Page 1 After Sales Service Dis. 594766 - 04/01 Grafica e Stampa: C.L.D. - Pontedera (PI) “© Copyright 2001 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved.” Data are subject to modification without notice. We decline all liability for the use of non-original spare parts or accessories that have not been tested and/or approved.
Page 2 SERVICE STATION MANUAL X9 500 cc This manual has been prepared by Piaggio & C. S.p.A. for use in the workshops of authorised Piaggio dealers and sub-agents. It is assumed that the person utilising this manual for servicing or repairing Piaggio vehicles has a knowledge of the principles of mechanics and standard procedures for vehicle repair.
Page 3: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION AND MAINTENANCE SPECIFIC TOOLS AUTOMATIC TRANSMISSION FINAL REDUCTION FLYWHEEL COVER FLYWHEEL AND STARTING SYSTEM THERMAL UNIT AND TIMING SYSTEM CRANKCASE AND DRIVING SHAFT INJECTION LUBRICATION COOLING SYSTEM STARTER...
Page 4: General Information And
TABLE OF CONTENTS GENERAL INFORMATION AND MAINTENANCE...
Page 5 General information and Maintenance Safety prescriptions Maintenance regulations - Use only genuine PIAGGIO spare parts and recom- - If the work to be carried out requires the vehicle engine to be running, make sure the workshop is mended lubricants. The use of non-original or non- well ventilated and use proper exhausters.
Page 6 General information and Maintenance Specifications (500 cc 4-stroke, 4-valves H 0 en- gine) ENGINE Type ........single-cylinder, 4-stroke Cooling system ....liquid, by means of motor- Bore ..............92 mm ized pump, 3-way thermo- Stroke ............. 69 mm stat and electric fan.
Page 7 General information and Maintenance Spark plug Check and replacement Warning - Remove the spark plug when the engine cold. Replace the spark plug every 12,000 Km. The use of unsuitable control units or spark plugs other than those specified can seriously damage the engine. Recommended spark plug: CHAMPION RG 6 YC NGK CR 7 EKB...
Page 8 A lack of engine oil can cause serious 1,500 cc of fresh oil through cap «A». Subsequently damage to the engine. start the engine, let it idle for a few minutes and then In all four-stroke engines, oil deterioration and con- switch it off.
Page 9 General information and Maintenance 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. Warning - To avoid burns, take care not to touch hot engine parts.
Page 10 - Remove the lower right-hand side panel and the right-hand footboard as described in Chapter 8- Bodywork of the X9- 500 cc manual; - Remove the sleeves from the water pump cover and the filler cap from the expansion tank and empty the cooling circuit.
Page 11 General information and Maintenance Checking the valve gear timing - With a wrench of the TORX type, remove the timing check plug located on the flywheel cover. - Remove the transmission cover and relevant insula- tion as described in Chapter 3-Automatic Transmis- sion.
Page 12 TABLE OF CONTENTS SPECIFIC TOOLING...
Page 13 Specific Tooling Specific tools for Piaggio X9 500 cc 4-stroke 4-valve RECOMMENDED TOOLS TOOL NAME PART NO. Circlip pliers 002465Y Steering thrust ring removing drift 020004Y Crankshaft aligning tool 020074Y Support for “METABO HG 1500/2” air heater 020150Y “METABO HG 1500/2” air heater...
Page 14 Specific Tooling NECESSARY TOOLS TOOL NAME PART NO. STEERING SEAT FITTING TOOL, to be fitted with parts 9 - Lower 001330Y bearing adaptor, 10 - Upper bearing adaptor Bell Ø 80 mm 001467Y002 20 mm pliers 001467Y006 Bell Ø 63 mm 001467Y007 18 mm pliers 001467Y008...
Page 15: Automatic Transmission
TABLE OF CONTENTS AUTOMATIC TRANSMISSION...
Page 16: Automatic Transmission
AUTOMATIC TRANSMISSION LUBRICATE WITH OIL APPLY PRODUCT WARNING: HANDLE WITH CARE LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE REFERENCE QUANTITY TORQUE N·m 90-92 23-26 17-20 160-175 65-75 11-13 3 - 2...
Page 17 Automatic transmission External transmission cover - Unloose the 5 fixing screws - Remove the external plastic cover 05_006 Transmission cover - Unloose the 7 fixing screws - Remove the cover and net filter N.B.: Disassemble the net filter only if it is to be re- placed.
Page 18 Automatic transmission - First fit the specific tool stop ring on the pulley until the groove is fully in contact. - Afterwards, insert the tool so that the studs on the ring fit the holes in the tool. - Tighten, also manually, the two fixing nuts of the tool - Unloose the central nut.
Page 19 Automatic transmission - Remove the specific tool - Unloose the 2 remaining fixing screws of the driven pulley axle support. - Remove the driven pulley axle support and the washer. - Remove the spacer below. 05_014 Clutch housing - Remove the clutch housing. 05_015 - Check that the clutch housing shows no signs of wear or damage.
Page 20 Automatic transmission Clutch disassembly - Remove the clutch and driven pulley by means of the specific tool; - Prepare the tool with the pins screwed in the «E» position on the internal side; - Assemble the driven pulley assembly on the tool and insert the pins in the ventilation holes;...
Page 21 Automatic transmission Fixed driven half pulley bearings - Check that the bush shows no signs of wear or damage; if necessary, replace the fixed driven half pulley. - Remove the stop ring with the pliers. 05_022 - Remove the ball bearing by inserting the specific tool in the roller bearing.
Page 22 Automatic transmission Mobile driven half pulley - Check the belt contact surface out for signs of wear. - Remove the 2 internal and external O rings. - Measure the mobile half pulley bush I.D. Maximum allowed diameter: 50.08 mm Standard diameter: 50.085 mm 05_026 Fixed driven half pulley bearings assembly - Fit a new roller bearing using the specific tool...
Page 23 Automatic transmission - Check the pins and collar condition, and then reas- semble them. - Lubricate the driven pulley assembly with a hook-bill greaser. Apply 10 gr. of TUTELA MRM2 grease through one of the holes inside the bush until grease comes out of the opposite hole.
Page 24 Automatic transmission Clutch reassembly - Prepare the specific tool as already done during the disassembly phase; - Preassemble the driven pulley unit with the driving belt according to its direction of rotation. - Insert the driven pulley unit, spring with sheath and clutch in the tool.
Page 25 Automatic transmission Rollers housing assembly - Fit the spacer with the internal beveling facing the insertion side. 05_041 - Put the rollers in the half pulley as shown in the figure. - The covered side must rest on the internal thrust side of the roller housing.
Page 26 Automatic transmission Driven pulley unit assembly - Fit the driven pulley unit and relevant belt. 05_045 Housing assembly - Fit the housing and the spacer 05_046 Driven pulley axle support assembly - Make sure the 2 centering dowels are properly fitted in the crankcase.
Page 27 Automatic transmission - Hold the driven pulley axle support by means of the specific tool 001467Y002. - Remove the bearing by means of the specific tool. N.B.: If the bearing decay has caused the external race to lose strength, replace the driven pulley axle support. Specific tools: Bell 001467Y002...
Page 28 Automatic transmission - Fit the washer and the nut. 05_049 - Insert the specific tool tooth in the hole on the hous- ing. - Tighten the 2 screws making sure that the catch is in contact with the driven pulley axle support. Specific tool: Clutch housing lock tool 020473Y...
Page 29 Automatic transmission Fixed driving half pulley assembly - Fit the spacer 05_053 - Fit the fixed driving half pulley making sure it is in contact with the spacer and with the sliding bush of the mobile driving pulley 05_054 - Fit the plain washer and the cup washer as shown in the figure.
Page 30 Automatic transmission - Turn the pulley central nut aligning its holes horizon- tally to be able to install the specific tool. N.B.: Make sure that the lock wrench fits easily in the pulley and engine crankcase. Specific tool: Driving pulley lock wrench 020474Y 05_009 - Fully insert the stop ring from the rear side.
Page 31 External transmission cover N.B.: Make sure that the air intake and the three air outlets are completely free. - Fit the plastic external transmission cover; - Tighten the 5 fixing screws to the prescribed torque. 05_006 3 - 17...
Page 32: Final Reduction
TABLE OF CONTENTS FINAL REDUCTION...
Page 33: Final Reduction
FINAL REDUCTION LUBRICATE WITH OIL APPLY PRODUCT WARNING: HANDLE WITH CARE LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE REFERENCE QUANTITY TORQUE N·m 24-27 15-17 4 - 2...
Page 34: Flywheel Cover
TABLE OF CONTENTS FLYWHEEL COVER...
Page 35: Flywheel Cover
FLYWHEEL COVER LUBRICATE WITH OIL APPLY PRODUCT WARNING: HANDLE WITH CARE LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE REFERENCE QUANTITY TORQUE N·m 11-13 24-30 8-10 1.5-2.5 12-16 1.5-2 3-4 3.5-4.5 5 - 2...
