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PIAGGIO X9 Evolution 500 Workshop Manual

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WORKSHOP MANUAL
633234
X9 Evolution 500

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Summary of Contents for PIAGGIO X9 Evolution 500

  • Page 1 WORKSHOP MANUAL 633234 X9 Evolution 500...

  • Page 2: Workshop Manual

    Not all versions shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2005 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 WORKSHOP MANUAL X9 Evolution 500 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Maintenance rules • Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non- original or non-conforming spares may damage the vehicle. • Use only the special tools designed for this scooter.

  • Page 8: Vehicle Identification

    X9 Evolution 500 Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix ZAPM 27000 ÷ 4000001 Engine prefix M271M ÷ 1001 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Total dry weight 206 Kg Width (at the mirrors) 910 mm...
  • Page 9 X9 Evolution 500 Characteristics Engine ENGINE Specification Desc./Quantity Engine Single-cylinder, four-stroke Bore 92 mm Stroke 69 mm Cubic capacity 460 cm³ Compression ratio 10.5: 1 Timing system Single overhead camshaft with integrated tone wheel, control from flywheel side chain, 4 valves and automatic start-up valve lifting device.

  • Page 10: Electrical System

    X9 Evolution 500 Characteristics Transmission TRANSMISSIONS Specification Desc./Quantity Transmission With automatic expandable pulley variator with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling. Capacities CAPACITIES Specification Desc./Quantity Cooling system approx. 1.8 l Fuel tank (including reserve ~ 2.5 l)

  • Page 11: Wheels And Tyres

    X9 Evolution 500 Characteristics Front fork This is to inform you that, starting from frame no. ZAPM2700004008122, the front fork has been re- placed to improve comfort. The new suspension differs from the previous one for a different stiffness of the springs and a higher quantity of oil: from 268 cc to 273 cc ± 2 cc of Selenia Fork 7.5 W...

  • Page 12: Tightening Torques

    X9 Evolution 500 Characteristics Tightening Torques STEERING UNIT Name Torque in Nm Steering wheel upper ring nut 36 ÷ 39 Steering wheel lower ring nut 10 ÷ 13 then loosen by 90° (see "Steering wheel ring nut lock- ing") Handlebar fixing screw (*) 43 ÷...

  • Page 13: Engine Unit

    X9 Evolution 500 Characteristics COMBINED BRAKE Name Torque in Nm Oil pipe union on combined brake pump 16 ÷ 20 Combined brake pipe union on front calipers 16 ÷ 20 Combined brake pipe union on rear calipers 16 ÷ 20 Front brake caliper pipe union on combined braking device 20 ÷...

  • Page 14: Overhaul Data

    X9 Evolution 500 Characteristics Name Torque in Nm Oil vent pipe fixing 3 ÷ 4 Minimum oil pressure sensor 12 ÷ 14 Fairlead bracket fixing 3 ÷ 4 Head/Cylinder/Crankcase fixing 10 ÷ 12 Revolution timing sensor fixing screw 3 ÷ 4 Coolant temperature sensor 10 ÷...

  • Page 15: Piston Rings

    X9 Evolution 500 Characteristics Cylinder - piston assy. (Values in mm) HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED Specification Desc./Quantity 10 mm 43 mm CATEGORIES OF COUPLING Name Initials Cylinder Piston Play on fitting Cylinder Piston 91.990 - 91.997 91.954 - 91.961...

  • Page 16: Sealing Rings

    X9 Evolution 500 Characteristics SEALING RINGS Name Initials Cylinder Piston Play on fitting 1st Compression ring 0.15 ÷ 0.35 </> Middle piston ring 0.25 ÷ 0.50 0.65 </> Oil scraper ring 0.25 ÷ 0.50 0.65 </> Crankcase - crankshaft - connecting rod...
  • Page 17 X9 Evolution 500 Characteristics Diameter of crankshaft bearings. Measure the capacity on both axes x-y. CRANKSHAFT Specification Desc./Quantity Cat. 1 Standard diameter: 40.010 ÷ 40.016 Cat. 2 Standard diameter: 40.016 ÷ 40.022 Crankshaft alignment Specific tooling 020335Y Magnetic support for dial gauge MAX.
  • Page 18 X9 Evolution 500 Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001098 Countershaft - Replacement TIME - 382...

  • Page 19: Cylinder Assy

    X9 Evolution 500 Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder piston - Replacement 001154 Pin-ring-piston assembly - Service 001129 Chain tensioner - Service and Re- placement TIME - 383...

