaching the following
components:

Right-hand side:
A) Voltage rectifier
B) Coolant pump
C) Flywheel connector
D) Ground ends B

F. 59

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 SPIDER MAX 500 - EURO 3 D
Left side
A) Coil
B) Ground ends
B

A
F. 60

BATTERY COMPARTMENT

• Remove the seat (S/D - P. 34).

• Remove the fuel filler cap.

F. 61

• Release the screws (V2).

V2

F. 62

• Extract the dripproofing protection and the drain hose.

• Remove the battery compartment cover.

F. 63

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 SPIDER MAX 500 - EURO 3 D
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).

F. 64

• Release the screw (V) at the bottom of the battery

compartment and remove the compartment, extracting
the battery cables and fusebox.
V

V 10 ± 20%

F. 65

ACCESSES

• Removing the battery compartment, allows reaching the starting relay and the corresponding 30 A fuse (recharge
protection).

F. 66

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 SPIDER MAX 500 - EURO 3 D
AIRBOX
V8
• Release the screws (V8) and remove the cover (A).

F. 67

• Release the gas recovery hose (C).

F. 68

• Release the hose (B) from the

throttle body.
• Extract the airbox.
B

F. 69

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 SPIDER MAX 500 - EURO 3 D
FRONT MUDGUARD

• Release the screws (V2)

• Release the screws (V) and corresponding nuts (A).

V 3,5 ± 10%

V2 3,5 ± 10%

V2 A

V2

F. 70

LOWER FAIRING MUDGUARD

NOTE - To remove the lower fairing mudguard, first remo-

ve the front wheel (S/E - P. 43) and the front mudguard.

F. 71

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 MECHANICAL
SPIDER MAX 500 - EURO 3
COMPONENTS E
FRONT WHEEL

REMOVAL

Before removing the front wheel, check for the perfect stability 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.

ODOMETER SPROCKET

• Release the screw (V) and extract the odometer

sprocket (A).

V2

A
V
F. 1

(RIGHT AND LEFT) FRONT BRAKE CALLIPERS

• Release the screws (V2) and release the V2

entire callipers.

V1
V2 30 ± 20%

WHEEL SPINDLE
• Slacken the screw (V1) from the wheel spindle clamp.
B
• Release the wheel spindle (B) and extract it, taking care
not to damage spacer (C) and the spacer (B1 - F.4). F. 2

V6 11 ± 10%

(FRONT BRAKE) DISCS E

V6
• To separate the discs (D) from the front
wheel, release and remove the screws
(V6) and the washers (E).

D
Check the discs (D) for wear and
replace if necessary (service limit 4.5 D
mm). In case of abnormal wear or signs
of scoring, carry out grinding.

E
V6
When reassembling the (right and left brake)
discs observe disc rotation direction, which
can be determined by the position of the
slots (Please refer: F. 32 - P.52). F. 3

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 SPIDER MAX 500 - EURO 3 E
Do not actuate the brake levers without the wheel, as the pads would close.

FRONT WHEEL
REASSEMBLY V
When reassembling the wheel, observe rotation A
direction, which can be determined by the position
of the spokes of the rim (Please refer: F. 32 - P. 52).

To reassemble the wheel, proceed as follows: C

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

• Insert the wheel spindle (B) and the spacer (B1).
• Insert the spacer (C).
B
Do not exchange the spacer (B1) with the
spacer (C).
B1
Tighten the spindle (B) to the specified torque. F. 4

B 45 ± 15%

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

• Refit the odometer sprocket (pick-up) (A - F. 4) and secure
it by means of the screw (V).

V1 20 ± 15%

V 10 ± 15%

V1

F. 5
BRAKE MASTER CYLINDERS

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

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

• Remove the front and rear handlebar cover (S/D - P. 33).

• Release and extract the coupling (A). C
• Remove the tube (B) and the gaskets (C).
• Disconnect the Stop switch (S). A
B

S
F. 6

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 SPIDER MAX 500 - EURO 3 E
• Release the screws (V2) and remove the clamp (D).
• Remove the pump unit (E).
• In order to reassemble the unit lock (by means of V2
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 D
two new gaskets (C)
And tighten the coupling A to the E
specified torque. C

NEW
A 20 ± 10% V2 28 ± 15%

NOTE - After reassembling the hydraulic pump,

always refill the system with new liquid.
B A

F. 7

BRAKE CALLIPERS
An abnormal resistance or an excessive travel of the brake levers may indicate the braking system
malfunctioning.
The (front and rear brake) pad service limit is mm 1.5.

FRONT CALLIPER REMOVAL

To disassemble the front callipers. Please refer: (S/E - P. 43).

