PIAGGIO 633234 Workshop Manual
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PIAGGIO 633234 Workshop Manual

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WORKSHOP MANUAL
633234
X9 Evolution 500

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Summary of Contents for PIAGGIO 633234

  • 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 Wheel base 2130 mm Length...

  • Page 9: Oil Filter

    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 Components

    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) ~ 14,5 l Rear hub...

  • Page 11: Wheels And Tyres

    IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE COR- RECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES REC- OMMENDED BY PIAGGIO. CHAR - 11...

  • 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 0.029 - 0.043 Cylinder Piston...

  • 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 Characteristic Drive shaft / crankcase axial clearance: 0.1 - 0.5 mm (when cold)
  • 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 Characteristics Specification Desc./Quantity Centre to centre distance on the crankcase 76.992 ÷ 76.962 The gears with centre to centre distance without clearance between 76.867 and 76.907 are considered universal and can be fitted to either crankcase type. Either the pair of gears or the crankcase is identified with the letter referring to the type (on the crank- case, this mark is found at the cylinder mouth, flywheel side).
  • Page 19 X9 Evolution 500 Characteristics Products PRODOTTI Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in- creased adhesiveness AGIP CITY HI TEC 4T Engine oil...

  • Page 20: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...

  • Page 21: Specific Tooling

    X9 Evolution 500 Tooling SPECIFIC TOOLING Stores code Description 001330Y Tool for fitting steering seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings 001467Y008 Pliers to extract 17 mm ø bearings 001467Y017 Driver for OD 36 mm bearings TOOL - 21...
  • Page 22 X9 Evolution 500 Tooling Stores code Description 001467Y031 Bell 001467Y034 Pliers to extract ø 15-mm bearings 001467Y035 Belle for OD 47-mm bearings 002465Y Pliers for circlips 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut TOOL - 22...
  • Page 23 X9 Evolution 500 Tooling Stores code Description 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump TOOL - 23...
  • Page 24 X9 Evolution 500 Tooling Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020358Y 37x40-mm adaptor TOOL - 24...
  • Page 25 X9 Evolution 500 Tooling Stores code Description 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25-mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y012 bush (valve removing tool) TOOL - 25...
  • Page 26 X9 Evolution 500 Tooling Stores code Description 020412Y 15 mm guide 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020439Y 17 mm guide 020444Y Tool for fitting/ removing the driven pulley clutch TOOL - 26...
  • Page 27 X9 Evolution 500 Tooling Stores code Description 020444Y009 46x55 Wrench 020456Y Ø 24 mm adaptor 020458Y Puller for lower bearing on steering tube 020459Y Punch for fitting bearing on steering tube 020460Y Scooter diagnosis and tester TOOL - 27...
  • Page 28 X9 Evolution 500 Tooling Stores code Description 020467Y Flywheel extractor 020468Y Piston fitting band 020469Y Reprogramming kit for scooter diagnosis tester 020470Y Pin retainers installation tool 020471Y Pin for countershaft timing TOOL - 28...
  • Page 29 X9 Evolution 500 Tooling Stores code Description 020472Y Flywheel lock wrench 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set 020477Y Adaptor 37 mm 020478Y Punch for driven pulley roller casing TOOL - 29...
  • Page 30 X9 Evolution 500 Tooling Stores code Description 020479Y Countershaft lock wrench 020480Y Petrol pressure check set 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30 mm guide 020512Y Piston fitting fork TOOL - 30...
  • Page 31 X9 Evolution 500 Tooling Stores code Description 020527Y Engine support base 020565Y Flywheel lock calliper spanner 020604Y011 Fitting adapter 494929Y Exhaust fumes analyser TOOL - 31...

  • Page 32: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 33: Maintenance Chart

    X9 Evolution 500 Maintenance Maintenance chart Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been sug- gested, which are included in the summary table on the following page. Any minor faults should be reported without delay to an Authorised Service Centre or Dealer without waiting until the next scheduled service to solve it.
  • Page 34 X9 Evolution 500 Maintenance AFTER 6,000 KM OR 12 MONTHS Action Engine oil - replacement Hub oil - level check Spark plug / electrode gap - check Air filter - cleaning Engine oil - change Valve clearance - check Base vent - check Variable speed rollers - replacement Driving belt - checking Coolant level - check...
  • Page 35 X9 Evolution 500 Maintenance AFTER 24,000 KM 255' Action Engine oil - replacement Hub oil - change Spark plug / electrode gap - replacement Air filter - clean Engine oil - change Fuel filter - check Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change...
  • Page 36 X9 Evolution 500 Maintenance Action Brake control levers - greasing Brake fluid hoses - replacement Transmission elements - lubrication Brake fluid level - check Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre inflation and wear - Check Vehicle and brake test - road test AFTER 48,000 KM...

