User manual PIAGGIO X9 500 SERVICE MANUAL

[. . . ] € 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. 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. [. . . ] Charge the battery using the specific charger 020333Y (single station) or 020334 (multiple station), by putting the charger selector on the type of battery to be recharged (use current at 1/10 of the battery rated power). Connection to the power supply must be made by means of the corresponding poles (+ with + and – with -). 4) Cleaning the battery Keep the battery clean, especially the top; coat the terminals with Vaseline. Warning - Never use fuses having a greater capacity than the one recommended. The use of a fuse of unsuitable capacity may result in serious damage to the whole vehicle or even cause a fire. 4 - 27 TABLE OF CONTENTS ENGINE 5 Engine Engine disassembly from frame Caution gine cold. - Perform these operation with the enWarning - When installing the battery, first fix the positive cable and then the negative cable. Caution - Take care when handling the petrol. - Remove the saddle, and the upper and lower body sides (Chapter 8 - Bodywork) - Drain the coolant (Chapter 3 - Maintenance) - Disassemble the muffler assembly and relevant support, as described below. - Remove the rear wheel (Chapter 6 - Front/Rear Suspension) - Remove the accelerator control transmissions and mark their position on the throttle body control. - Disconnect the air filter sleeve and the engine oil values collecting pipe. - Disconnect the earth cable from the engine. - Disconnect the electrical devices from the throttle body, head, and starter feed cable. - Detach the fuel delivery and return pipes to the injector and the coolant system pipes (head outlet and thermostat input) - Close the injector Tee Joint with rubber plugs to prevent dirt from entering. - Detach the generator harness from the vehicle electrical system. Muffler assembly disassembly - Unloose the two fixings of the exhaust manifold on the head. 05_001 - Unloose the 3 screws fixing the muffler to the supporting arm. 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. Shock absorber lower pin - Remove the bolt shown in the figure. : To be able to remove the shock absorber support, remove the two nuts on the brake caliper side and the screws. 05_004 Engine pin/swing arm disassembly Adequately support the engine. [. . . ] 1 2 Code 001089 001093 001088 Description Cylinder head cover - Replacement Spark plug - Replacement Cylinder head cover gasket - Replacement Time 70' 15' 70' 2 1 3 3 8 FLYWHEEL COVER Op. 1 2 3 4 5 6 7 8 9 Code 001087 001113 001123 001124 001057 001062 001150 001160 007011 Description Flywheel cover - Replacement Water pump - Replacement Oil filter - Replacement By-pass - Replacement Thermostat - Replacement Water pump control shaft - Replacement Flywheel cover gasket - Replacement Oil minimum pressure sensor - Replacement By pass sleeve-Thermostat-Drain valve Replacement Water pump connection pipe-Return pipe Replacement Drain valve - Coolant outlet pipe Replacement Time 105' 60' 15' 100' 55' 85' 100' 20' 70' 70' 70' 6 1 4 11 5 10 2 7 3 8 9 10 007019 11 007012 10 - 3 9 DRIVEN PULLEY AND CLUTCH Op. 1 2 3 Code 001022 003072 001012 001110 001155 001167 Description Clutch - Replacement Clutch assembly - Wear check Driven pulley - Overhaul Driven pulley - Replacement Clutch bell housing - Replacement Driven pulley shaft support Overhaul / Replacement Time 60' 50' 75' 60' 50' 60' 3-4 5 4 5 6 1-2 6 10 OIL PUMP Op. 1 2 Code 001112 001042 001051 001125 Description Oil pump - Replacement Oil pump - Overhaul Timing chain/belt - Replacement Chain guide shoes - Replacement Time 270' 280' 220' 225' 4 3 4 1-2 3 11 REDUCTION GEARING ASSEMBLY Op. [. . . ]