PIAGGIO X9 500 cc Service Manual
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PIAGGIO X9 500 cc Service Manual

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SERVICE STATION
MANUAL
• X9 500 cc
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.

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  • Page 1 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...
  • Page 2 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.
  • Page 3 TABLE OF CONTENTS VEHICLE SPECIFICATIONS AND OVERHAUL DATA SPECIFIC TOOLING MAINTENANCE AND TROUBLESHOOTING ELECTRICAL EQUIPMENT ENGINE FRONT AND REAR SUSPENSIONS BRAKING SYSTEM BODYWORK PREDELIVERY OPERATIONS TABLE OF WORKING TIMES...
  • Page 4 Vehicle overhaul data Assembly plays (Values in mm) DIAMETER 43.2 MEASURING HEIGHT 01_004 Mating between piston and cylinder (Values in mm) PART DIMENSIONS MATING CLASSES ASSEMBLY CODE CYLINDER PISTON CLEARANCE - 0.010 Cylinder 91.990 - 91.997 91.947 - 91.954 + 0.018 0.036 Ø...
  • Page 5 Vehicle overhaul data SHIMMING METHOD FOR LIMITING THE COMPRESSION RATIO: CR = 10.5 : 1 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.
  • Page 6 Vehicle overhaul data Crankshaft/connecting rod axial clearance 01_007 PART DIMENSIONS CLEARANCE Web, transmission side A =0.8 ± 0.025 + 0.05 Shaft section, transmission side B =19.6 - 0.10 Connecting rod C =22 - 0.15 D = 0.20 - 0.40 Shaft section, flywheel side E =19.6 + 0.05 Web, flywheel side...
  • Page 7 TABLE OF CONTENTS SPECIFIC TOOLING...

  • Page 8: Recommended Tools

    Specific Tooling Specific tools for Piaggio X9 500 cc 4-stroke 4-valve 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...
  • Page 9 Specific Tooling 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...
  • Page 10 Maintenance Spark plug Check and replacement Warning - 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.
  • Page 11 Maintenance Engine oil level In four-stroke engines oil is used to lubricate the valve Since a certain amount of oil remains in the circuit, the gear components, the crankshaft bearings and the replenishment must be made by adding approximately power plant. A lack of engine oil can cause serious 1,500 cc of fresh oil through cap «A».
  • Page 12 Maintenance Replacing the filter Warning - Do not dispose of the oil in the environ- ment. Carry out the disposal of the oil, the gasket and the filter in accordance with the law. Caution - To avoid burns, take care not to touch hot engine parts.
  • Page 13 Maintenance Engine cooling Adding coolant and bleeding air from the system The level of the fluid must be checked every 6,000 km when the engine is cold. Follow these steps: - Put the vehicle on the central stand on level ground. - Remove the expansion tank cap and top up if the coolant is below or near the MIN level in the expansion tank.
  • Page 14 Maintenance Adjusting the play of the valves - Checking the valve gear timing To adjust the play of the valves and to check the valve gear timing as described in Chapter 7-Thermal Unit and Timing system of the Engine manual, follow these preliminary steps: - Put the vehicle on the central stand;...
  • Page 15 Maintenance Warning - Keep the brake fluid away from the skin, the eyes and clothing. In case of contact, rinse gener- ously with water. Warning - The brake fluid is highly corrosive. Take care not to spill it on the paintwork. Warning - The brake fluid is hygroscopic, i.e.
  • Page 16 Maintenance - Push the bolt lightly and extract the retainer from the milled part shown in the figure. - Extract the bolt assembly from the lock body. - To refit, follow the reverse procedure. 03_016 Removal with lock in LOCK position The bolt retaining spring is not accessible in the LOCK position.
  • Page 17 TABLE OF CONTENTS ELECTRICAL EQUIPMENT...

