PIAGGIO 633234 Gebrauchsanweisung

WORKSHOP MANUAL

633234

X9 Evolution 500

WORKSHOP

MANUAL

X9 Evolution 500

The descriptions and illustrations given in this publication are not binding. While the basic specifications

as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

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.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

www.piaggio.com

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. Any important

changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this

manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are

unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along

with the specific tool catalogue. Important information in this manual is marked as follows.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sectionsmarked with this symbol indicatethe correct use of thevehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

•Should it be necessary to keep the engine running while servicing, make sure that the area

or room is well ventilated, and use special exhaust fans, if required. never let the engine run

in an enclosed area. Exhaust fumes are toxic.

•The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sul-

phuricacidis highly corrosive; in the event of contact with youreyesorskin, rinse thoroughly

with abundant water and seek immediate medical attention.

•The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid

sparks or flames near the battery, especially when charging it.

•Fuel is highly flammable, and in some conditions it can be explosive. Do not smoke in the

working area, and avoid open flames or sparks.

•Clean the brake pads in a well ventilated environment, directing the compressed air jet so

as to not inhale the dust produced by the wear of the friction material. Even though the latter

contains no asbestos, dust inhalation is harmful.

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.

•Always use new gaskets, sealing rings and split pins upon reassembly.

•After removal, clean the components using non-flammable or low fire-point solvent. Lubri-

cate all the work surfaces except the tapered couplings before refitting.

•After reassembly, check that all components have been installed properly and that they are

in good working order.

•Forremoval, overhaul and reassemblyoperations use only toolsprovided with metric meas-

ures. Metric bolts, nuts and screws are not interchangeable with coupling members with

English measurement. Using unsuitable coupling members and tools may damage the

scooter.

•Should any interventions to the scooter electrical system be required, check that the elec-

trical connections - especially earth and battery connections - have been implemented

properly.

X9 Evolution 500 Characteristics

CHAR - 7

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 1530 mm

Height (at the saddle) 780 mm

Height at the windscreen (high position) 1450 mm

Characteristics X9 Evolution 500

CHAR - 8

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.

Valve clearance: intake 0.15 mm (when cold)

Valve clearance: discharge 0.15 mm (when cold)

Valve clearance adjustment By threaded adjuster on the rockers

Engine idle speed 1500 ± 50 rpm

Air filter Dry paper filter.

CO % value (measured at the intake manifold) 1 - 1.5%

Starting system Electric starter system with freewheel.

Lubrication By trochoidal pump (inside the crankcase), pressure adjust-

ment by-pass and oil filter.

Lubrication pressure 4 bar

Minimum allowed (at 100° C) 0.8 bar

Fuel supply Electronic injection system with electric fuel pump, Ø 38 mm

throttle body and single injector.

Max. power (at crankshaft) 29.5 kW at 7500 rpm

Max. torque (at crankshaft) 43 Nm at 5500 rpm

Cooling system Fluid circulation through a motor-driven pump, 3-way thermo-

stat and electric fan.

X9 Evolution 500 Characteristics

CHAR - 9

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 ~ 250 cc

Engine oil (empty) 1.7 lt.

Engine oil (at oil and filter change) 1.5 lt.

Electrical system

ELECTRICAL COMPONENTS

Specification Desc./Quantity

1 Ignition type Inductive, high efficiency, integrated with injection, vari-

able advance and separate HV coil.

2 Spark advance (before TDC) Variable, controlled by the injection controller

3 Spark plug CHAMPION RG6YC; NGK CR7EKB

4 Battery 12V-14Ah

5 Fuses n.1 70A_n.1 30A_n.2 15A_n.3 10A_n.4 7,5A_n.2 5A_n.

1 3A

6 Generator in three-phase alternating current

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Type Welded structure consisting of steel pipes with asymmetrical

trestle structure, front crosspieces and union members made

of sheet steel.

Front suspension Hydraulic telescopic fork with dual effect, Ø 40 mm stems and

back pin with couplongs for dual brake calipers.

Front fork stroke 104 mm

Rear suspension Engine based on oscillating fork pivoted to the chassis by 2-

freedomdegreeoscillatingarmandpairofdualeffecthydraulic

shock absorbers with 4-position preload adjustment

Rear suspension range 76.6 mm (minimum spring preload)

X9 Evolution 125-250-500:

Please take note that, starting from chassis serial number ZAPM2300003509521, the front small chas-

sis fixing system has changed in order to improve its locking to the chassis. Therefore we have

introduced:

• N°2 screws drawing 432142

• N°2 4x11x0 external teeth spring washers drawing 012533

• N°2 nuts drawing 968224

Characteristics X9 Evolution 500

CHAR - 10

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