User manual PIAGGIO X9 SERVICE STATION 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. Warning Caution - 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. TABLE OF CONTENTS VEHICLE SPECIFICATIONS AND OVERHAUL DATA 1 2 3 4 5 6 7 8 9 10 SPECIFIC TOOLING MAINTENANCE AND TROUBLESHOOTING ELECTRICAL EQUIPMENT ENGINE FRONT AND REAR SUSPENSIONS BRAKING SYSTEM BODYWORK PREDELIVERY OPERATIONS TABLE OF WORKING TIMES Vehicle overhaul data Assembly plays 1 (Values in mm) DIAMETER MEASURING HEIGHT A B 43. 2 43 01_004 Mating between piston and cylinder (Values in mm) PART Cylinder ØC Piston ØP 0. 014 91. 961 -+0. 014 DIMENSIONS CODE 0. 010 92+- 0. 018 MATING CLASSES CYLINDER 91. 990 - 91. 997 91. 997 - 92. 004 92. 004 - 92. 011 92. 011 - 92. 018 PISTON 91. 947 - 91. 954 91. 954 - 91. 961 91. 961 - 91. 968 91. 968 - 91. 975 A B C D ASSEMBLY CLEARANCE 0. 036 0. 050 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. Piston rings Ring opening Assemble the rings 2 and 3 with the “Top” writing facing upwards. Arrange for the piston rings opening as shown in the figure “A” value of the ring inside the cylinder 01_005 (Values in mm) PART 1st Compression ring 2nd Compression ring Scraper ring DIMENSIONS 92 x 1. 5 92 x 1. 25 92 x 2. 5 CLEARANCE CODE A A A SEAT CLEARANCE 0. 15 - 0. 35 0. 25 - 0. 50 0. 25 - 0. 50 CLEARANCE AFTER USE 0. 5 0. 65 0. 65 1-7 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. [. . . ] - 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. - Disconnect the battery. - 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 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. - Remove the muffler assembly. 05_002 5-2 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. shock absorber lower pin - Remove the bolt shown in the figure. N. B. : 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. - Fit the right-hand bearing by following the same procedure as the other bearings. 06_006 - Refit the two front brake discs as described in Chapter 7-Braking system. - Fit the outer spacer and the related ring taking care not to compress it excessively against the wheel bearing. 06_007 - Check the condition of the speed sensor seal ring and of the related groove in the wheel rim. sheath. Tightening torques: Axle nut: 45 - 50 N·m Right-hand sheath lower screws: 6 - 7 N·m 06_008 6-4 Front and rear suspensions Removing the front fork - Remove the mudguard as described in Chapter 8Bodywork. - Loosen the two screws fastening the brake line supports (see figure). Note: It is also possible to remove one of the two fork rods after loosening the two related screws on the fork upper plate. 06_009 - Remove the two rings, the middle washer shown in the figure and the spacer below. Caution - Adequately support the vehicle so as to allow the steering tube to come out of the head tube. Warning - Before unscrewing both rings, support the fork assembly so as to prevent it from falling. Specific tool: Steering tube ring spanner: 020055Y 06_010 Replacing the steering bearings - Using the specially designed tool shown in the figure and a mallet, remove the upper ball bearing. 6 N. B. :Act at different times between the two points at 180°. Failure to observe this instruction may damage the housing. Specific tool: Steering thrust ring removing drift: 020004Y 06_011 - Use the same method to extract the seat of the lower roller bearing. N. B. : Act at different times between the two points at 180°. Failure to observe this instruction may damage the housing. Specific tool: Steering thrust ring removing drift: 020004Y 06_012 6-5 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. [. . . ] 1 2 3 4 Code 007002 007016 007003 007022 Description Radiator - Replacement Fan complete with support - Replacement Coolant delivery and return pipe - Replace. Coolant return pipe - Replacement Time 110' 100' 80' 60' 2 1 3 4 30 UNDERSADDLE COMPARTMENT Op. 1 2 Code 005033 005026 005027 004142 004016 002083 Description Glove compartment lamp switch - Repl. Helmet compartment lamp - Replacement Helmet compartment lamp support - Repl. [. . . ]