  • Page 37: Spark Plug

    X9 Evolution 500 Maintenance Action Electrical system and battery - check Headlight - adjustment Tyre inflation and wear - Check Vehicle and brake test - road test Transmission elements - lubrication Spark plug Check and replacement CAUTION THE SPARK PLUG MUST BE REMOVED WITH COLD EN- GINE.
  • Page 38 X9 Evolution 500 Maintenance Check - Take the vehicle to a flat ground and rest it on the central stand. - Unscrew the oil bar «A», dry it with a clean cloth and reinsert it, screwing it in thoroughly; - Pull out the bar and check that the oil level is be- tween the MAX and MIX levels indicated on the bar (see figure);...

  • Page 39: Air Filter

    X9 Evolution 500 Maintenance Air filter - Raise the saddle. - Remove the piston ring and the battery cover. - Loosen the 4 mounting screws shown in the fig- ure. - Loosen the mounting screw located under the in- take manifold. - Replace the air filter and reassemble the various components, reversing the removal procedure.

  • Page 40: Engine Oil

    X9 Evolution 500 Maintenance - An inspection and possible cleaning (with com- pressed air) of the air filter is scheduled every 6000 km in any case. - The air jet must be directed from the inside to the outside of the filter (i.e. opposite the direction of the air flow during normal operation of the engine).

  • Page 41: Engine Oil Filter

    X9 Evolution 500 Maintenance Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. The restoration level between the MIN and MAX levels implies a quantity of oil of approx. 400 cc. Engine oil filter CAUTION DO NOT DISPOSE OF OIL IN THE ENVIRONMENT.

  • Page 42: Oil Pressure Warning Light

    X9 Evolution 500 Maintenance - Start the engine and let it run for a few minutes and then turn it off. After 5 minutes check the level and top up, if necessary, never exceed the MAX. level. N.B. IF THE OIL IS CHANGED WITHOUT CHANGING THE CARTRIDGE FILTER (1ST COUPON) ADD AROUND 1500 CC OF OIL INSTEAD OF 1700 CC SINCE PART OF THE LUBRICATION CIRCUIT IS FILLED.

  • Page 43: Checking The Valve Clearance

    X9 Evolution 500 Maintenance obtained on the head, make the driving shaft per- form a further revolution. - Check that the two references match perfectly; if not, remove the timing belt and install it again. See also Cylinder assy. and timing system Checking the valve clearance - To check the clearance in the valves collimate the references between the cam shaft control pul-...

  • Page 44: Level Check

    X9 Evolution 500 Maintenance expansion tank. The fluid level should always be between the «MIN» and «MAX» level. - To have an indication of the fluid level, refer to a notch made in a cylindrical insert, coaxial to the filler and visible inside it once you remove the loading cap.

  • Page 45: Braking System

    X9 Evolution 500 Maintenance Braking system Level check - Rest the scooter on a flat ground and on the cen- tral stand. - Remove the brake pump cover as shown in the figure. - Check the brake fluid level by the special indica- tor located on the pump, as shown in the figure.

  • Page 46: Recommended Products

    X9 Evolution 500 Maintenance QUIRED. TOP UP THE PUMP TANK, IF REQUIRED, CONSIDERING THAT THE "MAX." LEVEL MUST ONLY BE OBTAINED WITH NEW PADS. Top-up To top up the fluid proceed as follows: Remove the right cover and/or the PICS display, then remove the tank cap loosening the relevant two screws, remove the intermediate rubber mem- brane and restore the level using the prescribed...

  • Page 47: Checking The End Compression Pressure

    X9 Evolution 500 Maintenance - Turn the headlight on, switch on the dipped beam and check that the horizontal limit line between the dark zone and the illuminated zone does not fall above the horizontal line traced on the screen. - Adjust the screw located under the front shield to change the headlight inclination and the light beam height.
  • Page 48 X9 Evolution 500 Maintenance MAIN - 48...

  • Page 49: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 50: Brakes Overheating

    X9 Evolution 500 Troubleshooting Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operation Faulty clutch Check that there is no grease on the masses. Check that the clutch mass contact surface with the casing is mainly in the centre with equivalent characteristics on the three masses.
  • Page 51 X9 Evolution 500 Troubleshooting Battery BATTERY Possible Cause Operation Battery This is the device in the system that requires the most frequent attention and the most thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically.

  • Page 52: Noisy Suspension

    X9 Evolution 500 Troubleshooting Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after mak- ing the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.
  • Page 53 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...

  • Page 54: Electrical System

    X9 Evolution 500 Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Outside temperature sensor Rear brake stop button Light switch with flash Indicators switch Horn button Emergency flashing button Front fuse holder box Fuse no.3 7,5A Horn Fuse 15A Side stand switch Intercom connectors Voltage regulator Electric side stand control unit...
  • Page 55 X9 Evolution 500 Electrical system Specification Desc./Quantity Front left-hand direction indicator with bulb Analogue instrument unit (5 bulbs) Radio display Digital instrument unit with no. 11 LED indicators Front headlight Front right-hand direction indicator with bulb Diode unit Diode 6A Diode 1A Main remote control switch 30A Socket 12V...

