PIAGGIO X9 500 cc Manuel utilisateur
SERVICE STATION
MANUAL
Piaggio & C. S.p.A.
Pontedera
After Sales Service
Dis. 594523 - 04/01
Grafica e Stampa:
C.L.D. - Pontedera (PI)
“© Copyright 2001 - PIAGGIO & C. S.p.A. Pontedera.
All rights reserved. Reproduction, in whole or in part, forbidden.”
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
10
9
8
7
6
5
4
3
2
1
1
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
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
- 0.15 D = 0.20 - 0.40
01_007
Crankshaft/connecting rod axial clearance
0
- 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
2
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
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
Warning
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