SERVICE STATION MANUAL
Contents
1. 003077 Silencer rear shock absorber support arm Overhaul 25 002070 Rear brake disc Replacement 40 002028 Rear wheel hub Replacement2. 05 004 Engine pin swing arm disassembly Adequately support the engine Remove the nut shown in the figure Remove the pin Now the engine is free 05 005 Engine assembly to vehicle Perform the assembly in the reverse order observing the tightening torques indicated in Chapter 1 Warning Take care not to invert the position of the two accelerator control transmissions Check that both show a slight play with the valve in contact with the register N B Carefully clean the injector Tee Joint before reassembling the quick connections Direct the injector in such a way as to avoid any interferences of the electrical cables with the coolant and fuel pipes Check the engine oil level top up if necessary with oil of the recommended type Fill the cooling system Chapter 11 Cooling Check the accelerator and electrical devices function 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 Remove the two counterpoises after loosening the side screws Remove the pumps after loosening the screws on the clevises shown in the figure Slide the throttle control off the handlebar after loos ening the fixing screws Remove the left handgrip Loosen the bolt fastening
3. Crankshaft alignment and diameters Measure the housings on both axes x and y NE Standard diameter 40 010 40 016 40 016 40 022 01 008 Max allowable runout 0 15 mm B 0 01 mm C 0 010 mm D 0 10 mm TABLE OF CONTENTS SPEGIFIG TOOLING 2 Specific Tooling Specific tools for Piaggio X9 500 cc 4 stroke 4 valve Support for METABO 1500 2 air heater 020150Y New tools TOOL NAME Specific Tooling NECESSARY TOOLS PART NO STEERING SEAT FITTING TOOL to be fitted with parts 9 Lower bearing adaptor 10 Upper bearing adaptor 001330Y Bell 80 mm 001467Y002 20 mm pliers 001467Y006 Bell 63 mm 001467Y007 18 mm pliers 001467Y008 Bell 45 mm 001467Y017 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 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 0
4. Fitting the steering bearing Checkthe condition of the bearing races and rollers Fit the upper bearing and the lower bearing housing by inserting the specific tool in the steering sleeve provided with 2 adapters Fit the dust cover ring and the roller bearing on the steering tube by means of a piece of tube having a suitable diameter and by resting against the inner race of the roller bearing Specific tool Steering seats assembly tool 001330Y Upper bearing adapter 001330Y010 Lower bearing adapater 001330Y009 06 014 Lubricate the steering bearing housing with grease of the TUTELA Z2 type Fit the steering tube into the sleeve Tighten the lower collar with a torque of 20 25 Nm 2 2 5 Kgm and then loosen it completely Tighten it again with a torque of 10 13 Nm 1 1 3 Kgm then loosen it by 90 degrees Insert the spacer Lock the upper collar with a torque of 30 36Nm 3 3 6 Specific tool i Wrench for Steering Tube Collar 020055Y 06 010 N B This procedure is also valid for the previous d 1 UPPER COLLAR versions with upper ball bearing SPACER LOWER COLLAR 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 Reinsert the fork rod Unscrew plug 2 Fit f
5. Code Headlight Replacement Headlight bulbs Wear check Headlight wiring harness Replacement Front turn indicator bulb Replacement Front turn indicators Replacement Turn indicators glass Replacement Description 005090 004141 005005 005066 005031 005032 005030 Code Stoplight bulbs Replacement Reflector Replacement Rear light Replacement Rear light bulbs Replacement Number plate light bulb Replacement Number plate light lens Replacement Rear light wiring harness Replacement Description 10 12 004057 004009 005048 005046 Tail lamp lower cover Replacement Rear mudguard Replacement Number plate holder Replacement Battery cover Replacement 45 ELECTRICAL DEVICES 005040 005041 005084 005095 005077 005039 005006 005003 Code Description Horn button Replacement Starting device button Replacement Hazard warning light button Replacement Electrical stand push button Replacement Emergency stop switch Replacement Lights selector switch Replacement Lights or turn indicator switch Replacement Horn Replacement Description 001069 005007 005011 005097 001094 005024 Code HV coil Replacement Battery Replacement Starting relay switch Replacement Electrical central stand electromagnetic switch Replacement Spark plug cap Replacement Battery fuse Replacement Description 005035 005073 001023
6. Code Headlight relay switch Replacement Decoder Replacement Electronic control unit Replacement Description 005009 005098 005088 005096 Voltage regulator Replacement Stand control unit Replacement Hazard warning light relay switch Replacement Injection components electromagnetic switch Replacement 10 13 49 RADIO INTERCOM Code Description 005092 005093 005094 Code Radio intercom control unit Replacement Radio Intercom cables Replacement Radio Intercom display Replacement Description 51 LOCKS 005001 005025 Code Electrical equipment Removal and reinstallation Battery fuse holder Replacement Description o 005016 004010 Code Ignition switch Replacement Security lock Replacement Description 10 14 ON Oo Om P ON 003037 003047 004123 006018 003063 003040 002041 005089 Front wheel rim Removal and refitting Front tyre Replacement Front wheel Replacement Wheel rim Painting Tyre pressure Check Front wheel bearings Replacement Front brake disc Replacement Speed sensor Replacement 53 REAR WHEEL Code Description Time 001071 Rear wheel rim Removal and refitting 45 004126 Rear tyre Replacement 45 001016 Rear wheel Replacement 35 006018 Wheel rim Painting 35 003063 Tyre pressure Check 5 003014 Rear suspension arm Replacement 20
7. Recharge within 24 hours by means of the specific charger 020333Y single station or 020334Y mul tiple station with intensity equal to about 1 10 of the battery rated power until the acid density reaches the value of about 1 27 corresponding to 31 B and until such values have stabilized 4 When the charging is over level off the acid by adding distilled water put the plugs back into place and clean thoroughly 5 Proceed to install the battery on the vehicle taking care to observe the connections described at item 3 of the paragraph Recharging the battery Removing and installing the battery Lift the saddle Remove the rear optical unit and the covering ele ment Disconnect the battery by detaching the negative cable first and then the positive cable Remove the battery strap and then the battery itself To install the battery follow these steps Fit the lower support shown in the figure on the battery compartment bottom 4 24 Hold tube upright Check visually Float must be disengaged ge i 04 018 Electrical equipment Fit the front element 04 019 At last fit the left side element 04 020 Cutthe 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 04 022 4 25 Electrical equipment Lock the pipe with a tear clamp and cut the end that sticks out of th
8. 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 9 DRIVEN PULLEY AND CLUTCH Code Description 10 OIL PUMP 001022 003072 001012 001110 001155 001167 Code Clutch Replacement Clutch assembly Wear check Driven pulley Overhaul Driven pulley Replacement Clutch bell housing Replacement Driven pulley shaft support Overhaul Replacement Description P gt 11 REDUCTION GEARING ASSEMBLY 001112 001042 001051 001125 Code Oil pump Replacement Oil pump Overhaul Timing chain belt Replacement Chain guide shoes Replacement Description 12 DRIVING PULLEY 001010 001156 003065 Code Reduction gearing Overhaul Reduction gearing cover Replacement Gear box oil Renewal Description 001086 001011 001006 001141 001066 Driving half pulley Replacement Drive belt Replacement Driving pulley Overhaul Belt antiflapping roller Replacement Driving pulley Disassembly and reassembly 13 TRANSMISSION COVER 001096 008002 Code Description Transmission crankcase cover Replacement Mechanical transmission cover Replacement Description 001020 001017 003064 Code Starter