After removing the callipers from their housing, place a container underneath in order to let the liquid
drain from the hydraulic system and dispose of it in compliance to the law in force.

Do not use the brake lever after removing the callipers: the piston may jump off, causing brake liquid
leaks. The liquid is corrosive and may cause serious personal damage.

FRONT CALLIPER REPLACEMENT

NOTE - The front callipers have the same technical specifications but are one right and one left.

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

the gaskets (B).

V 20 ± 10%

V B
A
B
A
F. 8

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 SPIDER MAX 500 - EURO 3 E
FRONT CALLIPER DISASSEMBLY
In order to extract the pads:
• Release and remove the screw (V).

F. 9

• Shift downward the stop plate (A), in order to release the

pins (B) and extract them from the other side of the calliper
unit.
B

A
F. 10

• Remove the stop plate.

D 20 ± 20%

D
F. 11

• Extract the pins (B).

B

F. 12

• Extract the pads.

NOTE - It is possible to remove and replace the pads

without removing the brake callipers from the vehicle.

F. 13

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 SPIDER MAX 500 - EURO 3 E
• Release the nut (D - F. 11).
• Remove the floating support (S) from the calliper body,
including the two slide pins.

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

F. 14

• Check the dust seals (P - P1) for wear. In case of signs

of (even light) wear or damage, replace them. C
• Open by means of a screwdriver (or any other similar P
tool), the bracket (B) fins (A). Remember to wear safety A
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 V2
torque, lean the fins (A) as before (Please refer:
F. 11). B
A P1
F. 15
V2 20 ± 20%

• Blow with a small compressed air flow to extract the two

pistons from the calliper body.

F. 16

An excessive pressure may cause the two

pistons (E) to jump off violently.
E
E

F. 17

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 SPIDER MAX 500 - EURO 3 E
• Remove the dust seal (A) and the seal ring (B)
from both the pistons.
NEW
During this operation, take care not
to damage the dust seal and seal
ring housing.

• Make sure there are no signs of scoring on

the pistons and their housing.
• Clean carefully and wash only with alcohol.

Always use new dust seals and seal

rings.
Refit the pistons, the seal rings (B)
and the dust seals (A), greasing with
brake liquid.
F. 18

Complete the check, clean, replace

and refit all the components repeating FRONT CALLIPER
the disassembly operations in the
reverse order.

After servicing the braking system,

always check that:
• The brake liquid tubes are not damaged,
squeezed or twisted.
• The brake discs and pads are not soiled with
oil or grease;
• All the screws and couplings are properly
tightened.
• There are no leaks from the couplings.
F. 19

REAR CALLIPER REMOVAL

• Release the screws (V2).
A
• Extract the calliper unit (A), including the brake liquid feed
tubes.

V2 30 ± 20%
V2

F. 20

REAR CALLIPER REPLACEMENT

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

V 20 ± 10%

After removing the callipers from their

housing, place a container underneath to let
the hydraulic system liquid drain, and dispose
of it in compliance with the law in force. V A
F. 21

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 SPIDER MAX 500 - EURO 3 E
(REAR BRAKE) DISC
During the check and the service on the rear brake
calliper, check the disc conditions (C). If the disc is too
worn out, (service limit 3.5 mm), replace it, releasing
and removing the screws (V6), including their washers B
(D). In case of irregular wear or scoring, carry out the
grinding. V
D

V6 11 ± 10% F. 22 C V6

During the disc reassembly, observe the

rotation direction of the disc, understandable D
from the orientation of the lightening holes (as
shown in pictures). B

REAR CALLIPER DISASSEMBLY

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

F. 23

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

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

F. 24
• Let a little compressed air in, so as to let the two pistons
out of their seats in the two housing halves composing
the calliper.

F. 25

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 SPIDER MAX 500 - EURO 3 E
• Release and remove the screws (V2).

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

the two pistons fall.

V2 20 ± 20%

V2
F. 26

• Remove the two pistons (D).

• Remove the two O-Rings (E). D

NEW

NEW E
F. 27

• 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.

Always fit new seal rings and dust seals.

Refit the pistons, the O-Rings, the seal rings
NEW
and the dust seals, lubricating with brake liquid.

F. 28

At the end of each operation on the braking SYSTEM, always check that:
• The brake liquid lines are not damaged, squeezed or twisted.
• The disc and the brake pads are not soiled with oil or grease.
• All the screws and couplings are properly tightened.
• There are no leaks from the couplings.
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 SPIDER MAX 500 - EURO 3 E
BRAKING DISTRIBUTOR

NOTE - To access the braking distributor (A), remove the

central fairing (S/D - P. 24). V2

Drain completely the circuit.

• Release the screws (V2).

F. 29 A
V2 10 ± 20%

D NEW D

C
• Release the couplings (B).
• Remove the lines (C) and the gaskets (D).