Page 36 Flywheel cover - Disassemble the flywheel cover by removing the 2 cooling system sleeves - Remove the 4 clamps shown in the figure N.B.: The clamps must be replaced. Remove the clamps by opening them with a screwdriver or by cutting them. Take care not to damage the plastic unions 05_081 - Remove the cooling tube bracket from the manifold...
Page 37 Flywheel cover Water pump cover disassembly - Unloose the 6 fixing screws and remove the water pump cover and relevant O ring. N.B.: If necessary, disassemble the pump cover com- plete with thermostat and sleeves. 05_085 Flywheel cover disassembly - Drain the engine oil by removing the drain plug. - Collect the oil in a suitable container.
Page 38 Flywheel cover - Unloose the 14 fixing screws. - Remove the flywheel cover and relevant gasket, and the stand stop bracket.. N.B.: Screws come supplied in 3 different lengths plus 2 for the stand stop. Take note of their positions. Warning - Avoid any interferences between the stator and rotor while removing the cover.
Page 39 Flywheel cover - Unloose the 2 fixing screws and remove the support of the reed valve with gate. 05_093 - Remove the blow-by reed valve and relevant seal gasket 05_094 - Unloose the fixing screw and remove the gas outlet pipe and relevant O-ring 05_095 - Remove the water pump rotor by unscrewing it from...
Page 40 Flywheel cover - Remove the shaft and relevant stop washer. 05_097 - Remove the O-ring 05_098 - Remove the ceramic ring and relevant gasket. 05_099 - Remove the O ring for the pump shaft lubrication by means of a properly shaped tool. 05_100 5 - 7...
Page 41 Flywheel cover - Remove the engine oil dipstick and the plug of the valve gear timing reference hole - Remove the oil minimum pressure sensor. 05_101 Checking the cover case components Cover case - Check that the case coupling surface shows no signs of wear or deformation.
Page 42 Flywheel cover - Check the 3 phases continuity. N.B.: The indicated values have been measured at ambient temperature. Higher values will be measured with stator at operative temperative. Approximate resistance of each phase: 0.2 - 1 Ω 05_105 - Check the earth insulation of each phase. - If troubles are noticed, remember to carefully check the harness as this is realized with 2 types of cables: stiff cables near the stator, and soft cables near the...
Page 43 Flywheel cover Water pump shaft - Check that the water pump shaft shows no signs of wear on the part in contact with the case, in the oil seal working area, and on the drive. - Check that the ceramic seal working areas are not scored or worn.
Page 44 Flywheel cover Reed valve - Check that the blow-by circuit reed closes correctly. 05_113 Assembling the flywheel cover components - Make sure that all the components are well clean before reassembling them. - Carefully check all the cover case lubrication ducts, in particular: - The 3 bypass channels.
Page 45 Flywheel cover - Oil pressure sensor supply duct 05_117 - Oil vapors decantation chamber exhaust. 05_118 - Refit the blowby reed valve with a new seal gasket. - Refit the support with gate and tighten the screws to the prescribed torque. Tightening torque: Support screws: 0.3 - 0.4 N·m 05_093...
Page 46 Flywheel cover - Preassemble the ceramic seal and relevant gasket. N.B.: The bevel must face the gasket. Take care not to dirty the ceramic ring with oil or grease in order not to compromise the seal. 05_120 - Fit the ceramic seal on the flywheel cover. N.B.: Assemble the seal by hand to avoid damaging it.
Page 47 Flywheel cover - Fit the harness guide and tighten the 2 screws to the prescribed torque. Tightening torque: Harness guide fixing screws: 3 - 4 N·m 05_091 - Temporarily fit the valve timing control hole plug and the engine oil dipstick - Fit the blow-by recovery duct with a new O ring.
Page 48 Flywheel cover - Turn the driving shaft as to align the countershaft drive with a reference mark on the crankcase (see figure) 05_125 - Align the water pump shaft with the same reference on the cover. N.B.: This is useful especially in case of interventions with the water pump cover assembled.
Page 49 Flywheel cover Thermostat cover assembly - Refit the thermostat N.B.: Check the thermostat as described in Chapter 9- Cooling. The thermostat seal provides for the sealing to the outside and for the internal sealing with the thermo- stat closed. 05_084 - Assemble the thermostat cover.
Page 50 Flywheel cover - Reassemble the prefilter and the engine oil drain plug. Tighten it to the prescribed torque. - Refill the engine with oil of the recommended type. Tightening torque: Oil drain plug: 24 - 30 N·m Recommended oil: Selenia HI Scooter 4 Tech 5W/40 05_086 5 - 17...
Page 51: Flywheel And Starting System
TABLE OF CONTENTS FLYWHEEL AND STARTING SYSTEM...
Page 52: Flywheel And Starting System
FLYWHEEL AND STARTING SYSTEM LUBRICATE WITH OIL APPLY PRODUCT WARNING: HANDLE WITH CARE LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE REFERENCE QUANTITY TORQUE N·m 13-15 11-13 115-125 6 - 2...
Page 53 Flywheel and starting system Flywheel cover disassembly - Remove the cooling system sleeves and the flywheel cover as described in Chapter 5-Flywheel Cover. 05_081 Starting motor disassembly N.B.: This operation can also be performed with the flywheel cover assembled. - Unloose the two fixing screws and remove the engine earth cable.
Page 54 Flywheel and starting system - Screw the flywheel lock tool bush on the threading intended for the extractor. 05_131 - Fully insert the specific tool as shown in the figure making sure that the pins perfectly fit in the holes previously aligned, and that it is almost in contact with the flywheel Specific tool:...
Page 55 Flywheel and starting system - Refit the nut as to slightly uncover the shaft and to free the space where the washer was. Warning - This operation is necessary as the fly- wheel is firmly locked, hence the cone detachment could cause the rotor to fall with consequent breaking of the magnetos.
Page 56 Flywheel and starting system - Remove the freewheel from the magneto flywheel by unloosing the 6 fixing screws. N.B.: To be able to disassemble the freewheel, it is recommendable to first unloose the 6 fixing screws with the flywheel still assembled on the driving shaft. 05_139 - The freewheel is precisely coupled with the flywheel;...
Page 57 Flywheel and starting system Starting ring gear and freewheel - Check that the freewheel “rollers” and the starting ring gear hub surface show no signs of anomalous wear or dents. - Check the hub outside diameter. + 0.008 Hub outside diameter: Ø 45,665 + 0.005 05_143 - Check the starting ring gear brass I.D.
Page 58 Flywheel and starting system N.B.: the torque limiter is provided with 4 gears that function as clutch driving plates. The driven plates are made with 4 Belleville washers with a splined shape; this assembly allows to transmit torques below 10 kgm. In case of wrong starting operations, any counterstrokes likely to damage the engine structure are avoided by the limiter, with consequent reversal of rotation of the...
Page 59 Flywheel and starting system Starting ring gear assembly on magneto flywheel - Oil the inner brass and the starting ring gear hub surface 05_149 - Fit the starting ring gear on the flywheel and turn it clockwise at the same time. 05_138 Idler gear with torque limiter assembly - Grease the gear housing on the engine crankcase.
Page 60 Flywheel and starting system Magneto flywheel assembly on engine - Insert the key on the driving shaft - Assemble the magneto flywheel making sure to cor- rectly insert the key. At the same time, mesh the torque limiter gear with the starting ring gear. 05_151 - Insert the washer and the nut on the driving shaft.
Page 61 Flywheel and starting system - Insert the specific tool making sure to perfectly fit the pins. Specific tool: Flywheel lock tool 020472Y 05_132 - Tighten the flywheel lock nut to the prescribed torque. Tightening torque: Flywheel lock nut: 115 - 120 N·m 05_153 - Assemble the chain guide shoe stop plate and tighten the 3 screws to the prescribed torque.
Page 62 Flywheel and starting motor Flywheel cover assembly - Grease the housing of the idler gear with torque limiter, located on the flywheel cover. - Align the water pump drive with a reference mark and fit the flywheel cover as described in Chapter 5- Flywheel cover.
Page 63: Thermal Unit And Timing System
TABLE OF CONTENTS THERMAL UNIT AND TIMING SYSTEM...
Page 64: Thermal Unit And Timing System
THERMAL UNIT AND TIMING SYSTEM LUBRICATE WITH OIL APPLY PRODUCT WARNING: HANDLE WITH CARE LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE REFERENCE QUANTITY TORQUE N·m 30-35 11-13 38-42 44-46 11-13 10-14 7-8,5 11-13 11-13 10-12 7 - 2...
Page 65 Thermal unit and timing system - Remove the external transmission cover and the transmission cover complete with net filter, as de- scribed in Chapter 3-Automatic Transmission. 05_006 - Remove the flywheel cover, the flywheel and the idler gear with torque limiter as described in Chapter 5- Flywheel Cover, and in Chapter 6-Flywheel and Start- ing system.
Page 66 Thermal unit and timing system Valve gear disassembly - Turn the engine until the intake valves close, that is the reference mark on the phonic wheel must be moved upwards as shown in the figure. 05_157 - Remove the central screw and the valve lifter weight stop bell by means of the specific tool.