  • Page 18: Electrical Equipment

    ELECTRICAL EQUIPMENT SIDESTAND SWITCH TURN INDICATOR SWITCH VOLTAGE REGULATOR HORN BUTTON STAND CONTROL UNIT HAZARD WARNING LIGHT BUTTON ELECTRONIC CONTROL UNIT RELAY SWITCH RESET BUTTON ENGINE STOP RELAY SWITCH TRUMPET HORN SERVICES ELECTROMAGNETIC SWITCH LH REAR LIGHT WITH 5W PARKING LIGHT BULB AND 10W FUSE BOX (3 X 7.5A, 1 X 15A) TURN INDICATOR BULB NO.
  • Page 19 Electrical equipment diagram Electrical equipment devices 41. Relay switch. 1. Digital instrument panel (11 LED indicators). 42. Lights switch. 2. Analog instrument panel (5 bulbs). 3. Headlight (2 parking light bulbs, 55/55W low/high 43. Start button. beam bulbs). 44. Stand button. 4.
  • Page 20 Schematic wiring diagrams Ignition section OFF RUN DOWN 04_002 IMMOBILIZER AERIAL IMMOBILIZER DECODER IGNITION SWITCH CONTACTS ENGINE STOP RELAY SWITCH MAIN RELAY SWITCH VOLTAGE REGULATOR FLYWHEEL MAGNETO 12V-14Ah BATTERY 30A FUSE INJECTION ELECTRONIC POWER UNIT ENGINE STOP SWITCH HV COIL SPARK PLUG 10A FUSE ELECTRONIC POWER UNIT ELECTROMAGNETIC SWITCH...
  • Page 21 Schematic wiring diagrams Lights section 04_003 7.5 A FUSE 12V-55W LOW BEAM BULB 15 A FUSE 12V-55W HIGH BEAM BULB 7.5 A FUSE LOW BEAM RELAY SWITCH 7.5 A FUSE HIGH BEAM RELAY SWITCH 30 A FUSE DIGITAL INSTRUMENT SET 12V-14Ah BATTERY LIGHTS SWITCH HELMET COMPARTMENT LAMP BUTTON...
  • Page 22 Schematic wiring diagrams Battery recharge and starter section DOWN OFF RUN 04_004 IGNITION SWITCH CONTACTS 30A FUSE FLYWHEEL MAGNETO 6A DIODE 7.5A FUSE 5 X 12V-2.3W BRAKE LIGHT BULB STARTER RELAY SWITCH INJECTION POWER UNIT VOLTAGE REGULATOR ENGINE STOP RELAY STARTER MOTOR ENGINE STOP SWITCH 12V-14Ah BATTERY...
  • Page 23 Schematic wiring diagrams Consent, electrohydraulic central stand device and level indicators section 04_005 DIGITAL INSTRUMENT 30A FUSE ANALOG INSTRUMENT SET 12V-14Ah BATTERY INJECTION ELECTRONIC CONTROL UNIT 70A FUSE OUTSIDE TEMPERATURE SENSOR STAND HYDRAULIC PUMP RELAY SWITCHES WHEEL REVOLUTION SENSOR STAND HYDRAULIC PUMP MOTOR FUEL LEVEL THERMISTOR STAND ELECTRONIC CONTROL UNIT OIL PRESSURE SENSOR...
  • Page 24 Schematic wiring diagrams Turn indicators, horn and accessories prewiring section 04_006 DIGITAL INSTRUMENT PANEL 7.5A FUSE TURN INDICATORS, 2 + 2 X 12V-10W BULB 7.5A FUSE TURN INDICATOR SWITCH MAIN RELAY SWITCH ACCESSORIES PREWIRING PRESETTING FOR INTERCOM POWER UNIT INPUT HORN BUTTON HORN PRESETTING FOR RADIO POWER UNIT SIDE...
  • Page 25 Schematic wiring diagrams Control panel, warning lights, instruments 04_007 ANALOG CARD GND MALFUNCTIONING BRAKE LIGHT WARNING LIGHT INPUT BATTERY POSITIVE TERMINAL (+30) FOR ANALOG CARD LH TURN INDICATOR OUTPUT ANALOG CARD SERIAL CLOCK OUTPUT TURN INDICATOR STOP BUTTON INPUT ANTITHEFT DEVICE LED OUTPUT RESET SERVICE BUTTON INPUT ANALOG CARD SERIAL DATE OUTPUT COOLANT TEMPERATURE SENSOR INPUT...
  • Page 26 Electrical equipment Battery recharge system The battery recharge system includes a three-phase generator with a permanent-magnet flywheel. The generator is directly connected to the voltage regulator. The latter is in turn directly connected to earth and to the battery positive terminal via the 30A fuse. Therefore, the system is not connected to the ignition switch.
  • Page 27 Electrical equipment Checking the stator winding Warning - The check can be performed with the stator in place. 1) Remove the undersaddle compartment door 2) Detach the connector between stator and regulator with the three yellow cables. 3) Measure the resistance between each of the yellow terminals and the other two.
  • Page 28 Electrical equipment Instrument panel The X9 is equipped with a dual instrument panel con- sisting of an analog section installed in the front fairing and a digital section mounted on the handlebars. The analog section includes: - A dual-scale (km/h-mph) speedometer controlled by the speed sensor by means of the digital section;...
  • Page 29 Electrical equipment 3 Four fuses «C» in the glove compartment, on the left side. Fuse Protected circuits 1 x 15 A Flash, horn, accessories 1 x 7.5 A Brake light buttons, start button, starter relay switch 1 x 7.5 A Lights switch, parking lights, number-plate light 1 x 7.5 A...