B 20 ± 10% B
D
C B
C
F.
F. 30
15

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.

F. 31

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 SPIDER MAX 500 - EURO 3 E

DX SX
F. 32
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 SPIDER MAX 500 - EURO 3 E

F. 33

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 SPIDER MAX 500 - EURO 3 E
BRAKING SYSTEM BLEEDING
A B
A) 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 bleed the circuit of the integral system, first

bleed the rear brake calliper.
F. 34
• 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.
B 12 ÷ 16
• 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 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. 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

(S/B - P. 20).

B) FRONT LEFT CALLIPER

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

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 SPIDER MAX 500 - EURO 3 E
HANDLEBAR
V4
To remove the handlebar:
• Remove the handlebar cover: upper, front and rear
(S/D - P. 32 - 33).
• Cut the clips securing wiring, tubes, and 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).
F. 35
• Release the screws (V4).
• Remove the plate securing the handlebar (A).
• Remove the handlebar (C).

V4 30 ± 20%
Tighten in a criss-cross pattern.

B D

M
V4
A P
C

F. 36

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 SPIDER MAX 500 - EURO 3 E
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.

F. 37

F. 38 F. 39

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 SPIDER MAX 500 - EURO 3

F. 40 F. 41

F. 42

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 SPIDER MAX 500 - EURO 3 E
FORK
STANCHION GROUP
Make sure that the motorcycle is really stable; in case, put a suitable support under the engine. The
front wheel will have to protrude over the runaway edge of the lift.
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). V

• Release the screw (V).

F. 46

• Release the upper screw (V2).

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

V2
STANCHION DISASSEMBLY
Lock the stanchion group in a suitable vice,
carefully protecting the slider side with soft A
jaws, as to avoid squeezing or scoring.

The stanchion group contains oil. Therefore, do

not turn it over or tilt it while it is removed or its
internal components are disassembled. F. 47

The hydraulic oil is corrosive and may cause

serious personal damages. D
T
NOTE - The disassembly of the stanchion can be de-
ducted from the picture shown hereafter. V2
E

F
A 20 ± 15% V 30 ± 25%

V2 20 ± 15% G

CHECK THE OIL LEVEL IN THE STANCHION

If there is the “limit switch” of the front fork, or irregular
noise, check the oil level inside the legs of the fork, A
proceeding as follows: V
• Release the upper cap (A). B
• Remove the O-Ring (B).
NEW
• Carefully remove the spring (C) and let it drip off
completely the oil in which it was previously plunged. C
• Bring to the limit (downwards) the leg, keeping it in perfect
vertical position.

F. 48

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 SPIDER MAX 500 - EURO 3 E
• Using a meter or the stick of a gauge, check the proper oil level,
which should be at mm 140 from the upper edge of the leg.
• If necessary, top up with oil:

Q8 FORK OIL

140 mm
FRONT FORK OIL REPLACEMENT
F. 49
• Place a suitable container under the stanchion and remove
the screw (V).
• Allow as much oil as possible to drain out. V 30 ± 15%
• 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 pour the new oil in the leg.Carefully pour the new oil in the leg.
V
Quantity per leg 370 cc
• Check the oil level, as previously described. V
• Refit the components of the legs and the legs themselves on the
motorcycle. F. 50

COMPLETE FORK
Place a suitable support under the engine. The front wheel will have to protrude over the runaway edge of
the lift , so that the fork can be removed, together with the wheel, if necessary (in order to remove the front
fork, the front wheel does not have to be removed).

NOTE - To remove the complete fork, first remove:

• front fairing (S/D - P. 27)
• front mudguard (S/D - P. 42)
• Front wheel (optional) (S/E - P. 43) D
• brake callipers (optional) (S/E - P. 45) 28 ± 15%
• 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 fall off.

Upper ball bearings

Sfere superiori CF==n°No.
... Ø18...¯1/4”
Lower ball bearings
Sfere inferiori D=G n°
= No.
... Ø18... ¯ 1/4”

• Before refitting the front fork, clean all the components, eliminating any sign of grease.
• Check the conditions of the components, and replace them, if necessary.
• Grease the ball bearings and their seats and reassemble the front fork.

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 SPIDER MAX 500 - EURO 3 E
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.

F. 52

F. 51

F. 53

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 SPIDER MAX 500 - EURO 3 E

F. 54

F. 55

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 SPIDER MAX 500 - EURO 3 E
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.

F. 58

F. 59

F. 60 F. 61

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 SPIDER MAX 500 - EURO 3 E
FUEL TANK
Fuel fumes are highly toxic, and therefore harmful to your health.
Ventilate the room before proceeding and, if necessary, wear a protection mask.