Page 67 Thermal unit and timing system - Unloose the tightener central screw. - Unloose the 2 fixing screws and remove the tightener and relevant gasket. 05_161 - Remove the internal hexagonal-head screw and the counterweight, as shown in the figure. 05_162 - Remove the timing chain gear from the camshaft - Remove the timing chain gear.
Page 68 Thermal unit and timing system - Remove the engine revs-stroke sensor and relevant O ring by unloosing the two fixing screws. N.B.: Check this component as described in Chapter 9- Injection. 05_165 Camshaft and equalizers disassembly - Unloose the 3 fixing screws and remove the camshaft stop bracket.
Page 69 Thermal unit and timing system Head disassembly - Remove the spark plug. - Remove the cooling system outlet union and relevant O ring by unloosing the 2 screws. 05_170 - Remove the coolant temperature sensor. N.B.: The sensor controls both the injection and the analogue instrument on the dashboard.
Page 70 Thermal unit and timing system N.B.: If necessary, the head can be removed together with the camshaft, equalizer pins and fixing bracket. - Unloose the 4 head to cylinder fixing nuts in 2-3 times in a crossed sequence. - Remove the head, the 2 centering dowels, the gasket and the lower chain guide shoe.
Page 71 Thermal unit and timing system Cylinder and piston disassembly - Remove the timing chain. - Unloose the fixing screw and remove the spacer and the tightener pad. N.B.: It is recommendable to mark the chain in order to refit it in the original direction of rotation. 05_178 - Remove the cylinder and relevant gasket, and the centering dowel.
Page 72: Crankcase And Driving Shaft
Thermal unit and timing system Checking connecting rod small end - Measure the connecting rod small end diameter by means of a reamer. + 0.025 Standard diameter: 22 + 0.015 N.B.: If the connecting rod small end diameter exceeds the standard value, if it shows signs of wear or over- heating, replace the driving shaft as described in Chap- ter 8-Crankcase and Driving Shaft.
Page 73 Thermal unit and timing system - Measure the cylinder inside diameter by means of a reamer in the directions shown in the figure and at three different heights. Standard diameter: 92 + 0.018 + 0.010 - Make sure that the lining is not exfoliated. - Check that the head coupling surface shows no signs of wear or deformation.
Page 74 Thermal unit and timing system Standard opening Max value Compression ring 0.15 - 0.35 mm 0.5 mm Scraper ring 0.25 - 0.50 mm 0.65 mm Scraper ring 0.25 - 0.50 mm 0.65 mm N.B.: Before replacing the rings, make sure that the instructions regarding the ring-slot and piston-cylinder allowances have been followed.
Page 75 Thermal unit and timing system - Assemble the gudgeon pin lock using the pin, as shown in the figure. Specific tool: Tool for gudgeon pin lock assembly 020470Y N.B.: The stop rings assembly tool must be used by hand. Warning - Using a hammer may damage the locks housing.
Page 76 Thermal unit and timing system Compression rings assembly - Put the scraper ring spring on the piston. - Assemble the scraper ring by keeping the opening opposite to the spring joint and with the top writing facing the piston crown. The chamfer must always be positioned towards the piston crown.
Page 77 Thermal unit and timing system Head check - Check that the head surface shows no signs of wear or deformations by means of a ground bar and a feeler gauge. Maximum allowed runout: 0.1 mm - In case of troubles, replace the head. - Check the sealing surface of the intake and exhaust manifold.
Page 78 Thermal unit and timing system Checking valve seat wear - Remove any carbon deposits from the valve seat. - Check the width of the imprint on the valve seat “V” by means of Prussian blue. - Measure the inside diameter of each valve guide. - Perform the measurement according to the thrust direction of the equalizer at three different heights.
Page 79 Gruppo termico e distribuzione - Check the valve head concentricity by placing a dial gauge at right angle to the valve head and turning the valve head on a “V” surface. Limit allowed: 0.03 mm 05_201_2 Valve-guide play check - After measuring the valve guide and valve stem diameters, check the guide-and-stem play.
Page 80 Thermal unit and timing system - If no troubles have been found after performing the above check, it is possible to use the same valves. To obtain a perfect sealing, it is recommendable to grind the valve seats by using a fine grain lapping com- pound.
Page 81 Thermal unit and timing system - Measure the spring free length Standard length: 44.4 mm Limit allowed after use: 43.7 mm 05_206 Valves assembly - Put the valve spring caps on the head. - Assemble, alternately, the 4 oil seals by means of the specific tool - Lubricate the oil seals and the valve guides.
Page 82 Thermal unit and timing system Camshaft check - Check that the camshaft supports show no signs of anomalous wear or scoring. - Measure the camshaft supports by means of a mi- crometer. Standard diameter Support A Ø: 42 - 0.060 - 0.085 Support B Ø: 20 - 0.020...
Page 83 Thermal unit and timing system Checking timing system parts - Check that the guide shoe and the tension pad are not excessively worn. - Check that the camshaft control timing gear and driving shaft pinion assembly show no signs of wear. - Replace the pads, or the whole assembly if the chain, or ring gear, are worn.
Page 84 Thermal unit and timing system - Make sure the head lubrication duct is well clean. If necessary, clean with a jet of compressed air. - Assemble the head. - Oil the studs and the 4 fixing nuts. - Screw the 4 fixing nuts in a crossed manner to the pre- torque value of 20 N·m - Afterwards, cross-tighten them to the prescribed torque.
Page 85 Thermal unit and timing system - Clean the cooling system outlet union with jets of compressed air. - Check the O ring sealing. - Assemble the union with the larger diameter facing the transmission side. Tighten the 2 fixing screws to the prescribed torque.
Page 86: Injection
Thermal unit and timing system - Remove any LOCTITE residuals from the camshaft stop bracket fixing screws by means of a brush. - Apply LOCTITE 242 to the fixing screws after clean- ing them from any residual of thread locking com- pound.
Page 87 Thermal unit and timing system - Assemble the idler gear with torque limiter, flywheel and flywheel cover as described in Chapter 6-Fly- wheel and Starting System and in Chapter 5-Fly- wheel Cover N.B.: To facilitate the assembly operation, assemble the flywheel cover without the cooling system sleeves. 05_089 - Remove the timing control plug by means of a TORX wrench.
Page 88 Thermal unit and timing system - Fit the chain on the camshaft timing gear - Fit the timing gear on the camshaft, aligning the reference marks. N.B.: During the timing check, keep the chain tensioned by pressing from the tightener compartment side. 05_227 - Assemble the counterweight - Center it by means of the bell fixing screws.
Page 89 Thermal unit and timing system - Turn the engine. Move the reference marks to the upper position as shown in the figure (intake end) 05_231 - Fit the valve lifter counterweight stop bell. - Tighten the fixing screw to the prescribed torque, using LOCTITE 242.
Page 90 Thermal unit and timing system - Set the tightener cursor in the rest position by keeping pressed the stop dog 05_235 - Assemble the tightener on the cylinder with a new gasket. - Tighten the two fixing screw to the prescribed torque. Tightening torque: Tightener fixing screws: 11 - 13 N·m 05_236...
Page 91 Thermal unit and timing system - Assemble the transmission cover complete with net filter, and the external transmission cover according to the procedure described in Chapter 3-Automatic Transmission 05_006 - Assemble the cooling system sleeves using new clamps. Follow the procedure described in Chapter 5- Flywheel cover.
Page 92 Thermal unit and timing system Injector assembly - Check that the components are well clean - Assemble new O rings and lubricate them with grease. - Apply thread locking compound LOCTITE 242 to the fixing screw and tighten it to the prescribed torque. Note.
Page 93 Thermal unit and timing system - Check that the throttle valve and relevant duct are well clean. - Also check that the additional air duct operated by the Stepper-motor is well clean. 05_243 Throttle body assembly to manifold - Perform the disassembly operations in the reverse order.
Page 94 TABLE OF CONTENTS CRANKCASE AND DRIVING SHAFT...
Page 95: Crankcase And Driving Shaft
CRANKCASE AND DRIVING SHAFT LUBRICATE WITH OIL APPLY PRODUCT WARNING: HANDLE WITH CARE LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE REFERENCE QUANTITY TORQUE N·m 25-29 8-10 11-13 10-12 8 - 2...
Page 96 Driving shaft crankcase - Remove the external transmission cover, the trans- mission cover complete with net filter and the driving pulley assembly as described in Chapter 3-Automatic transmission. 05_006 - Remove the flywheel cover with the cooling system sleeves as described in chapter 5-Flywheel cover 05_245 - Remove the magneto flywheel with the starting con- trol as described in Chapter 6-Flywheel and Starting...
Page 97 Driving shaft crankcase - Check the driving shaft end play before you open the engine crankcase. Use for this procedure a plate (e.g. specific tool) and a stand with dial gauge, specific tool Specific tool: Crankcase separating plate 020262Y Dial gauge and stand 020335Y Standard play: 0.10 - 0.50 mm Limit allowed after use: 0.60 mm...