  • Page 56: Components Location

    X9 Evolution 500 Electrical system SHOULD ANY INTERVENTIONS TO THE ELECTRIC SYSTEM BE REQUIRED, MAKE SURE THAT THE LEADS TO THE ELECTRONIC IGNITION DEVICE ARE PROPERLY CONNECTED ACCORD- ING TO POLARITY AND TO THE LEAD COLOURS. Components arrangement OMPONENTS LOCATION Specification Desc./Quantity Side stand switch...
  • Page 57 X9 Evolution 500 Electrical system Specification Desc./Quantity Light switch with flash Indicators switch Horn button Emergency flashing button Reset button Horn LH taillight with sidelights bulb 5W and flashing light bulb Rear tail light with 5 2.3W bulbs Number plate light bulb 12V-5W Rh taillight with sidelights bulb 5W and flashing light bulb Battery 12V-14Ah Front brake stop button...

  • Page 58: Ignition Section

    X9 Evolution 500 Electrical system GNITION SECTION Specification Desc./Quantity Anti-theft alarm fitting Side stand switch Engine stop switch Voltage regulator Battery 12V - 4Ah Start up button Diode Starter motor Fuse no. 13 30 A Remote starter switch Main remote control switch Diode Key switch contacts Two brake light buttons...
  • Page 59 X9 Evolution 500 Electrical system Specification Desc./Quantity Light switch Side stand switch Engine stop switch Voltage regulator Roof lamp for box helmet illumination with lamp Helmet compartment lighting button Battery 12V - 14 Ah Fuse no. 13 30 A Main remote control switch Diode Key switch contacts No.
  • Page 60 X9 Evolution 500 Electrical system Specification Desc./Quantity Voltage regulator Battery 12V - 4Ah Start up button Diode Starter motor Fuse no. 13 30 A Remote starter switch Main remote control switch Diode Key switch contacts Two brake light buttons No. 5 bulbs for brake light 12V-2,3W Digital instrument unit Control unit power supply remote control switch (engine...

  • Page 61: Checks And Inspections

    X9 Evolution 500 Electrical system Specification Desc./Quantity Diode Key switch contacts Engine warning indicator Engine not enable indicator Low fuel warning light High-beam warning light Wheel RPM sensor Outside temperature sensor Digital instrument unit Fuel level sender Control unit power supply remote control switch (engine stop) Electronic control unit components remote control switch Saddle opener receiver...

  • Page 62: Voltage Regulator/Rectifier

    X9 Evolution 500 Electrical system 1) Remove the door in the saddle compartment. 2) Disconnect the connector between the stator and regulator with the three yellow wires. 3) Measure the resistance between each of the yellow terminals and the other two. Electric characteristic Resistance: 0.2 - 1 Ω...
  • Page 63 X9 Evolution 500 Electrical system Lights list IGHTS LIST Specification Desc./Quantity Dipped beam light N° 1, 12V-55W, halogen Upper beam light N° 1, 12V-55W, halogen Front position lights N° 2, 12V-3W, all glass Front direction indicator lights N° 2, 12V-10W, spherical Rear position lights N°...
  • Page 64 X9 Evolution 500 Electrical system Specification Desc./Quantity Capacity: 5 A Protected circuits: Diagnostic outlet - Decoder and control unit enable signal 3. four fuses «C» into the trunk on the left side. Specification Desc./Quantity Capacity: 15 A Protected circuits: Horn - High beam bulb - Accesso- ries Capacity: 7,5 A Protected circuits: Start-up enable signal - Brake light...
  • Page 65 X9 Evolution 500 Electrical system Dashboard Vehicle X9 is provided with an instrument panel divided into 2 sections: the analogue section is fixed into the cap while the digital section is integral to the handlebar. The analogue section includes: - Tachometer with dual scale (MPH/KMH) control- led by the fifth wheel by the digital section;...
  • Page 66 X9 Evolution 500 Electrical system To ensure safety while riding, the "direction indicators control" function is connected to the odometer. If the indicator is left on, it automatically stops after 1 kilometre travelled. - The "engine disabled" indicator is activated by the side stand switch and by the emergency switch on the right side of the handlebar.
  • Page 67 X9 Evolution 500 Electrical system «Oil», «Service» and «Belt». The calendar is programmed from 2000 to 2050, to adjust the date and time use the two buttons «Clock» and «Set». To guarantee the vehicle safety, every time the key switch is set to «ON», all of the digital indications are checked.
  • Page 68 X9 Evolution 500 Electrical system Captions A = Satellite D = Mobile phone cable F = Telephone connector H = Spark plug inspection port J = Loudspeaker L = Microphone O = Headset clip R = Volume button- U = Passenger connection X = Volume button + B = Control unit E = Control unit power supply connector...
  • Page 69 X9 Evolution 500 Electrical system I = Headset cables N = Loudspeaker Q = Vehicle satellite connector T = Cable support plate W = DOWN button Z = Fixing of control unit to chassis The control unit PICS X9 (B) combines in a single product the traditional function of intercom for motor- riders and that of hadsfree kit for mobile phones and RDS radios.
  • Page 70 A mobile phone can be connected to the device using the special cable (D) (see Piaggio accessories); when a call is received, a tone is heard by both the passenger and the pilot; after the tone, the call is switched to the pilot, with the possibility of switching it to the passenger by button (Y).