Do not remove the tank, unless the latter has been previously emptied.

Do not smoke, nor use bare flames.

Do not carry out any the operation while working and producing sparks (such as welding, grinding, etc.).

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.

F. 62

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).
• Refit the original cap on the fuel filler, to prevent dirt from
entering the fuel tank, during the frame removal
operations.
B

F. 63

• Release the screws (V4)

V4 10 ± 20%

T V4
F. 64

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 SPIDER MAX 500 - EURO 3 E
• Extract the couplings (1 - 2) of the fuel pump, pressing
down with two fingers on the ring nut, at the base of the 1 2
couplings.

F. 65

• The coupling (1) (with the grey tube) has to

be fitted in the coupling (3) (with grey ring 1 2
nut).
• The coupling (2) (with the black tube) has
to be fitted in the coupling (4) (with the black
ring nut).

3 4
F. 66

• Disconnect the connector (A) of the fuel pump.

A
F. 67

• The fuel tank is blocked, in its rear side, by the two Silent
Blocks (B).
B

F. 68

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 SPIDER MAX 500 - EURO 3 E
• Extract the tank, sliding it from the front side of the frame,
downwards.

F. 69 T

• Disconnect the tube (C).

• After extracting the tank, release the screw (V - F. 64 -
69), releasing it from the support (T - F. 64 - 69).

F. 70

FUEL SUPPLY PUMP

A
• The procedure to remove the fuel supply pump (A) and
its float (B), can be understood from the picture on the C
side.
• Check the conditions of the gasket (C) and replace it, if
necessary.
• Carefully clean the mesh filter (D).
D
NOTE - All of the information on the pump can be de-
ducted by reading the Manual “Injection”.

F. 71

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 SPIDER MAX 500 - EURO 3 E
RADIATORS (including lines and
expansion reservoir) C1
• Remove the fairing (S/D - P. 24).
• Remove the leg protector (S/D - P. 30).
• Wait for the engine to cool down completely. B1
• Put a suitable container under the coolant pump (A).
• Remove the clip (B).
• Detach the tube (C) and fit it in the container.
• Remove the cap (D - F. 73) from the expansion reservoir. C
• In case radiators have to be removed together with lines, B
slacken the clip (B1) and detach the tube (C1). A
F. 72 V6

• Let the liquid completely drain into the container. Pour

the spent liquid in a container suitable for its ecological
disposal.

The coolant is potentially polluting, therefore it D E

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.

F. 73

• Disconnect the connector of the electrical fan wiring.

F. 74

Release the bleed screws (V) on both the radiators,

releasing both ground cable ends (M).

V
M
F. 75

• Cut all the clips securing the lines composing the cooling system circuit.

After refitting any of the components of the cooling system, fix the lines with new clips, in the
same position as before, and fix the ground cable end (M - F. 75) again, both to the right radiator
as well as to the left radiator.
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 SPIDER MAX 500 - EURO 3 E
RIGHT RADIATOR

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

(A).

V A
10 ± 20%
V

F. 76

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

V2 10 ± 20%

V2
• Remove the right radiator.

F. 77

NOTE - The radiators are fitted on Silent blocks (B); first

release them from the lower ones, and then extract them
from above.
While reassembling, first fit the radiators on the
upper silent blocks.

F. 78

V2

LEFT RADIATOR (including the electrical fan)

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

V2 10 ± 20%

• Remove the left radiator, including the electrical fan.

F. 79

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 SPIDER MAX 500 - EURO 3 E
ELECTRICAL FAN RADIATOR

NOTE - Please refer: (S/F - P. 88).

EXPANSION RESERVOIR V2
(coolant tank)
Drain the coolant from the circuit, as previously
described.

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

• Release the screws (V2). F. 81

• Release the screw (V) and remove the expansion

reservoir.

V2 10 ± 20%

V 10 ± 20%

F. 82 V

THERMAL EXPANSION VALVE

S
A
NOTE - The cooling system includes two thermal
expansion valves:

A - Thermal expansion valve for the right radiator

adjustment

• To remove it, release it from the clips (F) and slide it from
the support (S).

F. 83

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).

S B
F. 84

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 SPIDER MAX 500 - EURO 3 E
COOLANT CIRCUIT
FLOWCHART

F. 85

KEY

1) Main Radiator (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°

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 SPIDER MAX 500 - EURO 3 E
HOSE ROUTING (right-hand 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.