  • Page 30 Electrical equipment Battery (12V - 14Ah) Caution - The battery electrolyte causes severe burns as it contains sulphuric acid. Avoid contact with the eyes, the skin and clothing. In case of contact with the eyes or the skin, rinse generously with water for about 15 minutes and imme- diately seek medical attention.
  • Page 31 Electrical equipment - Fit the front element. 04_019 - At last, fit the left side element. 04_020 - Cut the breather pipe supplied as shown in the figure. 04_021 - Fit the pipe until it contacts the battery and in the direction shown in the figure.
  • Page 32 Electrical equipment - Lock the pipe with a tear-clamp and cut the end that sticks out of the clamp. 04_023 - Insert the battery in the compartment taking care to fit the breather pipe in the bottom hole. 04_024 - Insert the battery in the compartment taking care to fit the breather pipe in the bottom hole.
  • Page 33 Electrical equipment Checking the electrolyte level Warning - Normal drinking water contains salts Frequently check that the electrolyte reaches the upper that are harmful for batteries. Use only distilled water. level. To top up, only use distilled water. If you need to top up the battery too frequently, check Warning - To ensure maximum performance the the vehicle electrical equipment as the battery is cer-...
  • Page 34 TABLE OF CONTENTS ENGINE...
  • Page 35 Engine Engine disassembly from frame Caution - Take care when handling the petrol. Caution - Perform these operation with the en- gine cold. Warning - When installing the battery, first fix the positive cable and then the negative cable. - Disconnect the battery. - Remove the saddle, and the upper and lower body sides (Chapter 8 - Bodywork) - Drain the coolant (Chapter 3 - Maintenance)
  • Page 36 Engine Supporting arm disassembly - Unscrew and remove the r.h. shock absorber to supporting arm lower fixing bolt - Unloose the arm to engine 2 fixing screws. - Remove the split pin and unscrew the wheel axle nut; avoid the wheel turning by means of the integral brake.
  • Page 37 Front and rear suspensions Handlebar Removal - Begin by removing the radio-interphone and then disconnect the feeder cable. - Remove the digital panel support and the front and rear sections of the handlebar cover as described in Chapter 8-Bodywork. - Disengage the handlebar from the components in- stalled on it.
  • Page 38 Front and rear suspensions - Support the wheel to allow the removal of the internal parts. - Using a mallet and a drift of suitable diameter, simul- taneously drive out the inner spacer, the right-hand bearing and the outer spacer complete with the dust ring on the same side.
  • Page 39 Front and rear suspensions Removing the front fork - Remove the mudguard as described in Chapter 8- Bodywork. - Remove the handlebar and the front wheel as previ- ously described. - Loosen the two screws fastening the brake line sup- ports (see figure).
  • Page 40 Front and rear suspensions - Remove the lower roller bearing and the dust cover ring from the fork by means of the specific tool. - Use the larger half ring pair and the shorter steering tube protection. Specific tool: Steering tube lower bearing extractor: 020458Y 06_013 Fitting the steering bearing - Check the condition of the bearing races and rollers.
  • Page 41 Front and rear suspensions Replacing the seal ring and removing the fork rod - Remove lower screw (1). - Drain the oil from the suspension. - Remove the fork rod. - Replace seal rings (3), (4) and (5) with new ones. - Fit the new rings after lubricating their seats.
  • Page 42 Front and rear suspensions Rear wheel Removal - Remove the shock absorber as previously described. - Remove the silencer and the bracket as described in Chapter 5-Engine. - Remove the 5 screws fixing the rear wheel to the hub. - Take down the wheel. Fitting Fit the wheel using the reverse procedure to the re- 06_017...
  • Page 43 TABLE OF CONTENTS BRAKING SYSTEM...