Page 98 Driving shaft crankcase - Separate the crankcase by keeping assembled the driving shaft on the half crankcase, flywheel side. - Remove the coupling gasket N.B.: The support bush can be maintained in the half crankcase, flywheel side. 05_250 Driving shaft disassembly - Before disassembling the driving shaft, check the timing with the countershaft.
Page 99 Driving shaft crankcase Countershaft disassembly - Position the specific tool as shown in the figure. Specific tool Countershaft lock wrench: 020479Y 05_254 - Remove the fixing nut and relevant washer. 05_255 - Remove the specific tool and withdraw the countershaft complete with control gear.
Page 100 Driving shaft crankcase - Remove the oil pump complete with gear by unloosing the 2 fixing screws through the slots situated on the gear itself. 05_259 - Remove the gasket. 05_260 Replacing the countershaft bearings - Check the bearings out for anomalous noise or play. Replace if necessary.
Page 101 Driving shaft crankcase - Remove the bearing from the half crankcase trans- mission side by means of the specific tool. Specific tool: Pliers 001467Y008 Bell 001467Y007 05_263 - Before assembling a new bearing, heat the half crankcase flywheel side by means of the specific tool - Put the half crankcase on a wooden base Specific tool: Heater...
Page 102 Driving shaft crankcase - Before assembling the new bearing on the crank- case transmission side, heat the housing by means of the specific tool. Specific tool: Heater 020151Y 05_266 - Fit a new bearing on the specific tool after having greased the fitting slot - Assemble a new bearing on the engine crankcase by means of the specific tool.
Page 103 Driving shaft crankcase - Check the connecting rod diametral play. Standard play: 0.046 - 0.076 mm - Check that the end play containment surfaces show no signs of scoring. Measure the driving shaft width by means of a gauge, as shown in the figure. N.B.: Check that the measuring is not distorted by the driving shaft support radius.
Page 104: Lubrication
Driving shaft crankcase - Check the diameter of both the driving shaft supports according to the axis and planes shown in the figure. The half shafts are subdivided in Class 1 and Class 2, as shown in the table below. Standard diameter Class 1...
Page 105 Driving shaft crankcase Warning - If the driving shaft made up of two half shafts of different classes is to be replaced, it is also necessary to replace the two half crankcases and to match the two components (shaft and crankcase) with the same class.
Page 106 Driving shaft crankcase - For the half crankcase flywheel side, pay special attention to the lubrication ducts to the main bearing brasses, oil pump compartment and channels, and by-pass duct situated on the flywheel cover. N.B.: As already described in Chapter 10-Lubrication, it is very important that the by-pass housing on the flywheel cover shows no signs of wear that would compromise the sealing of the lubrication pressure...
Page 107 Driving shaft crankcase - Check the brasses diameter in the 3 directions shown in the figure. - Repeat the measuring on the other half of the brass. See figure. Coupling N.B.: Do not measure the mating of the 2 half bearings surface as the ends are splined to allow deformation while being fitted...
Page 108 Driving shaft crankcase Oil pump - Overhaul the oil pump as described in Chapter 10- Lubrication. 05_278 Countershaft - Measure the 2 countershaft supports by means of a micrometer, as shown in the figure. Standard diameter: 17 - 0.01 - 0.02 - Check that the water pump drive shows no signs of wear.
Page 109 Driving shaft crankcase - Assemble the countershaft with the gear on the half crankcase flywheel side - Fit the specific tool in the position shown in the figure Specific tool: Countershaft lock wrench 020479Y 05_254 - Hold the countershaft and fit the washer with nut - Tighten the nut to the prescribed torque, apply LOCTITE 242 - Remove the specific tool.
Page 110 Driving shaft crankcase - Lubricate the main bearing brass on the half crank- case flywheel side. - Grease the shim washer - Fit the shim washer on the driving shaft, in its original position - Insert the specific tool for the timing in the hole on the countershaft Specific tool: Countershaft timing pin...
Page 111 Driving shaft crankcase - Grease and assemble a new oil seal by means of the specific tool. Put it at 0.5 mm from the crankcase surface. Warning - The oil seal wrong position will compro- mise the lubrication oil circulation. Specific tool: Adapter 52x55 020360Y...
Page 112: Cooling System
Driving shaft crankcase - Assemble the thermal unit (cylinder, head, piston) as described in Chapter 7-Thermal unit and Timing system. 05_156 - Assemble the magneto flywheel with starting control as described in Chapter 6-Flywheel and Starting system. 05_246 - Assemble the flywheel cover with the cooling system sleeves as described in Chapter 5-Flywheel cover.
Page 113 TABLE OF CONTENTS FUEL INJECTION...
Page 114 Fuel injection INDEX INTRODUCTION ........................9-3 PRECAUTIONS ........................9-5 TROUBLESHOOTING......................9-6 COMPONENTS LAYOUT ..................... 9-7 LAYOUT OF THE EMS CONTROL UNIT TERMINALS AND IMMOBILIZER ....... 9-8 EMS SYSTEM DIAGRAM ..................... 9-9 FAULT SEARCH PROCEDURES ..................9-10 IMMOBILIZER SYSTEM ..................... 9-16 Non programmed system ....................
Page 115 Fuel injection INTRODUCTION EMS fuel injection system The fuel injection system used is of the integrated fuel injection and ignition type. Fuel is injected indirectly into the manifold by means of the electroinjector. Fuel injection and ignition are timed on a 4-stroke cycle via a phonic wheel splined to the cam shaft control and a reluctance variance sensor.
Page 116 Fuel injection The control unit has its own auto-diagnosis system connected to an indicator on the instrument panel. Anomalies may be discovered and cancelled with a 020460Y diagnosis tester. In any event, when the anomaly is no longer present, its memorization is automatically cancelled after 16 usage cycles (cold start, warm running, stopping).
Page 117 Fuel injection PRECAUTIONS 1 - Before proceeding with any repairs concerning the fuel injection system, check for the presence of registered anomalies. Do not disconnect the battery prior to checking the anomaly. 2 - The supply system is pressurized at 300 Kpa (3 BAR). Before disconnecting the quick-connection of a supply system tube, check that no open flames are present and do not smoke.
Page 118 Fuel injection TROUBLESHOOTING Suggestions for troubleshooting 1 Damage to the EMS system could derive most probably from the connections and not from the components. Before carrying out a search on the EMS system, carry out the following controls: 1 Electrical feed - Battery tension - Burnt out fuse - Electromagnetic switches...
Page 119 Fuel injection COMPONENTS LAYOUT 1 H.V. COIL 10 CONTROL UNIT DECODER CONTROL UNIT CONTR. ELECTROMAGNETIC SWITCH 2 INJECTOR 11 AERIAL DECODER 20 EMS DIAGNOSIS SOCKET 3 ENGINE REVOLUTIONS SENSOR 12 ELECTRICAL FAN 21 5A N°4 FUSE 4 LIQUID TEMP. SENSOR 13 FUEL INJECTION INDICATOR (FEED PANEL-LED-DECODER- EMS CONTROL UNIT) 5 AIR TEMP.
Page 120 Fuel injection LAYOUT OF THE EMS CONTROL UNIT TERMINALS AND IMMOBILIZER Representation of the control unit connector and the connector system side. CONTROL UNIT SIDE SYSTEM SIDE EMS CONTROL UNIT N° FUNCTION N° FUNCTION THROTTLE POTENTIOMETER FEED (+5V) STEPPER MOTOR DIGITAL INSTRUMENT (FUEL INJECTION INDICATOR - NEGATIVE) DIGITAL INSTRUMENT (REVOLUTIONS COUNTER CONTROL) 16 DECODER (SERIAL)
Page 121 Fuel injection EMS SYSTEM DIAGRAM DOWN 1 2 3 9 26 3 15 22 4 11 1 14 24 21 6 A2 B1 1) Electrical fan electromagnetic switch 20)3A Fuse 2) Electrical fan 21)Engine stop electromagnetic switch 3) Electromagnetic switch 22)Services electromagnetic switch 4) H.V.
Page 122 Fuel injection TROUBLESHOOTING 1) THE ENGINE DOES NOT START EVEN WITH NORMAL MOTORING OVER Proceed with the following controls: System uncodified System inefficient, repair according to Immobilizer consent self-diagnosis indications (see page 9-20) Pump relay (see page 9-41) Presence of anomalies revealed through fuel H.V.
Page 123: Starter
Fuel injection 2) DIFFICULT COLD START OR WARM START OF THE ENGINE Proceed with the following controls: Pump relay (see page 9-41) Presence of anomalies revealed through injection H.V. coil (see page 9-68) self-diagnosis Injector (see page 9-62) Phase revolutions sensor Air temperature Coolant temperature Atmospheric pressure...