F. 86

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 SPIDER MAX 500 - EURO 3 E
HOSE ROUTING (left-hand side cooling circuit)

F. 87

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 SPIDER MAX 500 - EURO 3 E
BLEEDING, COOLING CIRCUIT
A
To 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 reservoir with coolant, as

described: (S/B - P. 16).
F. 88

• 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 bleed nipple (coupling - A) and fill in up
to the rim of the main radiator. B

F. 89

• 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 C
tubes for liquid dripping, showing that the bleeding has
been correctly carried out.
• Close the coupling (A) back.
F. 90

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), which act as the ground
screw.
• Open the bleed nipple on the cylinder head and check D
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. F. 90/a
• Check the main radiator is completely refilled with coolant;
top up and refit the filler (B), if necessary.

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 SPIDER MAX 500 - EURO 3 E
SUBFRAME
NOTE - The subframe is made up of three parts (F. 93):
1 - Upper subframe
2 - Right-hand side subframe
3 - Left-hand side subframe

• To remove the subframe from the central aluminium frame, first remove all the components described up to this
paragraph.
• Cut all the clips from the subframe and release the different wirings.
• Disconnect the connectors of the electrical components to be removed.

• Disconnect the connector (A) from the switch placed on

the side stand.
• Remove the immobilizer ECU (B) (S/F - P. 86).

B
A

• While reassembling, refit the wirings and fix

them to the subframe, with new clips (as
before).

F. 91

E
D

• Release the screw (V) and release the lines of the brake
oil (D - E).
• Remove the braking distributor (F) (S/E - P. 51). V

V 10 ± 20%
F

F. 92

UPPER SUBFRAME (F. 93)

• Release and remove the two screws (V) and their washers.
• Release and remove the screws (V2) and their washers.
• Separate and extract the upper subframe (1) from the two side subframes.

SIDE SUBFRAMES (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 made up of the two symmetrical parts.
• Release (on both sides) the screws (V4) securing the aluminium frame to the rear frame.
• Release the central screws (V2a) and remove the spacer between the two half-frames.
• Release the lower screws (V2b) and remove the spacer (A).
• Release and remove the upper screws (V6) with their washers and nuts. Moreover these screws secure the headstock (B).
• Separate the two aluminium “half-frames“.

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 SPIDER MAX 500 - EURO 3
V6

1 V2

V2a

2 V4
V3

V3

M8 M10

A V2b
F. 93

V 10 ± 15% V2 10 ± 15% V2a 60 ± 15% V2b 60 ± 15% V3 25 ± 15%

V4 60 ± 15% V6 25 ± 15% M8 25 ± 15% M10 55 ± 15%

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 SPIDER MAX 500 - EURO 3 E
FRAME DIMENSION CHECK
• If the motorcycle has had an accident, which “appear” to have caused 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.

F. 94

F. 95

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 SPIDER MAX 500 - EURO 3 E
EXHAUST

Before operating on the exhaust and on the

exhaust manifold, wait for the components to
cool down and wear, always and in any case,
suitable safety gloves.

EXHAUST
• Slacken the screw (V) of the clip securing the exhaust/
exhaust manifold. V
F. 96
• Release and remove the screws (V3).
V3

V3 25 ± 15%

V3

F. 97

The upper screw (V3) has a nut (A).

V3
A

F. 98

• Extract the exhaust and its heat protection and the clip
securing it to the exhaust manifold.

F. 99

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 SPIDER MAX 500 - EURO 3 E
EXHAUST MANIFOLD
A
• Disconnect the Lambda sensor connector (A).

F. 100

B
• Release the cable from the two hose clamps (B).

F. 101

• Release the two nuts (C).

• Remove the exhaust manifold (D).
• Remove the gasket.
C

C 30 ± 10%

While reassembling, always use a new gasket.

F. 102

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 SPIDER MAX 500 - EURO 3 E
LAMBDA SENSOR
Removal
• Slacken the Lambda sensor (A) from the exhaust manifold
using a suitable locking system in order not to damage
the manifold.

F. 102/a

Reassembling
• Screw the Lambda sensor down with along cable and
connector.
• Tighten to the prescribed torque.

A 45 ± 15%

F. 102/b

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 SPIDER MAX 500 - EURO 3 E
REAR SHOCK ABSORBERS

Before carrying out any operation in the rear

shock absorbers, prepare a system ensuring
the vehicle perfect stability even without
shock absorbers.

NOTE - If during the operation the shock absorbers are

V2I
not to be completely removed, simply release the shock
absorbers, by releasing the lower screws (V2).
F. 103

V2S

• To completely remove the shock absorbers, release and

remove the upper screws (V2S) as well.

V2I

F. 103/a

V2S
R
D

D
R
V2S During both the removal and the
reassembly of the rear shock
absorbers, remember that the
V2I lower and the upper screws have
R washers (R) and nuts (D).

D
D V2I 30 ± 15%
R

V2S 45 ± 15%
V2I

F. 103/b

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 SPIDER MAX 500 - EURO 3 E
REAR ARM
Before removing the rear arm (A), check that the vehicle is in perfectly stable conditions.