  • Page 44: Braking System

    BRAKING SYSTEM LUBRICATE WITH OIL APPLY PRODUCT WARNING - HANDLE WITH CARE LUBRICATE WITH GREASE CLEAN CAREFULLY ALWAYS REPLACE CALLOUT QUANTITY TORQUE N·m 20-25 42-62 15-20 20-25 20-25 16-20 16-20 20-25 5-6,5 14-17 7 - 2...
  • Page 45 Braking system Checking and replacing the brake pads Removing the front brake pads: Follow these steps: - Loosen the two screws shown in the figure and disengage the calipers from their supports. - Remove the retaining ring and the pin. During the operation pay special attention to the pin retaining spring as it may spring off abruptly.
  • Page 46 Braking system Brake discs Checking disc thickness It is important to check the brake discs. The discs should always be perfectly clean and free from rust, grease and dirt and shown no deep scoring. Thickness of front discs when new ....4.0 mm Thickness of rear disc when new ....
  • Page 47 Braking system Note: When topping up or renewing the brake fluid, only General guidelines for servicing the hydraulic brak- use DOT4 - NHTSA 116 fluid. ing system Always ensure that all parts are perfectly clean. Caution The brake fluid is highly corrosive. Take care not to spill - The brake fluid is corrosive.
  • Page 48 Braking system Note: If air keeps coming out during the bleeding, check all connections. If these are tight, check the different pump seals and the caliper pistons. During the operation oil may trickle from the bleeder screw onto the caliper and the disc. In that case, carefully dry the caliper and degrease the disc.
  • Page 49 Braking system Removing the brake calipers Check the condition of the brake lines, the gaskets and the related connections. Should any fluid leak onto the calipers, replace them by following these steps: - Empty the circuit as previously described for the brake fluid renewal.
  • Page 50 Braking system Note: Take care to properly insert the specially designed projection on the pump clevis in the related hole in the handlebar (see figure). - Complete the overhaul by filling and bleeding the circuit. - The removing procedure is the same for both brake pumps (see figure).
  • Page 51 TABLE OF CONTENTS BODYWORK...
  • Page 52 BODYWORK : Perform all operations with great care. Plastics are easily damaged. : Avoid cleaning painted plastics with solvents containing petrol and its derivatives. LUBRICATE WITH OIL APPLY PRODUCT WARNING - HANDLE WITH CARE LUBRICATE WITH GREASE CLEAN CAREFULLY ALWAYS REPLACE 8 - 2...
  • Page 53 Bodywork Front central cover - Lift the rearview mirror covers. - Unscrew the five fixing screws shown in the figure. - Remove the front central cover with the weather strip. 08_001 Lower guard - Windscreen - Remove the rearview mirrors; - Unloose the 3 fixing screws shown in the figure and relevant spacers;...
  • Page 54 Bodywork Digital instrument panel support - Remove the three fixing screws. - Detach the electrical connectors. - Remove the support with the digital instrument panel. - Pay special attention to the electrical connectors. 08_005 Front handlebar cover - Loosen the two screws fixing the radio-interphone unit.
  • Page 55 TABLE OF CONTENTS TABLE OF WORKING TIMES...
  • Page 56 1 ENGINE Code Description Time 001001 Engine from frame - Removal and reinstallation 160' 1-2-3 001127 Engine - Complete overhaul 450' 003057 Engine anchorage - Tightening of nuts 2 CRANKCASE Code Description Time 001133 Crankcase - Replacement 410' 001153 Crankcase half gasket - Replacement 280' 001100 Oil seal clutch side - Replacement...
  • Page 57 5 CYLINDER HEAD Code Description Time 001126 Cylinder head - Replacement 250' 001045 Valves - Replacement 240'' 001049 Valves - Adjustment 001056 Cylinder head gasket - Replacement 210' 007023 Union tee head outlet - Replacement 005081 Temperature sensor - Replacement 6 ROCKER ARM SUPPORT ASSEMBLY Code Description...
  • Page 58 9 DRIVEN PULLEY AND CLUTCH Code Description Time 001022 Clutch - Replacement 003072 Clutch assembly - Wear check 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement 001167 Driven pulley shaft support - Overhaul / Replacement 10 OIL PUMP Code...
