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SERVICE
STATION
MANUAL
• Engine 500 cc
Piaggio & C. S.p.A.
Pontedera
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.
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. Any important changes in vehicle characteristics
or specific repair operations will be divulged by means of updates to this manual.
Satisfactory repair or service cannot be achieved without the necessary equipment and tools. Refer to the pages
of this manual concerning specific tools and equipment and the special tools catalogue.
Critical information in the manual is indicated as follows.
N.B.
: Important information for facilitating and explaining a procedure.
Warning
- Procedures that must be followed to avoid damage to the vehicle.
Caution
- Procedures that must be followed to eliminate the risk of injury to repair / service personnel.
TABLE OF CONTENTS
GENERAL INFORMATION AND
MAINTENANCE
1
SPECIFIC TOOLS
2
AUTOMATIC TRANSMISSION
3
FINAL REDUCTION
4
FLYWHEEL COVER
5
FLYWHEEL AND STARTING SYSTEM
6
THERMAL UNIT AND TIMING SYSTEM
7
CRANKCASE AND DRIVING SHAFT
8
INJECTION
9
LUBRICATION
10
COOLING SYSTEM
11
STARTER
12
TABLE OF CONTENTS
GENERAL INFORMATION AND
MAINTENANCE
1
General information and Maintenance
Safety prescriptions
Maintenance regulations
- If the work to be carried out requires the vehicle
engine to be running, make sure the workshop is
well ventilated and use proper exhausters. Do not
run the engine in closed places. Exhaust fumes are
toxic.
- Use only genuine PIAGGIO spare parts and recom-
mended lubricants. The use of non-original or non-
conforming spare parts can cause damage to the
vehicle.
- Battery electrolyte contains sulphuric acid. Protect
the eyes, clothes and skin. Sulphuric acid is highly
corrosive, if it comes into contact with eyes or skin,
wash the affected area abundantly with water and
seek immediate medical assistance.
- The only specific tools that can be used are those
expressly designed for this vehicle.
- Always fit new gaskets, seal rings and split pins when
reassembling parts.
- The battery produces hydrogen gas which is poten-
tially explosive. Do not smoke near the battery and
keep naked flames and sparks well clear, especially
when the battery is on charge.
- After disassembly, clean parts with non-flammable
solvent or a solvent with a high flash point. Lubricate
all surfaces before reassembly with the exception of
conical couplings.
- After reassembling, check that all the components
are correctly installed and that they work perfectly.
- Petrol is highly flammable and can be explosive in
certain conditions. Do not smoke in the work area
and do not introduce naked flames or sparks.
- Use only metric tools for disassembly, assembly and
maintenance work. Metric screws, nuts and bolts
cannot be interchanged with BS components. The
vehicle may be damaged if unsuitable tools or nuts,
bolts or screws are used.
- Clean brake shoes, drums and pads in a well
ventilated place. When using compressed air direct
the jet away from you to avoid inhaling the dust.
Although the brake linings are asbetos-free, inhala-
tion of the resulting dust is harmful.
- When working on the electrical system, ensure elec-
trical components are correctly installed, paying par-
ticular attention to ground and battery connections.
1 - 2
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