9. 03 005 03 006 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 To avoid burns take care not to touch hot engine parts Remove the silencer Remove filler plug A Remove and clean the drain plug gauze strainer with compressed air Using strap wrench for filters remove cartridge filter C Ensure that the O rings on the prefilter and the drain plug are in good condition Lubricate the O rings and then refit the gauze strainer and the oil drain plug Tighten the drain plug with the prescribed torque Fit a new cartridge filter after lubricating the O ring Turn in until the gasket makes contact and then tighten it with the prescribed torque Reinstall the silencer Add engine oil as previously described Tightening torque Tappo scarico olio motore Engine oil drain plug 24 30 N m Oil filter 12 16 N m Oil type Selenia HI Scooter 4 Tech Checking the hub oil level Put the vehicle on the central stand on level ground Unscrew oil dipstick A wipe it with a clean cloth reinsert it and then screw it in fully Pull out the dipstick again and check that the oil level is between the MIN and MAX marks see figure if the level is below the MIN mark top up with oil Reinsert the dipstick and screw it tight Renewing the hub oil Remove oil filler plug A
10. RADIO DISPLAY SIDE GNITION SWITCH CONTACT 2A DIODE 1 2 3 4 5 6 7 8 Control panel warning lights instruments Schematic wiring diagrams ANS VE COGO 69 62 69 amp 9 9 6 09 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 LIGHTS ON OUTPUT FUEL LEVEL SENSOR INPUT NOT CONNECTED BATTERY POSITIVE TERMINAL 30 1 2 3 4 5 6 7 8 NOT CONNECTED SENSOR POWER SUPPLY INJECTION WARNING LIGHT INPUT RELAY ALARM WARNING LIGHT INPUT GLUED SPEEDOMETER SENSOR EARTH RETURN RPM SENSOR INPUT MALFUNCTIONING BRAKE LIGHT OUTPUT BATTERY POSITIVE TERMINAL 30 RH TURN INDICATOR OUTPUT ANTITHEFT DEVICE LED RH TURN INDICATOR BUTTON INPUT KEY POSITIVE TERMINAL 15 LH TURN INDICATOR BUTTON INPUT SPEEDOMETER SENSOR INPUT HIGH BEAM WARNING LIGHT INPUT GND AIR TEMPERATURE SENSOR INPUT AIR TEMPERATURE SENSOR EARTH RETURN ENGINE START DISABLED WARNING LIGHT INPUT HAZARD WARNING LIGHT BUTTON INPUT OIL PRESSURE WARNING LIGHT INPUT LIGHTS ON INPUT Electrical equipment Battery recharge system
11. 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 The three phase generator allows considerable re charging power and a fair compromise between sup plied power and slow running stability at low rpm Recharging system Searching for leaks 1 Before measuring the output voltage ensure that no electrolyte is leaking from the battery 2 Turnthe ignition key to the OFF position and connect the tester terminals between the battery negative pole and the black cable 3 Detach the black cable from the battery negative pole while keeping the tester terminals connected 4 With the ignition key still in the OFF position the ammeter should read x 0 5 mA Checking the charging voltage Warning _ Before performing the check ensure that the battery is in good condition 1 Put the vehicle on the central stand 2 With the battery properly connected to the circuit position the multimeter prods between the battery terminals 3 Start the engine with all lights out and rev up while measuring the voltage VOLTAGE 14 0 15 0V at 5 000 rpm 4 12 Checking the stator winding Warning The check can be performed with the stator in place 1 Remove t
12. 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 re charged 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 ca pacity 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 Electrical equipment Warning Normal drinking water contains salts that are harmful for batteries Use only distilled water Warning To ensure maximum performance the battery must be charged before using the vehicle Failure to properly charge the battery before starting the vehicle will cause the battery premature breakdown Sealed battery Putting a sealed battery into service Ifthe vehicle is equipped with a sealed battery servicing is limited to checking the charge level and if necessary recharging the battery These operations mustbe performed during predelivery and every six months of open circuit storage Therefore in addition to checking and if necessary charging the battery before delivery it is necessa
13. motor Replacement Starter pinion Replacement Engine oil Replacement Description 16 THROTTLE BODY 001058 001067 001104 001151 Code Flywheel Replacement Stator Removal and reinstallation Starting free wheel Replacement Starting driven gear Replacement Description 001013 001047 001166 Intake manifold Replacement Injector Replacement Throttle body Replacement 17 AIR CLEANER Code Description 001015 Air filter box Replacement 001014 Air filter Replacement Cleaning 18 SILENCER Code Description 001009 Silencer Replacement 001092 Exhaust manifold Replacement 001095 Silencer guard Replacement 001136 Exhaust emissions Adjustment 19 TANK Code Description 004073 Fuel pump Replacement 004005 Fuel tank Replacement 004137 Fuel pump tube Replacement Code Description 004001 Frame Replacement 004146 Front frame Replacement 004116 Rear frame Replacement 21 SWINGARM 001072 003082 Code Description Engine frame connection swing arm Replacement Damper arm Replacement Description 23 SIDESTAND 004004 Code Stand Replacement Description 24 FRONT SHIELD 004102 005079 Code Side stand Replacement Stand switch Replacement Description 004064 006012 004149 006006 005085 Front shield front section Replacement Front shield Painting Front shiel
14. reinstallation Engine Complete overhaul Engine anchorage Tightening of nuts 1 ENGINE Code 001001 001127 003057 E n En BEN gt Code Description 001133 Crankcase Replacement 001153 Crankcase half gasket Replacement 001100 Oil seal clutch side Replacement 3 CRANKSHAFT Code Description 001117 Crankshaft Replacement Countershaft Replacement 001098 Description Code Cylinder piston Replacement 4 CYLINDER PISTON PISTON PIN ASSEMBLY 001002 Piston piston rings piston pin assembly Overhaul Chain stretcher Overhaul and replacement 001154 001129 5 CYLINDER HEAD 001126 001045 001049 001056 007023 005081 Code Description Cylinder head Replacement Valves Replacement Valves Adjustment Cylinder head gasket Replacement Union tee head outlet Replacement Temperature sensor Replacement Description 001044 001148 Code Camshaft Replacement Valve rocker arms Replacement Description 8 FLYWHEEL COVER o 001089 001093 001088 Code Cylinder head cover Replacement Spark plug Replacement Cylinder head cover gasket Replacement Description o OD Jo Om P ON 001087 001113 001123 001124 001057 001062 001150 001160 007011 007019 007012 Flywheel cover Replacement Water pump Replacement Oil filter Replacement By pass Replacement Thermostat
