PIAGGIO X9 500 cc Manuale utente

SERVICE STATION

MANUAL

Piaggio & C. S.p.A.

Pontedera

After Sales Service

Dis. 594523 - 04/01

Grafica e Stampa:

C.L.D. - Pontedera (PI)

Data subject to change without notice.

No responsibility is assumed for the use of non-genuine components and accessories other than those tested

and approved by the Manufacturer.

• X9 500 cc

SERVICE STATION

MANUAL

X9 500 cc

This manual has been designed by Piaggio for use in authorized dealers' and subdealers' workshops.

It is assumed that those who use this publication for maintaining and repairing Piaggio vehicles are familiar with the

principles of mechanics and with vehicle repairing procedures and techniques. Any significant changes to the

characteristics of the vehicles or to specific repairing procedures will be covered in updates of this manual.

Since satisfactory results cannot be obtained without the necessary equipment and tooling, we recommend referring

to the pages of this manual concerning the specific equipment required and to the catalogue of specific tools.

Pieces of particularly important information are identified as follows:

Note: Provides important information intended to simplify and clarify a procedure.

- Denotes specific procedures to be used to avoid damaging the vehicle.

- Identifies specific procedures to be followed to avoid injury to repairing personnel.

NOTE - For any intervention to the engine, refer to the “Service Station Manual” for 500 cc Engines.

Warning

Caution

TABLE OF CONTENTS

VEHICLE SPECIFICATIONS

AND OVERHAUL DATA

SPECIFIC TOOLING

MAINTENANCE AND TROUBLESHOOTING

ELECTRICAL EQUIPMENT

FRONT AND REAR SUSPENSIONS

BRAKING SYSTEM

BODYWORK

PREDELIVERY OPERATIONS

TABLE OF WORKING TIMES

ENGINE

1 - 7

PART DIMENSIONS MATING CLASSES ASSEMBLY

CODE CYLINDER PISTON CLEARANCE

Cylinder 92 - 0.010 A 91.990 - 91.997 91.947 - 91.954

Ø C B 91.997 - 92.004 91.954 - 91.961

Piston 91.961 + 0.014 C 92.004 - 92.011 91.961 - 91.968

Ø P D 92.011 - 92.018 91.968 - 91.975

+ 0.018

Vehicle overhaul data

Assembly plays

Mating between piston and cylinder

01_004

0.036

0.050

01_005

Piston rings

PART DIMENSIONS CLEARANCE SEAT CLEARANCE

CODE CLEARANCE AFTER USE

1st Compression ring 92 x 1.5 A 0.15 - 0.35 0.5

2nd Compression ring 92 x 1.25 A 0.25 - 0.50 0.65

Scraper ring 92 x 2.5 A 0.25 - 0.50 0.65

(Values in mm)

The piston must be fitted so that the arrow faces the exhaust side. The piston rings must be fitted so that the marks

face upwards.

DIAMETER

MEASURING

HEIGHT

A 43.2

B 43

(Values in mm)

- 0.014

Ring opening

Arrange for the

piston rings

opening as shown

in the figure

“A” value of the ring

inside the cylinder

Assemble the rings

2 and 3 with the

“Top” writing facing

upwards.

(Values in mm)

1 - 8

SHIMMING METHOD FOR LIMITING THE COMPRESSION RATIO: CR = 10.5 : 1

FIT THE GASKETS SHOWN IN THE TABLE

ACCORDING TO THE “A” MEASUREMENT

“A” MEASUREMENT

(WITH PISTON AT TDC)

NOTE: THE “A” MEASUREMENT MUST BE TAKEN WITH NO

GASKET FITTED BETWEEN CRANKCASE AND CYLINDER

01_006

Vehicle overhaul data

N.B.: The “A” measurement is referred to the piston

projection or recess value; it indicates the type of

gasket to be fitted on the cylinder to restore the

compression ratio. Therefore the more the surface

formed by the piston crown sticks out of the surface

formed by the cylinder top, the thicker the gasket will

be. Vice versa, the more the piston crown is hollow to

the cylinder top, the less thick the gasket will be.

Crankshaft/crankcase axial clearance 0.1 - 0.5 mm (cold engine)

01_010

“A” MEASUREMENT THICKNESS OF BASE GASKET

- 0.185 - - 0.10 0.4 ± 0.05

- 0.10 - + 0.10 0.6 ± 0.05

+ 0.10 - + 0.185 0.8 ± 0.05

1 - 9

Vehicle overhaul data

Crankshaft alignment and diameters

- Measure the housings on both axes x and y.

01_008

01_009

Max. allowable runout: A = 0.15 mm

B = 0.01 mm

C = 0.010 mm

D = 0.10 mm

Standard diameter

Class 1 40.010 - 40.016

Class 2 40.016 - 40.022

PART DIMENSIONS CLEARANCE

Web, transmission side A =0.8 ± 0.025

Shaft section, transmission side B =19.6 + 0.05

Connecting rod C =22 - 0.10

Shaft section, flywheel side E =19.6 + 0.05

Web, flywheel side F =13 ± 0.025

Crankshaft assembly G =63.5 + 0.1

- 0.15 D = 0.20 - 0.40

01_007

Crankshaft/connecting rod axial clearance

- 0.05

TABLE OF CONTENTS

SPECIFIC TOOLING 2

2 - 2

Specific tools for Piaggio X9 500 cc 4-stroke 4-valve

Specific Tooling

RECOMMENDED TOOLS

TOOL NAME PART NO.

