User manual PIAGGIO X9 500 SERVICE MANUAL

[. . . ] 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. Any significant changes to the characteristics of the vehicles or to specific repairing procedures will be covered in updates of this manual. [. . . ] Therefore, in addition to checking and, if necessary, charging the battery before delivery, it is necessary to carry out these operations before storing the vehicle, and subsequently every six months. RECHARGING THE BATTERY FOLLOWING OPENCIRCUIT STORAGE 1) Checking the voltage Before installing the battery on the vehicle, measure the open-circuit voltage with an ordinary multimeter. 5 x rating - Charging time: Recommended 10-12 hrs Minimum 6 hrs Maximum 24 hrs 3) Constant-current charging method - Initial charging current: 1/10 of rating - Charging time: Maximum 5 hrs Caution - When the battery is deeply discharged (far below 12. 6V), 5 hours’ recharging may not be enough to obtain optimum performance. In these conditions, however, to avoid damaging the battery beyond repair, it is essential not to recharge it for more than 8 consecutive hours. 4 Battery recharge Caution - Before charging the battery remove all cell plugs. When the battery has to be removed from the vehicle, disconnect the negative terminal first. 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. - 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. 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. [. . . ] 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. [. . . ]