  • Page 20: Cylinder Head Assy

    X9 Evolution 500 Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001049 Valves - Adjustments 001056 Head gasket - Replacement 001126 Head - Replacement 001083 Thermistor - Replacement 005116 Rpm timing sensor - Replacement 007012...
  • Page 21 X9 Evolution 500 Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Rocking lever valve - Replacement TIME - 385...

  • Page 22: Cylinder Head Cover

    X9 Evolution 500 Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement TIME - 386...

  • Page 23: Flywheel Cover

    X9 Evolution 500 Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001113 Water pump - Replacement 001123 Oil filter -Replacement 001124 By-pass valve - Replacement 001057 Thermostat - Replacement 001062 Water pump command shaft - Re-...

  • Page 24: Driven Pulley

    X9 Evolution 500 Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement TIME - 388...

  • Page 25: Oil Pump

    X9 Evolution 500 Time Oil pump OIL PUMP AND STARTER MOTOR Code Action Duration 001112 Oil pump - Replacement 001042 Oil pump - Overhaul 001051 Timing belt/chain - Replacement 001125 Chain guide sliding blocks - Replace- ment 001102 Net oil filter - Replacement / Cleaning...
  • Page 26 X9 Evolution 500 Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 001010 Geared reduction unit - Service 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 004125 Rear gear shaft - Replacement...

  • Page 27: Driving Pulley

    X9 Evolution 500 Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 rear-view belt - Replacement 001006 rear-view pulley - Service 001141 Belt anti-flapping roller - Replace- ment 001066 rear-view pulley - Replacement TIME - 391...

  • Page 28: Transmission Cover

    X9 Evolution 500 Time Transmission cover TRANSMISSION COVER Code Action Duration 001065 Internal transmission cover - Re- placement 001096 External transmission cover - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement 001170...

  • Page 29: Magneto Flywheel

    X9 Evolution 500 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001173 Rotor - Replacement 001067 Stator - Replacement 001058 Flywheel - Replacement 001104 Start-up freewheel - Replacement 001151 Start-up driven gearing - Replace- ment TIME - 393...

  • Page 30: Butterfly Valve

    X9 Evolution 500 Time Butterfly valve BUTTERFLY VALVE Code Action Duration 001013 Intake manifold - Replacement 001047 Injector - Replacement 001166 Throttle body - Replacement 001171 Throttle body - Overhaul TIME - 394...

  • Page 31: Exhaust Pipe

    X9 Evolution 500 Time Exhaust pipe EXHAUST Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 395...

  • Page 32: Air Cleaner

    X9 Evolution 500 Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - change 001014 Air filter - Replacement/Cleaning 001074 Oil vapour recovery pipe - Replace- ment TIME - 396...
  • Page 33 X9 Evolution 500 Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004146 Front frame - Replacement 004116 Rear frame - Replacement TIME - 397...

  • Page 34: Centre-Stand

    X9 Evolution 500 Time Centre-stand ELECTRO-HYDRAULIC CENTRE STAND/SIDE STAND Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Stand switch - Replacement 005122 Side stand electro-actuator - Re- placement 005123 End of stroke/enabling switches - Ad-...
  • Page 35 X9 Evolution 500 Time Legshield spoiler LEGSHIELD SPOILER AND REARVIEW MIRRORS Code Action Duration 004064 Front shield, front side - Replace- ment 006012 Front shield - Paintwork 004149 shield central cover - Replacement 006006 Headstock cover - Paintwork 004066 Rear view mirrors - Replacement...

  • Page 36: Rear Cover

    X9 Evolution 500 Time Rear cover REAR COVER Code Action Duration 004065 Front shield, rear part - Removal and refitting 004081 Glove box door - Replacement 002082 Fuel tank door opening drive - Re- placement 004156 Glove box flap and/or support - Re-...
  • Page 37 X9 Evolution 500 Time Central cover CENTRAL FRAME COVER Code Action Duration 004011 Central chassis cover - Replacement 004104 Left side cover - Replacement 004105 Right side cover - Replacement 004079 Rear footrest - Replacement 004143 Footrest support - replace...
  • Page 38 X9 Evolution 500 Time Underseat compartment UNDERSEAT COMPARTMENT Code Action Duration 005033 Trunk light switch - Replacement 005026 Helmet compartment light - Replace- ment 005027 Helmet compartment bulb - Replace- ment 004142 Plug socket - Replacement 004016 Helmet compartment - Replacement...
  • Page 39 X9 Evolution 500 Time Mudguard MUDGUARDS Code Action Duration 004167 Grill / radiator cover - replace 004009 Rear mudguard - Replacement 004002 Front mudguard - change 003087 Wheel housing - Replacement TIME - 403...