  • Page 71: Manual Intercom

    X9 Evolution 500 Electrical system STARTING (USING THE VEHICLE KEY) Specification Desc./Quantity No helmet inserted - Logo X9 Tuner - source - Speakerphone with external speakers Driver headphone inserted - Driver/passenger helmet - pas- Tuner - source - Speakerphone senger crossed out Passenger headphone inserted - Driver/passenger helmet - Tuner - source - Speakerphone driver crossed out...
  • Page 72 X9 Evolution 500 Electrical system Several functions are provided but few of them are used correctly. Basic functions as the AF (alternative frequencies), that allow listening to a fixed radio station on most of the territory during a journey, are not always used properly.
  • Page 73 X9 Evolution 500 Electrical system Intercom on icon Manual intercom icon Incoming call icon Incoming call icon only with driver headphone inserted. Incoming call icon only with passenger head- phone inserted. Telephone call with driver icon Telephone call with passenger icon Telephone conversation intercom icon PECIFICHE TECNICHE Specification...
  • Page 74 X9 Evolution 500 Electrical system Specification Desc./Quantity 10.5V ÷ 16V 1.5 mA max Maximum output power 500 mW per channel Power consumption vehicle off ~0 mA in stand-by ~280 mA at maximum power ~500 mA Frequency response audio 200 Hz - 20 kHz ± 3 dB intercom 200 Hz - 5 kHz ±...
  • Page 75 X9 Evolution 500 Electrical system to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to - ). Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Cleaning the battery The battery should always be kept clean, especially on its top side, and the terminals should be coated with vaseline.
  • Page 76 X9 Evolution 500 Electrical system - Insert the lower panel at the bottom of the battery compartment (A). - Insert the front element (B). - Place the battery fixing the vent pipe by the re- taining clip. N.B. THE VENT PIPE WITH THE RETAINING CLIP ARE AL- READY MOUNTED ON THE VEHICLE.

  • Page 77: Specific Tooling

    X9 Evolution 500 Electrical system the acid gravity is about 1.27, corresponding to 31 Bé and such values become steady. - After charging, top up the acid (adding distilled water). Close and clean carefully. - After carrying out the operations above, install the battery on the scooter, observing the connections described in point 3) of paragraph "Battery re- charge".
  • Page 78 X9 Evolution 500 Electrical system to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to - ). Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.
  • Page 79 X9 Evolution 500 Electrical system Check the signal Move the positive rod to the position shown in the photo. Turn the front wheel very slowly and check that the measured voltage is 0 V or battery voltage, depending on the position taken up. This condition should be repeated 16 times during a complete revolution of the wheel.
  • Page 80 X9 Evolution 500 Electrical system Specification Desc./Quantity Upper beam indicator input Air temperature sensor input Engine not actuable input Oil pressure indicator input (Not connected) LH direction indicator output Direction indicator stop button input Reset service management button input Water temperature sensor input Fuel level sensor input Battery positive (+30) Tachometer sensor power supply...
  • Page 81 X9 Evolution 500 Electrical system Immobiliser decoder IMMOBILIZER DECODER Specification Desc./Quantity Immobilizer LED control (negative) Base power supply (positive) Negative Electronic control unit EMS (serial) Continuous power supply (positive) Immobilizer aerial Engine rev. sensor REV SENSOR Specification Desc./Quantity Male Female Shielding Analogue odometer ANALOGUE ODOMETER...

  • Page 82: Battery Replacement

    X9 Evolution 500 Electrical system Remote seat opening The vehicle is equipped with a remote control to open the saddle. This remote control is supplied together with the keys and at the manufacturing stage, it has been programmed to work together with the ECU that control the opening device. If the remote control is lost, a new one can be requested and reprogram it by resetting the ECU memory and following the same steps as per programming the immobilizer system in the keys.
  • Page 83 X9 Evolution 500 Electrical system Programming - Remove the front shield to access the saddle opening reception/control unit. - In the wiring cover you can see the metal terminal of the white wire protruding from Pin 3 of the con- trol unit.