Page 124 Fuel injection 3) THE ENGINE DOES NOT MAINTAIN IDLING SPEED IDLING SPEED IS UNSTABLE IDLING SPEED IS TOO LOW Proceed with the following controls: Pump relay (see page 9-41) Presence of anomalies revealed through fuel H.V. coil (see page 9-68) injection self-diagnosis Injector (see page 9-62) Phase revolutions sensor (see page 9-64)
Page 125 Fuel injection 4) THE ENGINE DOES NOT TURN OVER ON IDLING SPEED IDLING SPEED TOO HIGH Proceed with the following controls: Pump relay (see page 9-41) Presence of anomalies revealed through injection H.V. coil (see page 9-68) self-diagnosis Injector (see page 9-62) Phase revolutions sensor (see page 9-64) Air temperature Coolant temperature...
Page 126 Fuel injection Intake manifold-head Throttle body-manifold Intake system seal (infiltrations) Air intake hose Filter box Fuel pump Pressure regulator Fuel supply (pressure low) Fuel filter Injector capacity Manifold-head Manifold-silencer Exhaust system seal (infiltrations) Analyser socket Silencer soldering Trimmer value adjustment (CO% adjustment) Analysis of exhaust gas prior to the catalytic converter 6) IRREGULAR RUNNING OF THE ENGINE WITH THROTTLE VALVE SLIGHTLY OPEN Proceed with the following controls:...
Page 127 Fuel injection 7) POOR ENGINE RUNNING ON FULL POWER IRREGULAR RUNNING OF THE ENGINE DURING ACCELERATION STAGE Proceed with the following controls: Pump relay (see page 9-41) Presence of anomalies revealed through injection H.V. coil (see page 9-68) Injector (see page 9-62) self-diagnosis Phase revolutions sensor (see page 9-64) Air temperature...
Page 128 Fuel injection IMMOBILIZER SYSTEM The EMS system is integrated with an immobilizer-type anti-theft device. The functions achieved are: - Starter initialization via key recognition - Blinking deterrent light System components The system is composed of: - EMS system control unit - decoder - aerial - master key (red)
Page 129 Fuel injection Unprogrammed system When the control unit (ECU) and the decoder are not programmed, the conditions described below occur: - Key switch in “OFF” position. Blinking deterrent light inactive. - Key switch in "ON" position. Ignition and fuel injection not activated and LED fixed light on. When the key switch is set to "ON", the LED is lit as indicated in the diagram.
Page 130 Fuel injection Set the commutator to "ON" and select the diagnosis tester menu on the immobilizer function. Scroll down the available pages to reveal the data present in the control unit. NOTE: The blank system can be revealed after initial assembly, or if the decoder and control unit are re- placed at the same time.
Page 131 Fuel injection WITH SERVICE KEYS “ON” 0,7 SEC. LED on LED off 2 - Blinking deterrent light LED on By setting from “ON” to “OFF” when the system is programmed, the LED gives an intermittent light, as a 46 mSEC. 46 mSEC.
Page 132 Fuel injection 4 - System reprogramming in case of component replacement 1 Cylinder replacement - Remove the transponder of the original master key and install it on the master key of the new cylinder. - Reprogramme the system as described previously. 2 Decoder replacement Following replacement of the decoder the full programming procedure must be followed.
Page 133 Fuel injection Using a multimeter check the continuity between Reset or replace the harness control unit pin 16 and decoder connector pin 6 Check the connec- Reset tions accurately Replace the decoder. Disconnect the Connect the battery battery, replace the Repeat the program- control unit, connect ming...
Page 134 Fuel injection Disconnect the aerial connector and check continuity (8 ± 2 Ω). Replace aerial Position correctly Check the correct positioning of the aerial Replace the decoder and check that the code is present 3 Diagnostic code n°3 Code n°3 indicates a system in which the decoder perceives a transponder not foreseen in the program- “ON”...
Page 135 Fuel injection 4 Diagnostic code n°4 Code n°4 indicates a system in which the decoder is blank and the control unit is programmed. “ON” Led acceso The key is recognized by the control unit. 0,5’’ 0,5’’ 0,5’’ 0,5’’ 2’’ - Starting inhibited - Indicator 2’’...
Page 136 Fuel injection Check that the LED lights up by earthing PIN N°2 of the decoder (grey wire) Disconnect the connector between the Replace the decoder and vehicle system and the fuel injection system. reprogramme Earth the connector yellow-grey wire, vehicle system side. (connector with control button) Check if the LED lights up.
Page 137 Fuel injection Check the presence of battery positive tension on PIN Reset or replace the harness 5/12 of the 12-way digital instrument Check continuity of the digital instrument between PIN: 6/12 (yellow-grey) - 4/8 (light blue) = 0Ω (continuity) Check continuity of the connection wire on the analogic instrument Replace the digital 4/8 (light blue) - 4 (analogic instrument) = 0Ω...
Page 138 Fuel injection The blinking deterrent light is missing Disuse for more than 48 hours Check the decoder programming Programme Replace the decoder and reprogramme 9 - 26...
Page 139 Fuel injection FEED CIRCUIT OF THE DECODER AND THE FUEL INJECTION CONTROL UNIT 1 Check that circuit feed is constant The basic feed on the decoder is necessary for the management of the blinking deterrent light. The feed on the injection control unit is necessary for the management of the stepper motor.
Page 140 Fuel injection Check efficiency of 3A fuse n°3. The fuel injection control unit is being fed safely. Eliminate any possible short circuit of the harness and replace the fuse. Interpose the special tool n° 020481Y between the control unit and the fuel injection system. See page 9-8 Check for a possible short circuit of the decoder or control unit.
Page 141 Fuel injection Using the special tool check the basic feed of the control unit PIN 17= positive battery PIN 23= negative battery Control unit basic feed is correct If lack of the battery negative is revealed, check the harness and earthing to the control unit clamp. If lack of the battery positive is revealed, disconnect the connection between the fuel injection system and the vehicle system.
Page 142 Fuel injection 2 Control of the feed circuit deriving from the key switch. - Lack of under-panel feeds inhibits functioning of the ignition and fuel injection. - If a feed problem is revealed, the diagnosis tester n° 020460Y gives the information "THE CONTROL UNIT DOES NOT RESPOND".
Page 143 Fuel injection Check efficiency of n°4 5V fuse Interpose the special tool n° 020481Y between the Eliminate any short circuit, replace the fuse If control unit and fuel injection system. See page 9-8 necessary check the decoder and control unit. Disconnect the main decoder connector and check the following conditions: Commutator set to "ON", switch set to RUN, side...
Page 144 Fuel injection Using special tool 020481Y check the under-panel feed of the control unit. Commutator set to "ON", switch set to "RUN", side stand raised. PIN 26= battery positive; PIN 23= battery negative Control unit with under panel feed is correct If lack of feed is revealed in only one component, check the connector concerned.
Page 145 Fuel injection Under-panel feed is correct (vehicle system section) Check the connector and continuity of the Key switch set to "ON" Check the stop engine electromagnetic switch connector and its efficiency. The connector is recognized by its thicker white wire. NOTE: check the coil resistance 85 - 86 = ~ 70Ω...
Page 146 Fuel injection DIAGNOSIS TESTER LINK CIRCUIT CIRCUIT DIAGRAM VEHICLE FUEL INJECTION SYSTEM SYSTEM DIAGNOSIS TESTER CONNECTOR Connect the diagnosis tester n° 020460Y see page 9-17. If the diagnosis tester gives the information "THE CONTROL UNIT DOES NOT RESPOND", remove the under-panel feed for 10 seconds and reset to "ON";...
Page 147 Fuel injection Check the following conditions: diagnosis socket - 10 control unit = continuity diagnosis socket - 23 control unit = earthed continuity diagnosis socket - 9 control unit = continuity 10 - 23 = isolation (> 1MΩ) 9 - 23 = isolation (> 1MΩ) The circuit functions correctly Disconnect the connection between the fuel injec- tion system and the vehicle system.
Page 148 Fuel injection FUEL INJECTION INDICATOR CIRCUIT CIRCUIT DIAGRAM DIGITAL INSTRUMENT 30A FUSE 7.5A FUSE CONTROL UNIT 7.5A FUSE TERMINAL CONDITIONS STANDARD VALUES - commutator set to "ON" during checks - side stand raised 15 - 23 - switch set to "RUN" after checks battery tension The fuel injection indicator is commanded whenever the setting is "ON"...
Page 149 Fuel injection Interpose special tool 020481Y between the control unit and the fuel injection system (see page 9-8). Key switch set to "ON". Side stand raised. Emergency switch set to "RUN". Wait for more than 5 seconds. 15 - 23 = battery tension Check the control unit connector Check the control unit Check the connector between the fuel injection system...
Page 150 Fuel injection SELF-DIAGNOSIS SYSTEM The fuel injection control unit has a self-diagnosis function. When an anomaly is revealed, the control unit proceeds to: - lighting of the fuel injection indicator (only when current). - activation of engine management controls on basic data entered in the control unit (where possible). - memorization of the anomaly (always).