15. the discs and the pads become contaminated with brake fluid replace the pads and clean the disc with a good quality solvent 07 008 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 Specific tool Vacuum pump MITIVAC type 020329Y Combined brake A control system allows the left brake lever to simultaneously operate the left hand front caliper and the rear caliper To empty the circuit follow the procedure given for the right hand front brake using the bleeder of both brake calipers front and rear To bleed the system follow these steps 1 Attach the specific Mityvac tool to the bleeder fitted on the pressure divider valve shown in the figure 2 Fill the left brake fluid reservoir to the maximum level 3 Slowly operate the left brake lever while pouring freshfluid into the reservoir until all the air has come out thus obtaining the bleeding of the first section of the combined brake line Tighten the bleeder valve with the prescribed torque 4 Proceed to bleed each caliper the front caliper first and then the rear caliper following the same procedure used for the front brake Specific tool Vacuum pump MITIVAC type 020329Y Tighte
16. the central stand Remove the relevant body sections to gain access to the pivot fixing the engine to the swingarm refer to Chapter 8 Bodywork Support the bottom of the engine e g with a jack Remove the engine from the frame as described in Chapter 5 Engine Shift the engine backwards to make room for the removal ofthe cylinder head cover until the swingarm cross member touches the starter motor After adjusting the play of the valves refit the compo nents by following the reverse procedure to the re moval Warning Do not lower the engine too much to prevent it from touching the stop push button of the electrohydraulic stand Note The checking areas are shown in the two figures at the right Play of valves Intake 0 15 mm cold engine Exhaust 0 15mm cold engine Checking the level To gain access to the front and rear brake fluid reser voirs remove the covers on the handlebar cover Follow these steps Put the vehicle on the central stand and turn the handlebar to the central position Remove cap A after loosening fixing screw B Check the level of the fluid through the sight A certain decrease in the level of the fluid occurs as a result of pad wear Restoring the brake fluid level Warning Only use brake fluid classified as DOT 4 Brake fluid type TUTELA TOP 4 Use the following procedure Remove the A covers and the tank cap by unscrew ing the two screws remove the g
17. 20434Y 17 mm guide countershaft bearings 020439Y Driven half pulley spring compressor 020444Y 46 55 mm spanner 020444Y009 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 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 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 Recommended spark plug CHAMPION RG 6 YC NGK CR 7 EKB Put the vehicle
18. AKE LIGHT BUTTON AND START INHIBITOR SWITCH MAIN RELAY SWITCH DIGITAL INSTRUMENT PANEL 2A DIODE k START BUTTON Schematic wiring diagrams Consent electrohydraulic central stand device and level indicators section NNA 2 ANALOG INSTRUMENT SET 17 12V 14Ah BATTERY INJECTION ELECTRONIC CONTROL UNIT 70A FUSE 4 OUTSIDE TEMPERATURE SENSOR STAND HYDRAULIC PUMP RELAY SWITCHES 5 WHEEL REVOLUTION SENSOR STAND HYDRAULIC PUMP MOTOR 6 FUEL LEVEL THERMISTOR STAND ELECTRONIC CONTROL UNIT 7 OIL PRESSURE SENSOR STAND INHIBITOR SWITCH 8 RESET BUTTON STAND LIMIT SWITCH 9 EMERGENCY BUTTON BUTTON 10 7 5A FUSE ELECTRIC FAN RELAY SWITCH IGNITION SWITCH CONTACTS 5A FUSE 12 RADIATOR ELECTRIC FAN MOTOR MAIN ELECTROMAGNETIC SWITCH 13 ENGINE TEMPERATURE SENSOR 2A DIODE 14 FLYWHEEL MAGNETO RELAY SIGNALER GLUED 15 VOLTAGE REGULATOR 1A DIODE Schematic wiring diagrams Turn indicators horn and accessories prewiring section 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 15A FUSE PRESETTING FOR
19. BULB 2 X STAND BUTTON NUMBER PLATE LIGHT 12V 5W STAND PUMP MOTOR PUMP ASSEMBLY WITH LEVEL INDICATOR RH REAR LIGHT WITH 5W PARKING LIGHT BULB AND 10W TURN INDICATOR BULB STARTER MOTOR 12V 14Ah BATTERY HELMET COMPARTMENT LAMP BUTTON FRONT BRAKE LIGHT BUTTON HELMET COMPARTMENT LAMP ENGINE STOP SWITCH 12V SOCKET WHEEL REVOLUTION SENSOR 2 X REAR FUSE BOX FOR CONTROL UNIT 1 X 1 X 5A 1 X 10 1 X 3A RH FRONT TURN INDICATOR 10W BULB MAIN RELAY SWITCH DIODE BOX 2 X 6 A AND 2 A DIODE LIGHTS SELECTOR SWITCH FUSE BOX 2 X 7 5A 1 X 15A AND 5A START BUTTON FUSE BOX WITH STRIP FOR STAND PUMP ELECTROMAGNETIC SWITCH NO 1 OF 70A STAND BUTTON IGNITION SWITCH DIGITAL INSTRUMENT SET 11 WARNING LIGHTS AND LEDS RADIO DISPLAY ANALOG INSTRUMENT SET 5 LAMPS ELECTRIC FAN RELAY SWITCH HEADLIGHT 2 X PARKING LIGHT BULB HIGH LOW BEAM 55 55W BULB 30A FUSE WITH SOLENOID STARTER RADIO CONROL UNIT INTERCOM SPEAKERPHONE LH FRONT TURN INDICATOR WITH 10W BULB No 2 PUMP ELECTROMAGNETIC SWITCHES REAR BRAKE LIGHT BUTTON RELAY SIGNALER GLUED LIGHTS SWITCH WITH HEADLIGHT FLASH No 2 HEADLIGHT ELECTROMAGNETIC SWITCHES Electrical equipment devices 1 Digital instrument panel 11 LED indicators 2 Analog instrument panel 5 bulbs 3 Headlight 2 parking light bulbs 55 55W low high beam bulbs 4 LH front tu
20. GNETO 12V 14Ah BATTERY INJECTION ELECTRONIC POWER UNIT 30A FUSE HV COIL ENGINE STOP SWITCH SPARK PLUG 10A FUSE DIGITAL INSTRUMENT SET ELECTRONIC POWER UNIT ELECTROMAGNETIC SWITCH 5A FUSE SIDE STAND SWITCH 3A FUSE 2A DIODE ojo N Lights section 12V 55W LOW BEAM BULB Schematic wiring diagrams 7 5 A FUSE 12V 55W HIGH BEAM BULB 15A FUSE LOW BEAM RELAY SWITCH 7 5 A FUSE HIGH BEAM RELAY SWITCH 7 5 A FUSE DIGITAL INSTRUMENT SET 30 A FUSE LIGHTS SWITCH 12V 14Ah BATTERY 2 x 12V 5W FRONT PARKING LIGHT BULB 2 x 12V 5W REAR PARKING LIGHT BULB 1 x 12V 5W NUMBER PLATE LIGHT BULB IGNITION SWITCH CONTACTS HELMET COMPARTMENT LAMP BUTTON 12V 5W HELMET COMPARTMENT LAMP BULB 12V 180W SOCKET MAIN RELAY SWITCH 15A FUSE FLYWHEEL MAGNETO LIGHTS SELECTOR SWITCH VOLTAGE REGULATOR 2A DIODE Schematic wiring diagrams Battery recharge and starter section IGNITION SWITCH CONTACTS 30A FUSE 909 69 C9 C9 FLYWHEEL MAGNETO 6A DIODE 7 5 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 STAND SWITCH FRONT BRAKE LIGHT BUTTON AND START INHIBITOR SWITCH 5A FUSE REAR BR
21. K position It is then necessary to drill the bolt as show in the figure to eject it Note To refit the bolt from this position first disengage the steering lock by putting the lock body inner and outer part in the OFF position Proceed as described in the previous paragraph Adjusting the headlight Place the unloaded vehicle on a level surface 10 metres from a half lit white screen with the tyres inflated to the prescribed pressure Ensure that the axis of the vehicle is perpendicular to the screen Draw a horizontal line on the screen 70 73 cm above the ground Switch on the headlight turn on the low beam and check that the horizontal line that divides the dark area from the lighted area is not above the line previously drawn on the screen To shift the head light use the specially designed screw in the front shield see figure Maintenance 03 017 03 018 TABLE OF CONTENTS ELECTRICAL EQUIPMENT 4 ELECTRICAL EQUIPMENT SIDESTAND SWITCH TURN INDICATOR SWITCH VOLTAGE REGULATOR HORN BUTTON STAND CONTROL UNIT HAZARD WARNING LIGHT BUTTON ELECTRONIC CONTROL UNIT RELAY SWITCH ENGINE STOP RELAY SWITCH RESET BUTTON TRUMPET HORN SERVICES ELECTROMAGNETIC SWITCH FUSE BOX 3 X 7 5A 1 X 15A LH REAR LIGHT WITH 5W PARKING LIGHT BULB AND 10W TURN INDICATOR BULB 1 2 3 4 5 6 7 8 NO 2 SOLENOID STARTERS 375W FLYWHEEL MAGNETO REAR BRAKE LIGHT 5 X 2 3W
22. SERVICE STATION PIAGGIO MANUAL e AH 500 cc Piaggio amp C S p A Pontedera After Sales Service Dis 594523 04 01 Grafica e Stampa C L D Pontedera PI Copyright 2001 PIAGGIO amp 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 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 Warning Denotes specific procedures to be used to avoid damaging the vehicle Identifies specific procedures to be followed to avoid i