  • Page 84: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 85 X9 Evolution 500 Engine from vehicle Exhaust assy. Removal - Loosen the two fasteners of the exhaust manifold from the head. - Loosen the 3 screws fixing the silencer to the supporting arm. - Remove the complete silencer. N.B. TO ENSURE THE SEAL OF THE SILENCER-EXHAUST MANIFOLD GROUP, YOU MUST REPLACE THE GRAPHITE COUPLING GASKET EVERY TIME THESE COMPONENTS ARE DETACHED.
  • Page 86 X9 Evolution 500 Engine from vehicle - Disconnect the HV cable from the spark plug. - Disconnect the alternator cable from the electrical system of the scooter. WARNING BE VERY CAREFUL WHEN HANDLING FUEL. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE LEAD.
  • Page 87 X9 Evolution 500 Engine from vehicle CAREFULLY CLEAN THE INJECTOR «T» BRANCH BEFORE REPLACING THE QUICK COU- PLINGS. - Orientate the injector so as to prevent interferences of the electric wiring with the cooling fluid and fuel pipes. - Check the engine oil level and top up using the recommended brand, if required. - Fill the cooling circuit.
  • Page 88 INDEX OF TOPICS NGINE...

  • Page 89: Automatic Transmission

    X9 Evolution 500 Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap. - Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush.
  • Page 90 X9 Evolution 500 Engine - Remove the four M8 screws. - Remove the transmission cover. - Check that the bearing rotates freely, otherwise replace it. - Loosen the 4 fastening screws - Extract the outside plastic transmission cover. Air duct - Remove the external transmission cover.

  • Page 91: Removing The Driven Pulley Shaft Bearing

    X9 Evolution 500 Engine Air duct filter - Remove the external air conveyor. - Unscrew the 2 fastening screws shown in the fig- ure to remove the conveyor filter. Removing the driven pulley shaft bearing - Remove the transmission cover. - Remove the Seeger ring.
  • Page 92 X9 Evolution 500 Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the bearing onto the special tool with a little grease to prevent it from coming out.

  • Page 93: Removing The Driven Pulley

    X9 Evolution 500 Engine Installation of belt anti-vibration roller - Install the anti-flapping roller with the lip facing the engine crankcase. - Tighten the central screw to the prescribed tor- que. N.B. TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE BELT IS OBTAINED.

  • Page 94: Removing The Clutch

    X9 Evolution 500 Engine - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. N.B. CHECK THE ECCENTRICITY MEASURED, 0.2 MM MAX. Characteristic Max. value: 160.5 mm Standard value: 160.2 mm Removing the clutch - To remove the clutch with the driven pulley it is necessary to use the special tool;...
  • Page 95 X9 Evolution 500 Engine - Remove the 4 guide pins. - Extract the moving driven half-pulley. Removing the driven half-pulley bearing - Check that the bushing is free from wear and damage; otherwise replace the fixed driven half- pulley. - Remove the lock ring using pliers. - Using the special tool inserted through the roller bearing, pull out the ball bearing.
  • Page 96 X9 Evolution 500 Engine - Remove the roller bearing using the special tool, supporting the fixed half-pulley with the bell. Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020364Y 25-mm guide 001467Y002 Driver for OD 73 mm bearing Inspecting the driven fixed half-pulley - Check that the belt contact surface is free from wear.

  • Page 97: Refitting The Driven Pulley

    X9 Evolution 500 Engine If you are working on the driven pulley unit fully assembled, use the special tool. Specific tooling 020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing - Install a new ball bearing using the special tool. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm...
  • Page 98 X9 Evolution 500 Engine Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length: 125.5 mm Admissible limit after use: 120 mm - Check the thickness of the clutch mass friction material.
  • Page 99 X9 Evolution 500 Engine Refitting the clutch - Prepare the special tool as for removal; - Preassemble the driven pulley unit with the drive belt according to its direction of rotation; - Insert the driven pulley unit, the spring with sheath and clutch into the tool.

  • Page 100: Removing The Driving Pulley

    X9 Evolution 500 Engine Refitting the driven pulley - Install the driven pulley assembly with belt. Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width: 25 mm Standard width: 26.2 mm Removing the driving pulley - Using a 27 mm wrench, turn the central pulley nut...
  • Page 101 X9 Evolution 500 Engine - First install the lock ring of the special tool onto the pulley so that the splines are completely en- gaged. - Then, insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself.
  • Page 102 X9 Evolution 500 Engine - Measure the pulley sliding bushing outside di- ameter shown in the figure. Characteristic Minimum admissible diameter Ø 29.95 mm Standard diameter: Ø 29.959 mm - Check that the rollers are not damaged or worn. Characteristic Minimum admissible diameter Ø...
  • Page 103 X9 Evolution 500 Engine Refitting the driving pulley Installing the fixed driving half-pulley - Insert the spacer. - Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the moving driving pulley. - Remove the flat washer and the spring washer as shown in the figure.
  • Page 104 X9 Evolution 500 Engine - Turn the central pulley nut to horizontally align the holes and install the special tool. N.B. CHECK THAT THE STOP WRENCH TOOL IS EASILY IN- SERTED INTO THE PULLEY AND IN THE ENGINE CRANK- CASE. Specific tooling 020474Y Driving pulley lock wrench - Install the lock ring from the rear so that the...