Page 151 Fuel injection - Cancellation of memorized anomalies After any repairs, connect the diagnosis tester 020460Y (see page 9-17). Select the function menu “ERROR CANCELLATION” Press OK and follow the instructions given. Carry out a trial run to check if the anomaly is repeated. For a guide to resolving any anomalies consult the related parts of this chapter.
Page 152 Fuel injection CIRCUIT DIAGRAM 30A FUSE FUEL PUMP 10A FUSE INJECTOR COMMUTATOR FUEL INJECTION CONTROL UNIT ENGINE STOP ELECTROMAGNETIC SWITCH MAIN ELECTROMAGNETIC SWITCH 5A FUSE 2A DIODE ELECTROMAGNETIC SWITCH ENGINE STOP SWITCH H.V. COIL STAND SWITCH Pump feed circuit The control unit intervenes by activating the pump under the following conditions: setting to "ON"...
Page 153 Fuel injection Circuit control Proceed as follows: Set to "ON" with the emergency switch set to "RUN" and the side stand raised. There is pump revolution for 2 seconds. The pump does not turn or turns Attempt ignition. continuously. Check that the engine revolution matches that of the pump.
Page 154 Fuel injection The control unit reveals an anomaly on the wire of pin 19 Earth wire Broken wire connection In this case the pump The relay cannot control the turns constantly when pump feed. under-panel tension is present. Check and reset the Install special tool 020481Y between the control unit earthing isolation of wires and fuel injection system - see page 9-8.
Page 155 Fuel injection Disconnect the vehicle system- fuel injection system connection. 23 - black - violet (vehicle system) = battery tension Check the connector and the Check continuity of the vehicle harness and continuity harness injection side of the relay coil. Relay control: 85 - 86 = 100 ±...
Page 156 Fuel injection Check efficiency of the pump command electromagnetic switch. Check continuity of the harness between electro- magnetic switch and pump. 87 (electromagnetic switch) - green - black (pump) = continuity Reset and repeat controls from the beginning. Disconnect the connectors to: fuel pump, HV coil, injector Check the earthing isolation of the harness 87 (pump electromagnetic switch) - 23 = isolation (>...
Page 157 Fuel injection Check resistance of the windings in the pump. Resistance ∼1.5 Ω Replace the fuse and proceed Proceed with control of absorbed with pump control. current (see page 9-53). Select the function menu "ACTIVE DIAGNOSIS" of the diagnosis tester 020460Y. Select the fuel pump simulation function.
Page 158 Fuel injection Hydraulics control and system maintenance Before carrying out controls concerning system pres- sure, carefully clean all the components of the supply system. To carry out the controls the special tool 020480Y from the fuel pressure control kit is required. Before proceeding to detach any quick-connection reduce system pressure.
Page 159 Fuel injection System pressure control, for practical reasons, must be carried out by connecting to the pump side. RUNNING DIRECTION Connect the manometer to the delivery duct (right side) and the extention tube to the return duct (left side). NOTE: before mounting check that the tool ducts are clean.
Page 160 Fuel injection Allow the system to purge for a few seconds. Check that the system has no external leaks. Check the adjusting pressure with pump feed tension of more than 12 V. Adjusting pressure = 300 - 320KPa (3 - 3.2 BAR) The pressure regulator is efficient Pressure too high Check that the return duct is not clogged...
Page 161 Fuel injection Replace the pressure regulator Replace the fuel pump See page 9-54 - pump support overhaul. See page 9-54 - pump support overhaul. Pump and fuel filter control This procedure is useful during maintenance to check the efficiency of the outlet filter. Connect the diagnosis tester 020460Y see page 9-17.
Page 162 Fuel injection Proceed with the system The pressure is lower seal control Carefully check the tension with the Activate the pump for 30 seconds using pump under pressure. diagnosis tester 020460Y. If tension is greater than 12 V replace After the pump stops wait the pump (see page 9-54 overhaul of for 3 minutes.
Page 163 Fuel injection Rate variations are not evaluated Repeat the test by squeezing the tube of the special tool 020480Y in the tract be- tween the derivation and the injector. Check if pressure reduces at the same rate as when the system is free. The pressure reduces much more slowly Proceed with controls and possible replacement of the injector due to insufficient seal...
Page 164 Fuel injection Check the free flow capacity Disconnect the pump connector, start the engine, wait for it to stop, reconnect the connector. Disconnect the fuel return duct from the pump support (left hand tube). Insert the return duct in a measuring container. Using the diagnosis tester 020460Y, activate the fuel pump for 10 seconds.
Page 165 Fuel injection Pump electrical controls Resistive check Disconnect the pump support connector. Using a tester measure the resistance of the pump windings. Connect the tester prods to the pump support pins as shown in the figure. Resistance = ~1.5 Ω On meeting with infinite resistance replace the pump.
Page 166 Fuel injection Fuel filter control For the fuel filter control, check: - Free flow capacity. See page 9-52 - Current absorbed by the pump. See page 9-53 An obstructed filter causes: - Performance decline, especially at full power - Increased pump absorption NOTE: Do not blow the filter with compressed air.
Page 167 Fuel injection For the replacement of components proceed as fol- lows. (1) Level indicator: - Take note of the mounting position and course of the two connecting wires. pos 2 = wire connected to the circuit pos 3 = wire connected to the moving arm The wires must pass through the hole made between the filter and the pressure regulator.
Page 168 Fuel injection (3) Fuel pump - Take note of the position of the feed wires on the support pos 1 = positive (red) pos 4 = negative (black) NOTE: the pump connections are not interchangeable. - Disconnect the feed wires - Cut the hose clamp from the delivery pipe on the support - Remove the fixing washer from the pump...
Page 169 Fuel injection - If the pump is to be replaced, remove the prefilter and ring support. - For the reassembly follow the dismantling procedure in the reverse order using a new clamp for the delivery pipe and a new fixing washer for the pump. NOTE: To clean the prefilter use fuel and compressed air.
Page 170 Fuel injection - Position the gasket on the tank. - Install the pump support into its seat taking care to align the connector with the longitudinal axis of the vehicle. NOTE: incorrect orientation may compromise the func- tioning of the level indicator. - Screw the fixing ring nut fully on.
Page 171 Fuel injection Connect the diagnosis tester 020460Y (see page 9-17) Select the "active diagnosis" function on the menu Select the "injector diagnosis" function. Activate the function with under-panel feed inserted and the engine stopped. The control unit commands the fuel pump constantly and at the same time activates opening of the injector.
Page 172 Fuel injection damage is also indicated as being present: Damage is also indicated as being present: HV coil - relay pump Control the feed circuit with the 10A fuse and the electromagnetic switch. Feed to the fuel pump is regular. (see: pump feed circuit page 9-40) Control the relay pump control circuit See: pump feed circuit.
Page 173 Fuel injection The electrical circuit of the injector is continuous. Repeat checks. If the anomaly persists check the control unit connector. If necessary replace the control unit. Disconnect the connector between the vehicle system and the fuel injection system. Disconnect the connector to the control unit. Check resistance between pin 13 and the terminal of the black-green wire on the connector fuel injection system side.
Page 174 Fuel injection Replace the injector Check continuity between: - injector feed connector (red-yellow) and pin 13. - injector feed connector and black-green wire terminal on the connector between the vehicle system and the fuel injection system. Reset continuity or replace the harness. Injector hydraulics control To carry out injector control, it is advisable to proceed to dismantling of the air-intake manifold Complete with throttle body and injector.
Page 175 Fuel injection During the 30 seconds of pump diagnosis, feed the injector via the wire and the auxiliary battery for 15 seconds. Using the measuring container, collect the fuel distributed from the injector. Supply pressure = 300 KPa (3 BAR) Quantity supplied = around 40 cm Proceed with the injector seal test.
Page 176 Fuel injection REVOLUTIONS SENSOR Terminals Conditions Standard 7-12 Starting speed 0,8 - 4.5 V~ CIRCUIT DIAGRAM CONTROL UNIT SENSOR ENGINE REVOLUTIONS The sensor allows recognition of the revolutions and the angular position of the driving shaft with reference to the TDC.
Page 177 Fuel injection To control the sensor and related circuit proceed as follows: Connect the diagnosis tester 020460Y. See page 9-17. Start the engine. The engine does not start The engine starts normally Select the “errors” function from the menu. Select the “errors” function from the menu. Check for the presence of anomalies concerning the "signals panel".
Page 178 Fuel injection Install the connection harness between the control unit and the fuel injection system. Tool 020481Y. See page 9-8 Do not carry out connection with the control unit. Disconnect the connection between the phase- revolutions sensor and the fuel injection system. Measure the resistance of the sensor connecting the multimeter between the terminals marked...
Page 179 Fuel injection Reconnect the phase-revolutions sensor. Repeat resistance control through the fuel injection harness on pins 7 - 12. 7-12 = 680 ± 15 % The value must be very near to that revealed directly to the sensor. Resistance 0 Ω Greater or infinite resistance.