23. Unscrew oil drain plug B and drain all the oil Retighten the oil drain plug and then fill the hub with fresh oil Recommended oil TUTELA ZC 90 Hub oil capacity 250 cc Maintenance 03 008 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 The level of the fluid should always be between the MIN and MAX marks To have an indication of the coolant level refer to the groove in the plastic strip that can be seen through the coolant filler hole The upper and lower parts of the groove correspond to the MAX and MIN levels re spectively The coolant consists of a 50 percent mixture of demineralized water and antifreeze solution with a base of ethylene glycol and corrosion inhibitors Total coolant capacity 1 8 It To check the presence of air in the circuit follow the procedure described in Chapter 11 Cooling in the manual of Engine 500 cc Switch off the engine and allow it to cool down After a few minutes remove the expansion tank cap and check the level of the fluid If necessary top up by pouring fresh coolant into the expansion tank up to the correct level Warning To prevent the coolant from leaking out o
24. as come out Close the bleeder valve 8 Fill the circuit reservoir to the maximum level with fluid of the prescribed type 9 Attach the pipe of the specific tool Mityvac type manual pump to the bleeding connection 10 While acting on the bleeder with the specific tool constantly pour fresh fluid into the reservoir so as to avoid sucking in air Stop pumping as soon as the fluid flows out of the bleeder with no air bubbles 11 Tighten the bleeder screw with the prescribed torque Tightening torque Drain screw 12 16 Braking system Note When topping up or renewing the brake fluid only use DOT4 NHTSA 116 fluid Always ensure that all parts are perfectly clean The brake fluid is highly corrosive Take care notto spill it on painted surfaces The brake fluid is hygroscopic i e it absorbs humidity from the air If the humidity contained in the fluid exceeds a given concentration the braking action be comes insufficient owing to a reduction in the boiling point of the liquid Note Always take the brake fluid from sealed contain ers Note Rubber parts must not be left immersed in alcohol for longer than 20 seconds After the washing dry the parts with a compressed air jet and wipe them with a clean cloth Seal rings must be immersed in the liquid of use The use of the PRF1 protective agent is permitted The braking action is decreased if brake fluid is present on the brake discs or pads Should
25. asic model Removal Release the springs Unloose the r h and l h nut Remove the screws Fitting Perform the above procedure in reverse order and then move the seal rings into their seats Warning Lubricate the following parts with TU TELA Z2 grease spring connection pins bushes on stand clamps Tightening torques Central stand bolt 25 30 06 017 06 018 TABLE OF CONTENTS BRAKING SYSTEM 7 BRAKING SYSTEM Lusricate WITH OIL APPLY PRODUCT A WARNING HANDLE WITH CARE 4 LUBRICATE WITH GREASE CLEAN CAREFULLY ALWAYS REPLACE CALLOUT QUANTITY TORQUE 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 Remove the two pads by pulling them downwards Check the thickness of the pads Wear limit 1 5 mm Repeat the operations on the brake caliper on the opposite side To fit the pads follow these steps Insert the two pads into the caliper Fit the pin retaining spring Press down the spring to allow the insertion of the pin see figure nsert the pin Fit the re
26. asket and restore the brake fluid level with liquid of the recommended type without exceeding the max level Maintenance 03 012 03 012 4 03 012 2 3 7 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 it absorbs humidity from the air If the humidity contained in the fluid exceeds a given concentration the braking action becomes insufficient Never draw the fluid from open or partly empty contain ers Under normal climatic conditions the fluid should be renewed every 20 000 km or in any case every two years N B Change the brake fluid and bleed the system as described in Chapter 7 Braking system Steering lock Disassembly with lock turned to OFF Remove the rear shield as described in Chapter 8 Bodywork Remove the immobilizer aerial shown in the figure Disconnect the wiring Pull out the retaining spring shown in the figure and remove the ignition switch 03 012 3 03 015 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 Removal with lock in LOCK position The bolt retaining spring is not accessible in the LOC
27. d central cover Replacement Steering head tube cover Painting Reset button Replacement 25 WINDSCREEN Code Description 004028 004066 Code Windscreen glass Replacement One rearview mirror Replacement Description 004065 004081 002082 004156 Code Front shield rear section Removal and refitting Glove compartment door Replacement Fuel tank door opening cable Replacement Glove compartment door and or support Replacement Description 004135 00401 1 004157 Code Fuel tank door Replacement Frame central cover Replacement Fuel tank door catch Replacement Description 007001 007013 001052 Expansion tank Replacement Expansion tank connection pipe radiator Replacement Coolant renewal and air bleeding Replacement 29 RADIATOR Description 007002 Radiator Replacement 007016 Fan complete with support Replacement 007003 Coolant delivery and return pipe Replace 007022 Coolant return pipe Replacement Code Description 005033 Glove compartment lamp switch Repl 005026 Helmet compartment lamp Replacement 005027 Helmet compartment lamp support Repl 004142 Electrical socket Replacement 004016 Helmet compartment Removal and refitting 002083 Saddle opening cable Replacement o Code Description 004075 1 front mat Replacement 004076 One rear mat Replacement 004068 One grab handle Replace
28. e clamp 04 023 Insertthe battery in the compartment taking care to fit the breather pipe in the bottom hole 04 024 Insertthe battery in the compartment taking care to fit the breather pipe in the bottom hole 04 025 Checking the electrolyte level Frequently check that the electrolyte reaches the upper level To top up only use distilled water If you need to top up the battery too frequently check the vehicle electrical equipment as the battery is cer tainly working in overload conditions which will lead to rapid deterioration Checking the battery charge After restoring the electrolyte level check its density with the special hydrometer see figure When the battery is charged electrolyte density must be between 30 and 32 B corresponding to specific gravity of 1 26 1 28 at a temperature not lower than 15 C If density has fallen below 20 B the battery is completely discharged and needs recharging If the vehicle is not used for some time 1 month or more the battery must be periodically recharged In three months the battery runs down completely When refitting the battery take care not to invert the connections the ground lead black is to be connected to the negative terminal and the other lead red must be connected to the positive terminal Battery recharge Before charging the battery remove all cell plugs Keep free flames or sparks away from the battery during recharge
