Piaggio X9 (500cc.) - Service Manual - Owners Manual

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PIAGGIO X9 (500CC.) - WORKSHOP MANUAL - PARTS MANUAL - OWNERS MANUAL

- English Service Manual, Owners Manual and Spare Parts Catalogue to motorcycles Piaggio X9 (500cc.)

CONTENTS:

WORKSHOP MANUAL

Characteristics

- Rules 
- Safety rules 
- Maintenance rules 
- Vehicle identification 
- Dimensions and mass 
- Engine 
- Transmission 
- Capacities 
- Electrical system 
- Frame and suspensions 
- Brakes 
- Wheels and tyres 
- Tightening Torques 
- Overhaul data 
- Assembly clearances 
- Cylinder - piston assy. 
- Piston rings 
- Crankcase - crankshaft - connecting rod 
- Slot packing system 
- Products

Tooling

Maintenance

- Maintenance chart 
- Spark plug 
- Hub oil 
- Check 
- Replacement 
- Air filter 
- Engine oil 
- Check 
- Engine oil filter 
- Oil pressure warning light 
- Checking the ignition timing 
- Checking the valve clearance 
- Cooling system 
- Level check 
- Braking system 
- Level check 
- Top-up 
- Headlight adjustment 
- Checking the end compression pressure

Troubleshooting

- Transmission and brakes 
- Clutch grabbing or performing inadequately 
- Insufficient braking 
- Brakes overheating 
- Braking vibrations or noise 
- Electrical system 
- Battery 
- Turn signal lights malfunction 
- Steering and suspensions 
- Controls 
- Heavy steering 
- Excessive steering play 
- Noisy suspension 
- Suspension oil leakage

Electrical system

- Components arrangement 
- Conceptual diagrams 
- Ignition 
- Headlights and automatic starter section 
- Battery recharge and starting 
- Level indicators and enable signals section 
- Checks and inspections 
- Battery recharge circuit 
- Stator check 
- Recharge system voltage check 
- Lights list 
- Fuses 
- Dashboard 
- Data check function 
- pics 
- Sealed battery 
- Dry-charge battery 
- Phonic wheel 
- Connectors 
- ECU 
- Seat opening receiver 
- Immobiliser decoder 
- Engine rev. sensor 
- Analogue odometer 
- Remote seat opening 
- Battery replacement 
- Zeroing 
- Programming

Engine from vehicle

- Exhaust assy. Removal 
- Removal of the engine from the vehicle

Engine

- Automatic transmission 
- Transmission cover 
- Air duct 
- Air duct filter 
- Removing the driven pulley shaft bearing 
- Refitting the driven pulley shaft bearing 
- Baffle roller 
- Plastic roller 
- Removing the driven pulley 
- Inspecting the clutch drum 
- Removing the clutch 
- Pin retaining collar 
- Removing the driven half-pulley bearing 
- Inspecting the driven fixed half-pulley 
- Inspecting the driven sliding half-pulley 
- Refitting the driven half-pulley bearing 
- Refitting the driven pulley 
- Inspecting the clutch spring 
- Refitting the clutch 
- Refitting the driven pulley 
- Drive-belt 
- Removing the driving pulley 
- Inspecting the rollers case 
- Refitting the driving pulley 
- Refitting the transmission cover 
- End gear 
- Removing the hub cover 
- Removing the wheel axle 
- Removing the hub bearings 
- Removing the wheel axle bearings 
- Removing the driven pulley shaft bearing 
- Inspecting the hub shaft 
- Inspecting the hub cover 
- Refitting the driven pulley shaft bearing 
- Refitting the hub cover bearings 
- Refitting the hub bearings 
- Refitting the ub cover 
- Flywheel cover 
- Removing the hub cover 
- Removing the flywheel cover components 
- Removing the stator 
- Inspecting the cover components 
- Refitting the stator 
- Refitting the flywheel cover components 
- Refitting the flywheel cover 
- Flywheel and starting 
- Removing the starter motor 
- Removing the flywheel magneto 
- Inspecting the flywheel components 
- Starter gear rim 
- Intermediate gear 
- Refitting the free wheel 
- Refitting the intermediate gear 
- Refitting the flywheel magneto 
- Refitting the starter motor 
- Cylinder assy. and timing system 
- Removing the intake manifold 
- Removing the rocker-arms cover 
- Removing the timing system drive 
- Removing the cam shaft 
- Removing the cylinder head 
- Removing the valves 
- Removing the cylinder - piston assy. 
- Inspecting the small end 
- Inspecting the wrist pin 
- Inspecting the piston 
- Inspecting the piston rings 
- Removing the piston 
- Choosing the gasket 
- Refitting the piston rings 
- Refitting the cylinder 
- Inspecting the cylinder head 
- Inspecting the timing system components 
- Inspecting the valve sealings 
- Inspecting the valve housings 
- Inspecting the valves 
- Inspecting the valve stem guide clearance 
- Inspecting the springs and half-cones 
- Refitting the valves 
- Inspecting the cam shaft 
- Refitting the head and timing system components 
- Refitting the timing chain 
- Inspecting the radial air gap 
- Refitting the rocker-arms cover 
- Refitting the intake manifold 
- Crankcase - crankshaft 
- Splitting the crankcase halves 
- Removing the crankshaft 
- Removing the countershaft 
- Replacing the countershaft bearings 
- Inspecting the crankshaft components 
- Inspecting the crankshaft alignment 
- Inspecting the crankcase halves 
- Inspecting the crankshaft plain bearings 
- Coupling chart 
- Countershaft 
- Refitting the crankshaft 
- Refitting the crankcase halves 
- Lubrication 
- Conceptual diagrams 
- General characteristics 
- Diagnosis guide 
- Oil pressure check 
- Oil pump 
- Removal 
- Inspection 
- Refitting 
- Inspecting the by-pass valve