Circlip pliers 002465Y

Steering thrust ring removing drift 020004Y

Crankshaft aligning tool 020074Y

Support for “METABO HG 1500/2” air heater 020150Y

“METABO HG 1500/2” air heater 020151Y

Mityvac-type vacuum pump 020329Y

Stroboscopic gun for two- and four-stroke engines 020330Y

Digital multimeter 020331Y

Single battery charger 020333Y

Multiple battery charger 020334Y

Magnetic stand and dial gauge 020335Y

Engine support connection 020482Y

Engine mount base 020527Y

Engine mount revolving base 020604Y11

= New tools

2 - 3

NECESSARY TOOLS

TOOL NAME PART NO.

STEERING SEAT FITTING TOOL, to be fitted with parts 9 - Lower 001330Y

bearing adaptor, 10 - Upper bearing adaptor

Bell Ø 80 mm 001467Y002

20 mm pliers 001467Y006

Bell Ø 63 mm 001467Y007

18 mm pliers 001467Y008

Bell Ø 45 mm 001467Y017

Bell Ø 60 mm 001467Y031

15 mm pliers 001467Y034

Hub bearing extraction bell 001467Y035

Steering tube ring spanner 020055Y

Oil pressure gauge 020193Y

Valve seal rings assembly tool 020306Y

37x40 mm adaptor 020358Y

42x47 mm adaptor 020359Y

52x55 mm adaptor 020360Y

20 mm guide (Driven pulley bearings) 020363Y

25 mm guide (Driven pulley bearings) 020364Y

Ø 28x30 mm adaptor 020375Y

Adapter sleeve 020376Y

Bushing (valve removing tool) 020382Y012

15 mm guide 020412Y

Valve oil seal extractor 020431Y

Oil pressure gauge unio 020434Y

17 mm guide (countershaft bearings) 020439Y

Driven half pulley spring compressor 020444Y

46-55 mm spanner 020444Y009

Ø 24 mm adaptor 020456Y

Steering tube lower bearing extractor 020458Y

Drift for fitting bearing on steering tube 020459Y

Injection tester kit 020460Y

Flywheel extractor 020467Y

Piston fitting band 020468Y

Injection tester reprogramming kit 020469Y

Piston pin retainer fitting tool 020470Y

Countershaft timing peg 020471Y

Flywheel retaining tool 020472Y

Clutch bell housing retaining tool 020473Y

Drive pulley stop spanner 020474Y

Piston position comparator support 020475Y

Pillar kit 020476Y

Ø 37 mm adaptor 020477Y

Driven pulley needle roller drift 020478Y

Countershaft stop spanner 020479Y

Fuel pressure measuring kit 020480Y

Control unit interface wiring harness 020481Y

30 mm guide 020483Y

Piston stop fork 020512Y

Compass wrench (valve lifter bell stop) 020565Y

Exhaust gas analyser 494929

Specific Tooling

3 - 3

Maintenance

Spark plug

Check and replacement

- Remove the spark plug when the engine

is cold. Replace the spark plug every 12,000 km. The

use of unsuitable ignition control units and spark plugs

other than those specified can seriously damage the

engine.

Recommended spark plug: CHAMPION RG 6 YC

NGK CR 7 EKB

- Put the vehicle on the central stand.

- Open the door on the left side of the vehicle by

levering in the recess in the lower part of the door after

removing the screw.

- Disconnect the spark plug HV cable cap.

- Unscrew the spark plug with the spanner provided.

- Check the spark plug to see if the insulator is cracked,

the electrodes are worn out or excessively sooty. Also

check the condition of the seal washer and measure

the spark gap with a suitable thickness gauge.

Spark gap: 0,7 - 0,8 mm

- If necessary adjust the spark gap by carefully bend-

ing the side electrode.

If the spark plug has any of the defects mentioned

above, replace it with a plug of the recommended

type.

- Insert the plug into the hole with the proper inclina-

tion, screw it in fully by hand and then tighten it with

the specially designed spanner.

Tightening torque: 10 N·m (1 Kg·m)

- Push the spark plug cap all the way down onto the

spark plug and then proceed to the reassembly.

03_002

03_001

Warning

Air filter

- Remove the left-hand lower side panel as described

in Chapter 8-Bodywork.

- Remove the cleaner cap after loosening the eight

fixing screws, including one screw of the knob type.

- Pull out the filter element.

- Replace the air filter with a new one.

Note: Check and if necessary blow the air filter every

6,000 km. Direct the air jet from the inside to the outside

of the filter (i.e. in the opposite direction to the air flow

during normal engine operation).

- If the vehicle is mostly used on dusty

roads, the air filter needs to be cleaned and replaced at

shorter intervals than indicated in the Maintenance

Schedule.

- Do not run the engine if the air filter is not

in place as this would result in excessive wear of the

cylinder and piston as well as in damage to the throttle

body.

03_004

03_003

Warning

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