29. e line sup ports 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 Remove the two rings the middle washer shown in the figure and the spacer below Adequately supportthe 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 Pull out the fork assembly Specific tool Steering tube ring spanner 020055Y Replacing the steering bearings Using the specially designed tool shown in the figure and a mallet remove the upper ball 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 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 020004 Y Front and rear suspensions 06 011 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
30. e to prevent any fluid residues from coming out Remove the two screws fastening the clevis to the handlebar Replace the broken pump Reassemble taking care to replace the copper gas kets Fasten the connection and tighten the two screws fixing the pump to the handlebar Braking system Note Take careto properly insertthe 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 Replacing the pressure divider valve Removal Should the braking action between the front left and rear calipers by unevenly distributed e g with the same surface and adhesive force on both wheels the rear brake jams while the front brake is not applied or vice versa or the brakes work in a completely different manner or the divider valve does not work properly follow these steps Empty the combined brake circuit as previously de scribed Remove the front countershield as described in Chap ter 8 Bodywork Unscrew rear caliper connection 1 see figure Note Place a rag under the divider valve to prevent brake fluid from soiling the brake pads or other compo nents Remove front brake caliper connection 2 Remove connection 3 conveying the fluid from the pump to the valve Removethe two cheese headed socket screws fixing the valve to the frame in
31. embly and relevant sup port 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 H V cable from the spark plug Detach the generator harness from the vehicle elec trical system Muffler assembly disassembly Unloose the two fixings of the exhaust manifold on the head 05 001 Unloose the 3 screws fixing the mufflerto the support ing arm Remove the muffler assembly 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 Remove the supporting arm 05 003 Disassembly of I h shock absorber lower 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
32. f the expansion tank during use be sure to never exceed the MAX level when refilling Water pump Ifthe water pump becomes noisy or liquid leaks through the pump drain hole check the water pump as de scribed in Chapter 5 Flywheel cover of the manuale Engine 500 cc Perform the following preliminary op erations Put the vehicle on the central stand on level ground Remove the lower right hand side panel and the right hand footboard as described in Chapter 8 Bodywork Remove the silencer to gain access to the flywheel cover as described in Chapter 5 Engine Remove the sleeves from the water pump cover and the filler cap from the expansion tank and empty the cooling circuit Warning is cold Perform the operation when the engine Remove the water pump cover shown in the figure after loosening the six fixing screws Cooling circuit capacity 1 8 It 03 010 As described in the manual Engine 500cc partially drain the system and overhaul the pump After solving the problem and refitting all components fill and bleed the cooling circuit again N B Change the coolant as described in Chapter 11 Cooling of the Manual Engine 500 cc Adjustingthe play ofthe 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
33. he 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 Resistance 02 10 4 Check that each yellow wire is insulated from earth 5 If the resistance is not as specified replace the stator Checking the peak current With the engine off and swithboard ON turn the vehicle lights on and let the battery tension set to 12V Connect the amperometric pliers to the 2 outlet re charge positive poles of the regulator With lights on start the engine and read the value on the pliers with the engine running at high speed With efficient battery the measured value is 20A Voltage regulator rectifier Specifications Electrical equipment STANDARD VALUE Voltage regulator rectifier Transistorized non adjustable three phase Voltage 14 15V at 5000 rpm with lights off 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 760 89 10N the speed sensor by means of the digital section 7 69 Atachometer controlled by a signal coming from the 2 CMM 3 4 power unit injection A fuel gauge controlled by a resistive se
34. icating the direction of rotation must face the outside of the vehicle Tightening torques Brake disc fixing screw 14 17 N m 7 4 07_004 07_005 07 007 General guidelines for servicing the hydraulic brak ing system The brake fluid is corrosive Always wear protective gloves when working on the hydraulic system In case of contact with the eyes rinse gener ously with water The used brake fluid is harmful to the environment Collect and dispose of used oil according to the regula tions in force Under normal climatic and riding conditions the brake fluid should be renewed every two years However if the brakes are subjected to heavy stress the fluid should be renewed at shorter intervals When reassembling reused parts should be perfectly clean and free from oil diesel fuel and grease It is therefore necessary to thoroughly clean them with denatured alcohol Braking system Renewing the brake fluid and bleeding air from the brake circuit Front brake Follow these steps 1 Putthe vehicle on the stand on level ground 2 Remove the brake fluid pump reservoir cap as described in Chapter 8 Bodywork 3 Remove the two screws shown in the figure and open the front brake fluid reservoir 4 Using the bleeder screw on the brake caliper empty the brake circuit through a pipe of suitable diameter Collect the used fluid in a suitable container 6 Operate the brake pump until all the fluid h
35. l glass 12V 5W x2 Front turn indicator bulb spherical 12V 10W x 2 Rear parking light bulb spherical 12V 5W x2 Brake light bulbs spherical 12V 2 3W x 5 Rear turn indicator bulb spherical 12V 10W x 2 Instrument panel lighting bulb all glass 12V 2W x 5 Glove compartment lamp bulb cylindrical 12V 5W Number plate light bulb cylindrical 12V 5W Electrical equipment Battery 12V 14Ah 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 In case of ingestion immediately drink large quantities of water or milk Subsequently administer milk of mag nesia beaten eggs or vegetable oil Immediately seek medical attention Batteries produce explosive gases Keep them away from open flames sparks and cigarettes If the battery is charged in a closed place ensure adequate ventila tion Always protect the eyes when working close to batter ies Keep out of reach of children Installing charged dry batteries 1 Remove the short closed tube and the plugs Fill the cells to the upper level with accumulator sul phuric acid specific weight 1 26 corresponding to 30 B at a temperature of at least 15 C 2 Leaveatrestforatleasttwo hours andthen restore the level by adding sulphuric acid 3
36. lack Warning When working on the electrical equip ment take special care to ensure that the leads that link up to the electronic control device are properly con nected by observing the polarity and colour coding of the connectors Electrical equipment diagram 41 Relay switch 42 Lights switch 43 Start button 44 Stand button 45 Immobilizer aerial 46 Ignition switch 47 Electric fan 48 Electric fan relay switch 49 Main relay switch 50 HV coil 51 Fuel gauge with pump 52 Starter motor 53 Helmet compartment lamp button 54 Helmet compartment lamp 55 12V socket 56 2 rear fuse boxes for control unit 1 x 3A fuse 1x 5A fuse 1 x 10A fuse 1 x 3A fuse 57 Radio display 58 Relay switch 59 Outside temperature sensor 60 Diode box 2 x 6A 2A diodes 61 Fuse box 2 x 7 5A fuse 1 x 15A fuse 1 x 5A fuse 62 Fuse box with base for stand pump 1 x 70A fuse 63 Intercom radio control unit 64 Intercom connectors 65 Relay signaler glued Schematic wiring diagrams Ignition section IMMOBILIZER DECODER IMMOBILIZER AERIAL IGNITION SWITCH CONTACTS ENGINE STOP RELAY SWITCH VOLTAGE REGULATOR MAIN RELAY SWITCH FLYWHEEL MA