Injection

- Precautions 
- Terminals setup 
- EMS circuit diagram 
- Troubleshooting procedure 
- Engine does not start 
- Starting difficulties 
- Engine stops at idle 
- Engine does not rev down 
- Exhaust backfires in deceleration 
- Engine revs irregularly 
- Poor performance at full throttle 
- Engine knocking 
- Decoder master-box circuit 
- Constant supply circuit check 
- Key-switch power supply circuit check 
- Diagnostic circuit 
- Injection warning light circuit 
- Self-diagnosis system 
- Fuel supply system 
- Circuit diagram 
- Removing the injector 
- Refitting the injector 
- Removing the butterfly valve 
- Refitting the butterfly valve 
- Pump supply circuit 
- Circuit check 
- Circuit leak test 
- Pressure regulator check 
- Fuel pump and filter check 
- Pump electrics check 
- Resistor check 
- Pump consumption check 
- Fuel filter check 
- Pump bracket overhaul 
- Pump bracket installation 
- Inspecting the injector circuit 
- Inspecting the injector hydraulics 
- Troubleshooting 
- Immobiliser circuit 
- System components 
- Virgin circuit 
- Setting the circuit 
- LED signals 
- Deterring blink 
- Checking master-box data 
- Resetting the circuit 
- Diagnostic codes 
- Code 1 
- Code 2 
- Code 3 
- Code 4 
- Diagnosis guide 
- Tachometer 
- HT coil 
- Circuit diagram 
- Inspecting the spark plug shielded cap 
- Spark advance 
- Coolant temperature sensor 
- Intake air temperature sensor 
- Pressure sensor 
- Throttle valve opening sensor 
- Zeroing the throttle 
- Step motor

Suspensions

- Front 
- Removing the front wheel 
- Front wheel hub overhaul 
- Refitting the front wheel 
- Handlebar 
- Removal 
- Refitting 
- Front fork 
- Removal 
- Overhaul 
- Refitting 
- Steering column 
- Overhaul 
- Steering bearing 
- Refitting 
- Rear 
- Removing the rear wheel 
- Refitting the rear wheel 
- Swing-arm 
- Removal 
- Overhaul 
- Refitting 
- Shock absorbers 
- Removal 
- Refitting 
- Centre-stand 
- Side stand 
- Electro-hydraulic stand 
- Removal 
- Overhaul 
- Refitting

Braking system

- Interventions rules 
- Rear brake calliper 
- Removal 
- Overhaul 
- Refitting 
- Front brake calliper 
- Removal 
- Overhaul 
- Refitting 
- Rear brake disc 
- Removal 
- Refitting 
- Disc Inspection 
- Front brake disc 
- Removal 
- Refitting 
- Disc Inspection 
- Front brake pads 
- Removal 
- Refitting 
- Rear brake pads 
- Removal 
- Refitting 
- Fill 
- Rear - combined 
- Front 
- Brake fluid level check 
- Front brake pump 
- Removal 
- Refitting 
- Rear brake pump - combined 
- Removal 
- Refitting

Cooling system

- Circuit diagram 
- Electric fan check 
- System sealing check 
- Coolant replacement 
- Water pump - overhaul 
- Thermostat 
- Check 
- diagnosis 
- Excessive system pressure 
- Cooling fluid consumption 
- Oil in the fluid

Chassis

- Seat 
- Rear handlebar cover 
- Instrument panel 
- Front handlebar cover 
- Headlight assy. 
- Frame central cover 
- Legshield 
- Knee-guard 
- Removing the ignition key-switch when on *off* 
- Removing the ignition key-switch when on *lock* 
- Front wheel housing 
- Taillight assy. 
- Footrest 
- Side fairings 
- License plate holder 
- Air filter 
- Rear mudguard 
- Helmet bay 
- spoiler 
- Fuel tank 
- Rear central cover 
- Front mudguard 
- Radiator fan 
- Expansion tank 
- Digital panel support 
- Front central cover 
- Flyscreen 
- Analogue instrument panel support 
- Radiator cover 
- Adjustable windscreen attachment 
- Pilot lights kit 
- Battery 
- Lower cover

Pre-delivery

- Aesthetic inspection 
- Tightening torques inspection 
- Electrical system 
- Levels check 
- Road test 
- Static test 
- Functional inspection

Time

- Engine 
- Crankcase 
- Crankshaft 
- Cylinder assy. 
- Cylinder head assy. 
- Rocker arms support assy. 
- Cylinder head cover 
- Flywheel cover 
- Driven pulley 
- Oil pump 
- Final gear assy. 
- Driving pulley 
- Transmission cover 
- Flywheel magneto 
- Butterfly valve 
- Exhaust pipe 
- Air cleaner 
- Frame 
- Centre-stand 
- Legshield spoiler 
- Rear cover 
- Central cover 
- Underseat compartment 
- Mudguard 
- Fuel tank 
- Radiator 
- Rear shock-absorber 
- Steering column bearings 
- Handlebar covers 
- Handlebar components 
- Swing-arm 
- Seat 
- Instrument panel 
- Locks 
- Turn signal lights 
- Front wheel 
- Rear wheel 
- Fuel pump 
- Electric devices 
- pics 
- Fuel tank filler flap 
- Footrests 
- Front mudguard 
- Helmet bay 
- Rear side fairings 
- Front suspension 
- Rear suspension 
- Cooling system 
- Braking system 
- Windscreen

SERVICE STATION MANUAL

ENGINE SERVICE MANUAL

WIRING DIAGRAM

PARTS MANUAL

USER MANUAL