  • Page 105: Transmission Cover Screw

    X9 Evolution 500 Engine - Assembly the half-pulley with the roller contrast plate and sliding blocks. - Insert the half-pulley on the crankshaft. - Insert the spacer bushing. Refitting the transmission cover - Install the driving pulley shaft cover, positioning the tooth gap on the lower part with the reference mark on the transmission crankcase.

  • Page 106: Driven Pulley Nut

    X9 Evolution 500 Engine - Ensure the correct installation on the crankcase of the 2 centring dowels. - Insert the transmission cover with the bearing and install the relevant retainers. - Lock the four M8 retainers. Locking torques (N*m) M8 retainers for transmission cover 23 ÷...
  • Page 107 X9 Evolution 500 Engine End gear Removing the hub cover - Drain the rear hub oil through the oil drainage cap located under the engine. - Drain the rear hub oil through the oil drainage cap located under the engine. -Remove the 7 fastening screws.
  • Page 108 X9 Evolution 500 Engine - Use the special extractor to disassemble the bearing on the engine chassis of the countershaft. Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y035 Belle for OD 47-mm bearings - Support the hub cover using the column kit. - Pull out the bearing using the special tool.
  • Page 109 X9 Evolution 500 Engine - Remove the oil guard using a screwdriver. Removing the driven pulley shaft bearing - If you have to remove the driven pulley shaft, the relevant bearing and the oil guard, remove the transmission cover and the clutch unit as descri- bed in the Automatic transmission chapter.
  • Page 110 X9 Evolution 500 Engine Connection diameter for countershaft: A = diameter 20 - 0.01 -0.02 mm Connection diameter for wheel shaft: B = diameter 30 - 0.010 -0.023 mm C = diameter 15 - 0.01 -0.02 mm Bearing diameter for driven pulley shaft: D = diameter 17 - 0.01 -0.02 mm E = diameter 20 - 0.01 -0.02 mm F = diameter 25 - 0.01 -0.02 mm...
  • Page 111 X9 Evolution 500 Engine - Heat the intermediate gear bearing seat. - Insert the intermediate shaft bearing using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP- PLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020363Y 20 mm guide...
  • Page 112 X9 Evolution 500 Engine Refitting the hub cover bearings - Heat the bearing seats on the cover using the heat gun. - Support the hub cover using the column kit. Specific tooling 020151Y Air heater 020476Y Stud bolt set - Insert the intermediate shaft bearing on the cover using the special tool.

  • Page 113: Recommended Products

    X9 Evolution 500 Engine - Support the hub cover using the column kit. - Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover. - Place the oil guard flush with the crankcase. Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020476Y Stud bolt set...

  • Page 114: Flywheel Cover

    X9 Evolution 500 Engine Locking torques (N*m) Rear hub cover screws 24 ÷ 27 Flywheel cover - Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover.
  • Page 115 X9 Evolution 500 Engine - Remove the oil filter using a filter tape or shaped cup wrench. - Loosen the 14 fastening screws. - Remove the flywheel cover with the relevant gas- ket and the cooling system sleeve support. N.B. THE SCREWS ARE OF 4 DIFFERENT LENGTHS.

  • Page 116: Removing The Stator

    X9 Evolution 500 Engine - Remove the by-pass and the relevant spring. - Remove the oil pump seal. Removing the stator - Remove the two retaining screws and the cable guide bracket. - Unscrew the 3 fastening screws and remove sta- tor and its wiring.