37. ment 004012 2 Rear body sides Removal and refitting 004129 Rear side panel Replacement 006005 Two side covers Painting 006008 Rear side fairing Painting 004059 Spark plug inspection door Replacementc 004079 Footrest 1 Replacement 004053 Spoiler Replacement 004015 Footboards Replacement AND A OON pe 2 32 FRONT MUDGUARDS Code Description 004002 Front mudguard Replacement 006003 Front mudguard Painting 33 SADDLE Code Description 004003 004144 004150 004067 004054 Code Saddle Replacement Bag Replacement Saddle damper Replacement Rider s backrest Replacement Saddle catch Replacement Description 004119 003002 003073 Code Steering upper thrust ring bearing Replace Steering thrust rings Replacement Steering play Adjustment Description 003051 003079 003048 Code Fork assembly Replacement Fork rod Replacement Fork oil seal Replacement Description 10 10 003007 Rear shock absorber Removal and refitting 37 INSTRUMENT PANEL Description 005014 Speedometer Replacement 005078 Speedometer glass Replacement 005082 Instrument panel wiring Replacement 005083 Trip computer Replacement Code Description 004151 Instrument panel support Replacement 004018 Handlebar front section Replacement 004019 Handlebar rear section Replacement 006013 Handlebar front secti
38. mirrors and under the front central cover Remove the lower guard and relevant weather strip Note When refitting take care to properly reinsert the weather strips into their seats Front lamp cluster Remove the three fixing screws Detach the electrical connectors Remove the front lamp cluster by pulling it forward Front shield Remove the two front screws Remove the two screws behind the wheel Unscrew the remaining six fixing screws Detach the electrical connectors Remove the front shield with the turn indicators Bodywork 08 001 08 002A 08 003 08 004 8 3 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 Front handlebar cover Loosen the two screws fixing the radio interphone unit Detach the electrical connectors Remove the radio interphone Remove the two handlebar cover lower screws one on each side Remove the brake fluid pump cover on the right side Remove the front handlebar cover Rear handlebar cover Remove the three fixing screws Detach the electrical connectors Remove the rear handlebar cover 08 005 08 007 08 008 TABLE OF CONTENTS TABLE OF WORKING TIMES 1 0 Time 160 450 20 Description Engine from frame Removal and
39. mpression ring 2nd Compression ring Scraper ring Vehicle overhaul data SHIMMING METHOD FOR LIMITING THE COMPRESSION RATIO CR z 10 5 1 N B The 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 A MEASUREMENT WITH PISTON AT TDC FIT THE GASKETS SHOWN IN THE TABLE ACCORDING TO THE A MEASUREMENT 01_006 NOTE THE A MEASUREMENT MUST BE TAKEN WITH NO E GASKET FITTED BETWEEN CRANKCASE AND CYLINDER 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 Crankshaft crankcase axial clearance 0 1 0 5 mm cold engine 01 010 Vehicle overhaul data Crankshaft connecting rod axial clearance 7 lt 01 007 DIMENSIONS CLEARANCE Web transmission side A 0 8 0025 Shaft section transmission side B 19 6 995 Connecting rod 22 010 Shaft section flywheel side E 19 6 205 Web flywheel side 13 0 025 Crankshaft assembly 63 5 01 0 05 0 20 0 40
40. ning torque Oil drain screw 12 16 07 010 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 Remove the caliper pipe connection shown in the figure Collect any fluid residues left in the pipe Remove the two screws fixing the caliper to the support Remove the caliper Remove the brake pads from the caliper as previ ously described Replace the caliper with a new one and then follow the reverse procedure to the removal Note Fit new copper gaskets on the connection Tighten the two fixing screws with the prescribed torque Complete the operation by filling and bleeding the circuit Use the same procedure for the three calipers the only difference being that the rear brake caliper must be removed from the vehicle together with its support This is obtained by loosening the two screws shown in the figure after removing the rear wheel as de scribed in Chapter 6 Front and rear suspensions Tightening torque Screws fixing caliper to support 20 25 N m Removing the brake pumps To remove and replace the brake pumps follow these steps Empty the related braking circuit as described in the previous paragraphs Remove the connection shown in the figure taking car
41. njury to repairing personnel NOTE For any intervention to the engine refer to the Service Station Manual for 500 cc Engines TABLE OF CONTENTS VEHIGLE SPEGIFIGATIONS AND OVERHAUL DATA MN SPECIFIC TOOLING MAINTENANCE AND TROUBLESHOOTING 3 ELECTRICAL EQUIPMENT 4 ND FRONT AND REAR SUSPENSIONS ep BRAKING SYSTEM N BODYWORK PREDELIVERY OPERATIONS O TABLE OF WORKING TIMES ee EN O Assembly plays Mating between piston and cylinder PART DIMENSIONS Cylinder OC Piston 92 0 010 0 018 91 961 0014 0 014 Vehicle overhaul data DIAMETER MATING CLASSES CYLINDER 91 990 91 997 PISTON 91 947 91 954 91 997 92 004 92 004 92 011 91 954 91 961 91 961 91 968 92 011 92 018 91 968 91 975 Values in mm Values in mm ASSEMBLY CLEARANCE 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 Arrange for the piston rings opening as shown in the figure Assemblethe rings bee 2 and 3 with the T ae 2 Top writing facing ke i x upwards A value of the ring inside the cylinder 01_005 Values in mm DIMENSIONS CLEARANCE CODE SEAT CLEARANCE 0 15 0 35 0 25 0 50 0 25 0 50 CLEARANCE AFTER USE 92 x 1 5 92 x 1 25 92 x 2 5 1st Co
42. nsor in the fuel tank Acoolant temperature indicator controlled by a resis tive sensor on the cylinder head These instruments are of the electrical type and are operated by step by step motors The digital section includes the following indicators Reserve fuel warning light amber Lights on and low beam warning light green High beam warning light blue Left hand turn indicator warning light green Right hand turn indicator warning light green Hazard warning lights four turn indicators red Engine disabled red Brake light bulb burnt out warning light red Oil pressure warning light red Injection warning light amber ALARM warning light electrohydraulic cable red 04 010 The reserve fuel turn indicator and hazard warning lights are activated by the electronics of the instrument For example the fuel reserve warning light comes on only when the reserve fuel indication from the fuel tank lasts a minimum of 13 5 seconds This prevents the warning light from blinking when the engine begins to run on reserve fuel The flashing function is built in the electronics of the instrument which allows the hazard warning lights to work when the ignition switch is in the OFF position and the control switch is disabled The control switch is active only when the instrument panel is on For greater riding safety the turn indicator control function is connected to the mileometer If the turn indicator