Page 180 Fuel injection HV COIL Terminals Conditions Standard 20-23 During pump timing Battery tension with engine stopped CIRCUIT DIAGRAM ELECTRONIC CONTROL UNIT INJECTOR H.V. COIL PUMP To the main CONTROL UNIT ELECTROMAGNETIC SWITCH electromagnetic switch 10A FUSE The ignition system integrated with the fuel injection is of the high-efficiency induction type. The control unit controls two important parameters: - Spark advance This is optimized on the spot on the basis of engine revolutions, engine load, temperature and environmental...
Page 181 Fuel injection The coil circuit control is efficient. Proceed with secondary control of the della HV coil, Install the connection harness between the control unit and fuel injection cable and shield cover Special tool 020481Y (see page 9-8) (see page 9-68 and 9-72) Measure the tension between pins 20 and 23 of the special tool during the fuel pump timing phase.
Page 182 Fuel injection Positive feed conforms. Check continuity between the pink-black wire of the connector and pin 20 pink-black-20 = Continuity Disconnect the connection between the vehicle System and fuel injection system. Check continuity of the pink-black wire in the two systems.
Page 183 Fuel injection Disconnect the connector between the vehicle system and the fuel injection system. Repeat control of the earthing isolation in the two sections. Repair or replace the harness concerned. Repeat control using “active diagnosis” from the menu for HV coil command simulation.
Page 184 Fuel injection Check the resistance of the secondary Measure the resistance between one of the two terminals of the primary and the spark plug cable outlet. Primary-HV cable outlet = 3.1KΩ ± 9% The coil conforms. Replace the coil. Shielded cap control Measure the resistance of the shielded cap Resistance = 5 KΩ...
Page 185 Fuel injection The spark advance value can be obtained at any time by means of the diagnosis tester 020460Y. Using stroboscopic lamp 020330Y it is possible to check if the spark advance, determined by the fuel injection system, corresponds to that truly activated on the engine.
Page 186 Fuel injection - Reassemble the flywheel side inspection plug. - Connect the diagnosis tester 020460Y. See page 9- - Start the engine. - Select the function from the menu "parameters". - Select the stroboscopic lamp command in the tradi- tional 4-stroke engine position (1 spark 2 revolutions). - Check correspondence between the revolutions values and actual spark advance and those stated by...
Page 187 Fuel injection The coolant temperature sensor mounted on the engine head, supplies indications to the digital instrument and fuel injection. It is constructed with two electrically distinct sections. The fuel injection section has a NTC sensor connected with a 5V feed circuit. The resistance variation causes a circuit tension variation.
Page 188 Fuel injection Disconnect the coolant temperature sensor connection. Measure the sensor resistance between the terminals indicated on the diagram. Check that the resistance corresponds with the RESISTANCE TEMPERATURE 9.6KΩ -10° C 5.975KΩ 3.81KΩ +10° C 2.5KΩ +20° C 1.68KΩ +30° C 0.3KΩ...
Page 189 Fuel injection Check that the sensor circuit is isolated from the earth. 4-23 = Ω infinity (>1MΩ) 22-23 = Ω infinity (>1MΩ) Reset or replace the harness Check the air temperature lines and throttle valve position. Connect the special tool 020481Y to the control unit.
Page 190 Fuel injection Check the connection to the Reset or replace the control unit. harness. Check the control unit feeds If necessary, replace la control unit. Start the engine and check that tension reduces progressively according to temperature increase as per the table. Replace the The temperature signal temperature sensor.
Page 191 Fuel injection The air intake temperature sensor is inserted in the lower part of the throttle body from the filter box side. The sensor is an NTC and has the same function layout as the coolant temperature sensor. This signal is used to optimize the engine functioning. It is, however, a less influential signal than that of the coolant temperature.
Page 192 Fuel injection Disconnect the air intake temperature sensor connector. Measure the resistance between the sensor terminals. Check that the resistance corresponds to the values stated on the basis of temperature. RESISTANCE TEMPERATURE 16.6 KΩ -10° C 9.75 KΩ 5.97 KΩ +10°...
Page 193 Fuel injection Check that the sensor circuit is isolated from the earth. 18-23 = Ω infinity (>1MΩ) 22-23 = Ω infinity (>1MΩ) Reset or replace the harness. Check the coolant temp. lines and throttle position. Connect the special tool 020481Y to the control unit. Set ignition to "ON"...
Page 194 Fuel injection PRESSURE SENSOR This sensor does not have an installation, in that it is inserted directly into the control unit. The sensor allows the control unit to optimize engine performance based on altimeter variations. To control the sensor proceed as follows. Connect the diagnosis tester 020460Y.
Page 195 Fuel injection T.P.S.=THROTTLE POSITION SENSOR Terminals Conditions Standard 1-22 Ignition set to "ON" 11-22 Opening the throttle gradually Volt= progressive progressive increase CIRCUIT DIAGRAM AIR TEMPERATURE SENSOR CONTROL UNIT THROTTLE POSITION SENSOR COOLANT TEMPERATURE SENSOR The TPS is set on the throttle body and is of the fixed type. This sensor receives a 5V feed from the control unit and sends it a gradually increasing tension as the throttle opening increases.
Page 196 Fuel injection Select the "parameters" function from the diagnosis tester menu. Check if the control unit recognizes the extreme positions: throttle valve to minimum throttle valve to maximum Check regulation of the throttle command flexible transmissions. Reset or replace. Gradually open the throttle valve, check that mV indication Increases gradually in proportion to opening variations.
Page 197 Fuel injection Disconnect the TPS connector. Check the continuity between the connector terminals and related pins on the control unit side. Light blue-green-22 = 0 Ω (continuity) Brown-yellow-1 = 0 Ω (continuity) Orange-light blue-11 = 0 Ω (continuity) Reset or replace the fuel injection harness. Check the earthing isolation of the three circuit wires.
Page 198 Fuel injection Measure the tension between terminals 1 and 22 of the special tool. 1-22 = 5±0.2 V Check the control unit connection. If necessary proceed with replacement of the control unit. Connect the TPS connector. Repeat tension measurement between terminals 1 and 22 of the special tool.
Page 199 Fuel injection Check that the tension measured on pins 11 and 22 corresponds with the tension indicated by the diagnosis tester set to "parameters". Replace the control unit. The TPS and related circuit conform. NOTE The TPS control has been set with voltometer checks in that resistance controls are rather unreliable. To check the potentiometer of a throttle body it is always advisable to connect it to a vehicle, even if only from an electrical point of view.
Page 200 Fuel injection Select the "TPS reset" function on the diagnosis tester Check that the throttle command is supported by the setscrews. Ensuring that this position is maintained, confirm the TPS reset procedure. Select the "parameters" function and check that the TPS reset “YES”...
Page 201 Fuel injection Reset must be carried out in the following cases: - on initial assembly - when the throttle body is replaced - when the fuel injection control unit is replaced. NOTE The TPS reset procedure must not be carried out on a used throttle body, in that possible wear of the throttle and the minimum opening stop, render the air flow different from that of precalibration.
Page 202 Fuel injection To control the stepper and related circuit, proceed as follows. Connect the diagnosis tester 020460Y. See page 9-17. Set ignition to "ON" with switch in position "RUN" and side stand raised. Lift the vehicle with the central stand. Select the “errors “...
Page 203 Fuel injection Check the coolant temperature sensor signal. See page 9-74. If necessary check the control unit. Select the “active diagnosis“ function from the menu Select "stepper" diagnosis Activate the diagnosis with the engine warm and idling. Check if the stepper commands any revolutions variation and await the response of the diagnosis tester.
Page 204 Fuel injection Proceed with control of the stepper circuit. Disconnect the stepper connection. Check the resistance of the stepper circuits connecting the tester as shown in the diagram. The two measurements must have the same value. Resistance = ~ 51 Ω Proceed with replacement of the throttle body.
Page 205 Fuel injection Repair or replace the harness. Connect the stepper connector. Repeat continuity control of the tool pins. 14-24 = ~ 51 Ω 6-21 = ~ 51 Ω Check the harness and connectors more accurately. Connect the control unit connector. Set ignition to position "ON"...
Page 206 Fuel injection The stepper circuit is efficient. Check the control unit connection If necessary replace la control unit. 9 - 94...
Page 207 Fuel injection MINIMUM CARBURATION REGULATION The fuel injection system control unit is programmed to guarantee optimum carburation during use on the road. Minimum carburation necessitates a refinement destined to compensate for the productive tollerances and adjustments of the engine. This regulation is carried out by modifying the opening time of the injector when the engine is idling. To carry out the regulation, proceed as follows: Minimum carburation regulation must be carried out on an engine in good working condition.
Page 208 Fuel injection Start the engine and allow it to warm up until the following conditions are reached: - coolant temperature = more than 70°C - air intake temperature = 25 - 30°C Activate the exhaust gas analyser and check the following conditions: - CO = 1.25±0.25% - CO2 = 14.50±1% Regulation is correct.