  • Page 59 13 TRANSMISSION COVER Code Description Time 001096 Transmission crankcase cover - Replacement 008002 Mechanical transmission cover - Replacement 14 STARTER MOTOR Code Description Time 001020 Starter motor - Replacement 001017 Starter pinion - Replacement 003064 Engine oil - Replacement 15 FLYWHEEL MAGNETO Code Description Time...
  • Page 60 17 AIR CLEANER Code Description Time 001015 Air filter box - Replacement 001014 Air filter - Replacement/Cleaning 18 SILENCER Code Description Time 001009 Silencer - Replacement 001092 Exhaust manifold - Replacement 001095 Silencer guard - Replacement 001136 Exhaust emissions - Adjustment 19 TANK Code Description...
  • Page 61 21 SWINGARM Code Description Time 001072 Engine-frame connection swing arm - Replacement 003082 Damper arm - Replacement 22 CENTRAL STAND/ELECTROHYDRAULIC Code Description Time 004004 Stand - Replacement 23 SIDESTAND Code Description Time 004102 Side stand - Replacement 005079 Stand switch - Replacement 24 FRONT SHIELD Code Description...
  • Page 62 25 WINDSCREEN Code Description Time 004028 Windscreen glass - Replacement 004066 One rearview mirror - Replacement 26 REAR SHIELD Code Description Time 004065 Front shield, rear section - Removal and refitting 004081 Glove compartment door - Replacement 002082 Fuel tank door opening cable - Replacement 004156 Glove compartment door and/or support - Replacement...
  • Page 63 29 RADIATOR Code Description Time 007002 Radiator - Replacement 110' 007016 Fan complete with support - Replacement 100' 007003 Coolant delivery and return pipe - Replace. 007022 Coolant return pipe - Replacement 30 UNDERSADDLE COMPARTMENT Code Description Time 005033 Glove compartment lamp switch - Repl. 005026 Helmet compartment lamp - Replacement 005027...
  • Page 64 33 SADDLE Code Description Time 004003 Saddle - Replacement 004144 Bag - Replacement 004150 Saddle damper - Replacement 004067 Rider’s backrest - Replacement 004054 Saddle catch - Replacement 34 STEERING THRUST RINGS Code Description Time 004119 Steering upper thrust ring/bearing - Replace. 003002 Steering thrust rings - Replacement 003073...
  • Page 65 37 INSTRUMENT PANEL Code Description Time 005014 Speedometer - Replacement 005078 Speedometer glass - Replacement 005082 Instrument panel wiring - Replacement 005083 Trip computer - Replacement 38 HANDLEBAR COVERS Code Description Time 004151 Instrument panel support - Replacement 004018 Handlebar front section - Replacement 004019 Handlebar rear section - Replacement 006013...
  • Page 66 41 BRAKE CALIPER Code Description Time 002007 Front brake shoes/pads - Replacement 003070 Front brake pads/shoes - Wear check 002039 Brake caliper - Removal and refitting 002048 Front brake caliper - Replacement 002002 Rear brake pads - Replacement 003071 Rear brake pads/hook - Wear check 1-2-5-6 42 HEADLIGHT Code...
  • Page 67 45 ELECTRICAL DEVICES Code Description Time 005040 Horn button - Replacement 005041 Starting device button - Replacement 005084 Hazard warning light button - Replacement 005095 Electrical stand push button - Replacement 005077 Emergency stop switch - Replacement 005039 Lights selector switch - Replacement 005006 Lights or turn indicator switch - Replacement 005003...
  • Page 68 49 RADIO - INTERCOM Code Description Time 005092 Radio / intercom control unit - Replacement 005093 Radio / Intercom cables - Replacement 005094 Radio / Intercom display - Replacement 50 WIRING (WIRING HARNESS) Code Description Time 005001 Electrical equipment - Removal and reinstallation 140' 005025...
  • Page 69 53 REAR WHEEL Code Description Time 001071 Rear wheel rim - Removal and refitting 004126 Rear tyre - Replacement 001016 Rear wheel - Replacement 006018 Wheel rim - Painting 003063 Tyre pressure - Check 003014 Rear suspension arm - Replacement 003077 Silencer/rear shock absorber support arm - Overhaul...

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