43. nt 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 Refitthe two bearings on the left side of the wheel rim Using a tube of suitable diameter on the outer race of the bearings push them home into their seats Fit the spacer in the right side of the wheel as shown in the figure Fit the right hand bearing by following the same procedure as the other bearings Refit the two front brake discs as described in Chap ter 7 Braking system Fit the outer spacer and the related ring taking care not to compress it excessively against the wheel bearing Checkthe condition of the speed sensor seal ring and of the related groove in the wheel rim Insertthe pin from the side by aligning the spacers Take care not to damage the phonic wheel Offset the drives beforehand by about 90 Tighten the wheel axle nut Tighten the two screws of the clamp on the pin housing on the r h sheath Tightening torques Axle nut 45 50 N m Right hand sheath lower screws 6 7 N m 6 4 06 006 06 007 06 008 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 brak
44. on Painting 006014 Rear handlebar protection Painting 004152 Trip computer cover Replacement 39 HANDLEBAR COMPONENTS o 2 Code Description 002060 Throttle control assembly Replacement 002037 Brake or clutch lever Removal 002071 Left handgrip Replacement 002024 Brake pump Removal and reinstallation 003001 Handlebar Removal and refitting 002063 Throttle control cable assembly Replacement 002059 Throttle twist grip Replacement 003061 Throttle control cable Adjustment 002088 All wheel brake pump Replacement o Jo Om E OON A 005017 Stoplight switches Replacement Code Description 002021 Front brake line Removal and refitting 002084 All wheel brake pump tube device Replacement 002085 Front caliper all wheel braking device tube Replacement 002087 All wheel braking rear rigid tube Replacement 002090 All wheel brake fluid Renewal and system bleeding 002047 Front brake oil and system draining Replacement 002089 Integral braking device Replacement 10 11 41 BRAKE CALIPER Code Description 002007 003070 002039 002048 002002 003071 Code Front brake shoes pads Replacement Front brake pads shoes Wear check Brake caliper Removal and refitting Front brake caliper Replacement Rear brake pads Replacement Rear brake pads hook Wear check Description 43 REAR LIGHT 005002 005008 005044 005067 005012 005091
45. 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 Checkthe spark plug to see ifthe 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 f 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 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 Directthe 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 Warning If the vehicle is mostly u
46. r switching off the engine Topping up If the oil level is too low top up by adding fresh oil without exceeding the MAX level Approximately 400 cc of oil are needed to restore the level between the MIN and MAX marks Cil pressure warning light A warning light on the instrument panel comes on when the ignition key is turned to the ON position The light must go out after the engine has started Should the warning light come on while braking idling or cornering check the oil level and the lubrication system as soon as possible Renewing the oil and the filter The oil and the filter must be renewed every 6 000 km Drain all the oil from the engine by removing gauze strainer drain plug B on the transmission side To facilitate the outflow also remove cap dipstick A Once the oil has drained completely through the drain hole unscrew oil filter cartridge C and remove it as described below 8 4 Since a certain amount of oil remains in the circuit the replenishment must be made by adding approximately 1 500 cc of fresh oil through cap A Subsequently start the engine let it idle for a few minutes and then switch it off After about 5 minutes check the level and if necessary top up without exceeding the MAX level The filter cartridge must be replaced every time the oil is changed For top ups and renewals use fresh oil of the Selenia HI Scooter 4 Tech type Note Renew the oil when the engine is hot
47. rn indicators 10W bulb 5 Rear brake light button 6 Lights selector switch with headlight flash 7 Turn indicator switch 8 Horn button 9 Hazard warning light button 10 Reset button 11 Trumpet horn 12 Sidestand switch 13 Voltage regulator 14 Stand control unit 15 Engine stop relay switch 16 Electronic control unit relay switch 17 Stand pump relay switches 18 LH rear light BW parking light bulb 10W turn indicator bulb 19 Rear brake light 5 x 2 3W bulbs 20 Number plate light with bulb 21 RH rear light BW parking light bulb 10W turn indicator bulb 22 12 14 battery 23 Fuse box 3 x 7 5A fuse 1 x 15A fuse 24 Starting relay switch 25 Flywheel magneto 375W 26 Engine oil pressure sensor 27 Coolant temperature sensor 28 Engine rpm sensor 29 Air temperature sensor 30 Idle speed adjusting motor 31 Throttle potentiometer 32 Petrol injector 33 2 stand switches 34 Stand pump motor 35 Injection electronic control unit 36 Decoder 37 Front brake light button 38 Engine stop switch 39 Wheel revolution sensor 40 RH front turn indicator 10W bulb ELECTRICAL CABLES COLOUR B White Bl Blue G Yellow Mr Brown N Black BV White Green GN Yellow Black Gr Grey Rs Pink R Red Vi Violet V Green VN Green Black BN White Black BBl White Blue GV Yellow Green Ar Orange Az Azure GrBl Grey Blue GrN Grey B
48. rom the top a suitable wrench of 12mm in order to block the pumping element Refit the lower screw 1 Pour in 90 cc of Fork PG SAE 20W oil Reassemble by following the reverse procedure 06 015 Rear shock absorbers Removal Follow these steps Put the vehicle on the central stand Using a jack slightly lift the engine so as to free both shock absorbers Remove the silencer Unloose the shock absorber spring assembly fixing screw from the support fixed to the engine on one side and from the one fixed to the muffler support on the other side Unscrew the two upper nuts one on each side fixing the shock absorber spring assemblies to the frame and then remove the assemblies themselves Fitting Perform the removing procedure in reverse order taking care to observe the prescribed tightening torques Tightening torques Shock absorbers lower fixing screw 33 41 N m Shock absorbers upper fixing screw 33 41 Nm Front and rear suspensions Rear wheel Removal Removethe 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 moval Tighten the rear wheel fixing screws and the axle locknut with the prescribed torques Tightening torque Rear wheel rim screws 20 25 Central stand B
49. ry to carry out these operations before storing the vehicle and subsequently every six months RECHARGING THE BATTERY FOLLOWING OPEN CIRCUIT STORAGE 1 Checking the voltage Before installing the battery on the vehicle measure the open circuit voltage with an ordinary multimeter If the voltage exceeds 12 60 V the battery can be installed without recharging fthevoltageislessthan 12 60 V recharge the battery as described at item 2 2 Constant voltage charging method Constant voltage 14 40 14 70 V nitial charging current 0 3 0 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 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 itis essential notto recharge itfor more than 8 consecutive hours TABLE OF CONTENTS Engine Engine disassembly from frame Perform these operation with the en gine cold Take care when handling the petrol Warning When installing the battery first fix the Disconnect the battery 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 ass