Page 209 Fuel injection To increase CO it is necessary to increase fuel injection timing. To decrease CO it is necessary to decrease fuel injection timing. Regulate the trimmer value according to indications given in the table: TRIMMER FUEL INJECTION TIMING VALUE +100 HIGH INCREASES...
Page 210 Fuel injection When the CO percentage is correct and the HC (PPM) value is greater than the maximum allowed limit, check: - spark plug - valves play - timing phase - exhaust valve seal If it proves necessary to replace the control unit it is important to carry out TPS reset and preventively preset the trimmer value of the original control unit (if available).
Page 211 Fuel injection ELECTRICAL FAN CONTROL CIRCUIT Terminals Conditions Standard 5-23 Set ignition to position "ON" Switch on "RUN" Battery Side stand raised tension Electrical fan stopped CIRCUIT DIAGRAM CONTROL UNIT KEY IGNITION ELECTRICAL FAN ELECTRICAL FAN ELECTROMAGNETIC SWITCH 30A FUSE The electrical ventilation system is fed by an electromagnetic switch connected under the panel and controlled by the fuel injection control unit.
Page 212 Fuel injection To control the circuit, proceed as follows: Connect the diagnosis tester 020460Y see page 9-17. Set ignition to "ON" with switch in position "RUN" and side stand raised. Select the “ERRORS “ function from the menu Check if the control unit has registered anomalies concerning the electrical ventilation control circuit.
Page 213 Fuel injection Disconnect the electrical fan control electromagnetic switch Check continuity of the excitation coil. 85 - 86 = 150±50 Ω Replace the electromagnetic switch. Connect the special tool, 020481Y between the control unit and the fuel injection system (see page 9-8) Do not connect to the control unit.
Page 214 Fuel injection Keeping the electromagnetic switch disconnected, check continuity between 86 of the electromagnetic switch connector and 5 of the control unit. 86 (Green-White) - 5 = 0 Ω (continuity) Disconnect the connector between the vehicle system and fuel injection system.
Page 215 Fuel injection Connect the electromagnetic switch and check the presence of tension between terminals 5 and 23 with the key switch set to "ON". 5 - 23 = battery tension with panel set to "ON". Repeat the control with the control unit connected and the engine cold. 5 - 23 = battery tension with panel set to "ON".
Page 216 Fuel injection REVOLUTIONS COUNTER CONTROL CIRCUIT Terminals Conditions Standard Ignition set to "ON" Switch set to "RUN" 3 - 23 9 - 10 Volt Side stand raised Engine stopped CIRCUIT DIAGRAM VEHICLE FUEL INJECTION SYSTEM SYSTEM CONTROL UNIT DIGITAL INSTRUMENT The analog revolutions counter receives commands from the digital instrument panel which in turn receives signals from the fuel injection control unit.
Page 217 Fuel injection Check if the revolutions counter has reached the bottom scale. Check the analog instrument and the digital instrument panel. Connect the diagnosis tester, 020460Y see page 9-17 Set ignition to "ON" with switch in position "RUN" and side stand raised. Select Active diagnosis on the menu Activate diagnosis of the revolutions counter.
Page 218 Fuel injection Disconnect the digital instrument. Keep the control unit disconnected. Check continuity of the wire from the control unit to the digital instrument. Yellow (terminal 4/12) - 3 = 0 Ω (continuity) Disconnect the connection between the vehicle system and the fuel injection system.
Page 219 Fuel injection Connect the control unit. Ignition set to "ON"' with switch on "RUN" and side stand raised. Measure the tension between pins 3 and 23 with engine stopped. 3 - 23 = 9 - 10 V Using the diagnosis tester carry out a revolutions counter control.
Page 220 TABLE OF CONTENTS LUBRICATION...
Page 221 Lubrication SPECIFICATIONS Sump capacity Overhaul 1.7 litres Oil and filter change 1.5 litres Recommended engine oil Selenia HI Scooter - 4Tech specification API SJ 5W/40 Oil pump Type Trochoidal Rotor thicknesses 8 mm Assembly clearances lobe ends 0.05 - 0.008 mm Radial play of the external rotor 0.05 - 0.12 mm End play of the rotors...
Page 222 Lubrication GENERAL CHARACTERISTICS OF THE LUBRICATION SYSTEM The lubrication system is divided into two sections: - high pressure - low pressure All the components forming part of the high pressure section are situated on the engine crankcase; whilst the low pressure section exclusively concerns the thermal unit.
Page 223 Lubrication DIAGNOSTICS GUIDE Lighting up of the minimum oil pressure indicator with a warm engine. Remove the electrical connector of the minimum pressure switch. Check that the indicator lamp turns off. Check and reset the electrical Control the actual oil pressure. system.
Page 224 Lubrication Replace the oil filter and repeat the pressure control with oil at 80°C. The anomaly is resolved. Recommend respect for the advised miles covered. Remove the flywheel cover and proceed with efficiency checks of the by-pass and seal of the cover towards the crankcase inner side, as described in chapter 5 - FLYWHEEL COVER.
Page 225 Lubrication Checking the oil pump - Remove the two screws and the oil pump cover. 05_483 - Remove the internal rotor retaining ring turning it so that the opening is in correspondence with the shaft facing. 05_484 - Remove the rotors and clean them accurately with petrol and compressed air.
Page 226 Lubrication - Using a thickness gauge check the distance between the rotors in the position shown in the figure. Clearance limit allowed: 0.012 mm 05_487 - Check the distance between the external rotor and the pump casing, see figure. Clearance limit allowed: 0.25 mm 05_488 - Check the rotors end play using a ground bar as a reference plane as shown in the figure.
Page 227 Lubrication DIAGNOSTICS GUIDE On discovering an oil leak from the coupling gasket of the flywheel cover or from the oil filter, proceed with lubrication pressure control. Install the specific tool. Specific tools: Manometer 020193Y Adapter 020434Y - Check the system pressure with cold engine and medium-high running speed. Standard pressure <...
Page 228 TABLE OF CONTENTS COOLING SYSTEM...
Page 229 Cooling Expansion tank Radiator Drainage 2 Cylinder 3-way thermostat integrated into the pump cover Head Drainage 1 05_491 11 - 2...
Page 230 Cooling SPECIFICATIONS Cooling system capacity 1.8 l Recommended fluid 50% mixture of water and sealed circuit fluid (PARAFLU 11 FE) Seal pressure Plug calibrated to 0.9 bar THERMOSTAT Type wax, with switch Initial opening 75 ± 2 °C Opening stroke at 90° C 4 mm ELECTROVENTILATION Type...
Page 231 Cooling System description The cooling system is made with a centrifuge pump coaxial to the counter shaft and as such completes a number of revolutions identical to that of the driving shaft. The pump has two ducts, one for inlet and one for outlet. The outlet duct feeds the cylinder and consequently the head;...
Page 232 Cooling - Loosen the drain situated on the joint exiting from the head; - Keep it open until the air discharge has stopped completely; - Retighten the drain screw; - Start the engine for a few seconds; - Repeat the drain operation at the head exit; - Repeat these operations several times until only fluid is discharged;...
Page 233 Cooling - On revealing values or gradual heating considerably different to that of the engine, proceed with thermo- stat control; - Remove the thermostat cover and the thermostat itself as described in Chapter 5- FLYWHEEL COVER. 05_084 - Visually check that the thermostat has no mechanical damage;...
Page 234 Cooling Electroventilation control - Connect the fuel injection diagnosis tester and select the “ERRORS” function from the menu. - Check the presence of anomalies in the electrical fan control circuit (See Chapter “FUEL INJECTION”). Specific tool: Fuel injection diagnosis tester 020460Y 05_497 - Select the “ACTIVE DIAGNOSIS”...
Page 235 Cooling System seal control - Check adequate seal of the circuit when it is under pressure and heated; - For a more complete control wait until the system has cooled because small leaks, invisible due to evaporation phenomena, may occur; - The water pump has a drainage hole for any leaks resulting from mechanical seal of the cooling system or of the oil seal from the spindle seal;...
Page 236 TABLE OF CONTENCTS STARTING...
Page 237 With regard to checking the consensus circuit, see Chapter 4-ELECTRICAL EQUIPMENT in the X9 500 cc vehicle Service Station Manual; whilst for controls of the driving shaft command transmission, take action as described in Chapter 6-FLYWHEEL AND ENGINE IGNITION SYSTEM.
Page 238 Starting Controls and diagnostics guide The starting motor is marketed as complete. Before deciding to replace it, it is necessary to proceed with the following checks: Battery Check repose tension (several hours). Tension > 12,5 V. Check the electrolyte density of each element. Bé...
Page 239 Starting Activate engine ignition (with vehicle movement blocked) for sufficient time to note the revolutions and absorption of the starting motor. Absorption in running speed: from 80 to 120A Running speed: from 300 to 400 rpm N.B.: The stated revolutions value is that indicated by the diagnosis tester. The revolutions reading does not correspond to the actual revolutions, however it is valid for the diagnosis.

PIAGGIO 500 cc Service Manual

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