  • Page 117: Water Pump Impeller

    X9 Evolution 500 Engine - Remove the blow-by reed valve with the relevant sealing gasket. - Unscrew the fastening screw and remove the gas outlet union with the relevant O-ring. - Remove the water pump impeller by unscrewing it from the relevant shaft. N.B.
  • Page 118 X9 Evolution 500 Engine - Remove the sealing ring. - Remove the ceramic ring and the relevant gas- ket. - Remove the sealing ring for the pump shaft lu- brication using a suitably shaped tool. - Remove the engine oil filling cap/dipstick and the check hole cover for the distribution timing.
  • Page 119 X9 Evolution 500 Engine Inspecting the cover components - Check that the mounting surface of the crankcase is not worn or deformed. - Check that the by-pass valve seat, the torque limiter and the water pump shaft are free from wear.
  • Page 120 X9 Evolution 500 Engine - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. Electric characteristic Resistance: 0.2 - 1 Ω - Check the ground insulation of each phase.
  • Page 121 X9 Evolution 500 Engine - Install the supply hose to the cylinder and con- nect the return hose to the pump cover using 3 new clamps. N.B. TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS, PAYING ATTENTION NOT TO CONSTRICT THE HOSES BUT ALSO TAKING CARE TO TIGHTEN THE CLAMPS SUF- FICIENTLY.
  • Page 122 X9 Evolution 500 Engine - Temporarily install the distribution timing check hole cover and the engine oil filling cap/bar. - Insert the blow-by recovery duct using a new O- ring. - Tighten the screws to the prescribed torque. Locking torques (N*m) Blow-by recovery duct fixing screws 3 - 4 - Insert the spring and the by-pass piston on the...
  • Page 123 X9 Evolution 500 Engine - Oil feeding duct at the water pump shaft connec- tion. - Pump drainage duct. - Oil pressure sensor feeding duct. - Oil vapour decantation chamber ENG - 123...
  • Page 124 X9 Evolution 500 Engine - Reinstall the blow-by reed valve using a new sealing gasket. - Reinstall the support with head and tighten the screws to the prescribed torque. Locking torques (N*m) Supporting screws with bulkhead 0.3 - 0.4 - Install a new sealing ring for the pump shaft using the special tool - Install the oil minimum pressure sensor and tight- en to the prescribed torque.
  • Page 125 X9 Evolution 500 Engine - Screw the impeller and tighten to the prescribed torque. Locking torques (N*m) Water pump impeller 4 ÷ 5 Refitting the flywheel cover - Install a new gasket on the engine crankcase. - Check the presence of the three centring dowels. - Turn the crankshaft in order to align the counter- shaft movement sensor with a reference point on the crankcase (see figure).

  • Page 126: Flywheel Cover Screw

    X9 Evolution 500 Engine FAILURE TO OBSERVE THIS INSTRUCTION MAY RESULT IN DESTRUCTION OF THE CERAMIC MAGNETS. - Tighten the 14 retaining bolts of the cover to the prescribed torque. N.B. THE BOLTS HAVE FOUR LENGTHS: - THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE FIGURE.
  • Page 127 X9 Evolution 500 Engine Specific weight: 1.25 - 1.26 YES go to 2 NO go to 3 2 - Make sure the negative terminals (battery neg- ative and starter negative) are correctly connected to each other and to the frame. YES go to 4 NO go to 5 3 - Recharge and if necessary replace the battery.

  • Page 128: Starter Motor

    X9 Evolution 500 Engine <40 A YES go to 10 NO go to 11 7- Low trailing speed High electrical absorption Carry out a test of the engine rotation (example: possible melting of the bushes) and if no anomalies are found, replace the starter motor. 8- Low trailing speed Low electrical absorption Repeat the test, bridging the power terminals of the starter remote control switch or even better replacing...

  • Page 129: Removing The Starter Motor

    X9 Evolution 500 Engine The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure of the engine and the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations. The freewheel is used for a sufficiently silent starting. The starter control (energised remote control) is slaved to enabling signals by the side stand and the emergency OFF/RUN switch, which does not allow starting given dangerous conditions.
  • Page 130 X9 Evolution 500 Engine - Unscrew the 3 fastening screws and remove the chain guide sliding block retain plate and the start- up rim. - Align the holes obtained on the flywheel with the crankcase housing to allow the introduction of the special tool.
  • Page 131 X9 Evolution 500 Engine - Loosen the magneto flywheel fastening nut. - Remove the special tool and the fastening nut. - Remove the washer. - Insert the nut again so as to slightly uncover the shaft and free the space that was occupied by the washer.
  • Page 132 X9 Evolution 500 Engine - Remove the extractor. - Remove the nut and extract the flywheel with the start-up rim. - Remove the crankshaft key. - To remove the start-up rim from the freewheel it is necessary to turn it clockwise and pull it out. - Remove the freewheel from the flywheel by loos- ening the 6 fastening screws.
  • Page 133 X9 Evolution 500 Engine - Extract the intermediate gear provided with tor- que limiter. Inspecting the flywheel components - Check the integrity of the magnets. - Check that the magnet support cage is free from deformation or cracks. - Check that the flywheel splines exhibit no loos- ening.