  • Page 40: Fuel Tank

    X9 Evolution 500 Time Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 004109 Fuel tank bleed - Replacement TIME - 404...

  • Page 41: Radiator Fan

    X9 Evolution 500 Time Radiator RADIATOR FAN Code Action Duration 007002 Radiator - Replacement 007016 Fan complete with support - Re- placement 007003 Coolant delivery and return pipe - Repl. 007024 Expansion tank cap - Replacement 007001 Expansion tank - Replacement...
  • Page 42 X9 Evolution 500 Time Rear shock-absorber REAR SHOCK-ABSORBER Code Action Duration 003007 Rear shock absorbers - Replace- ment TIME - 406...
  • Page 43 X9 Evolution 500 Time Steering column bearings STEERING COLUMN BEARINGS AND FRONT FORK Code Action Duration 003051 Fork assembly - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003076 Fork oil sheath - Replacement 004119 Bearing / Steering support fifth wheel...

  • Page 44: Handlebar Covers

    X9 Evolution 500 Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004151 Instrument panel support - Replace- ment 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 004152 Board computer cover - Replace- ment TIME - 408...

  • Page 45: Handlebar Components

    X9 Evolution 500 Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002060 Complete gas command - Replace- ment 002037 Brake or clutch lever - Replacement 003001 Handlebar - Removal and refitting 002063 Throttle control transmission - Re- placement 002059 Right hand grip - Replacement...
  • Page 46 X9 Evolution 500 Time Swing-arm SWING-ARM Code Action Duration 001072 Engine/chassis fixing oscillating arm - Replacement 003082 Damper arm - Replacement TIME - 410...
  • Page 47 X9 Evolution 500 Time Seat SEAT Code Action Duration 004003 Saddle - Replacement 004144 Bag - Replacement 004067 Back - Replacement TIME - 411...

  • Page 48: Instrument Panel

    X9 Evolution 500 Time Instrument panel INSTRUMENT PANEL Code Action Duration 005014 Odometer - Replacement 005078 Odometer plastic cover - Replace- ment 005082 Instrument panel cable harness - Re- placement 005083 Onboard computer - Replacement TIME - 412...
  • Page 49 X9 Evolution 500 Time Locks SEAT LOCK AND LOCKS Code Action Duration 002083 Saddle opening transmission - Re- placement 002092 Transmission splitter/ hook transmis- sion - Replacement 005099 Electric saddle opening device - Re- placement 005016 Key switch - Replacement...

  • Page 50: Turn Signal Lights

    X9 Evolution 500 Time Turn signal lights FRONT HEADLIGHTS Code Action Duration 005002 Front headlamp - Replacement 005008 Front headlamp bulbs - Replacement 005044 Front lights cable unit - replace TIME - 414...
  • Page 51 X9 Evolution 500 Time REAR HEADLIGHTS Code Action Duration 005090 Stop light bulb - Replacement 005028 Rear optical unit plastic cover - Repl. 005066 Rear light bulbs - replace 005068 Rear turn indicator bulb - Replace- ment 005005 Taillight - change...

  • Page 52: Front Wheel

    X9 Evolution 500 Time Front wheel FRONT WHEEL Code Action Duration 003037 Front wheel rim- Replacement 003047 Front tyre - Replacement 004123 Front wheel - Replacement 003063 Tyre pressure - Check 003040 Front wheel bearings - Replacement 002041 Front brake disc - Replacement...

  • Page 53: Rear Wheel

    X9 Evolution 500 Time Rear wheel REAR WHEEL Code Action Duration 001071 Rear wheel rim - Replacement 004126 Rear wheel tyre - Replacement 001016 Rear wheel - Replacement 003063 Tyre pressure - Check 003014 Rear suspension arm - Replacement 003077...

  • Page 54: Fuel Pump

    X9 Evolution 500 Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement TIME - 418...