After removing the exhaust (the exhaust manifold does not have to be removed) and releasing the shock absorbers,
as described in the previous pages, proceed as follows:

• Release the screw (V) and release the plate securing the
shock absorber (C) from the arm (A).
• Release the nuts (B). B

C V2
B 33 ÷ 41
A

V
V 30 ± 10%
V
F. 104

Remove:

• Anti-vibration O -Ring (1)

• Spilt pin (2)
• Cover (3)
1
• Release the underlying nut (D).
• Remove the shim (S) and release the arm (A).
3

D 100 ± 15%
2

F. 105

NEW D
3 S
During the removal and the reassembly of the
rear arm, make sure to place the two spacers NEW
2
between arm/wheel and arm/nut (D).
1

SHOCK ABSORBER SUPPORTING PLATE

Right: if the shock absorber and the exhaust have

already been released, in order to remove the
F. 106
plate supporting the shock absorber (C - F. 104),
simply release the screw (V - F. 104) and remove
the washers and nut.

If the exhaust has not been removed, release A

the exhaust upper screw (V3 - F. 98).

F. 107

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 SPIDER MAX 500 - EURO 3 E
Left: after releasing the shock absorber, release the
screws (V2) and remove their washers and nuts.

V2 30 ± 10%

V2

F. 108

REAR WHEEL
NOTE - To extract the rear wheel, first remove the brake
calliper, and the exhaust.
• Release and remove the screw (V) securing the right
shock absorber, on the rear arm.
• Remove the washers and the nut.
• Once the shock absorber has been released, move it
upwards and hold it, so that it will not impede the
subsequent operations.
• Remove the rear arm, as described in the previous page. V
• Extract the rear wheel.
F. 109
V 30 ± 10%

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 wirings connected to the engine. V2
• Release the screws (V2) (double ground screws on the
starter motor). F. 110
• Disconnect the accelerator transmission cables (A).
• Disconnect the manifold (B) from the thermal expansion
valve. A

Do not cut nor damage the transmission cables

of the accelerator control, since they are not to
be replaced during the reassembly of the engine.

To make the removal easier, we suggest to

remove the rear wheel after sliding the engine
from the frame.
B
F. 111

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 SPIDER MAX 500 - EURO 3 E
• Slacken the clips and release the coolant manifolds from
the pump. P
Place the coolant manifolds so that they will
not impede the engine removal, taking care not
to bend nor damage them.

F. 112

Support suitably the engine with systems

ensuring both the top safety for the operators
during the removal, as well as the perfect
stability of the vehicle, before, during and after
the operation. Bear in mind that only the left
shock absorber will be kept “active”, once the
engine will be removed.

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

• Detach the engine shaft (P - F. 112).
• Extract carefully the engine, using safety gloves and an
assistant. D

F. 113

ENGINE REASSEMBLY
B
• 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 the prescribed torque.

D 65 ± 15%
C
While reassembling, do not exchange spacer
(B) with spacer (C).

F. 114

ENGINE MOUNT
A
To remove the engine mount (A) (after removing the
engine), proceed as follows:

• Release the self-locking nut (B).

• Slacken the lock nut (D).
• Release the threaded bushing (C).
D

F. 115

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 SPIDER MAX 500 - EURO 3 E
• Detach the (upper) mount shaft (E).
• Remove the engine mount and the spacers.
E
While reassembling, take care not to interfere
and exchange the spacers, which will have to
be lubricated with bearing grease.

F. 116

ANTI-VIBRATION CONNECTING RODS

• After removing the engine and its mount, release

the nut (F - F. 118).

• Remove the screw (V) and the washer (G).

• Remove the anti-vibration connecting rods (H).

V 65 ± 15% V

F. 117

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 E
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 X
torque. D
C
C 10 ± 15% Y B

B 35 ± 15%
A
U
If the bushing (C) was X
H
tightened too much, it may
cause annoying vibrations
V
to the vehicle and
irreparable damages to the G
Y
bearing (U). F. 118 H
F
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 ELECTRICAL AND
SPIDER MAX 500 - EURO 3 ELECTRONIC
COMPONENTS
F
LIGHTING SYSTEM

G
F
G

B D
E

A B

F. 1

LAMPS
A) (Front) parking light: 12V - 5W (W5W)
B) 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)

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 SPIDER MAX 500 - EURO 3 F
DASHBOARD
• To remove the dashboard, please refer: S/D - P. 26.

BULB CHANGE
The burnt out bulbs always have to be replaced
with new ones, with the same specifications.

PARKING LIGHT
• To access the bulb of the parking light, remove the central
fairing: S/D - P. 24.