  • Page 134: Intermediate Gear

    X9 Evolution 500 Engine IF THE FAULTS DISCOVERED AFFECT THE HUB, REPLACE THE STARTER RING GEAR AND FREEWHEEL. IF ONLY THE BUSHING IS WORN, IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE START- UP RIM. IN THAT CASE, CHECK ALSO THE DIAMETER AND THE SURFACE OF THE CONNEC- TION ON THE CRANKSHAFT.
  • Page 135 X9 Evolution 500 Engine - Degrease the threading of the holes in the free wheel and the clamping screws. - Apply the recommended product to the end of the screws. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e.
  • Page 136 X9 Evolution 500 Engine - Insert the intermediate gear with torque limiter - Lubricate the inside bushing and the starter ring gear hub surface. - Install the start-up rim on the flywheel turning it clockwise and inserting at the same time. Refitting the flywheel magneto - Insert the key on the crankshaft.
  • Page 137 X9 Evolution 500 Engine - Insert washer and nut on the crankshaft. - Tighten thoroughly the guide bushing of the fly- wheel lock tool and loosen by 1/4 turn. N.B. FAILURE TO OBSERVE THIS RULE CAUSES THE LOCK- ING OF THE GUIDE ON THE FLYWHEEL. Specific tooling 020472Y Flywheel lock wrench - Align the 2 holes of the flywheel with the case...
  • Page 138 X9 Evolution 500 Engine - Tighten the flywheel lock nut to the prescribed torque. Locking torques (N*m) Flywheel fixing nut 115 - 125 - Install the chain guide retain plate tightening the 3 screws to the prescribed torque. N.B. BEFORE TIGHTENING THE SCREWS, MOVE THE START- UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIREC- TION.

  • Page 139: Removing The Intake Manifold

    X9 Evolution 500 Engine - Remove the flywheel cover, the flywheel and the torque limiter. Removing the intake manifold - Remove the 3 mounting screws. - Remove the intake manifold unit. Removing the rocker-arms cover - Loosen the 6 special screws with stop and the relevant rubber gaskets.
  • Page 140 X9 Evolution 500 Engine Removing the timing system drive - Turn the engine to close the intake valves, i.e., moving the reference on the tone wheel to the top, as shown in the figure. - Remove the central screw and the valve lifting device mass stop bell using the special tool.
  • Page 141 X9 Evolution 500 Engine - Loosen the central screw on the tensioner first. - Unscrew the 2 fastening screws and remove the tensioner with relevant gasket. Remove the inside hexagon screw and the coun- terweight as shown in the figure. - Remove the timing belt rim from the camshaft.

  • Page 142: Removing The Cam Shaft

    X9 Evolution 500 Engine - Remove the engine revolution timing sensor and relevant O-ring by loosening the fastening screw and removing the mounting band from the special hole obtained on the head gasket. N.B. TO CHECK THIS COMPONENT, SEE THE INJECTION CHAPTER.

  • Page 143: Removing The Cylinder Head

    X9 Evolution 500 Engine Removing the cylinder head - Remove the spark plug. - Remove the cooling system outlet sleeve with thermostat. - Remove the coolant temperature sensor. N.B. THE SENSOR CONTROLS BOTH INJECTION AND THE AN- ALOGUE INSTRUMENT ON THE PANEL. TO CHECK THIS COMPONENT, SEE THE INJECTION CHAPTER.

  • Page 144: Removing The Valves

    X9 Evolution 500 Engine - Loosen the 4 head-cylinder fastening nuts in 2 or 3 times and in a crossed sequence. - Remove the head, the 2 centring dowels, the gasket and the lower chain guide sliding block. N.B. DO NOT REMOVE THE DOWELS IF THEY ARE FORCED INTO THEIR SEAT.
  • Page 145 X9 Evolution 500 Engine - Remove the spring supports. N.B. BLOW THE SEATS WITH COMPRESSED AIR TO FACILI- TATE THE SPRING SUPPORT REMOVAL. Removing the cylinder - piston assy. - Remove the timing chain. - Loosen the fastening screw and remove the spacer and the tightening sliding block.

  • Page 146: Inspecting The Small End

    X9 Evolution 500 Engine - Remove the piston sealing rings and the oil scra- per. CAUTION NOTE THE ASSEMBLY POSITIONS OF THE LININGS TO PREVENT INVERTING THE POSITION IN CASE OF REUSE. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.

  • Page 147: Inspecting The Piston

    X9 Evolution 500 Engine - Calculate the piston pin coupling clearance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE AC- CORDING TO THE PISTON AXIS. Characteristic Standard clearance: 0.001 ÷ 0.010 mm Inspecting the piston - Carefully clean the seal housings.
  • Page 148 X9 Evolution 500 Engine - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. Characteristic Standard diameter: 92 + 0.018 +0.010 mm - Check that coating is free from flakes. - Check that the head matching surface exhibits no deformations or wear.

  • Page 149: Removing The Piston

    X9 Evolution 500 Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Insert the locking ring into the special tool, with the opening in the position indicated on the tool. S = left D= right - Place the wrist pin stop ring into position using a...
  • Page 150 X9 Evolution 500 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, without any base gasket. - Install a comparator on the special tool using the short union, as shown in the figure. Specific tooling 020475Y Piston position checking tool - Using an abutment plane, reset the comparator with a preload of a few millimetres.

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