  • Page 55: Electric Devices

    X9 Evolution 500 Time Electric devices VEHICLE WIRING Code Action Duration 005001 Electric system - Removal and reas- sembly 005045 Starter motor wire group - Replace- ment 005025 Battery fuse box - Replacement 005114 Electrical system - Service TIME - 419...
  • Page 56 X9 Evolution 500 Time BATTERY AND H.T. COIL Code Action Duration 001069 HV coil - Replacement 005007 Battery - Replacement 005011 Start-up remote control switch - change 005097 Electric central stand remote control switch - Replacement 001094 Spark plug cap - Replacement...
  • Page 57 X9 Evolution 500 Time ELECTRICAL DEVICES ON HANDLEBARS Code Action Duration 005040 Horn button - Replacement 005041 Starter button - Replacement 005084 Emergency light switch - Replace- ment 005095 Electric stand button - Replacement 005077 Emergency stop switch - Replace-...
  • Page 58 X9 Evolution 500 Time INJECTION MASTER-BOX - VOLTAGE REGULATOR Code Action Duration 001023 Injection ECU - Replacement 005009 Voltage regulator - Replacement 005098 Side stand control unit - Replace- ment 005088 Emergency stop remote control - Re- placement 005096 Remote control for injection compo-...
  • Page 59 X9 Evolution 500 Time pics PICS Code Action Duration 005092 Radio/intercom control unit - Re- placement 005093 Radio/intercom wires - Replacement 005094 Radio/intercom display - Replace- ment TIME - 423...
  • Page 60 X9 Evolution 500 Time Fuel tank filler flap CENTRAL TUNNEL COVER AND FUEL TANK FILLER FLAP Code Action Duration 004135 Fuel tank lid - Replacement 004011 Central chassis cover - Replacement 004157 Fuel port coupling - Replacement TIME - 424...
  • Page 61 X9 Evolution 500 Time Footrests SPOILER AND FOOTREST Code Action Duration 004075 Front mat - Replacement 004079 Footboard (1) - Replacement 004015 Footboard (2) - Replacement 004068 Passenger handgrip - Replacement 004129 Rear fairing - Replacement 004012 Rear side panels (2) - Replacement...

  • Page 62: Front Mudguard

    X9 Evolution 500 Time Front mudguard FRONT MUDGUARD AND RADIATOR COVER Code Action Duration 004002 Front mudguard - change 004167 Radiator grille/cover - Replacement TIME - 426...

  • Page 63: Helmet Compartment

    X9 Evolution 500 Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - replace 005033 Glove-box light switch - Replace- ment 005026 Helmet compartment light - Replace- ment 004142 Plug socket - Replacement 005027 Helmet compartment bulb support -...
  • Page 64 X9 Evolution 500 Time Rear side fairings REAR SIDE FAIRINGS Code Action Duration 004057 Taillight lower cover - Replacement 004136 License plate holder support - Re- placement 005048 Licence plate holder - Replacement 005046 Battery cover - Replacement TIME - 428...

  • Page 65: Front Suspension

    X9 Evolution 500 Time Front suspension FRONT SUSPENSION Code Action Duration 003051 Complete fork - Replacement 003010 Front suspension - service 003076 Fork housing - replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003073 Steering clearance - Adjustment...

  • Page 66: Rear Suspension

    X9 Evolution 500 Time Rear suspension REAR SUSPENSION Code Action Duration 003085 Suspension strut - Replacement 003007 Rear shock absorber - Replacement 004120 Rear suspension linkage - Replace- ment 003086 Suspension strut support - replace- ment TIME - 430...

  • Page 67: Cooling System

    X9 Evolution 500 Time Cooling system COOLING SYSTEM Code Action Duration 007002 Water cooling radiator - Replace- ment 007016 Fan with support - Replacement 007001 Expansion tank - Replacement 007024 Expansion tank cap - Replacement 007019 Coolant return pipe - replacement...

  • Page 68: Braking System

    X9 Evolution 500 Time Braking system BRAKING SYSTEM Code Action Duration 002021 Front brake piping - Replacement 002084 Integral break pump pipe, device - Replacement 002085 Integral brake device pipe- front cal- liper - Replacement 002087 Rear caliper integral braking device...
  • Page 69 X9 Evolution 500 Time Windscreen WINDSCREEN Code Action Duration 004028 Windshield glass - Replacement 004101 Windshield - Replacement TIME - 433...
  • Page 70 Air filter: 39, 363 Battery: 51, 59, 61, 74, 75, 82, 373 Brake: 325, 329, 331, 333, 334, 336, 340–342 Brake fluid: 340 Coolant: 270, 348 Engine oil: 40 Fuel: 224, 234, 238, 365, 404, 418, 424 Fuses: 63 Headlight: 46, 356 Hub oil: 37 Identification: 8 Immobilizer:...
  • Page 71 Tank: 365, 367, 404, 424 Technical Data: Transmission: 10, 50, 89, 105, 392 Tyres: 11...

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