FRONT HEADLIGHTS (ACCESS)

F. 2
• 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 DIRECTION INDICATORS

• The bulb holders of the front direction indicators are in-
tegrated in the front headlights.
• To access the bulbs of the front direction indicators, re-
move the inserted side covers (A).
A

F. 4

B C

DIRECTION INDICATORS AND TAIL LIGHTS

• Lift the 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.

F. 5

FRONT HEADLIGHTS

• To remove the front headlights, first remove the front fairing (S/D - P. 27).
NOTE - The front fairing is made up of two parts. In order to operate only on one headlight, divide and remove the
concerned part, after disconnecting the wiring connector.
The front headlight glass cannot be replaced. If the glass is broken, replace the whole headlight.

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 SPIDER MAX 500 - EURO 3 F
TAIL LIGHTS
• Tail lights can be accessed by removing the helmet com-
partment (S/D - P. 36) and the rear fairing (S/D - P. 37).
• Disconnect the wiring. V3
• Release the screws (V3).
• Remove the cable clamps (A).
• Remove the headlight concerned.

While reassembling, refit the cable clamps as

before.
A
The tail lights glass cannot be replaced. If it is
F. 6
broken, replace the whole headlight.

HORN

NOTE - To access the horn (A) first remove the front

fairing.

• Disconnect the two clamps (B).

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

While reassembling, take care not to invert the A V

fitting of the Faston connectors.
Blue cable (+)lower terminal F. 7
Orange cable (-) upper terminal.

V 10 ± 20%
B

IMMOBILIZER ECU
A
After removing the front right fairing (S/D - P. 27):
• Disconnect the three connectors (D).
• Release the screws (V2).
• Remove the Immobilizer ECU (E).

V2 10 ± 20%
F. 8

If the Immobilizer ECU is replaced, store two or

more ignition keys. (please refer:
DIAGNOSTICS MANUAL of the ELECTRICAL
SYSTEM AND EMS INJECTION SYSTEM,
chapter “Immobilizer”).

Before refitting the different connectors, make V2

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

F. 9

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 SPIDER MAX 500 - EURO 3 F
KEY SWITCH
NOTE - First remove: front fairing (S/D - P. 27) and leg
protector (S/D - P. 30).
• Disconnect the seat opening transmission cable (A).
• Disconnect the helmet compartment opening transmis- V2
sion cable (B).
B
Take care not to damage the cables during the
operation. Squeezing or cuts of some of the
fibres of the cables imply their complete
replacement. A
• Disconnect the two-way connector connected to the Im-
mobilizer (S/F - P. 86) (F. 9).
F. 10

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

To disassemble the key switch, use the special

insert: “Torks t 30” for special screws.

cod. 08606600 C

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 V2
ELECTRICAL SYSTEM AND EMS INJECTION
SYSTEM).
F. 11 V2

V2

SIDE STAND SWITCH

• Release the screws (V2).

• Remove the switch (A).

V2 5 ± 20% V2
A

• Open the front fairing. F. 12

• Disconnect the connector (B) and detach the whole wiring
(if necessary), after releasing its clips.
B
NOTE - While assembling a new complete wiring, refit new
clips, placed and fixed as before.

F. 13

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 SPIDER MAX 500 - EURO 3 F
ELECTRICAL FAN

• Remove the fairing (S/D - P. 24).

• Remove the leg protector (S/D - P. 30).
• Cut the clip securing the electrical fan wiring.

NOTE - While reassembling, use a new clip, like the origi-

nal one and fixed as before.

F. 14

• Release the screws (V3).

• Disconnect the connector of the electrical fan wiring. • Remove the electrical fan (A) from the radiator.

V3 2 ± 20%

A
V3

F. 15 F. 16

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

A) 15 A Lights
B) 7.5 A Stop + Direction
indicators
C) 5A ECU under the panel
D) 5A Relay
E) 25 A Main fuse
F) 10 A Coil - Pump fuel - Injector
G) 7.5 A Electrical fan
H) 3A ECU supply support

• To replace one or more fuses, simply open the F. 17

central door of the leg protector and extract the
burnt 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
F. 18
case of short circuit.
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 SPIDER MAX 500 - EURO 3 F
BATTERY ASSEMBLY
• The battery is placed in the central tunnel.
• To access the battery compartment, first remove the seat (S/D - P. 34).
• Please refer further S/D - P. 39.
• After suitably charging the battery, apply some adhesive tape, taking off the two protection films placed on the edges
on the adhesive part (P).

• Extract from the battery compartment the wiring with the

red cables (+) and the two black cables (-).
• Connect the wiring cable ends to the battery terminals.

Never invert the cables connection.

• Fit the battery inside the compartment.