50. s are inadvertently left on they are automatically switched off after 1 kilometre The engine start disabled warning light is activated by the sidestand switch and the emergency switch on the right side of the handlebar The indication brake light bulb burnt out is activated when at least two of the five bulbs fail to operate The warning light is controlled by a circuit that measures the absorption of the brake light bulb The liquid crystal display shows a 5 digit total mileage count in either kilometres or miles Naturally this counter can never be reset To select the unit with key turned to OFF press the Trip and M buttons at the same time and turn the ignition switch to the ON position If the two buttons are depressed for longer than three seconds the word SET is displayed and then the unit toggles between kilometres and miles Electrical equipment 3 Four fuses C in the glove compartment on the left side Fuse Protected circuits Flash horn accessories Brake light buttons start button starter relay switch Lights switch parking lights number plate light Digital instrument panel PICS control unit power supply 04 016 4 One fuse D of 30A main fuse located next to the battery on the solenoid starter A spare fuse is also provided underneath List of bulbs Function Type Power Low beam bulb halogen 12V 55W High beam bulb halogen 12V 55W Front parking light bulb al
51. sed on dusty roads the air filter needs to be cleaned and replaced at shorter intervals than indicated in the Maintenance Schedule Warning Do notrun 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 Maintenance 03 001 03 002 03 004 3 3 Maintenance Engine oil level In four stroke engines oil is used to lubricate the valve gear components the crankshaft bearings and the power plant A lack of engine oil can cause serious damage to the engine In all four stroke engines oil deterioration and con sumption are to some extent normal especially during running in Consumption partly depends on the riding style for example constantly riding at full throttle increases oil consumption Checking the oil level Perform this operation when the engine cold as de scribed below 1 Put the vehicle on its central stand on a flat surface 2 Unscrew dipstick A dry it with a clean cloth and refit by screwing it completely 3 Remove the dipstick again and check that the oil level is between the MAX and MIN marks on the dipstick top up if necessary The MAX level mark indicates an amount of about 1700 cc of engine oil The level will be lower if checked after using the vehicle i e when the engine is hot To obtain a correct indication of the oil level wait for at least 10 minutes afte
52. tainer Fitthe caliper on its support and then tighten the two screws with the prescribed torque Tightening torques Screws fixing caliper to support 20 25 N m N B If during the assembly it is not possible to fit the caliper on the disc refit the pistons in the caliper carefully Removing and replacing the rear brake pads Follow these steps Remove the left hand rear shock absorber support with the shock absorber itself and the rear wheel as described in Chapter 6 Front and rear suspensions Unloose the two screws fixing the brake caliper sup port to the engine Remove the caliper from its support Remove the retaining ring and the pin Remove the two pads by pulling them downwards Check the thickness of the pads Wear limit 1 5 mm If the thickness of the pads is less than the prescribed limit replace them Refit the parts by following the same procedure used for the front brake pads Tighten the two screws fixing the caliper supportto the engine with the prescribed torque Tightening torques Screws fixing caliper to support 20 25 N m Screws fixing caliper support to engine 20 25 N m Braking system 07 003 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
53. the handlebar to the steer ing tube shown in the figure and then remove it Remove the handlebar and the plastic support Note If the handlebar is removed to proceed to the removal of the front fork simply overturn the handlebar onto the front of the vehicle without removing the parts fitted on it Take care not to damage the flexible trans missions the pipes or the bodywork Fitting Perform the removing procedure in reverse order To align the handlebar with the steering tube align the notch on the handlebar with the notch on the sterring tube Tighten the fasteners with the torques specified in Chapter 1 Tightening torques Handlebar fastening bolt 43 47 N m Removing the front wheel Remove the two brake calipers as described in Chapter 7 Braking system Unscrew the axle locknut Disengage the axle by loosening the two screws on the right hand fork sheath see figure While supporting the wheel remove the axle on the right side of the vehicle When removing the wheel take care not to damage the speed sensor Overhauling the front wheel Check the bearings for any excessive play or stickiness causing noise and uneven rotation of the wheel Should the wheel bearings need to be replaced follow these steps Using a suitable extractor on the inner race remove the two bearings on the left side of the wheel speed sensor side Front and rear suspensions 06 001 06 004 6 3 Fro
54. the two holes shown in the figure Remove the valve and replace it with a new one Fitting Follow the reverse procedure to the removal Note Fit new copper gaskets on the connections Tighten the screws fixing the valve to the frame and above all the connections on the brake lines with the prescribed torque Fill and bleed the brake circuit as previously de scribed 07 015 24 fr LA 7 14 Le OU AM E De AM eer ZA eee Tightening torques Oil pump Integral braking device tube connection 16 20 N m Front brake caliper Integral braking device con nection 20 25 Rear brake caliper Integral braking device connec tion 20 25 TABLE OF CONTENTS BODYWORK Perform all operations with great care Plastics are easily damaged Avoid cleaning painted plastics with solvents containing petrol and its derivatives Lusricate WITH OIL APPLY PRODUCT WARNING HANDLE WITH CARE 4 LUBRICATE WITH GREASE CLEAN CAREFULLY ALWAYS REPLACE 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 Lower guard Windscreen Remove the rearview mirrors Unloose the 3 fixing screws shown in the figure and relevant spacers Remove the upper windscreen Unloose the 4 fixing screws with washers located under the rearview
55. when new 5 0 mm Wear limit front discs 3 5 mm Wear limit rear caesen 4 5 mm Checking disc distortion Take down the wheel and using suitable equipment check that the axial runout of the braking surface does not exceed the specified limit Max axial runout 0 1 mm Ifthe runout exceeds the specified limit replace the disc as described below and repeat the measurement If the problem persists check and if necessary replace the wheel hub Note When refitting thoroughly clean the disc and its seat on the hub Replacing the front brake discs Follow these steps Remove the front wheel as described in Chapter 6 Front and rear suspensions For each disc loosen the five screws shown Carefully clean the seats on the front wheel hub and the discs When fitting the disc take care to position it properly by referring to the arrow stamped on it Tighten the screws with the prescribed torque and smearthem with LOCTITE Threadlocker medium 242 Note The disc side bearing the arrow indicating the direction of rotation must face the outside of the vehicle Tightening torques Brake disc fixing screws 5 6 Replacing the rear brake disc Remove the rear wheel as described in Chapter 6 Front and rear suspensions Remove the hub with the brake disc Follow the same procedure used for the front brake discs Note The disc side bearing the arrow ind
Download Pdf Manuals
Related Search