• Place properly the wiring cables.
• Refit:
- Battery compartment cover
- Dripproofing protection (fuel) and drain hose.
- Fuel filler cap
- Seat

Before refitting the removed parts, we suggest to

test the “control panel” in order to check the
connections are properly fitted.

The original battery, supplied by “Malaguti”, is

a hermetic type (12V - 14A). If replaced, install P
a battery having the same specifications. In
fact, the battery compartment cannot host a
battery with a drain hose. 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
specifications different from those indicated by “Malaguti”.

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

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

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

It is important to keep the battery always completely charged; therefore, in winter or when the vehicle is not
used, it should be recharged at least once a month. When the battery is left flat, it is highly degraded,
sometimes irreversibly.

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SPARK PLUG

Replace every 12.000 Km

• To access the spark plug cap, remove the inserted left

side cover (A).

• Remove moderately the cap (B), slightly rotating it in the

two directions.

• Remove the spark plug (C) when the engine is still hot A
(taking care to avoid burns).

• The carbon deposits and the colour of the insulating ma-

terial (around the central electrode) give useful informa-
tion on the heat rating of the spark plug, on the carbu-
F. 20
retion, on the lubrication and on the general conditions
of the engine.
• The light brown colour (of the insulating material) shows
the proper general functioning.
• Black, dry (to touch), sooty and tarnished deposits
show that the functioning temperature is too low (the heat
rating of the spark plug is too high), carburetion too
rich or faulty ignition.
• Whitish insulating material shows an “extremely light”
mixture or the heat rating of the spark plug too low
(spark plug too “hot”).
B C
Check and clean every 6.000 km. F. 21

• 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
entering the engine and refit it by tightening it by hand all
Cs - N*m
the way in; then, tighten it to the prescribed torque.
12 ÷ 14

Spark plugs with heat rating different from the

one deductible from the abbreviations
suggested, can seriously damage the engine.
F. 22
Spark plugs suggested:CHAMPION RG6YC
NGK CR7 EKB

COIL

NOTE - To access the coil, remove the rear fairing

(S/D - P. 37).

• Disconnect the connector (A).

• Release the screws (V4).
• Remove the coil (B).
A B V4
F. 23

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VOLTAGE RECTIFIER
A V2
NOTE - To remove the voltage rectifier, first remove the
rear fairing (S/D - P. 37).

• Release the screws (V2).

• Remove the wiring cable ends from the right screw
• Remove the voltage rectifier (A).
• Disconnect the flywheel connector (A1), if necessary.

A1

F. 24

ELECTRONIC INJECTION ECU

A
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).

F. 25

• Release the screws (V4).

• Remove the ground cable end (B) on the ECU (C) (do 1
not forget to refit it during the reassembly of the ECU).

4 3

B V4

F. 26

• Extract the ECU (C) with care, since it is fixed to the

D
underlying connector (D).

F. 27

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 SPIDER MAX 500 - EURO 3 F
ECU MOUNT REMOVAL
• After removing the Electronic injection ECU, disconnect
the connector (A) of the flasher (B).
B

• Extract the relays (1 - 2 - 3 - 4) (F. 26) and remove their A

supports, releasing their screws.

F. 28

• Extract the starting relay (C), including

the 30A fuse (battery recharge
protection).

If the starting relay is replaced,

take special care to the assembly
of the red and blue cable (Please
refer: DIAGNOSTICS MANUAL of
the ELECTRICAL SYSTEM AND
EMS INJECTION SYSTEM).
C
F. 29

• Release the two front screws (V2).

V2

F. 30

• Release the rear screw (V1) (placed under the red relay
support).

V1

F. 31

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 SPIDER MAX 500 - EURO 3 F

• Disconnect the connector of the anti-tilting device.

F. 32

• 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.

F. 33

ACCESSES
A) Injector A C
B) Engine temperature sensor
C) Engine rpm sensor
D) Potentiometer connector (TPS) throttle D
body
E) Stepper motor.

NOTE - All of the information concerning

these components can be deducted by
reading the DIAGNOSTICS MANUAL of
the ELECTRICAL SYSTEM AND EMS
INJECTION SYSTEM.
E

F. 34

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 SPIDER MAX 500 - EURO 3 F
COMPLETE WIRING
NOTE - The pictures hereafter show all of the wirings on the vehicle, intended for the check of the original cable routing,
in case they are removed.
The wirings have to be refitted in the way established by “Malaguti”, 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 faster
identification of the routing of the concerned wiring.

F. 36

F. 37

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F. 38

F. 39

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F. 40

F. 41

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F. 42

F. 43

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F. 44

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F. 45

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F. 46

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F. 47

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F. 48

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F. 49

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F. 50

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